Shop Manual WA800-3

SEBM013409
WA800-3
MACHINE MODEL SERIAL NO.
WA800-3 50001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
• WA800-3 mount the SA12V140-1 engine.

For details of the engine, see the 12V140-1 Series Engine Shop Manual.
© 2004 1 00-1
All Rights Reserved
Printed in Japan 04-04(01) (9)
CONTENTS
No. of page
01 GENERAL ........................................................................ 01-1
10 STRUCTURE AND FUNCTION ...................................... 10-1
20 TESTING AND ADJUSTING .......................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................. 30-1
40 MAINTENANCE STANDARD ......................................... 40-1
90 OTHERS........................................................................... 90-1
00-2 WA800-3
1
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary actions Mark Indication Action required
be taken to these pages according to the table below.
fi Page to be newly added Add
‡ Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGE
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
‡ 00- 1 (9) ‡ 00-22 10-15 10-41 10-65-1 (6)

00- 2 (1) 10-16 10-42 10-65-2 (6)
‡ 00- 2-1 (9) 10-17 10-44 10-65-3 (6)
‡ 00- 2-2 (9) 01- 1 10-18 10-45 10-65-4 (6)
‡ 00- 2-3 (9) 01- 2 10-19 10-46 10-65-5 (6)
‡ 00- 2-4 (9) 01- 3 (6) 10-20 (8) 10-47 10-65-6 (6)
‡ 00- 2-5 (9) 01- 4 (6) 10-21 10-48 10-65-7 (6)
‡ 00- 2-6 (9) 01- 5 (6) 10-21-1 (8) 10-49 10-65-8 (6)
‡ 00- 2-7 (9) 01- 6 (6) 10-21-2 (8) 10-50 10-65-9 (6)
‡ 00- 3 01- 7 (6) 10-22 10-51 10-65-10 (6)
‡ 00- 4 01- 8 (6) 10-23 (8) 10-52 10-66
‡ 00- 5 01- 9 10-24 (8) 10-53 10-67
‡ 00- 6 10-25 (8) 10-54 10-68
‡ 00- 7 10-26 (8) 10-56 10-69
‡ 00- 8 10- 1 (6) 10-27 (8) 10-57 10-70
‡ 00- 9 10- 2 10-28 10-58 10-71
‡ 00-10 10- 3 10-29 10-59 10-72
‡ 00-11 10- 4 10-30 10-60 (5) 10-73
‡ 00-12 10- 5 10-31 10-60-1 (5) 10-74
‡ 00-13 10- 6 10-32 10-60-2 (5) 10-75
‡ 00-14 10- 7 10-33 10-61 (5) 10-76
‡ 00-15 10- 8 10-34 10-61-1 (5) 10-77 (5)
‡ 00-16 10- 9 10-35 10-62 (6) 10-78
‡ 00-17 10-10 10-36 10-63 (6) 10-79
‡ 00-18 10-11 10-37 10-63-1 (6) 10-79-1 (5)
‡ 00-19 10-12 10-38 10-63-2 (6) 10-79-2 (5)
‡ 00-20 10-13 10-39 10-64 (6) 10-79-3 (5)
‡ 00-21 10-14 10-40 10-65 (6) 10-79-4 (5)
WA800-3 00-2-1
(9)

10-79-5 (5) 10-111 (6) 10-137-1 (6) 10-161 10-177-22 (4)

10-80 10-112 (5) 10-137-2 (6) 10-162 10-177-23 (6)
10-81 10-113 (6) 10-137-3 (6) 10-163 (6) 10-177-24 (6)
10-82 10-114 (6) 10-137-4 (6) 10-164 10-177-25 (6)
10-83 10-114-2 (5) 10-137-5 (6) 10-165 (6) 10-177-26 (6)
10-84 10-114-3 (6) 10-137-6 (6) 10-166 10-177-27 (6)
10-86 10-114-4 (6) 10-137-7 (6) 10-167 (6) 10-177-28 (6)
10-87 10-114-6 (5) 10-138 (6) 10-168 (6) 10-177-29 (6)
10-88 (6) 10-114-7 (6) 10-139 (6) 10-169 (5) 10-177-30 (6)
10-89 (6) 10-114-8 (6) 10-139-1 (6) 10-170 (5) 10-178
10-89-1 (6) 10-114-10 (6) 10-139-2 (6) 10-171 (5) 10-178-1 (6)
10-89-2 (6) 10-114-11 (6) 10-140 (6) 10-173 10-178-2 (6)
10-90 (6) 10-114-12 (6) 10-140-1 (6) 10-174 10-179
10-91 (6) 10-115 10-141 (6) 10-175 10-180
10-92 10-115-1 (6) 10-142 10-176 10-181 (6)
10-93 10-116 10-143 (6) 10-176-1 (6) 10-182
10-94 10-117 10-144 10-176-3 (6) 10-183
10-94-2 (6) 10-118 10-144-1 (6) 10-176-4 (6) 10-184
10-94-3 (6) 10-119 (6) 10-144-2 (6) 10-177 (6) 10-184-1 (5)
10-94-4 (6) 10-120 (6) 10-145 (6) 10-177-1 (4) 10-184-2 (5)
10-94-5 (6) 10-121 (6) 10-146 (6) 10-177-2 (4) 10-184-4 (6)
10-94-6 (6) 10-121-2 (6) 10-147 (6) 10-177-3 (4) 10-184-5 (5)
10-95 10-121-3 (6) 10-148 (6) 10-177-4 (4) 10-184-6 (6)
10-96 10-121-4 (6) 10-149 (6) 10-177-5 (4) 10-184-7 (5)
10-97 10-122 10-150 (6) 10-177-6 (4) 10-184-8 (5)
10-98 10-123 10-150-1 (6) 10-177-7 (4) 10-184-9 (5)
10-99 (6) 10-124 (6) 10-150-2 (6) 10-177-8 (4) 10-184-10 (6)
10-100 10-125 10-150-3 (6) 10-177-9 (4) 10-184-11 (5)
10-101 10-126 10-150-4 (6) 10-177-10 (4) 10-185
10-102 10-127 10-150-5 (6) 10-177-11 (4) 10-186
10-103 10-128 10-150-6 (6) 10-177-12 (4) 10-187 (6)
10-104 (6) 10-129 10-152 10-177-13 (4) 10-188
10-104-1 (6) 10-130 10-153 10-177-14 (4) 10-189
10-105 10-131 10-154 10-177-15 (4) 10-190
10-106 10-132 10-155 10-177-16 (4) 10-191
10-107 (6) 10-133 10-156 10-177-17 (4) 10-192
10-108 10-134 10-157 10-177-18 (4) 10-193
10-109 10-135 10-158 10-177-19 (4)
10-110 10-136 10-159 10-177-20 (4)
10-110-2 (6) 10-137 (6) 10-160 10-177-21 (4) 20- 1
00-2-2 WA800-3
(9)

20- 2 20-115 20-153 20-224 (7) 20-245

20- 3 20-116 20-154 20-225 (7) 20-301
20- 4 20-117 20-155 20-226 (7) 20-302
20- 5 (8) 20-118 ‡ 20-156 (9) 20-227 (7) 20-303
‡ 20- 6 (9) 20-119 20-157 (5) 20-228 (7) 20-304
20- 7 20-120 20-158 (5) 20-229 (7) 20-305
20- 8 20-121 20-159 (7) 20-230 (7) 20-306
20- 9 (5) 20-122 20-160 (7) 20-230-1 (7) 20-307
20-10 (5) 20-123 (8) 20-161 (7) 20-230-2 (7) 20-308
20-11 (5) 20-124 20-162 (7) 20-230-3 (7) 20-309
20-12 (5) 20-125 20-163 (7) 20-230-4 (7) 20-310
20-13 (5) 20-126 20-230-5 (7) 20-311
20-14 (5) 20-127 20-201 (7) 20-230-6 (7) 20-312
20-15 (5) 20-128 20-202 20-230-7 (7) 20-313
20-16 (5) 20-129 20-203 20-230-8 (7) 20-314
20-17 (5) 20-130 20-204 20-230-9 (7) 20-315
20-18 (5) 20-131 (5) 20-205 20-230-10 (7) 20-316
20-19 (5) 20-131-1 (5) 20-206 20-230-11 (7) 20-317
20-20 (5) 20-131-2 (5) 20-207 20-230-12 (7) 20-318
20-21 (5) 20-132 20-208 20-230-13 (7) 20-319
20-22 (5) 20-133 20-209 20-230-14 (7) 20-320
20-23 (5) 20-134 20-210 20-230-15 (7) 20-321
20-24 (5) 20-135 20-211 (3) 20-231 (5) 20-322
20-25 (5) 20-136 20-212 20-231-1 (7) 20-323
20-26 (5) 20-137 20-213 (5) 20-232 (5)
20-138 20-214 (5) 20-233 (5) 20-401 (5)
20-101 (7) 20-139 20-215 (7) 20-234 (5) 20-402 (5)
20-102 20-140 20-215-1 (5) 20-235 (5) 20-403 (5)
20-103 20-141 20-215-2 (5) 20-236 (5) 20-404 (5)
20-104 20-142 20-215-3 (7) 20-236-1 (5) 20-405 (5)
20-105 20-143 20-215-4 (7) 20-236-2 (5) 20-406 (5)
20-106 20-144 20-216 20-237 (5) 20-407 (5)
20-107 20-145 20-217 (5) 20-238 (5) 20-407-1 (5)
20-108 20-146 20-218 (5) 20-238-1 (5) 20-407-2 (5)
20-109 20-147 20-219 20-238-2 (5) 20-407-3 (5)
20-110 20-148 (2) 20-220 20-239 20-407-4 (5)
20-111 20-149 20-220-1 (5) 20-241 20-408 (5)
20-112 20-150 20-221 (7) 20-242 (7) 20-409 (5)
20-113 20-151 20-222 (7) 20-243 20-409-1 (5)
20-114 20-152 20-223 (7) 20-244 20-409-2 (5)
WA800-3 00-2-3
(9)

20-410 (5) 20-514 20-610 20-724 20-852 (5)

20-411 (5) 20-515 20-611 20-725 20-854
20-412 (5) 20-516 20-612 20-726 20-855
20-413 (5) 20-517 20-613 20-727 20-856
20-414 (5) 20-518 20-614 20-728 20-857
20-415 (5) 20-519 20-615 20-730 20-858 (5)
20-416 (5) 20-520 20-616 20-731 20-859 (5)
20-417 (5) 20-521 20-617 20-732 20-860
20-418 (5) 20-522 20-618 20-733 20-861
20-419 (5) 20-523 20-619 20-862
20-420 (5) 20-524 20-620 20-801 (5) 20-863
20-421 (5) 20-525 20-621 20-802 20-864
20-422 (5) 20-526 20-622 20-803 20-865
20-423 (5) 20-527 20-623 20-804 20-866
20-424 (5) 20-528 20-624 20-805 20-867
20-425 (5) 20-529 20-625 20-806 (5) 20-868
20-426 (5) 20-530 20-807 (5) 20-869
20-427 (5) 20-531 20-701 20-808 (5) 20-870
20-428 (5) 20-532 20-702 20-809 (5) 20-871
20-429 (5) 20-533 20-703 (5) 20-810 (5)
20-430 (5) 20-534 20-704 (5) 20-811 (5) 20-901 (5)
20-431 (5) 20-535 20-705 (5) 20-812 (5) ‡ 20-902 (9)
20-432 (5) 20-536 20-706 20-813 (5) 20-904 (5)
20-433 (5) 20-537 20-707 20-814 (5) 20-905 (5)
20-434 (5) 20-538 20-708 20-815 (5) 20-906 (5)
20-435 (5) 20-539 20-709 20-816 (5) 20-907 (5)
20-436 (5) 20-540 20-710 20-817 (5) 20-908 (5)
20-541 20-711 20-818 (5) 20-909 (5)
20-501 20-542 20-712 20-819 (5) 20-910 (5)
20-502 20-543 20-713 20-820 (5) 20-911 (5)
20-503 20-714 20-821 (5) 20-912 (5)
20-504 20-601 20-715 20-822 (5) 20-913 (5)
20-506 20-602 20-716 20-823 (5) 20-914 (5)
20-507 (5) 20-603 (5) 20-717 20-824 (5) 20-915 (5)
20-508 20-604 20-718 20-825 (5) 20-916 (5)
20-509 20-605 20-719 20-826 (5) 20-917 (5)
20-510 20-606 20-720 20-827 (5) 20-918 (5)
20-511 20-607 20-721 20-828 (5) 20-919 (5)
20-512 20-608 20-722
20-513 20-609 20-723 20-851 (5) 20-1001 (7)
00-2-4 WA800-3
(9)

20-1002 (7) 20-1043 (7) 20-1083 (7) 30-29 (1) 30-69 (1)
20-1003 (7) 20-1044 (7) 20-1084 (7) 30-30 (1) 30-70 (1)
20-1004 (7) 20-1045 (7) 20-1085 (7) 30-31 (1) 30-71 (1)
20-1005 (7) 20-1046 (7) 20-1086 (7) 30-32 (1) 30-72 (1)
20-1006 (7) 20-1047 (7) 20-1087 (7) 30-33 (1) 30-73 (1)
20-1007 (7) 20-1048 (7) 20-1088 (7) 30-34 (1) 30-74 (1)
20-1008 (7) 20-1049 (7) 20-1089 (7) 30-35 (1) 30-75 (1)
20-1009 (7) 20-1050 (7) 20-1090 (7) 30-36 (1) 30-76 (1)
20-1010 (7) 20-1051 (7) 20-1091 (7) 30-37 (1) 30-77 (1)
20-1011 (7) 20-1052 (7) 30-38 (1) 30-78 (8)
20-1013 (7) 20-1053 (7) 30-39 (1) 30-79 (8)
20-1014 (7) 20-1054 (7) 30- 1 (1) 30-40 (1) 30-80 (8)
20-1015 (7) 20-1055 (7) 30- 2 (3) 30-41 (1) 30-81 (8)
20-1016 (7) 20-1056 (7) 30- 3 (1) 30-42 (1) 30-82 (1)
20-1017 (7) 20-1057 (7) 30- 4 (1) 30-43 (1) 30-83 (1)
20-1018 (7) 20-1058 (7) 30- 5 (1) 30-44 (1) 30-84 (8)
20-1019 (7) 20-1059 (7) 30- 6 (1) 30-45 (1) 30-85 (8)
20-1020 (7) 20-1060 (7) 30- 7 (1) 30-46 (1) 30-86 (8)
20-1021 (7) 20-1061 (7) 30- 8 (1) 30-47 (1) 30-87 (8)
20-1022 (7) 20-1062 (7) ‡ 30- 9 (9) 30-48 (1) 30-88 (8)
20-1023 (7) 20-1063 (7) ‡ 30-10 (9) 30-49 (1) 30-89 (8)
20-1024 (7) 20-1064 (7) 30-11 (1) 30-50 (1) 30-90 (1)
20-1025 (7) 20-1065 (7) 30-12 (1) 30-51 (1) 30-91 (8)
20-1026 (7) 20-1066 (7) ‡ 30-13 (9) 30-52 (1) 30-92 (8)
20-1027 (7) 20-1067 (7) ‡ 30-14 (9) 30-53 (1) 30-92-1 (8)
20-1028 (7) 20-1068 (7) 30-14-1 (3) 30-54 (1) 30-93 (8)
20-1029 (7) 20-1069 (7) 30-15 (1) 30-55 (1) 30-94 (8)
20-1030 (7) 20-1070 (7) 30-16 (1) 30-56 (1) 30-95 (8)
20-1031 (7) 20-1071 (7) 30-17 (1) 30-57 (1) 30-96 (8)
20-1032 (7) 20-1072 (7) 30-18 (1) 30-58 (1) 30-96-1 (8)
20-1033 (7) 20-1073 (7) 30-19 (1) 30-59 (1) 30-97 (1)
20-1034 (7) 20-1074 (7) 30-20 (1) 30-60 (1) 30-98 (8)
20-1035 (7) 20-1075 (7) 30-21 (1) 30-61 (1) 30-99 (8)
20-1036 (7) 20-1076 (7) 30-22 (1) 30-62 (1) 30-100 (8)
20-1037 (7) 20-1077 (7) 30-23 (1) 30-63 (1) 30-101 (8)
20-1038 (7) 20-1078 (7) 30-24 (1) 30-64 (1) 30-102 (8)
20-1039 (7) 20-1079 (7) 30-25 (1) 30-65 (1) 30-103 (8)
20-1040 (7) 20-1080 (7) 30-26 (1) 30-66 (1) 30-104 (8)
20-1041 (7) 20-1081 (7) 30-27 (1) 30-67 (1) 30-105 (8)
20-1042 (7) 20-1082 (7) 30-28 (1) ‡ 30-68 (9) 30-106 (8)
WA800-3 00-2-5
(9)

30-107 (8) 30-147 (1) 30-187 (1) 30-215-12 (3) 30-246 (1)
30-108 (8) 30-148 (1) 30-188 (1) 30-215-13 (3) 30-247 (1)
30-109 (1) 30-149 (1) 30-189 (1) 30-215-14 (3) 30-248 (1)
30-110 (1) 30-150 (1) 30-190 (1) 30-215-15 (3) 30-249 (1)
30-111 (1) 30-151 (1) 30-191 (1) 30-215-16 (3) 30-250 (1)
30-112 (1) 30-152 (1) 30-192 (1) 30-215-17 (3) 30-251 (1)
30-113 (1) 30-153 (1) 30-193 (1) 30-215-18 (3) 30-252 (1)
30-114 (1) 30-154 (1) 30-194 (1) 30-215-19 (3) 30-253 (1)
30-115 (8) 30-155 (1) 30-195 (1) 30-215-20 (3) 30-254 (1)
30-116 (8) 30-156 (1) 30-196 (1) 30-215-21 (3) 30-255 (1)
30-117 (8) 30-157 (1) 30-197 (1) 30-216 (1) 30-256 (1)
30-118 (1) 30-158 (1) 30-198 (1) 30-217 (1) 30-257 (1)
30-119 (8) 30-159 (1) 30-199 (1) 30-218 (1) 30-258 (1)
30-120 (8) 30-160 (1) 30-200 (1) 30-219 (1) 30-259 (1)
30-121 (8) 30-161 (1) 30-201 (1) 30-220 (1) 30-260 (1)
30-122 (8) 30-162 (1) 30-202 (1) 30-221 (1) 30-261 (1)
30-123 (8) 30-163 (1) 30-203 (1) 30-222 (1) 30-262 (1)
30-124 (1) 30-164 (1) 30-204 (1) 30-223 (1) 30-263 (1)
30-125 (8) 30-165 (1) 30-205 (1) 30-224 (1) 30-264 (1)
30-126 (8) 30-166 (1) 30-206 (1) 30-225 (1) 30-265 (1)
30-127 (8) 30-167 (1) 30-207 (1) 30-226 (1) 30-266 (1)
30-128 (8) 30-168 (1) 30-208 (1) 30-227 (1) 30-267 (1)
30-129 (8) 30-169 (1) 30-209 (1) 30-228 (1) 30-268 (1)
30-130 (8) 30-170 (1) 30-210 (1) 30-229 (1)
30-131 (8) 30-171 (1) 30-211 (1) 30-230 (1)
30-132 (8) 30-172 (1) 30-212 (1) 30-231 (1) 40- 1 (6)
30-133 (1) 30-173 (1) 30-213 (1) 30-232 (1) 40- 2
30-134 (1) 30-174 (1) 30-214 (1) 30-233 (1) 40- 3
30-135 (1) 30-175 (1) 30-215 (1) 30-234 (1) 40- 4
30-136 (1) 30-176 (1) 30-215-1 (3) 30-235 (1) 40- 5
30-137 (1) 30-177 (1) 30-215-2 (3) 30-236 (1) 40- 6
30-138 (1) 30-178 (1) 30-215-3 (3) 30-237 (1) 40- 7 (6)
30-139 (1) 30-179 (1) 30-215-4 (3) 30-238 (1) 40- 8
30-140 (1) 30-180 (1) 30-215-5 (3) 30-239 (1) 40- 9
30-141 (1) 30-181 (1) 30-215-6 (3) 30-240 (1) 40-10 (8)
30-142 (1) 30-182 (1) 30-215-7 (3) 30-241 (1) 40-11
30-143 (1) 30-183 (1) 30-215-8 (3) 30-242 (1) 40-12 (8)
30-144 (1) 30-184 (1) 30-215-9 (3) 30-243 (1) 40-13 (8)
30-145 (1) 30-185 (1) 30-215-10 (3) 30-244 (1) 40-13-1 (8)
30-146 (1) 30-186 (1) 30-215-11 (3) 30-245 (1) 40-14
00-2-6 WA800-3
(9)

40-15 40-52
40-16 40-54
40-17 40-55
40-18 40-56
40-19
40-20
40-21 90- 1 (6)
40-22 90- 3 (5)
40-23 90- 5 (5)
40-24 90- 7 (5)
40-25 90- 9 (5)
40-26 90-11 (5)
40-27 90-13 (5)
40-28 90-15 (5)
40-29 90-17 (5)
40-30 90-19 (5)
40-32 90-21 (5)
40-33 90-23 (5)
40-34 90-25 (5)
40-35 90-27 (5)
40-36 90-29 (5)
40-38 (6) 90-31 (5)
40-39 (6) 90-33 (5)
40-39-1 (6) 90-35 (6)
40-40
40-42
40-43
40-44
40-45
40-46
40-47
40-48
40-49
40-49-1 (6)
40-49-2 (6)
40-49-3 (6)
40-50 (6)
40-51 (6)
40-51-1 (6)
40-51-2 (6)
WA800-3 00-2-7
(9)
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:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
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
date information before you start any work.
k
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) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
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
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(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.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
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
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
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°.
★ 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)
★ The adapter can be pushed in about 3.5
mm.
★ 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)
★ 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)
★ 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)
★ 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
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene 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 sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, 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, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ 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
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ 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 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
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 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 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
Pri-
1 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 Yellow & Green &
Color White & Blue — Black & Red Red & Yellow 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 n
6
Color — — — Red & Blue Yellow & White Green & Blue n
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 mil-
limeters 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.
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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
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
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
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
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
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
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
01 GENERAL
General assembly drawing .......................... .Ol-2

Specifications .................................................. 01-3
Weight table .................................................. 01-6
List of lubricant and water.. ........................ 01-8
WA800-3 01-l
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
I-
0109 ‘1 001
98L9 L OFP
OOE6 909
J
swwo3817
WA8003
01-2
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA800-3
Serial No. 50001 – 50025 50026 and up

Operating weight kg 98,300
Weight
Distribution (front) kg 57,300
Distribution (rear) kg 41,000

Bucket capacity (piled) m3 11.0
Rated load kg 19,800
Travel speed FORWARD 1st km/h 7.0

FORWARD 2nd km/h 12.3
FORWARD 3rd km/h 28.0

Performance
REVERSE 1st km/h 7.1

REVERSE 2nd km/h 12.4
REVERSE 3rd km/h 28.3
Max. rimpull kN {kg} 588.4 {60,000}

Gradeability deg 25
Center of outside wheel mm 9,200

Min. turning
radius Outside portion of chassis mm 10,900
Overall length mm 13,730 (with tooth)
Overall width (chassis) mm 4,585
Bucket width mm 4,760 (Cutting edge)

5,045 (Tire guard)
Overall height (top of ROPS cab) mm 5,275

(Bucket raised) mm 9,300
Wheelbase mm 5,450
Dimensions
Tread mm 3,350
Min. ground clearance mm 550
Height of bucket hinge pin mm 6,785
Dumping clearance (tip of edge) mm 5,010

Dumping reach (tip of edge) mm 2,150
Bucket dump angle deg 50 (Max. height)
Bucket tilt angle (SAE carrying position) deg 50

Digging depth (10° dump) (tip of edge) mm 430
WA800-3 01-3
01-3
(6)

Serial No. 50001 – 50025 50026 and up
Model SA12V140
Type 4-cycle, water-cooled, V type,

12-cylinder direct injection, with
2-turbocharger, after-cooler
No. of cylinders – bore × stroke mm 12 – 140 × 165
Piston displacement ¬ {cc} 30.48 {30,480}

Flywheel horsepower kW/rpm {HP/rpm} 636/2,000 {853/2,000}
Engine
Performance
Maximum torque Nm/rpm {kgm/rpm} 3,727/1,400 {380/1,400}
Fuel consumption ratio g/kW·h {g/HP·h} 202.6 {151}

High idling speed rpm 2,220
Low idling speed rpm 650/850
Starting motor 24 V 7.5 kW × 2

Alternator 24 V 75 A
Battery 12 V 200 Ah × 4
Torque converter 3-element, 1-stage, single-phase

(TCA51-1A)
Power train
Transmission Planetary gear, multiple-disc, hy-

draulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear
Final drive Planetary gear, single reduction,

oil bath
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating

Axle, wheel
Rear axle Center pin support type, full-floating
Tire 45/65-45-46PR(L-5)
Wheel rim 36.00 × 45WTB

Inflation pressure kPa {kg/cm2} 515 {5.25}
Main brake Front/rear wheel braking, separate

front/rear wheel, wet disc,
Brakes
hydraulically actuated
Parking brake Mounted on front axle input shaft, dry
disc, hydraulically release spring apply
01-4
01-4 WA800-3
(6)

Serial No. 50001 – 50025 50026 and up
Steering
Type Articulated type

system
Structure Fully hydraulically power steering
Torque converter, ¬/min 421 421

transmission pump (Gear type: (Gear type:
SAR(4)112+SAR(3)100) SAR(4)112+SAR(3)100)
Steering pump ¬/min 307 307

(Fixed capacity piston (Fixed capacity piston
pump: HPF76+71) pump: HPF76+71)
Switch pump ¬/min 405 405

(Fixed capacity piston (Fixed capacity piston
Hydraulic pump: HPF90+90) pump: HPF95+95)
pump
Delivery PPC pump ¬/min 68 68
(Gear type: (Gear type:
SAR(1)032) SAR(1)032)
Brake pump ¬/min 29 29

(Gear type: (Gear type:
Hydraulic system
SAR(1)014) SAR(1)014)
Work equipment pump ¬/min 405 405

(Variable capacity piston (Variable capacity piston
pump: HPV90+90) pump: HPV95+95)
Transmission valve MPa {kg/cm2} 2.5 {25}

(Spool type, electric control)
Steering demand valve MPa {kg/cm2} 31.4 {320}

Control
(Fully hydraulic type)
valve
Set PPC valve MPa {kg/cm2} 3.7 {38}
pressure (2-lever type)
Main control valve MPa {kg/cm2} 31.4 {320}

(2-spool type)
Steering cylinder Reciprocating piston

No. – bore × stroke mm 2 – 160 × 503
Boom cylinder Reciprocating piston

Cylinder
No. – bore × stroke mm 2 – 260 × 1,368
Bucket cylinder Reciprocating piston

No. – bore × stroke mm 1 – 300 × 906
equipment
Link type Single Z bar link

Work
Bucket edge type Spade nose bucket with teeth
WA800-3 01-5
01-5
(6)
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is a guide for use when transporting or handling components.
Unit: kg
Serial No. 50001 – 50025 50026 and up

Engine 3,200 3,200
Radiator 1,200 1,200
Torque converter 590 590

Transmission 2,300 2,300
Damper 178 178
Upper drive shaft 58 58

Center drive shaft 184 184
Front drive shaft 171 171
Rear drive shaft 184 184

Center support 165 165
Front axle 8,190 8,190
Rear axle 7,700 7,700

Front differential assembly 1,226 1,226
Rear differential assembly 1,256 1,256
Planetary carrier assembly (each) 238 238

Planetary hub assembly (each) 600 600
Axle pivot (Rear axle) 286 286
Wheel (each) 874 874

Tire (each) 2,630 2,630
Steering demand valve 66 66
Steering cylinder (each) 206 206

Hydraulic tank 824 824
Work equipment pump 150 150
Parking brake assembly 185 185

Torque converter charging + PPC + brake pump 49 49
Switch pump 145 157
Steering pump 145 145

Fender and guard assembly 1,393 1,393
PPC valve 4 4
01-6
01-6 WA800-3
(6)
GENERAL WEIGHT TABLE
Unit: kg
Serial No. 50001 – 50025 50026 and up

Main control valve (each) 95 95
Boom cylinder (each) 998 998
Bucket cylinder 1,210 1,210

Engine hood 88 (Top) 88 (Top)
28 (Side) 28 (Side)
Front frame 7,319 7,319
Rear frame 8,800 8,800

Bucket link (including bushing) 593 593
Bellcrank (including bushing) 1,850 1,850
Boom (including bushing) 8,495 8,495

Bucket (with teeth) 11,430 11,430
Counterweight 2,900 2,900
Fuel tank 780 780

Battery (each) 59 59
Cab 430 430
Air conditioner unit 55 55

Operator’s seat 48 48
Floor plate 348 348
ROPS support assembly 1,387 1,387
WA800-3 01-7
01-7
(6)
GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER

AMBIENT TEMPERATURE CAPACITY
RESERVOIR KIND OF
FLUID –22 –4 14 32 50 68 86 104 122°F
–30 –20 –10 0 10 20 30 40 50°C
Specified Refill
SAE 30
SAE 10W
Engine oil pan 140 ¬ 132 ¬
SAE 10W-30
SAE 15W-40
Engine SAE 30
Transmission case 164 ¬ 140 ¬
oil SAE 10W
Hydraulic system SAE 10W 1,065 ¬ 725 ¬
Brake SAE 10W 42 ¬ 31 ¬
Axle
(Front and rear) See Note 1 360 ¬ 360 ¬
(each)
Pins Grease NLGI No.2 [ª1, 2] – –
Diesel ASTM D975 No.2

Fuel tank 1,425 ¬ –
fuel ª
Cooling system Water Add antifreeze 301 ¬ –
ª ASTM D975 No.1
Note 1:
For axle oil, use only recommended oil as follows. fl In cold areas when the hydraulic oil
SHELL: DONAX TD temperature is low, if the steering wheel is
MOBILE: MOBILFLUID 424 turned and the machine is stopped in that
ESSO: TORQUE FLUID 56 position, there may be a time lag before
It is possible to substitute engine oil CLASS-CD the machine turns and stops.
SAE30 for axle oil. If this happens, turn the steering wheel
If noise comes from the brake, it is no problem of slowly to the left and right (repeat for about
durability. 10 minutes) and the oil inside the steering
valve will be warmed up.
[ª1]: When working in particularly severe
conditions, use a multi-purpose grease
containing 3 – 5% molybdenum.
[ª2]: For machines equipped with an auto-
grease system, if the machine is operated
in temperatures below –20°C, use lithium-
based grease No. 0 for the grease.
01-8
01-8 WA800-3
(6)
GENERAL LIST OF LUBRICANT AND WATER
REMARK
When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic mainte-
nance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5%.
I
Change interval of oil in
Fuel sulphur content
engine oil pan
0.5 to 1.0% l/2 of regular interval
Above 1.0% l/4 of regular interval
When starting the engine in an atmospheric tem-

perature of lower than O”C, be sure to use en-
gine oil of SAEIOW, SAEIOW-30 and SAE15W-
40, even though an atmospheric temperature
goes up to 10°C more or less in the day time.
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 (SAEIOW-30, 15W-401, but
be sure to add single grade oil that matches the
temperature 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 sys-
tem during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
WA8003 01-9
10 STRUCTURE AND FUNCTION
Power train ................................................... 10- 2 Brake ............................................................ 10-103

Power train system ...................................... 10- 3 Parking brake .............................................. 10-104
Engine control .............................................. 10- 4 Spring cylinder ........................................... 10-106
Servo cylinder .............................................. 10- 5 Parking brake solenoid valve .................... 10-107
Radiator and cooler ..................................... 10- 9 Hydraulic piping ......................................... 10-108
Damper .......................................................... 10-10 Work equipment hydraulic circuit diagram .. 10-112
Torque converter and Work equipment lever linkage .................. 10-115
transmission piping ............................... 10-11 Hydraulic tank ............................................. 10-116
Transmission hydraulic Main piston pump ...................................... 10-119
system diagram ..................................... 10-12 ES valve ...................................................... 10-127
Transmission hydraulic Servo valve ................................................. 10-129
circuit diagram ....................................... 10-13 PPC valve .................................................... 10-132
Torque converter .......................................... 10-14 PPC relief valve .......................................... 10-136
Transmission ................................................ 10-19 Accumulator (for PPC valve) ..................... 10-137
Transfer ......................................................... 10-27 Work equipment control lever .............. 10-137-1
Transmission control valve ......................... 10-28 Work equipment EPC valve .................. 10-137-4
Torque convertor oil cooler ........................ 10-46 Work equipment neutral lock
Drive shaft ..................................................... 10-47 solenoid valve ................................... 10-137-7
Center support .............................................. 10-48 Main control valve ..................................... 10-138
Axle ................................................................ 10-49 Lubrication of work equipment ................ 10-152
Final drive ..................................................... 10-54 Work equipment linkage ........................... 10-154
Axle mount ................................................... 10-56 Bucket positioner and boom kick-out ...... 10-156
Center hinge pin ........................................... 10-58 Operation of proximity switch .................. 10-158
Tire and wheel .............................................. 10-59 Cab ............................................................... 10-162
Steering piping diagram ............................. 10-60 ROPS canopy .............................................. 10-163
Steering column ........................................... 10-61 Air conditioner ............................................ 10-164
Joystick linkage ......................................... 10-61-1 Electric circuit diagram .............................. 10-167
Steering pump .............................................. 10-62 Machine monitor system........................... 10-168
Switch pump ................................................ 10-64 Main monitor .............................................. 10-170
Steering demand valve ............................... 10-66 Maintenance monitor ................................. 10-176
Steering unit (Orbit-roll valve) .................... 10-77 Multi monitor system (if equipped) ......... 10-177-1
Proportional solenoid valve .................... 10-79-1 Work equipment control system ......... 10-177-23
EPC valve ................................................... 10-79-2 Work equipment controller................... 10-177-29
Rotary valve ............................................... 10-79-3 Engine starting circuit ................................ 10-178
Tow-way restrictor valve ............................. 10-80 Engine stop circuit ..................................... 10-179
Diverter valve ............................................... 10-81 Preheating circuit ....................................... 10-180
Brake piping .................................................. 10-86 Electric transmission control ..................... 10-181
Brake circuit diagram ................................... 10-88 Kick-down, hold switch ............................. 10-184
Brake valve ................................................... 10-90 Joystick steering system ....................... 10-184-1
Charge valve ............................................... 10- 95 AJSS (Advanced joystick
Accumulator (for brake) ............................ 10- 99 steering system) ............................... 10-184-6
Slack adjuster ............................................. 10-100 Electric parking brake control ................... 10-185
WA800-3 10-1
10-1
(6)
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
SWW03667
OUTLINE
. The power from engine (16) is transmitted . The output shaft of transmission (IO) trans-
from the flywheel to damper (15) through mits the power to the output shaft of trans-
the ring gear. The damper alleviates the tor- fer (9) through the gear. The power from
sional vibration caused by the variation of the output shaft of the transfer is transmit-
the engine torque and transmits the power ted to both the front axle (5) and the rear
to torque converter (I 1) through upper drive axle (21).
shaft (14). The torque converter converts the In the front section of the chassis, the power
delivered torque according to the variation is transmitted to front axle (5) through center
in load on the oil used as the medium, and drive shaft (7) and front drive shaft (6).
transmits the power to the input shaft of In the rear section, the power is transmitted
transmission (IO). Then, the engine power is to rear axle (21) through. rear drive shaft
transmitted to steering pump (121, main (24).
pump (131, switch pump (17). and torque . The power transmitted to front axle (5) and
converter charging pump + PPC pump + rear axle (21) is reduced through pinion and
brake pump (18) through the pump driving ring gears in differential (22) and (I), and is
gear in torque converter (II), thereby driv- transmitted to the axle shafts.
ing the pumps. . The power from the axle shafts is reduced
. In transmission (IO), the five hydraulically- through final drive (19) and (3) and trans-
operated clutches are operated by the for- mitted to wheel (20) and (4) through the
ward-reverse spool and the speed change planetary carrier.
spools in the transmission valves, which are
themselves activated by solenoid valves.
Thus, the desired travel speed can be se-
lected from among the 3 forward and 3 re-
verse gear speeds.
1o-2 WA800-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POW R TRAIN SYSTEM
L-i
0 0
Ez3
88
0 0 SWWO3668
A
1. Front differential 11. Torque converter 20. Rear wheel

2. Front brake 12. Steering pump 21. Rear axle
3. Front final drive 13. Main pump 22. Rear differential
4. Front wheel 14. Upper drive shaft 23. Rear brake
5. Front axle 15. Damper 24. Rear drive shaft
6. Front drive shaft 16. Engine 25. Center support
7. Center drive shaft 17. Switch pump 26. Parking brake
8. Emergency steering pump 18. Torque converter charging pump (x 2)
9. Transfer + PPC pump + brake pump
IO. Transmission 19. Rear final drive
WA800-3 1o-3
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
1. Solenoid OUTLINE
2. Accelerator pedal 1. An engine low idling selection mechanism
3. Cable is used, and when the engine low idle switch
4. Servo cylinder is operated, the engine low idling speed can
5. Absorber be switched in two stages.
6. Injection pump 1) The engine low idling speed is set to
7. Transmission oil filler approx. 650 rpm. Use for normal opera-
tions such as when waiting for a dump
truck at low idling -+ OFF.
2) The engine low idling speed is set to
approx. 850 rpm.
Used on busy jobsites where it is needed
to reduce the cycle time + ON.
2. A hydraulic assist engine control (servo cyl-
inder (4)) is used to reduce the operating
effort for the accelerator pedal.
1o-4 WA800-3
STRUCTURE AND FUNCTION SERVO CYLINDER
SERVO CYLINDER
Z SEW01315
1. Rod OUTLINE
. The servo cylinder is installed to the engine
2. Spring
3. Body control linkage.
4. Piston This acts to reduce the operating force with-
5. Yoke out changing the amount of movement of
the accelerator pedal cable and injection
pump rod.
A. Oil outlet port (Drain to transmission oil filler)
B. Oil inlet port (From oil filter)
WA800-3 1o-5
OPERATION
1. Accelerator pedal not depressed
To transmission valve
0
Accelerator pedal (6) is not being depressed,

so the servo cylinder is not actuated.
The pressurized oil from the transmission
oil filter passes through the middle of rod
(I) and flows to port A.
2. Accelerator pedal depressed
oil filter
When accelerator pedal (6) is depressed, ca-

ble (7) moves rod (I) to the left in the direc-
tion of the arrow.
The oil from the transmission filter flows
from port A through the hole in piston (4)
and goes to chamber B.
1 O-6 WA800-3
SWWO3820
When the oil flowing to chamber B reaches As a result, the length of movement of rod
the specified pressure, it overcomes the force (I) becomes equal to the length of move-
of spring (2) and moves piston (4) to the left ment of the piston, and the operating force
in the direction of the arrow. is reduced by the hydraulic pressure.
Piston (4) continues to move until the hole
in piston (4) is closed.
3. Accelerator pedal released
to transmisson
When accelerator pedal (6) is released, ca-

ble (7) moves rod (I) to the right in the di-
rection of the arrow.
As a result, the oil at chamber B is drained.
When this happens, piston (4) is moved to
the right by spring (2) until the hole in pis-
ton (4) is closed.
WAND3 1o-7
ENGINE LOW IDLING SELECT SYSTEM
OUTLINE
. By using the engine low idling selector de-
vice to set the engine low idling speed to
two stages, it is possible to carry out opera-
tions more efficiently.
OPERATION
Engine low idle switch OFF

From oil filter
When the engine low idle switch is OFF, no electric 0
current flows to solenoid (I), so the solenoid is not
To.trans
actuated and the engine speed is set to 650 rpm.
SWWO3822
Engine low idle switch ON

When the engine low idle switch is turned ON, electric 2 From oil filter
current flows to solenoid (I), and the solenoid is
actuated. x
The solenoid rod is connected by a link to accelerator

pedal (21, so the accelerator pedal is depressed by an
amount equal to the movement of the rod. When this
happens, the engine speed is set to approximately
850 rpm.
SWWO3823
10-8 WA800-3
STRUCTURE AND FUNCTION RADIATOR AND COOLER
RADIATOR AND COOLER
SVW03672
1. Radiator cap Specification

2. Water level sensor Core type: Model PF2-7
3. Fan guard Total heat dissipating area: 201.00 m*
4. Upper tank Cross-sectional area of water tubes: 288.52 cm*
5. Radiator
6. Hydraulic oil cooler
7. Lower tank
WA800-3
1o-9
STRUCTURE AND FUNCTION DAMPER
DAMPER
5
SWWO3673
1. Shaft FUNCTION
2. Breather . The damper reduces the torsional vibration
3. Rubber cushion caused by changes in the engine torque, and
4. Inner body acts to protect the units of the power train
5. Outer body beyond the engine from the effects of tor-
sional vibration.
OPERATION
. The power of the engine is transmitted from
the flywheel to outer body (5). The torsional
vibration of the engine is absorbed by rub-
ber cushion (31, passes through inner body
(4) and shaft (I), and is transmitted to the
upper drive shaft between the torque con-
verter.
10-10 WA800-3
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND TRANSMISSION PIPING
1. Accelerator pedal
2. Transmission control valve
3. Torque converter
4. Servo cylinder
5. Torque converter oil cooler
6. Torque converter charging pump (x 2)
7. Torque converter oil filter
8. Transmission oil level gauge
9. Transfer
WA800-3 10-l 1
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

(Engine running, F.R. lever in NEUTRAL, speed lever in 1st)
22
22
22
22
22
t:
SWWO3676
A. To PPC valve
B. To brake line
C. From hydraulic tank
D. From brake oil tank
10-12 WA800-3
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
9 .xx Serial No. I
5000 1 -* : 2.45~20MPa(25'~k/cm21
._ : 2.65~z0MPa~27*~ko/~m~l
SWWO3866
1. Transfer case 12. Torque converter regulator 23. Reverse spool

2. Strainer valve 24. Forward spool
3. Torque converter charging pump 13. Oil cooler 25. 2nd spool
(SAR&112) 14. Lubrication relief valve 26. 1st spool
4. Torque converter charging pump 15. Pilot oil filter 27. 3rd spool
(SAR3-100) 16. Pilot reducing valve 28. Reverse clutch
5. PPC pump (SARI-0321 17. Priority valve 29. Forward clutch
6. Brake pump (SARI-014) 18. Modulating valve 30. 2nd clutch
7. Torque converter oil filter 19. Quick return valve 31. 1st clutch
8. Torque converter oil filter 20. Reducing valve 32. 3rd clutch
9. Servo cylinder 21. Solenoid valve 33. Torque converter
IO. Main relief valve 22. Emergency manual spool 34. Transmission lubrication
11. Torque converter relief valve
WA8OG3 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
1. Torque converter regulator valve

2. Torque converter outlet oil pressure pick-up (PTV8)
3. Torque converter inlet oil pressure pick-up (PT1/8)
4. Switch pump mounting
5. Main pump mounting
6. Coupling
7. Steering pump mounting
8. Torque converter charging pump +
PPC pump + brake pump mounting
A. Torque converter outlet port

B. Torque converter oil temperature sensor mount-
ing pot-t
C. Torque converter inlet port
D. Drain port (to transmission)
W
SEW01327
10-14 WA800-3
TORQUE CONVERTER
STRUCTURE AND FUNCTION
Y-Y
SEW01328
9. Turbine
IO. Stator
11. PTO gear (Teeth 86)
12. Housing
Specifications
13. Gear (Teeth 81)
Model: TCA51-IA
14. Pump
Type: 3-element, single stage, single phase
15. Transmission input shaft
Stall torque ratio: 2.84
16. Gear (Teeth 81)
10-15
WA800-3
Flow of motive force

. The torque converter is installed between
the damper and transmission. The motive
force from the damper passes through the
drive shaft and enters coupling (6).
Coupling (6), pump (14) and PTO gear (drive)
(11) are fixed with bolts. They are rotated
.I4
directly by the rotation of the engine. The
motive force of pump (14) uses oil to rotate
turbine (9). This transmits motive force to
transmission input shaft (15).
. The motive force of coupling (6) passes
through PTO gear (drive) (11) and is also
,I5
used as the motive force to drive the pump.
I SEW01 329
Flow of oil
l The oil pressure is adjusted by the torque
converter relief valve and then enters inlet
port A, passes through the oil passage in ,I
housing (12) and flows to pump (14). In pump
(14) centrifugal force is applied. The oil en-
ters turbine (9) and the energy of the oil is
I4
transmitted to the turbine.
Turbine (9) is fixed to transmission input
shaft (15), so the motive force is transmitted
to the transmission input shaft (15).
The oil from turbine (9) is sent to stator (IO)
and again enters the pump. However, part
15
of the oil passes from the stator through
outlet port B and is sent to regulator valve
(1).
The oil sent to regulator valve (I) passes
through the oil cooler to be cooled, and is
then used to lubricate the transmission.
\ t-J
SEW01330
lo-16 WA800-3
TORQUE CONVERTER RELIEF VALVE
OUTLINE
. The torque converter relief valve is inside
the transmission valve, and acts to keep the
oil entering the torque converter at a con-
stant pressure. If the specified pressure is
exceeded, it drains the oil.
FUNCTION
. The oil from the pump passes through trans-
mission main relief valve (I), enters port A,
and then flows to the torque converter.
T/C
regulator
,+Ta priority valve

(To Pilot reducina
B
From Pump SDWOI 653
. If the oil at port A exceeds the specified

pressure, the oil from orifice a of torque con-
verter relief valve (2) enters port B and moves
torque converter relief valve (2) to the left in
the direction of the arrow.
As a result, the oil from port A flows from
port C, lubricates the transmission, and is To priority valve
drained. ITo rilct reducing
,,
4
v
B
From Pump SDW01654
WA800-3 10-17
TORQUE CONVERTER REGULATOR VALVE
1. Valve body
;I_
2. Spring
0 3. Spool
A. Oil inlet port
0 B.
(From torque converter)
Oil outlet port
(to oil cooler)
l The torque converter regulator valve is in-

stalled in the output circuit of the torque
converter to regulate the hydraulic pressure
inside the torque converter to the specified
To oil cooler
pressure. 2
\
OPERATION
. The oil from the torque converter flows from
port A to port B. However, the hydraulic pres-
sure at port B is lower than the tension of
spring (2), so spool (3) does not move.
From torque converter

SDWOI655
To oil cooler
l When the hydraulic pressure at port B be-
comes higher than the tension of spring (2),
it pushes spool (3) in the direction of the
arrow, and the oil at port A flows to port C.
From torque converter

SDW01656
lo-18 WA800-3
STRUCTURE AND FUNCTION TRANSMISSION
SEW01339
1. Transmission
2. Transmission control valve
3. Transfer
4. Oil filler
5. Transfer output coupling
6. Drain plug
7. Transfer output coupling
A. To torque converter charging pump
WA800-3 10-19
Serial No.: 50001 – (T/M No. 101138)
10-20 WA800-3
(8)
1. Input shaft
2. Reverse sun gear (Teeth 26)
3. Reverse ring gear (Teeth 90)
4. Gear (Teeth 90)
5. Reverse clutch
6. Planetary gear (Teeth 30)
7. Ring gear (Teeth 86)
8. Forward sun gear (Teeth 38)
9. Forward clutch
11. Forward ring gear (Teeth 90)
12. Sun gear (Teeth 38)
16. 2nd clutch
18. 2nd ring gear (Teeth 140)
19. 2nd sun gear (Teeth 27)
20. Gear (Teeth 89)
21. 1st clutch
22. 1st sun gear (Teeth 27)
23. 1st ring gear (Teeth 89)
25. 3rd clutch
26. Hub (Teeth 112)
27. Idle shaft
28. Output shaft
29. 1st carrier
30. 2nd carrier
31. Forward carrier
32. Reverse carrier
WA800-3 10-21
Serial No.: (T/M No. 101139) and up
10-21-1 WA800-3
(8)
1. Input shaft
2. Reverse sun gear (Teeth 26)
3. Reverse ring gear (Teeth 90)
4. Gear (Teeth 90)
5. Reverse clutch
8. Forward sun gear (Teeth 38)
9. Forward clutch
11. Forward ring gear (Teeth 90)
12. Sun gear (Teeth 38)
16. 2nd clutch
18. 2nd ring gear (Teeth 140)
19. 2nd sun gear (Teeth 27)
20. Gear (Teeth 89)
21. 1st clutch
22. 1st sun gear (Teeth 27)
23. 1st ring gear (Teeth 89)
25. 3rd clutch
26. Hub (Teeth 112)
27. Idle shaft
28. Output shaft
29. 1st carrier
30. 2nd carrier
31. Forward carrier
32. Reverse carrier
WA800-3 10-21-2
(8)
CLUTCH
OUTLINE
. The transmission consists of a S-FORWARD, Speed range Clutch combination
3-REVERSE speed planetary gear transmis-
sion, transfer, and transmission control valve. Fl F, 1st
. In the transmission, the motive force of the F2 F, 2nd
input shaft is changed by the combination
F3 F, 3rd
of Forward or Reverse clutch with Ist, 2nd,
3rd clutch to give FORWARD I - 3 or RE- RI R, 1st
VERSE 1 - 3 speed, and is transmitted to the R2 R, 2nd
output shaft. R3 R, 3rd
OPERATION OF CLUTCH From transmission

control valve
Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the trans-
mission. When it reaches the rear of piston (2),
it moves piston (2).
When piston (2) moves, disc (4) and plate (5)
are pressed together. Ring gear (6) is meshed
with disc (4), so the rotation is stopped.
Disengaged
When the supply of oil from the transmission 5 4 3 To t ransmission
control valve is shut off, the pressure of the oil

acting on the rear of piston (2) is reduced. The
piston is then pushed back to the right by return
spring (3), and disc (4) and plate (5) are sepa-
rated. Ring gear (6) then rotates freely, and no
motive force is transmitted.
1o-22 WA800-3
FORWARD 1st
1 8 9 10 11 12 13 15 21 22 23 24 27 28
31 29
SEW01343
fl The transfer shown in this figure is for serial Nos. 50001 – (T/M No. 101138).
• In the case of FORWARD 1st, FORWARD • Ring gear (15) is being held in position, so
clutch (9) and 1st clutch (21) are engaged. the rotation of carrier (31) is transmitted
The power from the torque converter trans- through planet gear (13) to sun gear (12). It
mitted to input shaft (1) is transmitted to is also transmitted through intermediate
output shaft (28). shaft (27) to sun gear (22).
• FORWARD clutch (9) is actuated by the hy- • Ring gear (23) is being held in position by
draulic pressure applied to the clutch piston 1st clutch (21). For this reason, the rotation
and holds ring gear (11) in position. 1st clutch of sun gear (22) is transmitted from carrier
(21) is actuated by the hydraulic pressure (29) through planet gear (24) to output shaft
applied to the clutch piston and holds ring (28).
gear (23) in position.
• The power from the torque converter is trans-
mitted to input shaft (1). The rotation of the
input shaft is transmitted through sun gear
(8) to planet gear (10). Ring gear (11) is be-
ing held in position by FORWARD clutch (9),
so the rotation of planet gear (10) rotates
carrier (31).
WA800-3 10-23
10-23
(8)
FORWARD 2nd
1 8 9 10 11 12 13 15 16 17 18 19 22 23 24 27 28
31 30 29
SEW01344
• In the case of FORWARD 2nd, FORWARD • Ring gear (15) is being held in position, so
clutch (9) and 2nd clutch (16) are engaged. the rotation of carrier (31) is transmitted
The power from the torque converter trans- through planet gear (13) to sun gear (12).
mitted to input shaft (1) is transmitted to • It is also transmitted through intermediate
output shaft (28). shaft (27) to sun gears (19) and (22). Ring
• FORWARD clutch (9) is actuated by the hy- gear (18) is being held in position by 2nd
draulic pressure applied to the clutch piston clutch (16). For this reason, the rotation of
and holds ring gear (11) in position. 2nd sun gear (19) is transmitted through planet
clutch (16) is actuated by the hydraulic pres- gear (17) to carrier (30). It is then transmit-
sure applied to the clutch piston and holds ted to ring gear (23).
ring gear (18) in position. • The rotation of ring gear (23) and the rota-
• The power from the torque converter is trans- tion of sun gear (22) passes through planet
mitted to input shaft (1). The rotation of the gear (24) and is transmitted to carrier (29). It
input shaft is transmitted through sun gear is then transmitted to output shaft (28).
(8) to planet gear (10).
• Ring gear (11) is being held in position by
FORWARD clutch (9), so the rotation of planet
gear (10) rotates carrier (31).
10-24 WA800-3
(8)
FORWARD 3rd
1 8 9 10 11 12 13 15 25 26 27 28
31
SEW01345
• In the case of FORWARD 3rd, FORWARD • Ring gear (15) is being held in position, so
clutch (9) and 3rd clutch (25) are engaged. the rotation of carrier (31) is transmitted
The power from the torque converter trans- through planet gear (13) and goes from sun
mitted to input shaft (1) is transmitted to gear (12) to intermediate shaft (27).
output shaft (28). • Intermediate shaft (27) and output shaft (28)
• FORWARD clutch (9) is actuated by the hy- are formed into one unit by 3rd clutch (25).
draulic pressure applied to the clutch piston For this reason, the rotation of intermediate
and holds ring gear (11) in position. 3rd shaft (27) is transmitted to output shaft (28).
clutch (25) is actuated by the hydraulic pres-
sure applied to the clutch piston and en-
gages output shaft (28) and hub (26).
• The power from the torque converter is trans-
mitted to input shaft (1). The rotation of the
input shaft is transmitted through sun gear
• Ring gear (11) is being held in position by
FORWARD clutch (9), so the rotation of planet
gear (10) rotates carrier (31).
WA800-3 10-25
10-25
(8)
REVERSE 1st
1 2 5 6 7 12 15 21 22 23 24 27 28
32 31 29
SEW01346
• In the case of REVERSE 1st, REVERSE clutch • Carrier (32) is being held in position by RE-
(5) and 1st clutch (21) are engaged. The VERSE clutch (5), so the rotation of planet
power from the torque converter transmit- gear (6) rotates ring gear (7). The direction
ted to input shaft (1) is transmitted to output of rotation of ring gear (7) is the opposite of
shaft (28). the rotation of the engine.
• REVERSE clutch (5) is actuated by the hy- • The rotation of ring gear (7) is transmitted
draulic pressure applied to the clutch piston to carrier (31). Ring gear (15) is being held
and holds carrier (32) in position. 1st clutch in position, so the rotation of carrier (31) is
(21) is actuated by the hydraulic pressure transmitted through sun gear (12) to inter-
applied to the clutch piston and holds ring mediate shaft (27). Ring gear (23) is being
gear (23) in position. held in position by 1st clutch (21). For this
• The power from the torque converter is trans- reason, the rotation of sun gear (22) is trans-
mitted to input shaft (1). The rotation of the mitted from carrier (29) through planet gear
input shaft is transmitted through sun gear (24) to output shaft (28).
10-26 WA800-3
(8)
STRUCTURE AND FUNCTION TRANSFER
TRANSFER
Serial No.: 50001 – (T/M No. 101138) Serial No.: (T/M No. 101139) and up
OUTLINE 1. Transmission output shaft

• The transfer is installed at the power output 2. Transfer input gear (Teeth 32)
end of the transmission and is secured to 3. Transfer idler gear (Teeth 33)
the transmission case by bolts. 4. Idler gear (Teeth 34)
5. Output shaft
TRANSMISSION PATH 6. Front coupling
• Output shaft (1) of the transmission is cou- 7. Strainer
pled to transfer input gear (2) by a spline. 8. Rear coupling
The motive force is transmitted to output 9. Output gear (Teeth 44)
shaft (5) through idler gears (3), (4) and out-
put gear (9).
Part of the power transmitted to the output
shaft is transmitted to the front axle through
the center drive shaft and front drive shaft.
The rest of the power is transmitted to the
rear axle through the rear drive shaft.
WA800-3 10-27
10-27
(8)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
r
i/
SEW01 348
1. Pilot oil filter A. Pilot reducing pressure pick-up

2. Main relief valve B. Modulating valve piston load pressure pick-up
3. Torque converter relief valve C. Torque converter relief pressure pick-up
4. Transmission solenoid valve D. Transmission lubricating pressure pick-up
5. Emergency manual spool E. Modulating pressure pick-up
6. Connector F. Modulating pressure pick-up
7. Lower valve (After quick return valve)
8. Upper valve
9. Breather
1O-28 WA800-3
TRANSMISSION SOLENOID VALVE
10. REVERSE solenoid valve

11. FORWARD solenoid valve
12. 2nd solenoid valve
13. 1st solenoid valve
14. 3rd solenoid valve
Actuation table for solenoid valve and clutch
STRUCTURE
. The transmission solenoid valve is installed
to the transmission together with the trans-
mission valve. When the directional lever or
speed control lever are operated, the sole-
noid valve is actuated and moves the spool
inside the transmission valve.
WA800-3 1O-29
LOWER VALVE
1. Transmission solenoid valve 10. Emergency manual spool

2. FORWARD spool 11. Priority valve
3. REVERSE spool 12. Pilot valve
4. Pilot oil filter 13. Load piston
5. Torque converter relief valve 14. Quick return valve
6. Main relief valve 15. Lubrication valve
7. 2nd spool 16. Pilot reducing valve
8. 1st spool 17. Modulating valve
9. 3rd spool
1O-30 WA800-3
UPPER VALVE
x-x SEW01351
OUTLINE
l The oil from the torque converter charging . The other oil line flows to modulating valve
pump enters port A of main relief valve, and (17) and quick return valve (14). The action
passes through priority valve (11) via by main of modulating valve (17) and quick return
relief valve. It is then divided into three lines; valve (14) raises the clutch pressure smoothly.
there are; to the clutch pistons, to pilot re- This reduces the shock when actuating the
ducing valve (16) and main relief valve. Pri- FORWARD, REVERSE and Ist, 2nd and 3rd
ority valve (11) acts to control the three lines speed clutches to change gear.
so that pilot reducing valve (16) is the prior- . Lubrication valve (15) controls the lubrica-
ity circuit. tion oil inside the transmission.
l The oil flowing to pilot reducing valve (16)
controls the pilot pressure used to actuate
the directional and speed spools. The oil
regulated by pilot reducing valve (16) presses
through the orifice in each spool and fills
the spool.
WA800-3 10-31
PILOT OIL FILTER
OUT IN
A-A
SEW01352
1. Oil filter head Specification:

2. Element Filtration area: 370 cm2
3. Case Mesh: 105 pm
1O-32 WA%OO-3
MAIN RELIEF VALVE
FUNCTION
. The main relief valve acts to supply the nec-
essary oil to the clutch when shifting gear.
When the gears are not being shifted, it
sends all of the oil directly to the torque
converter.
OPERATION
. The oil from the pump passes through the
oil filter and enters port A of main relief
valve (1).
. Until the specified pressure is reached, the
oil flows to the priority valve.
SDWOl662
. When the pressure goes above the specified

level, oil passes through the orifice in relief
valve (I), pushes poppet (2), and moves re-
lief valve (1) to the left. The oil is relieved to
the torque converter, so the specified pres-
sure is maintained.
* Specified pressure: 2.75 MPa (28 kg/cm*)
' $2
From PUMP SDW01663
WA800-3 1o-33
PILOT REDUCING VALVE
FUNCTION
l The pilot reducing valve acts to control the
pressure needed to actuate the transmission
spools.
OPERATION
Clutch
l The oil from the pump passes through the
pilot filter and enters port A of pilot reduc-
ing valve (I). The oil passes through port B
and enters through the orifice of transmis-
sion spool (2) to fill the inside of port C.
A’fj ’
From oil filter
SOWOI 664
. When the pressure inside port C rises, pres- Clutch

surized oil flows from orifice “a” of pilot re-
ducing valve (I) and goes to port D.
As a result, pilot reducing valve (I) moves
to the left, and port A and B are shut off, so
the pressurized oil at port C is maintained at
the same pressure.
t Specified pressure: 1.96 MPa (20 kg/cm*}
c return valve
From oil filter
SDWOl665
1o-34 WA800-3
TRANSMISSION SOLENOID VALVE
FUNCTION
l There is one solenoid valve installed for each
directional and speed spool in the transmis-
sion valve.
When the directional lever and speed con-
trol levers in the operator’s compartment are
operated, the solenoid valve is actuated, and
oil is drained to actuate the directional and
speed spools.
OPERATION
1) Solenoid valve OFF Clutch
The oil of spool (2) enters port A. However,

valve (1) shuts off the oil, so directional and
speed spool (2) does not move.
0 A return Valve
B
From oil filter
SOW01666
2) Solenoid valve ON Clutch

When the directional and gear shift lever are
operated, the solenoid valve is pulled up.
The oil from directional and speed spool (2)
enters port A and flows from port B to the
drain circuit. Therefore, port C becomes the
high pressure circuit and port A becomes
the low pressure circuit, and directional and
speed spool (2) is moved to the left, and the
oil from the quick return valve flows to the
clutch.
--ii---
From 011 filter
SDWOl667
WA800-3 1o-35
PRIORITY VALVE
FUNCTION
. Priority valve (I) controls the minimum pres-
sure of pilot reducing valve (2). In addition,
priority valve (I) gives the oil flow to pilot
reducing valve (2) priority over the other cir-
cuit.
OPERATION
. The oil from the pump flows to port A of To quick return valve
priority valve (I) and port B of pilot reducing

valve (2).
To speed
PI lot
To T/M main
relief valve
B
From Pump
SOW01668
. The oil entering port A flows from orifice “a” To suick return valve
of priority valve (I) to port D. The hydraulic
B 5
pressure and force of poppet spring (3) push
back spring (4) and move priority valve (I)
to the left. When this happens, port A and
To speed
port C are connected, and the oil flows from C
port C to the modulating valve (5).

* Specified pressure: 1.96 MPa I20 kg/cm?
03
PI lot
T/M maIn
Iief valve
B
From Pump
SDW01669
1 O-36 WAND3
MODULATING VALVE AND QUICK RETURN VALVE
FUNCTION tee1 ~na t Ime

The modulating valve, and quick return valve MPa~b/cm~l
act together to raise the transmission clutch pres- 2. 9(301
sure smoothly. This reduces shock when shift-
ing speed range, and prevents the generation of x -
peak torque in the power train. Therefore, op- F
2 2.0(201-
erator fatigue is reduced to give better operat-
:L
ing comfort, and at the same time, the durabil- a
ity of the power train is increased. -
0 I. O(lOl-
5000 1 -* : 2.5{251
. Y : 2.7(271
OiOl
(Second)
OPERATION Time
SWWO3864
1. Immediately after shifting gear (point A)
When the gear shift lever is operated to en-
gage the clutch, the passage from the pump
to the clutch cylinder is opened and oil flows
to the clutch cylinder.
Using the force of this flow, quick return
valve (2) moves to the right in the direction
of the arrow, and connects port E and port
To s
G. When the back pressure of piston (3) is
removed, the tension of springs (4) and (5)
move modulating valve (I) to the right in
the direction of the arrow. At the same time,
piston (3) is returned to the left in the direc-
tion of the arrow.
om oriorlty valve
SDW01671
2. Hydraulic pressure starts to rise

Clutch
When the oil sent under pressure from pump
fills the circuit from port A to the clutch cyl-
inder, the hydraulic pressure starts to rise.
The oil passing through orifice a of quick
return valve (2) moves quick return valve (2)
to the left in the direction of the arrow. As a ”
result, the passage between port E and port To s olenoid valve
G is closed.
&;
” ’ From
0
Priority valve
SDWOI 672
WA8003 1o-37
In addition, the oil passes through orifice b Clutch

of modulating valve (I) and flows to port C
to push piston (6). In reaction to this, modu-
lating valve (I) compresses springs (4) and
(51, and moves to the left in the direction of
the arrow. As a result, modulating valve (I)
restricts the passage to port B.
The oil passing through orifice a of quick
return valve (2) passes through the center
passage and then flows from orifice c to
port E, and to back pressure port F of piston
(3). For this reason, piston (3) moves to the
right in the the direction of the arrow and
compresses springs (4) and (5).
m Priority valve
As the hydraulic pressure in the circuit rises, Clutch

the back pressure of piston (3) rises and pis-
ton (3) moves to the right in the direction of
the arrow. The tension of springs (4) and (5)
opens the passage between port A and port
B of modulating valve (1).
In addition, as the hydraulic pressure push-
ing piston (6) rises, the reaction moves
modulating valve (I) to the left in the direc-
tion of the arrow and compresses springs
(4) and (5) to close port A and port B.
lo-38 WABOO-3
3. Rise in hydraulic pressure completed Clutch

The operation described above is repeated
continuously to increase the load on springs
(4) and (5). The hydraulic pressure rises
gradually and finally piston (3) comes into
contact with the valve stopper and does not
move any further. -9
To so Ienoid valve
When this happens, modulating valve (I)
stops in a position where the passage to
port B is kept closed, and this completes the
rise in hydraulic pressure.
B
-1
SDW01675
WA800-3 1o-39
REDUCING VALVE
FUNCTION
. The reducing valve is in the circuit between
the quick return valve and the 3rd speed
spool. It acts to protect the 3rd clutch by
reducing the hydraulic pressure acting on
the 3rd clutch.
The maximum pressure of the oil in the cir-
cuit is set by the transmission main relief
pressure.
OPERATION (3rd speed spool actuated) II

. The oil from quick return valve (I) enters
port A, flows from port B to the 3rd speed
spool, and the 3rd clutch is engaged.
utch
From modulalna valve
SOW01676
. When oil fills the 3rd clutch, and the hydrau-

lic pressure rises, the oil passes from port B
through orifice a and enters port C.
The pressure of the oil pushes poppet (31, +n
utch
To solenoid
and the reaction compresses spring (4) and valve
moves reducing spool (2) to the right in the
direction of the arrow.
. As a result, port A and port B are closed,
and the oil stops flowing.
The hydraulic pressure at this point is 1.96
MPa (20 kg/cm2}.
From modulatine valve
SDWOl677
1O-40 WA8003
EMERGENCY MANUAL SPOOL
FUNCTION
. If there is any failure in the electrical circuit
of the transmission control system, and the
solenoid valve does not work, the emergency
manual spool is used. This spool is attached
to each directional and speed spool and is
used to operate the transmission valve me-
chanically. (It is used to drive the machine
to a place where it can be repaired.)
* Particular attention must be paid for
when using this spool.
Clutch
OPERATION
1. When solenoid valve is normal:
(Emergency manual spool is at normal posi-
tion)
When the solenoid valve is working normally,
the spool is maintained in this position.
Oil from directional and speed spool (I) en-
ters port A, but it is shut off by solenoid
valve (2).
A return valve reducine valve
SDW01676
2. When solenoid valve is abnormal: Clutch

a. Clutch in disengaged position
(Emergency manual spool is pushed to
the right)
Emergency manual spool (3) is pushed
to the right, and the oil at port A is shut
off regardless of the action of solenoid
valve (2). The oil cannot flow to port B,
so the clutch is not actuated.
3 return valve reducina valve
SDW01679
Clutch
b. Clutch in engaged position
(Emergency manual spool is pulled to
the left)
When emergency manual spool (3) is
pulled to the left, the oil at port A is
drained to port B regardless of the op-
eration of solenoid valve (2). As a result,
the clutch is actuated.
return valve reducina va
SDU
WA800-3 10-41
TRANSMISSION LUBRICATION VALVE
FUNCTION
l The transmission lubrication valve protects
the transmission lubrication circuit from ab-
normally high pressure.
OPERATION
. The oil from the oil cooler and torque con-
From torque
verter relief valve passes from port A and converter relief
lubricates the transmission. The oil entering valve
w
port A passes through orifice a and enters
port B.
From suick
return valve
In this condition, if abnormally high pres-

From torque
sure is generated by the restriction in the converter relief
lubricating circuit, the oil entering port B valve
8
compresses spring (2) and moves spool (I) From oil
cooler +
to the left in the direction of the arrow. This From quick
opens port A and port C, as the oil in the return valve
lubricating circuit is relieved to port C. The
hydraulic pressure at this point is 0.3 MPa 13
kg/cm21
SDW01682
1 O-42 WA&XI-3
HYDRAULIC CIRCUIT SCHEMATICS
FORWARD IST
SWW03676
A. To PPC valve
B. To brake line
C. From hydraulic tank
D. From brake oil tank
1o-44 WA%OO-3
OPERATION
. When the directional and speed control le- The other oil line flows from priority valve
vers are moved to FORWARD Ist, solenoid (13) to quick return valve (14). It then flows
valves (I) and (2) are opened. through orifice “a”, and directional and speed
. The oil from pumps (3) and (4) is divided into spools (II) and (12), and flows to the FOR-
three lines, but when the gears are being WARD clutch and 1st clutch. When it starts
changed, the oil flows mainly to each clutch. to flow to the clutch, it passes through ori-
. In one of the three lines, the oil passes from fice “a” and creates a difference in pressure
main relief valve (5) through torque converter between port C and port D. Quick return
(6). It then lubricates the transmission and valve (14) moves to the right, and the oil at
returns to the transfer case. the rear of modulating valve piston (17) flows
. One of the two oil lines flows from pilot to drain circuit E. When each clutch is filled
reducing valve (IO) through the orifice of with oil, the difference in pressure between
each speed spool to the solenoid valve. How- port C and port D disappears. The valve is
ever, solenoid valves (I) and (2) of FORWARD pushed back to the left by the difference in
spool (11) and 1st spool (12) are open, so area of the valves, and drain circuit E is
the oil passing through the orifice flows to closed.
the drain circuit. As a result, a difference in At this point, each clutch is filled with oil,
pressure is created between port A and port but the oil has not reached the specified
B, and this overcomes the force of springs. pressure. The oil at port D flows through
The port to the clutch is then connected. orifice “b” and reaches the back of modulat-
ing piston (17). Piston (17) moves to the right
and the clutch pressure rises slowly. When
the modulating piston reaches the end of its
stroke, the clutch pressure reaches the speci-
fied level, and the clutch is completely en-
gaged.
WA800-3 1o-45
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL COOLER
TORQUE CONVERTER OIL COOLER
SVWO3677
1. Torque converter oil cooler OUTLINE

. The oil which comes out from the torque
A. Oil inlet port converter outlet port is at a high tempera-
(From torque converter regulator valve) ture because of the energy used in transmit-
B. Oil outlet port (To transmission lubricating) ting the motive force. This torque converter
C. Water inlet port (From water pump) oil passes through oil cooler port A and en-
D. Water outlet port (To engine block) ters the oil cooler. Here it is cooled by the
engine cooling water. The oil then flows out
from oil outlet port B, lubricates the trans-
mission and returns to the transfer case.
1 O-46 WA800-3
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
OUTLINE
. The motive force from the engine passes l When the body is articulated, or when
through the damper, upper drive shaft (5), there is shock from the road surface dur-
torque converter, transmission and transfer. ing traveling, or when there is shock dur-
Part of this motive force passes through rear ing operations, the axle in front and be-
drive shaft (4) and goes to the rear axle; the hind the engine and transmission change
rest of the motive force passes through position.
center drive shaft (3), center support (2) and To allow the motive force to be transmit-
front drive shaft (I) and is sent to the front ted without damage to parts of the ma-
axle. In addition to transmitting the motive chine when there is shock or when the
force, the drive shafts have the following components move position, the drive
purposes. shafts have a universal joint and a sliding
joint. This allows them to handle changes
in angle and length.
Front drive shaft

Center support
Center drive shaft
Rear drive shaft
Upper drive shaft
WAND3 1o-47
STRUCTURE AND FUNCTION CENTER SUPPORT
CENTER SUPPORT
A-A SEW01377
FUNCTION
1. Front coupling . The center support is installed to the front
2. Case
frame between the center drive shaft and
3. Grease nipple
the front drive shaft.
4. Rear coupling . With the articulating frame, this part is con-
stantly twisting from side to side, so there is
liable to be large stress on the drive shaft.
Therefore, the center support is used to
transmit the power smoothly, to reduce the
stress on the drive shafts, and in this way
improve the durability of the drive shafts.
1O-48 WA8Oc)-3
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT AXLE
I
I
I
I
I
I
\,
‘\
1. Front differential
2. Drain plug
3. Front axle
4. Brake
5. Final drive
6. Parking brake
7. Spring cylinder
WA800-3 1o-49
FRONT DIFFERENTIAL
swwo3682
1. Bevel gear (Teeth 39) 5. Shaft

2. Housing 6. Bevel pinion (Teeth IO)
3. Differential side gear (Teeth 28)
4. Differential pinion gear (Teeth 22)
1O-50 WA800-3
REAR AXLE
SEW01380
1. Rear differential
2. Rear axle
3. Brake
4. Final drive
5. Drain plug
WA8003 1o-51
REAR DIFFERENTIAL
1. Bevel pinion (Teeth IO)

2. Bevel gear (Teeth 39)
3. Shaft
4. Differential pinion gear
5. Differential side gear
6. Differential housing
7. Coupling
1o-52 WA800-3
OUTLINE
. The motive force from the drive shaft passes
through bevel pinion (I) and is transmitted
to bevel gear (5). The bevel gear changes
the direction of the motive force by 90”, and
at the same time reduces the speed. It then
transmits the motive force through differen-
tial (4) to axle shaft (2).
SEW00077
When driving straight forward

. When the machine is driven straight forward,
the rotating speed of the left and right wheels
is the same, so pinion gear (4) inside carrier
(6) is sent through pinion gear (4) and side
gear (3) and is transmitted equally to the left
and right axle shafts (2).
SEW00078
When turning
. When turning, the rotating speed of the left
and right wheels is different, so pinion gear
(4) and side gear (3) inside the differential
assembly rotate in accordance with the dif-
ference between the rotating speed of the
left and right wheels. The motive force of
carrier (6) is then transmitted to axle shafts
(2).
SEW00079
WA800-3 1o-53
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
SWWO3683
1. Axle shaft OUTLINE

2. Brake . To gain a large drive force, the final drive
3. Planetary gear (Teeth 39) uses a planetary gear system to reduce the
4. Ring gear (Teeth 99) speed and send drive force to the tires.
5. Drain plug
6. Housing
7. Sun gear (Teeth 18) OPERATION
8. Wheel . The motive force transmitted from the dif-
ferential through axle shaft (1) to sun gear
(7) is transmitted to planetary gear (3). The
planetary gear rotates around the inside of
fixed ring gear (4) and in this way transmits
rotation at a reduced speed to planetary car-
rier. This motive force is then sent to wheels
(8) which are installed to planetary carriers.
1o-54 WA800-3
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
A-A
SWWO3684
10-56 WA800-3
STRUCTURE AND FUNCTION AXLE MOUNT
Z SWWO3685
1. Front frame Front axle

. Front axle (4) receives the force directly dur-
2. Rear frame
3. Rear axle ing operations, so it is fixed directly to front
4. Front axle frame (1) by axle mounting bolts.
5. ROPS support
Rear axle
. Rear axle (3) has a structure which allows
the center of the rear axle to float, so that all
tires can be in contact with the ground when
traveling over soft ground.
WA800-3
1o-57
STRUCTURE AND FUNCTION CENTER HINGE PIN
CENTER HINGE PIN
A-A B-B SWWO3811
1. Front frame OUTLINE

2. Rear frame . The front frame and rear frame are joined
3. Rear axle by the center hinge pin through a bearing.
4. Front axle The steering cylinders adjust the angle of
5. Upper hinge pin curvature to the left and right of the front
6. Lower hinge pin and rear frame (in other words, they adjust
the turning radius).
1O-58 WA800-3
STRUCTURE AND FUNCTION TIRE AND WHEEL
TIRE AND WHEEL
SWWO3666
1. Tire
2. Rim
3. Valve
4. Lock ring
5. Side ring
OUTLINE Specifications
. The tires act to absorb the shock that the Tire type: 45/65-45-46PR
machine receives from the road surface, and TRA code: L5
at the same time, they provide drive force Nominal wheel: 36.00 x 45WTB
by rotating in contact with the ground. Normal inflation pressure: 515 kPa (5.25 kg/cm*)
. Depending on the purpose of use, there are
various types of tire available, so it is
important to select the correct tire to match
the type of work and bucket capacity.
WA800-3 1o-59
STRUCTURE AND FUNCTION STEERING PIPING DIAGRAM
STEERING PIPING DIAGRAM

STEERING WHEEL SPECIFICATION
1. Steering demand valve fl Since the steering hydraulic circuit is shown

2. Steering unit (Orbit-roll valve) together with the work equipment circuit dia-
3. Hydraulic tank gram, see “WORK EQUIPMENT HYDRAULIC
4. Steering pump CIRCUIT DIAGRAM”.
5. Stop valve
6. Steering cylinder
10-60 WA800-3
5
STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION

2. Steering unit (Orbit-roll valve) together with the work equipment circuit dia-
3. Hydraulic tank gram, see “WORK EQUIPMENT HYDRAULIC
5. Proportional solenoid valve
6. Stop valve
WA800-3 10-60-1
5
AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION

2. Hydraulic tank together with the work equipment circuit dia-
3. EPC valve gram, see “WORK EQUIPMENT HYDRAULIC
5. Rotary valve
10-60-2 WA800-3
5
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Joint
4. Orbit-roll valve
WA800-3 10-61
10-61
5
JOYSTICK LINKAGE JOYSTICK LINKAGE
JOYSTICK LINKAGE
1. Joystick (Steering lever) 7. Rotary valve

2. Potentiometer (Lever operating angle) 8. Potentiometer (Steering angle)
3. Upper joint 9. Rod
4. Universal joint 10. Bracket
5. Lower joint 11. Front frame
6. Universal joint
10-61-1 WA800-3
5
STRUCTURE AND FUNCTION STEERING PUMP
STEERING PUMP
Serial No.: 50001 – 50025
1. Shaft (front) 10. Cradle (rear) Specification

2. Cradle (front) 11. Shaft (rear) Steering pump
3. Case (front) 12. Case (rear)
4. Swash plate 13. End cap (rear) Model HPF 76 + 71
5. Shoe 14. End cap (front) Rated delivery pressure 31.4 MPa {320 kg/cm2}
6. Piston 15. Servo piston Rated rpm 2120 rpm
7. Cylinder block 16. Collar
Theoretical delivery (front) 76.2 cc/rev
8. Valve plate 17. Collar
9. Impeller Theoretical delivery (rear) 71.5 cc/rev
Max. delivery 161.6 + 151.6 ¬/min
OUTLINE
• This pump consists of 2 fixed-displacement • For explanation of the operation, see the
swash plate-type piston pumps and 1 section of the work equipment pump. The
impeller pump between them. work equipment pump is of the variable dis-
• The front pump and rear pump are origi- placement type, however, since its swash
nally of the variable displacement type, but plate (4) can move.
their displacement is fixed since inserted
collars (16) and (17) disable servo piston (15)
and fix swash plate (4).
10-62 WA800-3
(6)
WA800-3 10-63
10-63
(6)
Serial No.: 50026 and up
1. Shaft (front) 10. Cradle (rear) Specification

2. Cradle (front) 11. Shaft (rear) Steering pump
3. Case (front) 12. Case (rear)
4. Swash plate 13. End cap (rear) Model HPF 76 + 71
5. Shoe 14. End cap (front) Rated delivery pressure 31.4 MPa {320 kg/cm2}
6. Piston 15. Servo piston Rated rpm 2120 rpm
7. Cylinder block 16. Collar
9. Impeller Theoretical delivery (rear) 71.5 cc/rev
OUTLINE
nally of the variable displacement type, but plate (4) can move.
collars (16) and (17) disable servo piston (15)
and fix swash plate (4).
10-63-1 WA800-3
(6)
WA800-3 10-63-2
(6)
STRUCTURE AND FUNCTION SWITCH PUMP
SWITCH PUMP
Serial No.: 50001 – 50025
1. Shaft (front) 9. Impeller Specification

2. Cradle (front) 10. Cradle (rear) Switch pump
3. Case (front) 11. Shaft (rear)
4. Swash plate 12. Case (rear) Model HPF 90 + 90
5. Shoe 13. End cap (rear) Rated delivery pressure 31.4 MPa {320 kg/cm2}
6. Piston 14. End cap (front) Rated rpm 2120 rpm
7. Cylinder block 15. Servo piston
Theoretical delivery (rear) 97.4 cc/rev
OUTLINE
nally of the variable displacement type, but plate can move.
collar (16) disable servo piston (15) and fix
swash plate (4).
10-64 WA800-3
(6)
WA800-3 10-65
10-65
(6)

2. Cradle (front) 10. Cradle (rear) Switch pump
4. Swash plate 12. Case (rear) Model HPF 95 + 95
5. Shoe 13. End cap (rear) Rated delivery pressure 31.4 MPa {320 kg/cm2}
6. Piston 14. End cap (front) Rated rpm 2120 rpm
OUTLINE
nally of the variable displacement type, but plate can move.
collar (16) disable servo piston (15) and fix
swash plate (4).
10-65-1 WA800-3
(6)
WA800-3 10-65-2
(6)
2-STAGE HYDRAULIC SYSTEM SPECIFICATION
1. Front servo valve 8. Front pump Specification

2. ES valve 9. Pump sub-assembly Switch pump
3. CO valve · NC valve 10. Front servo valve
4. Rear servo valve assembly Model HPV 95 + 95
5. Relief valve 11. Rear servo valve Rated delivery pressure 31.4 MPa {320 kg/cm2}
6. Control pump assembly Rated rpm 2120 rpm
7. Rear pump 12. Impeller pump
OUTLINE
• This pump consists of 2 variable-displace- For explanation of the operations of the
ment swash plate-type piston pumps, 1 switch pump, control pump, relief valve, ES
impeller pump (installed between the front valve, and servo valve, see the section of
pump and rear pump), and 1 control pump. the work equipment pump.
10-65-3 WA800-3
(6)
1. PISTON PUMP
WA800-3 10-65-4
(6)
1. Shaft (front) 9. Impeller

2. Cradle (front) 10. Cradle (rear)
4. Swash plate 12. Case (rear)
5. Shoe 13. End cap (rear)
6. Piston 14. End cap (front)
8. Valve plate
10-65-5 WA800-3
(6)
2. CO · NC VALVE
WA800-3 10-65-6
(6)
CO VALVE NC VALVE
1. Plug 10. Plug
2. Cover 11. Sleeve
3. Seat 12. Piston
4. Spring 13. Spool
5. Seat 14. Body
6. Spool 15. Seat
7. Piston 16. Spring
8. Sleeve 17. Plug
9. Plug 18. Cover
10-65-7 WA800-3
(6)
3. CO VALVE
1) When the switch pump discharging pressure is
less than the relief pressure
Function Operation
• During operation, CO valve carries out the cut- • Spool (1) is pushed downward to the stroke
off function; when the load is increased, end by spring (2). As a result, port a and port
switch pump discharging pressure is in- b are fully opened, and control pump output
creased and approaches to the relief pressure, pressure PSV equals to CO valve output pres-
pump delivery is decreased and relief loss is sure Pec. Therefore the CO valve output pres-
reduced. sure Pec becomes maximum and the switch
• The CO valve is controlled by the balance be- pump delivery becomes maximum.
tween switch pump discharging pressure PA2
+ CO valve output pressure Pec and the spring
force.
WA800-3 10-65-8
(6)
2) When the switch pump discharging pressure ap-

proaches to the relief pressure
• When the load is increased and switch pump

discharging pressure PA2 approaches to the
relief pressure, switch pump discharging pres-
sure PA2 pushes piston (3). At the same time,
CO valve output pressure Pec pushes piston
(3), and spool (1) moves upward. As a result,
because the flow from port a to port b is
throttled, the opening area of port b and port
c (drain port) are increased. This causes CO
valve output pressure Pec to lower, and the
pump delivery is minimized.
10-65-9 WA800-3
(6)
4. NC VALVE
Operation
• Function of NC valve is canceled.
• Because Pt and Pd are always interconnected
by a hose, opening area of port c and port b
become maximum (always opened). There-
fore, NC valve output pressure Pecn always
equals to CO valve output pressure Pec.
WA800-3 10-65-10
(6)
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
STEERING DEMAND VALVE
1. Overload relief valve

2. Main relief valve
3. Steering spool
4. Demand spool
5. Surge cut relief valve
A. To steering cylinder
B. To steering cylinder
PI. From steering pump
P2. From switch pump
PB.To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
/ \
5 4
A-A
SEW01395
1O-66 WA800-3
OVERLOAD RELIEF VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
FUNCTION
. The overload relief valve is installed in the cylin-

der circuit of the steering demand valve. When
the demand valve is at neutral and any impact is
applied to the steering cylinder and abnormal
pressure is generated, this valve functions as a
safety valve to relieve the circuit to prevent break-
age of the cylinder or hydraulic piping.
It also functions to prevent any vacuum if any
negative pressure is generated at the cylinder
end.
OPERATION
I 2 3
1. Operation of relief valve
l Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The
oil passes through the hole in poppet (I) and
acts on the area of diameters dl and d2.
Checkvalve poppet (3) and relief valve pop-
pet (2) are securely seated.
SDW01397
. When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens and the oil goes around pilot poppet
(4) and flows to port B.
WA800-3 1 O-67
When pilot poppet (4) opens, the pressure at

the rear of poppet (I 1drops, poppet (I) moves
to the right, and it is seated with pilot poppet
(4).
SDW01399
l Compared with the pressure at port A, the

pressure on the inside is low, so relief valve
poppet (2) opens and the oil flows from port
A to port B to prevent any abnormal pres-
sure.
A i3
SOW01400
2. Operation of suction valve 3

Negative pressure is generated at port A, the
l
difference in the area of diameters d3 and d4

opens checkvalve poppet (3), and the oil flows
from port B to port A to prevent a vacuum
d
from forming in the circuit.
SDWO1401
1O-68 WA800-3
MAIN RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
I
SDWO1402
. The main relief valve of the steering demand

valve is inside the valve and sets the maximum
pressure in the steering circuit when it is oper-
ated. In other words, when the valve is being
operated and the steering circuit goes above
the set pressure of this valve, it relieves the oil
and actuates the flow control spool of the demand
valve to drain the oil to the steering circuit.
WA800-3 lo-69
OPERATION OF STEERING RELIEF VALVE
To main control valve
From steering PUMP
SDW01631
. When the pressure in the circuit rises and l When demand spool (4) moves, the oil from
reaches the pressure set by spring (21 and ad- the steering pump is drained and the oil from
justment screw (I), pilot poppet (3) opens and the switch pump is relieved to the main con-
drains the oil. trol valve, so the steering circuit pressure is
. When this happens, the balance of the pres- prevented from going above the set value.
sure in pressure receiving chamber (I) and
pressure receiving chamber (II) is lost, and
demand spool (4) moves to the left.
1O-70 WA800-3
OPERATION OF DEMAND VALVE

When steering spool is at neutral
To ma,” control valve
From switch PUMP
t
From steerlna
SDWOl632
. The oil from the steering pump enters port A l When the pressure in pressure receiving cham-
and the oil from the switch pump enters port ber (I) reaches a certain value (set by spring
B. (3)), notch f opens and the oil from the steer-
. When steering spool (2) is at the neutral posi- ing pump goes to the drain circuit. Notch g is
tion, pressure receiving pressure chamber (II) closed, so the oil from the switch pump all
is connected to the drain circuit through ori- flows to the main control valve.
fice b, and notch c is closed.
. Notch c is closed, so the pressure of the oil at
port A and port B rises. This pressure passes
through orifice a, goes to pressure receiving
chamber (I) and moves demand spool (I) to
the left.
WA8003 1o-71
WHEN STEERING SPOOL IS OPERATED

Engine running at low speed
valve
v -4 SDW01633
. When the steering is operated, oil flows from l

The merged oil passes through notches c and
the Orbit-Roll to steering spool (2) and pushes d, pushes load check valve (5), and flows to
steering spool (2) to the right. The circuit be- the cylinder. The return oil from the cylinder
tween pressure receiving chamber (II) and the passes through notch e and flows to the drain
drain circuit is shut off, and at the same time, circuit.
notch c opens. . When this happens, the pressure before
As a result, the pressure in pressure receiving passing through notch c is sent to pressure
chamber (II) rises, and demand spool (1) receiving chamber (I) and the pressure after
moves to the right until notch h closes. passing through notch c is sent to pressure
The passage from port B to the main control receiving chamber (II). Demand spool (I) is
valve is shut off, so the oil from the switch actuated so that the difference in pressure
pump pushes up pump merge-divider check on both sides of notch c is kept constant.
valve (4) and merges with the oil from the Therefore, an oil flow corresponding to the
steering pump at port A. opening of notch c is supplied to the cylinder
port. These pressure differences (control pres-
sure) are set by spring (3).
1o-72 WA800-3
Engine running at high speed
control valve
From switch Pump

r
4t
From steer ina Pump
SDWO1634
. . The oil from the steering pump passes through

There is no need for supply of extra oil from
the switch pump, so the steering pump pres- notches c and d, pushes load check valve (5),
sure rises until notch g closes and shuts off and flows to the cylinder. The return oil from
the merge passage from port B. the cylinder passes through notch e and flows
. The pressure difference on both sides of notch to the drain circuit.
. Notch g is closed, so the oil from the switch
c is controlled only by notch f, and the excess
oil from the steering pump is drained from pump all flows from port B and is sent to the
notch f to the drain circuit. (At this point, notch main control valve.
g is completely closed.)
WA800-3 1o-73
OPERATION OF STEERING VALVE

Neutral
4
To main control val
From steering
SDWOIB
. The steering wheel is not being operated, so l When the pressure at ports A and B rises, de-
steering spool (2) does not move. mand spool (I) moves to the left, so the oil
. The oil from the steering pump enters port A. from the steering pump passes through port
The oil from the switch pump enters port B. C of the spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.
1o-74 WA800-3
Turning right
From orbit-roll
control valve
From steering Porno

\
SDH 101636
. When the steering wheel is turned to the right, ders passes through load checkvalve (5) of the
the Orbit-roll valve is operated and steering steering spool and is drained. The oil from the
spool (2) moves to the left. switch pump enters port B, goes through de-
The oil from the steering pump enters port A, mand spool (I ), pushes open check valve (4),
then flows to steering spool (2) through de- and is merged with the oil from the steer Gng
mand spool (I). The oil pushes open load pump.
check valve (6) of the spool, and flows to the
bottom end of the left cylinder and the rod end
of the right cylinder to turn the machine to
the right. The oil from the left and right cylin-
WA800-3 1o-75
Turning left
orbit-roll valve
:/
J3
To II lain cant 101 valve
‘itch P”tlP
SD101637
. When the steering wheel is turned to the left, ders passes through load checkvalve (6) of the
the Orbit-roll valve is operated and steering steering spool and is drained. The oil from
spool (2) moves to the right. the switch pump enters port B, goes through
The oil from the steering pump enters port A, demand spool (I), pushes open check valve
then flows to steering spool (2) through de- (4), and is merged with the oil from the steer-
mand spool (I). The oil pushes open load ing pump.
check valve (5) of the spool, and flows to the
rod end of the left cylinder and the bottom end
of the right cylinder to turn the machine to
the left. The oil from the left and right cylin-
1O-76 WA8OG3
STRUCTURE AND FUNCTION STEERING UNIT
STEERING UNIT (ORBIT-ROLL VALVE)

1. Neutral position spring a. To hydraulic tank

2. Valve body b. To steering cylinder (demand valve port Pb)
3. Check valve c. To steering cylinder (demand valve port Pa)
4. Spool d. From PPC pump
5. Sleeve
6. Gear rim
7. Gear
8. Cover
9. Drive shaft
10. Center pin
WA800-3 10-77
10-77
5
OUTLINE
. The steering unit is directly connected to the shaft

of the steering wheel. The oil from the PPC pump
passes through the steering demand valve, and
is switched to the left and right steering cylinders
to determine the direction of travel of the ma-
chine.
. The steering unit can be broadly divided into the
following: spool (4) and sleeve (5), which have a
rotor type direction selection function, and the
gear set (combination of gear (7) and gear rim
(6)), which acts as a hydraulic motor when the
steering is operated.
u-u u--LA
‘7
SEW01414
STRUCTURE
l Spool (4) is interconnected with the drive shaft of connecterto

the steering wheel and is connected to sleeve (5) steering wheel shaft
by neutral position spring (I) and center pin (IO) +

(when the steering wheel is at neutral, it does not
contact the spool). I 4 5
The top of drive shaft (9) is meshed with center
l
0
0
pin (IO) and forms one unit with sleeve (5). The : I
bottom is meshed with the spline of gear (7) of I :
the gear set. @Q@0
. Valve body (2) has four ports. These are connected D D
::: ::::
respectively to the pump circuit, tank circuit, and r
pilot circuit of the steering demand valve. SEW01638
In addition, the port at the pump end and the port
at the tank end are connected by check valve (3)
inside the housing. If there is any failure in the
PPC pump, oil is sucked in directly from the tank
end by the check valve. 6
SEW01416
1O-78 WA8QG3
OPERATION
When turning
To steerfna demand valve
To hydraulic From PPC Pump

tank
SEW01639
. When the steering wheel is turned, spool (4) l When the steering wheel is turned, the oil in-
overcomes neutral position spring (I) and side gear (7) flows, passes inside sleeve (5)
turns slightly in relation to sleeve (5). Because and spool (41, operates the spool of the steer-
of this rotation, the ports of sleeve (5) and ing demand valve, and actuates the steering
spool (4) overlap, so a passage is formed for cylinders.
the oil to flow, and the oil flows to gear (7).
At neutral
To steering demand valve
--
.7
L
To hydraulic From PPC Pumri
SEW01640
. When the turning of the steering wheel is l When the non-reaction type steering valve is
stopped (the rotation of the spool is stopped), at the neutral position, the steering cylinder
the return force of neutral position spring (I) and spool (4) and sleeve (5) are blocked, so
returns spool (4) and sleeve (5) to the neutral the reaction from the machine is not transmit-
position, so the oil passage is shut off and the ted to the steering wheel.
oil stops flowing.
WA800-3 1o-79
STRUCTURE AND FUNCTION PROPORTIONAL SOLENOID VALVE
PROPORTIONAL SOLENOID VALVE

A. To stop valve Function

B. To stop valve • The proportional solenoid valve controls the
P. From PPC pump oil flow to the stop valve with the electro-
T. To hydraulic tank magnetic proportional valve that is control-
led by the command current from the trans-
1. Solenoid a mission and joystick steering controller.
2. Solenoid b
10-79-1 WA800-3
5
STRUCTURE AND FUNCTION EPC VALVE
EPC VALVE
1. Min. pressure assurance pressure reducing

valve
2. Electromagnetic proportional valve
P1. From PPC pump

P2. From diverter valve
C. To rotary valve
D. To hydraulic tank
Outline
• The EPC valve controls the oil flow to the • Even if the electromagnetic proportional
rotary valve with the electromagnetic pro- valve does not work because of a controller
portional valve controlled with the command trouble, the minimum pressure assurance
current from the work equipment and joy- pressure reducing valve supplies the mini-
stick controller. mum oil pressure to the rotary valve.
WA800-3 10-79-2
5
STRUCTURE AND FUNCTION ROTARY VALVE
ROTARY VALVE
1. Neutral position spring a. To hydraulic tank

2. Valve body b. To port Pb of steering demand valve
3. Check valve c. To port Pa of steering demand valve
4. Spool d. From PPC pump
5. Sleeve
6. Feedback spool
7. Feedback sleeve
8. Loose spring
9. Drive shaft
10. Center pin
11. Body
10-79-3 WA800-3
5
Outline
• The steering lever is connected to the top of
the rotary valve. The direction of the oil sent
from the PPC pump through the EPC valve
to this valve is changed with the steering
lever to move the spool of the steering de-
mand valve. As a result, the steering cylin-
der is operated to set the steering direction
of the machine.
• The link installed to the front frame is con-
nected to the bottom of the rotary valve to
feed back the steering angle of the machine.
Accordingly, the position of the steering le-
ver is matched to the steering angle of the
machine.
Structure
• Spool (4) is connected through pin (10)
(which is not in contact with the spool while
the steering lever is in “neutral”) and neu-
tral position spring (1) to sleeve (5).
• The top and bottom of drive shaft (9) are
engaged with pin (10) and assembled into
one unit together with sleeve (5) and feed-
back sleeve (7).
• Feedback spool (6) is connected through pin
(10) (which is not in contact with the spool
while the steering lever is in “neutral”) and
loose spring (8) to feedback sleeve (7).
• Valve body (2) has four ports, which are con-
nected to the pump circuit, tank circuit, and
pilot circuit of the steering demand valve
respectively.
WA800-3 10-79-4
5
Operation
• If the steering lever is operated, spool (4)
rotates along sleeve (5), against neutral po-
sition spring (1).
By this rotation, the port of spool (4) is
matched to that of sleeve (5) to form an oil
passage, then the oil flows in the steering
demand valve.
If the steering lever is operated more than
the allowable displacement of neutral posi-
tion spring (1), loose spring (8) absorbs the
displacement through drive shaft (9).
• If the oil flows in the steering cylinder and
steering operation starts, the link installed
to the front frame turns sleeve (5) through
feedback spool (6) and drive shaft (9) so that
the deviation of sleeve (5) from spool (4)
will be offset.
If the machine is steered to the position
matched to the operating distance of the
steering lever, deviation of spool (4) from
sleeve (5) is eliminated and the oil passage
is closed.
10-79-5 WA800-3
5
STRUCTURE AND FUNCTION TWO-WAY RESTRICTOR VALVE
TWO-WAY RESTRICTOR VALVE
1. Poppet
2. Spring
3. Body
I 2
SEW01410
FUNCTION
l To reduce the shock caused by the inertia of
the machine when the steering is operated,
an orifice is installed in the oil line of the
return circuit from the cylinder. This applies
pressure to the returning oil, and regulates
the movement of the cylinder piston.
OPERATION
. When the oil is flowing to arrow *, it pushes
spring (2) and flows through the orifice, and
between poppet (I) and the poppet seat.
SEW01687
. When the oil is flowing to arrow *, the oil

flows only from orifice a inside poppet (I), z
so the flow is controlled. m
>
1O-80 WA800-3
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE
I I
x-x
4 SEW01419
1. Check valve A. To emergency pump FUNCTION

2. Check valve B. Sensor mounting port l The diverter valve is a selector valve which
3. Check valve C. To hydraulic oil tank senses the pilot pressure from the steering
4. Check valve D. To steering valve pump and if there is no abnormality in the
5. Spool E. From hydraulic tank steering circuit, it drains the oil from the
6. Valve body F. From steering circuit emergency pump to the tank. If no pilot pres-
sure from the steering pump reaches the
diverter valve, the oil from the emergency
pump is switched to the steering circuit and
flows to enable the machine to be steered.
WA800-3 1O-81
EMERGENCY STEERING RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
i ET SDW01420
FUNCTION
Compared to the steering valve relief pressure
of 31.4 MPa {320 kg/cm*), the rated pressure of
the emergency steering pump and diverter valve
are both 20.6 MPa (210 kg/cm*). Therefore, to
protect the emergency steering pump and
diverter valve, there is a relief valve in the pip-
ing from the diverter valve to the steering valve.
When the emergency steering is being oper-
ated, and the hydraulic pressure generated by K”l I
I, SDWO1421
the steering exceeds 20.6 MPa {210 kg/cm*}, the
relief valve is actuated.
OPERATION
. Port A is connected to the pump circuit, and
port C is connected to the drain circuit. The
oil passes through the orifice in main valve
(1) and fills port B. Pilot poppet (3) is in
contact with valve seat (2).
SDW01422
. When the pressure inside port A and B

reaches the pressure set by the poppet spring
(set pressure), pilot poppet (3) opens and
the hydraulic pressure at port B escapes from
port D to port C. This lowers the pressure at
port B.
l When the pressure at port B drops, the ori-
fice of main valve (I) generates a difference
in pressure between port A and port B. Main \i;;3 I SDW01423
valve (I) is opened by the pressure at port A
and the oil at port A is relieved.
1 O-82 WA800-3
HYDRAULIC CIRCUIT SCHEMATICS FOR EMERGENCY STEERING
SDWOi669
Sensor 8 hmergpsncyp steering pump

Relief valve arn urn
From steering cylinder @ Steering pump
To steering cylinder @ Switch pump
To main control valve
Hydraulic tank
Oil cooler
Oil filter
From orbit-roll valve
When the steering pump and engine are work-

ing normally, the main pump, steering pump,
and switch pump are rotated by the engine.
Therefore, oil is sent to the steering valve, and
the machine can be steered. In addition, the
emergency steering pump is rotated by the trans-
mission, so oil from port A of the diverter valve
pushes open check valve (2) and enters port B.
Pressure oil from the steering pump is flowing
to port D, so it pushes spool (3) in the direction
of the arrow. As a result, the oil from port B
flows to port C and is drained to the hydraulic
tank.
WA800-3 1 O-83
Failure in pump or engine when machine is

tl
0 SDW01691
@Sensor Emergency steering pump

@ Relief valve Main pump
@ From steering cylinder Steering pump
@ To steering cylinder Switch pump
@ To main control valve
@ Hydraulic tank
@ Oil cooler
@ Oil filter
0 From Orbit-roll valve
If there is a failure in the pump or engine when

the machine is traveling, the rotation of the
wheels is transmitted through the transmission
to rotate the emergency steering pump.
The steering pump is not rotating, so no pres-
sure oil is formed at port D. As a result, spool
(3) is pushed in the direction of the arrow by
spring (4).
The oil from the emergency steering pump
passes from port A through port B and flows to
the steering valve to make steering possible.
Emergency steering Dump
SEW01692
* The emergency steering pump is designed

so that it can rotate both directions.
1 O-84 WA800-3
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
1O-86 WAND3
STRUCTURE AND FUNCTION BRAKE PIPING
1. Front brake (right)

2. Brake valve (right)
3. Parking brake switch
4. Rear brake (right)
5. Strainer
6. Slack adjuster (rear)
7. Torque converter charging (x 2), PPC,
brake pump
8. Rear brake (left)
9. Charge valve
10. Brake oil tank
11. Accumulators
12. Brake valve (left)
13. Front brake (left)
14. Parking brake spring cylinders
15. Slack adjuster (front)
16. Parking brake solenoid valve
WAKD3 1O-87
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM

Serial No.: 50001 – 50025
10-88 WA800-3
(6)

brake pump
1A. Torque converter charging pump
1B. Torque converter charging pump
1C. PPC pump
1D. Brake pump
2. Strainer
3. Charge valve
3A. Safety relief valve
3B. Relief valve
3C. Filter
4. Check valve
5. Low pressure switch
6. Rear brake accumulator
7. Front brake accumulator
8. Emergency brake switch
10. Transmission cut-off switch
12. Stop lamp switch
13. Rear slack adjuster
14. Front slack adjuster
17. Parking brake spring cylinder
18. Parking brake pilot lamp switch
19. Brake oil tank
WA800-3 10-89
10-89
(6)
10-89-1 WA800-3
(6)

brake pump
1A. Torque converter charging pump
1B. Torque converter charging pump
1C. PPC pump
1D. Brake pump
2. Strainer
3. Charge valve
3A. Safety relief valve
3B. Relief valve
3C. Filter
4. Check valve
5. Low pressure switch
6. Rear brake accumulator
7. Front brake accumulator
8. Emergency brake switch
10. Transmission cut-off switch
12. Stop lamp switch
13. Rear slack adjuster
14. Front slack adjuster
17. Parking brake spring cylinder
18. Parking brake pilot lamp switch
19. Brake oil tank
WA800-3 10-89-2
(6)
STRUCTURE AND FUNCTION BRAKE VLAVE
BRAKE VALVE
Serial No.: 50001 – 50025
(RIGHT AND LEFT)
1. Brake pedal A. Pilot port

2. Rod B. To brake (left)
3. Pilot piston C. To brake (right)
4. Spool D. Drain
5. Upper cylinder E. From brake pump
6. Spool
7. Lower cylinder
10-90 WA800-3
(6)
OUTLINE
• There are two brake valves installed in
parallel under the front of the operator’s
compartment. They are actuated when the
pedal is depressed.
• When the right brake pedal is depressed, oil
is sent to the brake cylinder to actuate the
brake. In addition, pilot oil is sent to the left
brake valve and the brake is actuated in the
same way as when the left brake pedal is
depressed.
• In addition, when the brake pedal is de-
pressed, the transmission cut-off switch
“ON” acts to actuate the transmission
solenoid valve electrically and shift the
transmission to neutral.
WA800-3 10-91
10-91
(6)
Operation
When brake is actuated
Upper
. When pedal (I) is depressed, the operating
effort is transmitted through rod (2) and
spring (4) to spool (3).
When spool (3) goes down, drain port a
closes. As a result, the oil from the pump
and accumulator flows from port A to port
C, and actuates the front left brake cylinder. To front
Ief t brake
CY I inder
Lower
. When pedal (I) is depressed, the operating Accumulate To front
ii0 ht brake
effort is transmitted through rod (2) and CYI inder
spring (4) to spool (3).
When spool (3) goes down, spool (5) is SWW03824
moved down by plunger (6) and this closes

Right brake valve
drain port b. As a result, the oil from the
pump and accumulator flows from port B to
port D, and actuates the front right brake
cylinder.
When brake is actuated (interconnected with

left brake valve)
. When pedal (I) is depressed, spool (3) is
pushed down by rod (2) and spring (4), and
drain port a closes. As a result, the oil from
the pump and accumulator flows from port
A to port C.
. Port C of the right brake valve and port PP
of the left brake valve are connected, so the
oil flowing to port C flows to pilot port PP of
the left brake valve.
. The oil entering pilot port PP enters port G
from orifice d and pushes pilot piston (8).
The piston pushes the spring, so spool (3A) Left Lreke valve
is pushed down, and the brake is actuated
in the same way as when the left brake valve
is depressed.
Accumulator@ b
From PornP@~,,~~ $$
right brake
4 CYI inder
SWW03825
1 O-92 WA800-3
Actuation of brake when upper valve fails

. Even if there is leakage of oil from the upper
piping, when pedal (I) is depressed, spool (5)
is moved down mechanically, so the lower
portion is actuated normally.
The upper brake is not actuated.
Actuation of brake when lower valve fails

. Even if there is leakage of oil from the lower
piping, the upper portion is actuated normally.
When actuation is in balance

Upper
. When the front left brake cylinder is filled
To front
with oil, and the pressure at port A and port c3 left brake
C becomes high, the oil entering port H CY I inder
through orifice e of spool (3) acts against

To front
spring (4). As a result, spool (3) is pushed right brake
up and port A and port C are shut off. When CYI inder
this happens, drain port a remains closed,

so the oil stays in the brake cylinder and the SWWO3826
brake is kept applied.
Lower
. Spool (3) of the upper brake moves up. As a
result, at the same time that port A and port
C are shut off, the front right brake cylinder
is also filled with oil, and the pressure at
port B and port D becomes high. The oil
entering port J through orifice f of spool (5)
pushes up spool (5) by the amount of
movement of spool (3), so port B and port D
are shut off. Furthermore, drain port b is
closed, so the oil stays in the brake cylinder
and the brake is kept applied.
. The pressure in the space in the upper
portion balances the operating effort of the
Accumulator
pedal, and the pressure in the space in the To front
left brake
lower portion balances the pressure in the CYI under
space in the upper portion. When spools (3)

To front
and (5) move the full stroke, the circuits
right brake
between ports A and C, and between ports I
CY inder
B and D are completely opened, so the space

SWW03827
in the upper and lower portions and the oil
pressure in the left and right brake cylinders
is the same as the oil pressure from the
pump.
Therefore, the braking effect can be controlled
by the amount the pedal is depressed until
the piston moves the full stroke.
WAKD3 1o-93
When brake is released

Upper
. When pedal (I) is let back and the operating
effort is removed from the top of the spool,
spool (3) is moved up by the back pressure
from the brake cylinder and the spool return
spring. Drain port a is opened, and the oil
from the brake cylinder flows to the brake
oil tank return circuit, so the front left brake
is released.
Lower
. When the pedal is let back, upper spool (3)
is moved up, and at the same time, spool (5)
From front
is moved by the back pressure from the brake 0 left brake
CYI inder
cylinder and the spool return spring. Drain
port b is opened, and the oil from the brake
cylinder flows to the brake oil tank return right brake
cylinder
circuit, so the front right brake is released.
5 SWWO3828
1o-94 WA800-3
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE (RIGHT)
1. Brake pedal (Right and left brakes) A. Pilot port (Right brake)
2. Rod (Right brake) B. To front brake (Right brake)
3. Pilot piston (Right brake) C. To rear brake (Right brake)
4. Spool (Right brake) D. Drain (Right and left brakes)
5. Upper cylinder (Right brake) E. From brake pump (Right and left brakes)
6. Spool (Right brake) F. To pilot port (Left brake)
7. Lower cylinder (Right brake)
8. Rod (Left brake)
9. Spool (Left brake)
10. Cylinder (Left brake)
10-94-2 WA800-3
(6)
BRAKE VALVE (LEFT)
Outline
• There are two brake valves installed in par- In addition, the left brake pedal operates the
allel under the front of the operator’s cab, transmission cut-off switch to actuate the
and these are actuated by depressing the transmission solenoid valve electrically and
pedal. set the transmission to neutral.
• When the right pedal is depressed, oil is
sent to the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent
to the right pedal to apply the brakes in the
same way as when the right pedal is de-
pressed.
WA800-3 10-94-3
(6)
Operation
Brake applied (right brake valve)
Upper portion
• When brake pedal (1) is depressed, the op-
erating force is transmitted to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, drain port a is closed, and
the oil from the pump and accumulator flows
from port A to port C and actuates the front
brake cylinders.
Lower portion
• When brake pedal (1) is depressed, the op-
erating force is transmitted to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, spool (5) is also pushed down
by plunger (6). When this happens, drain
port b is closed, and the oil from the pump
and accumulator flows from port B to port D
and actuates the rear brake cylinders.
Brake applied (left brake pedal)

• When pedal (7) is depressed, spool (10) is
pushed up by rod (8) and spring (9), and
drain port c is closed. The oil from the pump
and the accumulator flows from port E to
port F.
• Port F of the left brake valve and port PP of
the right brake valve are connected by a
hose, so the oil flowing to port F flows to
pilot port PP of the right brake valve.
• The oil entering pilot port PP enters port G
from orifice d, and pushes pilot piston (11).
The spring pushes spool (3) down, so the
operation is the same as when the right brake
valve is depressed.
10-94-4 WA800-3
(6)
Applying brake when upper valve fails (right

brake valve)
• Even if there is leakage of oil in the upper
piping, spool (5) is moved down mechani-
cally when pedal (1) is depressed, and the
lower portion is actuated normally.
The upper brake is not actuated.
Applying brake when lower valve fails (right
brake valve)
• Even if there is leakage of oil in the lower
piping, the upper portion is actuated nor-
mally.
When actuation is balanced

Upper portion
• When oil fills the front brake cylinder and
the pressure between port A and port C be-
comes high, the oil entering port H from
orifice e of spool (3) pushes against spring
(4). It pushes up spool (3) and shuts off the
circuit between port A and port C. When this
happens, drain port a stays closed, so the
oil entering the brake cylinder is held and
the brake remains applied.
Lower portion
• When spool (3) in the upper portion moves
up and the circuit between port A and port C
is shut off, oil also fills the rear brake cylin-
der at the same time, so the pressure in the
circuit between port B and port D rises. The
oil entering port J from orifice f of spool (5)
pushes up spool (5) by the same amount
that spool (3) moves, and shuts off port B
and port D. Drain port b is closed, so the oil
entering the brake cylinder is held, and the
brake is applied.
• The pressure in the space in the upper por-
tion is balanced with the operating force of
the pedal, and the pressure in the space in
the lower portion is balanced with the pres-
sure in the space in the upper portion. When
spools (3) and (5) move to the end of their
stroke, the circuits between ports A and C
and between ports B and D are fully opened,
so the pressure in the space in the upper
and lower portions and the pressure in the
left and right brake cylinders is the same as
the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of
the brake can be adjusted by the amount
that the pedal is depressed.
WA800-3 10-94-5
(6)
Brake released (right brake valve)

Upper portion
• When pedal (1) is released and the operat-
ing force is removed from the top of the
spool, the back pressure from the brake cyl-
inder and the force of the spool return spring
move spool (3) up. Drain port a is opened
and the oil from the brake cylinder flows to
the hydraulic tank return circuit to release
the front brake.
Lower portion
• When the pedal is released, spool (3) in the
upper portion moves up. At the same time,
the back pressure from the brake cylinder
and the force of the spool return spring move
spool (5) up. Drain port b is opened and the
oil from the brake cylinder flows to the hy-
draulic tank return circuit to release the rear
brake.
10-94-6 WA800-3
(6)
STRUCTURE AND FUNCTION CHARGE VALVE
CHARGE VALVE
-
P’
E x
T A
D SDWOZR04
A: To brake oil tank FUNCTION

ACC: Plug l The charge valve is actuated to maintain the
PP: To brake valve oil pressure from the pump at the specified
P: From pump pressure and to store it in the accumulator.
. When the oil pressure reaches the specified
T: Drain
pressure, the oil from the pump is connected
to the drain circuit to reduce the load on the
pump.
WA800-3 1o-95
A-A
c-c
1. Valve body
2. Main relief valve (R3)
3. Relief valve (RI)
4. PPC relief valve (R2)
5. Relief valve (HI) E-E SDW02805
6. Filter
1 O-96 WA800-3
OPERATION
1. When no oil if being supplied to accumulator
(cut-off condition)
. The pressure at port B is higher than the set
pressure of the relief valve (RI), so piston (8)
is forcibly pushed up by the oil pressure at
port B. Poppet (6) is opened, so port C and
port T are short circuited.
accumulator
. The spring chamber at the right end of spool
(15) is connected to port C of the relief valve
(RI), so the pressure becomes the brake oil
tank pressure. The oil from the pump enters
port P, pushes spool (15) to the right at a low
pressure equivalent to the load on spring (14),
and flows from port A to brake oil tank. At the
same time, it also passes through orifices (171,
(18), and (161, and flows to the brake oil tank.
2. When oil is supplied to accumulator

1) Cut-in condition
. When the pressure at port B is lower than
the set pressure of the relief valve (RI),
piston (8) is pushed back down by spring
(5). Valve seat (7) and poppet (6) are
brought into tight contact, and port C and
port T are shut off.
. The spring chamber at the right end of accumulator
spool (15) is also shut off from port T, so

the pressure rises, and the pressure at port
P also rises in the same way.
. When the pressure at port P goes above
the pressure at port B (accumulator pres-
sure), the supply of oil to the accumula-
tor starts immediately. In this case, it is
decided by the size (area) of orifice (17)
and the pressure difference (equivalent to
the load on spring (14)) generated on both
sides of the orifice. A fixed amount is sup-
plied regardless of the engine speed, and
the remaining oil flows to port A.
kzL
accumu-/
Iator p /
I,
I7 I5
SWWO3830
WA8003 1o-97
2) When cut-out pressure is reached

. When the pressure at port B (accumu-
lator pressure) reaches the set pressure
of the relief valve (RI), poppet (6) sepa-
rates from valve seat (7), so an oil flow is
8
generated and the circuit is relieved.
. When the circuit is relieved, a pressure dif-
Front
ference is generated above and below pis- accumulator
ton (8), so piston (8) moves up, poppet
(6) is forcibly opened, and port C and port
T are short circuited.
. The spring chamber at the right end of
spool (15) is connected to port C of the
relief valve (RI ), so the pressure becomes
the brake oil tank pressure.
. The pressure at port P drops in the same
way to a pressure equivalent to the load
on spring (141, so the supply of oil to port
B is stopped.
3. Safety relief valve (R3)

. If the pressure at port P (pump pressure)
goes above the set pressure of the relief
valve (R3), the oil from the pump pushes
spring (3). Ball (11) is pushed up and the oil tank
oil flows to the brake oil tank circuit, so
this sets the maximum pressure in the
brake circuit and protects the circuit.
accumulator
lo-98 WA800-3
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR (for brake)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
SEW00120
FUNCTION Specifications
• The accumulator is installed between the Gas used: Nitrogen gas
charge valve and the brake valve. It is charged Charge amount: 6,000 cc
with nitrogen gas between cylinder (3) and Charging pressure: 3.43 MPa {35 kg/cm2} (at 50°C)
free piston (4), and uses the compressibility
of the gas to absorb the pulse of the hydrau-
lic pump or to maintain the braking force and
to make it possible to operate the machine if
the engine should stop.
WA800-3 10-99
10-99
(6)
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
A A
SEW01449
1. Piston Specifications
2. Cylinder Maximum available pressure:
3. Check valve 5.9 MPa 160 kg/cm?
4. Spring (Safety valve set pressure:
5. Bleeder 0.97 MPa 19.9 kg/cm?)
Normal pressure: 4.6 MPa {47 kg/cm21
(Governor set pressure:
0.81 MPa 18.3 kg/cm?)
Check valve cracking pressure:
1.1 + 0.05 MPa U1.1 + 0.5 kg/cm?
FUNCTION
. The slack adjuster is installed in the brake
oil line from the brake valve to the brake
piston. It acts to keep the clearance between
the brake piston and discs constant even
when the brake discs are worn. In this way it
acts to keep a constant time lag when the
brake is operated.
10-100 WA800-3
OPERATION
1. Brake pedal depressed

The oil pumped out from brake valve (9)
flows in from port P of the slack adjuster.
From port P the oil is divided and sent to left
and right cylinders (2) and moves piston (4)
a distance of stroke S to the right or left.
Because of this, an amount of oil correspond-

ing to stroke S flows from port C to brake
cylinder (7). When this happens, the clear-
ance between the brake piston and disc be-
comes 0, so no braking force is generated.
Accumulator
From PUMP G
Accumulator
SWWO3834
WA800-3 10-101
If the oil pressure in brake valve (9) goes

above a certain specified pressure, check
valve (3) opens and the oil flows through
pilot circuit D and applies pressure to port
C. This gives the braking force.
As a result, there is a constant time lag when
the brake is applied.
2. Brake pedal released

When the brake is released, pressure is ap-
plied to the back of the brake piston be-
cause of the hydraulic pressure of the brake.
Piston (4) is moved back stroke S and the
disc clearance returns to normal.
ACC
From
Act
From
SWW03636
10-102 WA800-3
STRUCTURE AND FUNCTION BRAKE
BRAKE
I I
“i i
1. Guide pin Operation

2. Return spring . When the brake pedal is depressed, moves
3. Brake piston brake piston (3) to the right, and presses
4. Plate disc (5) and plate (4) together to hold them
5. Disc in position. Disc (5) is rotating together with
6. Floating seal the wheel, so when it is held in position, the
rotation stops, the brake is actuated, and the
machine is stopped. When the brake pedal
is released, the pressure at the rear face of
FUNCTION
piston (3) is released, and the piston is
. The brakes are wet-type multiple disc brakes,
moved to the left by the force of return spring
and are fitted to all four wheels.
(2) to release the brake.
WA800-3 10-103
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
Serial No.: 50001 – 50021
1. Parking brake display switch
1. Spring cylinder OUTLINE

2. Caliper • The parking brake is a disc type and is in-
3. Disc stalled on the front axle.
4. Caliper • The force of the spring inside spring
5. Spring cylinder cylinders (1) and (5) is used to apply the
6. Differential case brake mechanically; it is released by oil
pressure.
• The parking brake caliper is fixed to the front
differential case.
The disc is installed to the differential yoke
and rotates together with the coupling.
10-104
10-104 WA800-3
(6)
1. Spring cylinder
2. Caliper
3. Disc
4. Caliper
5. Spring cylinder
6. Differential case
7. Spring
WA800-3 10-104-1
(6)
OPERATION
To parking
Parking brake
When the parking brake switch is turned ON, solenoid
valve
l
the solenoid valve is actuated and the oil pres-

sure from the brake pump is shut off by the
solenoid valve. The oil inside spring cylinder
(1) is drained to the brake oil tank from the
solenoid valve port.
Therefore, the piston and rod of spring cylin-
der (I) are pushed by the force of the spring,
so lever (2) rotates and the parking brake is
applied. \ !
. Lever (2) rotates piston shaft (3) and moves ‘\ ;
piston (4) in the axial direction, so the pad is “,_i”
pushed against the disc, and the parking brake
is applied.
SWWO3886
Traveling
From parking
. When the parking brake switch is turned OFF, brake
the solenoid valve is actuated and the valve solenoid
valve
opens the drain port.
At the same time, the oil pressure from the
brake pump enters the bottom of the piston
of spring cylinder (1). It overcomes the force
of the spring and pushes the piston to rotate
lever (2). This rotates piston shaft (31, moves
piston (4), and releases the parking brake.
Therefore, hydraulic pressure is applied to the
spring cylinder and the parking brake is kept
released.
WA800-3
STRUCTURE AND FUNCTION SPRING CYLINDER
SPRING CYLINDER
slJw03203
1. Outer spring OUTLINE

2. Inner spring l The oil pressure from the parking brake sole-
3. Piston noid valve pushes the spring and releases the
4. Cylinder parking brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by springs (I) and (2), so the ma-
chine is prevented from moving.
lo-106 WA800-3
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Solenoid valve assembly FUNCTION

2. Block • When the parking brake switch is turned ON/
OFF, the solenoid valve is energized or
B: Outlet port deenergized, so the brake oil pressure is taken
B1: Port for parking brake pilot lamp switch to the brake spring cylinder or removed from
P: Inlet port the brake cylinder to set the parking brake at
T: Drain port the PARKED position or TRAVEL position.
• Parking brake solenoid valve
Energized: TRAVEL
Deenergized: PARKED
WA800-3 10-107
10-107
(6)
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
SWWO3708 -+
lo-108 WABOO-3
swwo3709
1. Bucket cylinder
2. PPC valve
3. Accumulator
4. Main piston pump
6. 4th gear pump
(Torque converter charging (x 2) + PPC + brake)
7. Switch piston pump
8. Transmission
9. Boom cylinder
10. Main control valve (x 2)
+
WA800-3 10-109
. The work equipment system consists of the

hydraulic circuit and steering circuit. The
hydraulic circuit controls the operation of
the bucket and attachment.
. The oil from hydraulic tank is sent from main
pump (4), and switch pump (7) through the
steering valve to two main control valves
(IO). If the bucket and boom spools of the
main control valve are both in neutral, the
oil passes through the drain circuit of the
main control valve, is filtered by the filter
inside the hydraulic tank, and returns to the
tank.
. The bucket or boom spool in PPC valve is
activated by operating the work equipment
control lever, causing each spool in the work
equipment valve to be hydraulically acti-
vated. Thereby, the oil is allowed to flow
from the work equipment valve to boom cyl-
inder (9) or bucket cylinder (I), thus operating
the boom or the bucket.
. The maximum pressure of the hydraulic cir-
cuit is regulated by the relief valve inside
the main control valve. There are two safety
valves (with suction valve) and an unloader
valve in the bucket cylinder circuit to protect
the circuit.
. Even when engine is at rest, the boom can
be lowered to the ground because accumu-
lator (3) is provided in the circuit.
. Hydraulic tank is a pressurized, sealed type
and has a breather with a relief valve. This
acts to pressurize the tank and at the same
time prevents negative pressure. This pro-
tects the pump from cavitation.
. In the hydraulic tank there is pressurizing
valve installed to pressurize the hydraulic
tank with air pressure. It is used to carry out
air bleeding of the pump when changing the
oil inside the tank or when assembling after
removing the piping of the piston pump and
pump.
10-110 WA800-3
EPC WORK EQUIPMENT LEVER SPECIFICATION
1. Main control valve (x 2)

2. Differential pressure regulating valve
3. Accumulator
4. Work equipment neutral lock solenoid valve
5. EPC valve
6. Switch piston pump
7. Main piston pump
10-110-2 WA800-3
(6)
WA800-3 10-111
10-111
(6)
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

10-112
10-112 WA800-3
5
• On the machines serial No. 50022 and up, the pilot circuits (PA2 and PB2) in which the oil from PPC
valve (11B) to boom spools (12F) are reversed.
WA800-3 10-113
10-113
(6)
1. Hydraulic tank
2. Torque converter charging (x 2), PPC and
brake pump
4. Main pump (HPV90 + HPV90)
(Serial No.: 50001 – 50025)
Main pump (HPV95 + 95)
(Serial No.: 50026 and up)
4A. Control pump (BAR025)
4B. Relief valve
(Set pressure: 2.9 MPa {30 kg/cm2})
5. ES valve
6. Servo valve
7. Servo valve
8. PPC relief valve
9. Accumulator
11. PPC valve
11A. Bucket spool
11B. Boom spool
12. Main control valve
12A. Main relief valve
12B. Bucket spool
12C. Safety valve (with suction valve)
12D. Unloader valve
12E. Float selector valve
12F. Boom spool
13. Boom cylinder
14. Bucket cylinder
15. Switch pump (HPF90 + HPF90)
(Serial No.: 50001 – 50025)
Switch pump (HPF95 + HPF95)
16. Steering pump (HPF76 + HPF71)
17. Emergency steering pump (SAM(3)100 + 100)
18. Diverter valve
19. Emergency lamp switch
20. Emergency relief valve
21. Steering demand valve
21A. Demand spool
21B. Steering spool
21C. Steering relief valve
22. Two-way restrictor valve
24. Steering unit (Orbit-roll valve)
25. Stop valve
10-114
10-114 WA800-3
(6)
10-114-2 WA800-3
5
WA800-3 10-114-3
5
(6)
1. Hydraulic tank
brake pump
(Serial No.: 50001 – 50025)
4B. Relief valve
5. ES valve
6. Servo valve
7. Servo valve
8. PPC relief valve
9. Accumulator
11. PPC valve
11A. Bucket spool
11B. Boom spool
12B. Bucket spool
12D. Unloader valve
12F. Boom spool
13. Boom cylinder
14. Bucket cylinder
(Serial No.: 50001 – 50025)
18. Diverter valve
21A. Demand spool
21B. Steering spool
24. Steering unit (Orbit-roll valve)
25. Stop valve
26. Solenoid valve
10-114-4 WA800-3
5
(6)
10-114-6 WA800-3
5
WA800-3 10-114-7
5
(6)
1. Hydraulic tank
brake pump
(Serial No.: 50001 – 50025)
4B. Relief valve
5. ES valve
6. Servo valve
7. Servo valve
8. PPC relief valve
9. Accumulator
11. PPC valve
11A. Bucket spool
11B. Boom spool
12B. Bucket spool
12D. Unloader valve
12F. Boom spool
13. Boom cylinder
14. Bucket cylinder
(Serial No.: 50001 – 50025)
18. Diverter valve
21A. Demand spool
21B. Steering spool
24. Rotary valve
25. Oil pressure switch
26. Lock valve
27. EPC valve
10-114-8 WA800-3
5
(6)
AJSS (ADVANCED JOYSTICK STEERING SYSTEM) AND EPC WORK EQUIPMENT LEVER
SPECIFICATION
10-114-10 WA800-3
5
(6)
• On the machines serial No. 50022 and up, the pilot circuits (PA2 and PB2) in which the oil from EPC
valve (16) to boom spools (23) and (29) are reversed.
WA800-3 10-114-11
5
(6)
1. Hydraulic tank
2. T/C, T/M, PPC, brake pump
3. Differential pressure valve
4. Work equipment pump (HPV95 + 95)
5. ES valve
6. Servo valve
7. Servo valve
8. Control pump (BAR025)
9. Relief valve
Set pressure: 2.9 MPa {30 kg/cm2}
10. Switch pump (HPV95 + 95)
12. Emergency steering pump (SAM (3) 100+100)
13. Diverter valve
15. Oil cooler
16. EPC valve
17. Work equipment neutral lock solenoid valve
18. Accumulator
19. PPC relief valve
20. Oil filter
21. Work equipment relief valve
22. Bucket spool
23. Boom spool
24. Float selector valve
25. Unload valve
26. Safety valve (suction)
27. Work equipment relief valve
28. Bucket spool
29. Boom spool
30. Float selector valve
Set pressure: 3.3 ± 0.05 MPa {33.5 ± 0.5 kg/cm2}
31. Unload valve
32. Safety valve (suction)
33. Bucket cylinder
34. Boom cylinder
36. Demand spool
37. Steering spool
38. Steering relief valve
39. 2-way restrictor valve
41. Rotary valve
42. Oil pressure switch
43. Lock valve
44. EPC valve
45. CO valve
46. NC valve
10-114-12 WA800-3
5
(6)
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
suwo3209
1. Kick-down switch 5. Solenoid valve for bucket lever

2. Boom lever 6. Solenoid valve for boom lever
3. Bucket lever 7. PPC valve
4. Safety lever
WA&XI-3
10-115
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
1. Bucket control lever

2. Boom control lever
3. Holding switch
4. Safety lock lever switch
5. Safety lock lever
10-115-1 WA800-3
(6)
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
swwo3712
1. Filter bypass valve OUTLINE

2. Hydraulic filter . The oil from the hydraulic tank is sent from
3. Strainer the pump through the control valve to the
4. Drain valve cylinders. in the return circuit, the oil from
5. Strainer various parts merges. A part of oil is cooled
6. Breather in the oil cooler, passes through hydraulic
7. Oil filler filter (2) and returns to the tank.
. Hydraulic filter (2) filters ail the oil in the
A. Oil cooler return port circuit. if hydraulic filter (2) becomes clogged,
B. Main return port bypass valve (1) acts to allow the oil to re-
C. Gear pump suction turn directly to the tank. This prevents dam-
D. Main piston pump suction port age to filter (2). Bypass valve (1) is also actu-
E. Emergency pump suction ated when negative pressure is generated in
F. Emergency pump return port the circuit.
10-l 16 WA800-3
OPERATION OF OIL FILTER BYPASS

VALVE
When the filter is clogged.

Bypass valve (I) opens and the oil returns directly
to the tank without passing through the filter.
Bypass valve set pressure: 125 kPa {I .27 kg/cm*}
From mai n cant rol

“a I ve
To hydraulic tank SDW02312
When negative pressure is formed in the return

circuit.
Valve (2) moves up and acts a check valve.
Check valve set pressure: 25.5 kPa IO.26 kg/cm21
To main control
B
From hydraulic tank SDW0’2313
WA8003 10-117
BREATHER
1. Body
2. Filter element
3. Poppet
4. Sleeve
SEW00141
Preventing negative pressure inside the tank

The tank is pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank
when the oil level drops during operations.
When this happens, the difference in pressure
between the tank and the outside atmospheric
pressure opens poppet (31, and air from the
outside is let into the tank to prevent negative
pressure.
Preventing rise in pressure inside the tank

When the hydraulic cylinder are being used, the
oil level in the hydraulic circuit changes and the
temperature rises. If the hydraulic pressure rises
above the set pressure, sleeve (4) is actuated to
release the hydraulic pressure inside the tank.
lo-118 WA800-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP
MAIN PISTON PUMP

Serial No.: 50001 – 50025
MODEL: HPV90 + 90
1. ES valve (Engine sensing) OUTLINE

2. Front servo valve • These pump assemblies consist of two vari-
3. Rear servo valve able displacement swash-plate type pumps,
4. Front main pump two servo valve units, and impeller pump
5. Rear main pump (built in between the front main pump and
6. Control pump (BAR025) the rear main pump), a control pump and a
7. Relief valve relief valve.
8. Front servo valve
9. Rear servo valve
WA800-3 10-119
10-119
(6)
1. PISTON PUMP

2. Cradle (front) 10. Cradle (rear) Model : HPV 90 + 90
3. Case (front) 11. Shaft (rear) Rated delivery pressure : 34.3 MPa {350 kg/cm2}
4. Swash plate 12. Case (rear) Rated rpm : 2100 rpm
5. Shoe 13. End cap (rear) Theoretical delivery : front 97.4 cc/rev
6. Piston 14. End cap (front) rear 97.4 cc/rev
7. Cylinder block 15. Servo piston Max. delivery : 204.5 + 204.5 ¬/min
8. Valve plate
10-120
10-120 WA800-3
(6)
WA800-3 10-121
10-121
(6)

MODEL: HPV95 + 95
1. ES valve (Engine sensing) OUTLINE

2. Front servo valve • These pump assemblies consist of two vari-
3. Rear servo valve able displacement swash-plate type pumps,
4. Front main pump two servo valve units, and impeller pump
5. Rear main pump (built in between the front main pump and
6. Control pump (BAR025) the rear main pump), a control pump and a
7. Relief valve relief valve.
8. Pump sub-assembly
9. Front servo valve assembly
10. Rear servo valve assembly
11. Impeller pump
WA800-3 10-121-2
(6)
1. PISTON PUMP

2. Cradle (front) 10. Cradle (rear) Model : HPV 95 + 95
3. Case (front) 11. Shaft (rear) Rated delivery pressure : 34.3 MPa {350 kg/cm2}
4. Swash plate 12. Case (rear) Rated rpm : 2100 rpm
5. Shoe 13. End cap (rear) Theoretical delivery : front 97.4 cc/rev
6. Piston 14. End cap (front) rear 97.4 cc/rev
7. Cylinder block 15. Servo piston Max. delivery : 204.5 + 204.5 ¬/min
8. Valve plate
10-121-3 WA800-3
(6)
WA800-3 10-121-4
(6)
FUNCTION
. The engine rotation and torque transmitted
to the pump shaft is converted into hydrau-
lic energy, and pressurized oil is discharged
according to the load.
. It is possible to change the delivery amount
by changing the swash plate angle.
STRUCTURE
4 5 6 7 0 9 IO
Suction Port
SDI ine SEW01717
. Cylinder block (7) is supported to shaft (I) Piston (6) carries out relative movement in
by a spline, and shaft (1) is supported by the the axial direction inside each cylinder cham-
front and rear bearings. ber of cylinder block (7).
. The tip of piston (6) is spherical, and shoe Cylinder block (7) seals the pressure oil to
(5) is caulked to it to form one unit. Piston valve plate (8) and carries out relative rota-
(6) and shoe (5) form a spherical bearing. tion. This surface is designed so that the oil
. Rocker cam (4) has plane surface A, and pressure balance is maintained at a suitable
shoe (5) is always pressed against this sur- level. The oil inside each cylinder chamber
face while sliding in a circular movement. of cylinder block (7) is sucked in and dis-
Rocker cam (4) brings high pressure oil at charged through valve plate (8).
cylindrical surface B with cradle (21, which is Impeller (9) is connected to shaft (I) through
secured to the case, and forms a static pres- the spline boss (IO) and rotates together with
sure bearing when it slides. the shaft. The oil sucked in through the suc-
tion port is sent to the cylinder chamber by
centrifugal force to make suction easier.
1o-1 22 WA800-3
OPERATION
Operation of pump
Cylinder block (7) rotates together with shaft
(I), and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle a be-
tween center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle ct is called the swash plate
angle.)
Center line X of rocker cam (4) maintains

swash plate angle CI in relation to the axial
direction of cylinder block (71, and flat sur-
face A moves as a cam in relation to shoe
(5). In this way, piston (6) slides on the in-
side of cylinder block (7), so a difference
between volume E and F is created inside
cylinder block (7). The suction and discharge
is equal to this difference E - F.
In other words, when cylinder block (7) ro-
tates and the volume of chamber E becomes
smaller, the oil is discharged during that
stroke. On the other hand, the volume of
chamber F becomes larger, and as the vol-
ume becomes bigger, the oil is sucked in. \
\ F
X
SEW01467
2) If center line X of rocker cam (4) is in line

with the axial direction of cylinder block (7)
(swash plate angle = O), the difference be-
tween volumes E’ and F’ inside cylinder block
(7) becomes 0, so the pump does not carry
out any suction or discharge of oil.
SEW01468
WA800-3 lo-123
2. Control of discharge amount

If swash plate angle α becomes larger, the
difference in volumes E and F becomes
larger and the discharge volume increases.
Swash plate angle α is changed by servo
piston (15). Servo piston (15) moves in a
reciprocal movement ( ) in accordance
with the command from the servo valve.
This straight line movement is transmitted
through the rod of rocker cam (4) to rocker
cam (4), and rocker cam (4), which is sup-
ported by the cylindrical surface to cradle
(10), slides in an oscillating movement in
direction ( ) along the cylindrical surface.
10-124
10-124 WA800-3
(6)
2. CONTROL PUMP (BAR0251
Intake
+ port
n Relief valve
mounting Port
A-A
SEW01718
1. Collar Specification
2. Body Model : BAR 25
3. Housing Theoretical delivery : 25 cc/rev.
4. Drive gear Max. delivery pressure : 2.9 MPa I30 kg/cm21
5. Driven gear
WA800-3 10-125
RELIEF VALVE
1 2 3
1. Adjustment screw
2. Lock nut
3. Pilot valve spring
4. Pilot valve
5. Main valve spring
6. Main valve
sowo1471
Set pressure: 2.9 MPa {30 kg/cm*}
(at 50 g/min)
FUNCTION
The relief valve is built in the body of control
pump. It relieves the oil delivered from the pump.
Flow of the oil

. Chamber A forms a pump circuit and cham-
ber C forms a tank drain circuit. The oil flows
into chamber B through the main relief valve
orifice to keep the chamber filled.
Pilot valve is set in the valve seat.
SDW01472
. If the pressure in chamber B reaches the

pilot valve spring force (set pressure), the
pilot valve moves, allowing the oil in cham-
ber B to flow into chamber C. In addition,
the oil flows from chamber A to B through
orifices.
SDW01473
. If the oil flows through the orifice of valve

(61, a differential pressure occurs between
the chambers A and B, moving valve (6) to
the left. This allows the oil in chamber A to
flow into chamber C.
6 SD101474
lo-126 WA800-3
STRUCTURE AND FUNCTION ES VALVE
ES VALVE (Engine Sensing valve)
Pes
/
--------
Pl P2
J
(A) ---QQ-- !-------1
I
(B)
I /
I
j
Pd r
I
I L___-
I
x Peo
es
9
P2
eo
dr
Pl
SEW01475
1. Plug FUNCTION
2. Valve body . This valve acts to control the delivery amount
3. Shaft of the hydraulic pump to match the changes
4. Plug in the engine speed.
5. Plug
6. Spool
7. Spool
8. Plug
9. Plug
WA800-3 10-127
STRUCTURE AND FUNCTION ES VALUE
FUNCTION
. A variable displacement piston pump is used b
7
for the hydraulic pump to save energy by ”
reducing the consumption of hydraulic pres- 2 97.4
L.
sure when the engine is running at low .- a
speed. At the same time, it is also used to :
increase the engine acceleration from low % 30.0
_ (MPa( ke/cm'l 1
speed. -Lz
a:
For this reason, a pressure difference valve 0.12* 0.0 I 0.31*0.02 PI lot pressure
11.24+0.11 (3.2 f 0.21 difference
is used to detect the engine speed by using
a pressure difference system. The delivery
(delivery per rotation) is then adjusted to
Approx. 800 Approx. 1100
match the engine speed.
Ena ine speed lrpm) SDW0171!3
OPERATION When the pilot pressure difference is below point a

. Oil from the PPC pump passes through pres-
sure difference valve (I) and is sent to the “’
PPC valve. Pilot pressure from the inlet and

outlet ports (ports (A) and (B)) of the pres-
sure differential valve is supplied to the ES
valve (2).
The difference in pilot pressure becomes
larger as the flow from the PPC pump in-
creases (in other words, as the engine speed
increases).
When the pilot pressure difference reaches
point a (0.12 MPa (1.24 kg/cm*}), the ES valve
starts to operate, and actuates the servo
valve and servo cylinder to change the swash
plate angle of the pump.
When the swash plate angle is changed, the
piston stroke also changes to change the
delivery of the pump (delivery per rotation). When the pilot pressure difference is above point b
Until the difference in pilot pressure reaches
0.31 MPa {3.2 kg/cm*}, the pump delivery
(delivery per rotation) increases in propor-
tion with the increase in the difference in
pilot pressure (in other words, the increase
in the engine speed).
When the difference in pressure reaches 0.31
MPa (3.2 kg/cm?, the pump delivery (deliv-
ery per rotation) reaches the maximum.
SDW01721
1O-l 28 WA800-3
STRUCTURE AND FUNCTION SERVO VALUE
SERVO VALVE
Servo actuator Port
SEW01722
1. Sleeve
2. Body Servo actuator port Servo actuator port
3. Spool
4. Arm
5. Plug
6. Sleeve
7. Spool
8. Plug
Pir SDW01723
WA800-3 lo-129
STRUCTURE AND FUNCTION SERVO VALVE
OPERATION
1. Increasing of delivery amount (swash plate

angle changes to the right)
chamber F 1 / L.-l \ \ I
\
Control Pump
Main Dump SDW01724
. Input signal pressure Pi acts on chamber E l With the movement of guide spool (121, port
in the control piston from port D. Pressure B and port A connect to each other, allow-
PC in the charging pump is guided into port ing oil pressure PC, in the control pump to
B. act on chamber F in servo piston (I I). Servo
. If input signal pressure Pi is raised a little, piston (I I) is then pushed rightward, increas-
the oil pressure acting on chamber E will ing the swash plate angle of the main piston
increase accordingly. Control piston (9) there- pump. Thus, the pump discharge is in-
fore moves to a position (rightward) where creased.
the force of spring (IO) is in balance with l Since arm (4) turns counterclockwise on pin
the oil pressure in chamber E, thus allowing (13), guide spool (12) moves leftward, caus-
arm (4) to swing rightward with servo pis- ing port B, port C and drain port A to close.
ton (11) serving as the supporting point. As The pump discharge, therefore, increases
a result, guide spool (12) moves to the right. with the change in input signal pressure Pi.
10-130 WA800-3
STRUCTURE AND FUNCTION SERVO VALVE
2. Decreasing of delivery amount (swash plate

angle changes to the left)
w--L-J-“““‘“‘
chamber f [ 1 /
- \
\
14
SDWOl725
. Next, let’s examine the case where servo On the other hand, port B and port C are
piston (I I) is moved leftward. Assume that connected to each other, allowing the oil
the servo piston is in a balanced position at to flow into chamber H in the servo cylin-
a certain location. If Pi is decreased, control der. Servo piston (11) is then pushed left-
piston (9) moves to a position where the oil ward by the force of spring (14), decreas-
pressure in chamber E balances with the ing the swash plate angle of the main
force of spring (IO). Then, arm (4) swings piston pump. Thus, the pump discharge
leftward, using servo piston (11) as a sup- is decreased.
port point, and cause, guide spool (12) to . Since arm (4) rotates clockwise on pin (13),
move leftward. guide spool (12) moves rightward, shut-
With the movement of guide spool (12), port ting off port B, port C and port A. The
B and port A are shut off and port A be- pump discharge, therefore, decreases with
comes open to the drain. the change in input signal pressure Pi.
WA8003 10-131
STRUCTURE AND FUNCTION WC VALUE
PPC VALVE (Proportional Pressure Valve)
A C
C A
I
.I;
,
\
I ,
J
P2 P4
P : From pump
T : To tank (drain)
PI: To boom cylinder (Raise)
P2: To bucket cylinder (Dump)
P3: To boom cylinder (Lower)
P4: To bucket cylinder (Tilt)
SEW01483
lo-132 WA800-3
STRUCTURE AND FUNCTION PPC VALVE
A-A
1. Bolt
2. Piston c-c SWWO3416
3. Plate
4. Collar
5. Retainer
6. Center spring
7. Metering spring
8. Valve
9. Body
WA8003 10-133
STRUCTURE AND FUNCTION PPC VALUE
OPERATION
1. Control lever at “neutral” (Fig. I):

Ports PA,, P2, PB, and P4 are connected to
drain chamber D through fine control hole
(f) in spool (IO).
2. Control lever operated slightly (fine control)

(Fig. 2):
When piston (4) starts to be pushed by plate
(21, retainer (7) is pushed. Valve (IO) is also
pushed by spring (9) and moves down.
When this happens, fine control hole (f) is
shut off from drain chamber D. At almost
the same time it is connected to pump pres-
sure chamber PP, and the pilot pressure of
the control valve is sent through fine control
hole If) to port P2 and PA,. When the pres-
sure at port P2 rises, valve (IO) is pushed
back. Fine control hole (f) is shut off from
pump pressure chamber PP. At almost the
same time it is connected to drain chamber
D, so the pressure at port P2 escapes to drain
chamber D.
Valve (IO) moves up and down until the force

of spring (9) is balanced with the pressure
of port P2.
The position of valve (IO) and body (II)
(when fine control hole (f) is midway be-
tween drain chamber D and pump pressure
chamber PP) does not change until the head
of valve (IO) contacts the bottom of piston
(4).
Therefore, spring (9) is compressed in pro-
portion to the travel of the control lever, so
the pressure at port Pz also rises in propor-
tion to the travel of the control lever. The
spool of the control valve moves to a posi-
tion where the pressure of port PA, (same as
pressure at port P2) and the force of the
return spring of the control valve are bal-
anced.
PA1 (Fig. 2) PBl SDWOI
10-134 WA800-3
STRUCTURE AND FUNCTION PPC VALUE
3. Control lever moved back from slightly op-

erated position to neutral (Fine control)
(Fig. 3):
When plate (2) starts to be pushed back,
piston (4) is pushed up by a force corre-
sponding to the force of centering spring (8)
and the pressure at port P2.
At the same time, fine control hole (f) of
valve (IO) is connected to drain chamber D,
so the oil at port P2 escapes.
If the pressure at port P2 drops too far, valve
(IO) is pushed down by spring (9). Fine con-
trol hole (f) is shut off from drain chamber
D, and at almost the same time it is con-
nected to pump pressure chamber PP. The
pump pressure is supplied until the pres-
sure at port P2 return to a pressure equiva-
lent to the position of the lever.
When the spool of the control valve returns,
the oil in drain chamber D flows in from fine
control hole (f’) of the valve which has not
moved. The extra oil then flows through port
P4 to chamber Pe,.
487
4. Control lever operated to end of travel

(Fig. 4):
Plate (2) pushes piston (4) down, and piston
(4) forcibly pushes in valve (IO).
Fine control hole (f) is shut off from drain
chamber D, and is connected to pump pres-
sure chamber PP.
Therefore, pressure oil from the charging
pump passes through fine control hole (f),
and flows from port Pz to chamber PA, to
push the spool of the control valve.
The oil returning from chamber A2 flows
from port Pe, through fine control hole (f’) to
drain chamber D.
PA1 (Fig. 4) PBl SDWOI 488
WA800-3
STRUCTURE AND FUNCTION PPC RELIEF VALVE
PPC RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Set pressure: 3.7 MPa {38 kg/cm*}
FUNCTION
. The PPC relief valve is between the PPC
pump and the PPC valve. When the PPC
valve is not being actuated, or when abnor-
mal pressure is generated, the oil sent from
the pump is relieved through this valve to
protect the pump and circuit from damage.
(Sets maximum pressure in the circuit).
OPERATION
. Port A is connected to the pump circuit, and
port C is connected to the drain circuit.
The oil passes through the orifice of main
valve (I) and fills port B. Pilot poppet (3) is
in close contact with valve seat (2).
. If the pressure at ports A and B reach the

pressure set by the poppet spring, pilot pop-
pet (3) opens and the pressure oil at port B
flows through port D to port C. As a result,
the pressure at port B drops.
. If the pressure at port B drops, a pressure

difference is generated between ports A and
B due to the orifice in main valve (1). Main A ’
I B
valve (I) is pushed open by the pressure at
port A, and the oil at port A is relieved.
C
SDW01492
10-136 WA800-3
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR (FOR PPC VALVE)
1. Cap 4. Bladder
2. Nut 5. Oil port
3. Body 6. Nut
Specifications
Type of gas: Nitrogen gas
Gas amount: 3,000 cc
Max. actuation pressure: 2.9 MPa {30 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
FUNCTION
• The accumulator is installed between the
hydraulic pump and PPC valve. An inflatable
bladder is filled with nitrogen gas, and the
compressibility is used to store the pressure
of the oil. As a result, the boom and bucket
can be lowered under their own weight even
after the engine has been stopped.
OPERATION Before operation After operation

• After the engine stops, when the PPC valve
is a NEUTRAL, chamber A (volume of nitro-
gen gas: 3000 cc) inside the bladder is com-
pressed by chamber B.
• When the PPC valve is operated, the pres-

sure in chamber B drops below 2.9 MPa {30
kg/cm2} and the pressure of the nitrogen gas
in chamber A makes the bladder expand.
The actuating pressure is 1.2 to 2.9 MPa {12
to 30 kg/cm2}.
From PPC pump To PPC valve
WA800-3 10-137
10-137
(6)
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL LEVER
WORK EQUIPMENT CONTROL LEVER

1. Boot
2. Ring
3. Bolt
4. Plate
5. Plate
6. Connector for solenoid (2-pin)
7. Connector for potentiometer (4-pin)
8. Bolt
9. Clamp
10-137-1 WA800-3
(6)
FUNCTION Operating effort characteristics chart A

1. Operating effort characteristics
1) Boom RAISE, LOWER, and bucket TILT op-
erations
• When the solenoid power is turned ON, the
electric detent mechanism operates and the
lever is held at the stroke end (point F).
• When the work equipment cylinder moves
by a certain distance, the solenoid power is
turned OFF according to the signal of the
proximity switch, etc. As a result, the detent
is turned OFF and the lever is returned to
the neutral position and the work equipment
is held.
2) Bucket DUMP operation

Operating effort characteristics chart B
• Free return
WA800-3 10-137-2
(6)
2. Output voltage characteristics

• The control unit is installed to the right con-
trol stand and the control lever is installed
directly onto it.
• The operating angle (stroke) of the control
lever is sensed with potentiometers and out-
put as a signal voltage to the controller.
• A potentiometer is installed for each of boom
RAISE/LOWER operation and bucket DUMP/
TILT operation. Each potentiometer outputs
2 signal voltages which are opposite to each
other as shown in the figure at right.
10-137-3 WA800-3
(6)
STRUCTURE AND FUNCTION WORK EQUIPMENT EPC VALVE
WORK EQUIPMENT EPC VALVE

1. Bucket DUMP EPC P: From control pump

2. Bucket TILT EPC T: To tank
3. Boom RAISE EPC C1: Bucket DUMP
4. Boom LOWER, FLOAT EPC C2: Bucket TILT
5. Block C3: Boom RAISE
6. Body C4: Boom LOWER, FLOAT
7. Spool
8. Spring
9. Push pin
10. Coil
11. Plunger
12. Connector
WA800-3 10-137-4
(6)
FUNCTION
• The EPC valve consists of the proportional
solenoid section and the hydraulic valve sec-
tion.
• On receiving signal current “i” from the
pump controller, the EPC valve generates an
EPC output pressure in proportion to the sig-
nal current and applies it to the control valve.
OPERATION
1. When signal current is 0
(Coil is demagnetized)
• While the signal current from the controller
is not flowing in coil (10), coil (10) is demag-
netized.
• Accordingly, spool (7) is pressed by spring
(8) to the right.
• Port P is closed and the hydraulic oil from
the control pump does not flow in the con-
trol valve.
• The hydraulic oil from the control valve is
drained through ports C and T into the tank.
10-137-5 WA800-3
(6)
2. When signal current is small

(Coil is magnetized in fine control mode)
• If a small signal current flows in coil (10),
coil (10) is magnetized and a thrust to the
left is generated in plunger (11).
• Push pin (9) pushes spool (7) to the left and
the hydraulic oil from port P flows in port C.
• The pressure in port C rises. If the total of
the force applied to face “a” of spool (7) and
the load of spring (8) exceeds the thrust of
plunger (11), spool (7) is pushed to the right.
• Ports P and C are disconnected from each
other and port C and port T are connected
to each other simultaneously.
• As a result, spool (7) moves to the right or
left until the thrust of plunger (11) is bal-
anced with the total of the pressure in port
C and the load of spring (8).
• Accordingly, the pressure in the circuit be-
tween the EPC valve and control valve is
controlled in proportion to the signal cur-
rent.
3. When signal current is maximum

(Coil is magnetized in full operation)
• If the signal current flows in coil (10), coil
(10) is magnetized.
• Since the signal current is at the maximum,
the thrust in plunger (11) becomes maxi-
mum.
• Accordingly, push pin (9) presses spool (7)
to the left.
• As a result, the maximum hydraulic oil flows
from port P to port C and the pressure in the
circuit between the EPC valve and control
valve becomes highest.
• At this time, port T is closed and the oil
does not flow in the tank.
WA800-3 10-137-6
(6)
STRUCTURE AND FUNCTION WORK EQUIPMENT NEUTRAL LOCK SOLENOID VALVE
WORK EQUIPMENT NEUTRAL LOCK SOLENOID VALVE

1. Connector
2. Variable core
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
FUNCTION
• The work equipment neutral lock solenoid
valve is installed between the PPC pump
and EPC valve. If the safety lock lever is set
in the LOCK position, the work equipment
neutral lock solenoid is turned ON to cut the
basic pressure of the EPC valve according to
the current from the work equipment con-
troller.
OPERATION
When solenoid is turned off
• Since the signal current does not flow from
the work equipment controller, coil (3) is
demagnetized off.
• Accordingly, spool (6) is pressed by spring
(5) to the left (in the direction of ←).
• By this operation, the port P is connected to
port A and the hydraulic oil from the PPC
pump flows in the EPC valve.
When solenoid is turned on

• The signal current flows from the work equip-
ment controller to coil (3), and the latter is
magnetized.
• Accordingly, spool (6) is pressed by push
pin (4) to the right (in the direction of →).
• By this operation, port P is closed and the
hydraulic oil from the PPC pump does not
flow in the EPC valve. At the same time, the
oil from the EPC valve flows from port A to
port T, and then it is drained into the hy-
draulic tank.
10-137-7 WA800-3
(6)
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

Serial No.: 50001 – 50021
1. Main relief valve PA1 : From PA1 of PPC valve

2. Bucket spool return spring PA2 : From PA2 of PPC valve
3. Boom spool return spring PB1 : From PB1 of PPC valve
4. Boom spool PB2 : From PB2 of PPC valve
5. Bucket spool A1 : To bucket cylinder bottom side
6. Body A2 : To boom cylinder bottom side
7. Suction valve B1 : To bucket cylinder rod side
8. Unloader valve B2 : To boom cylinder rod side
9. Float selector valve P : Pump port
10. Safety valve (with suction) P1 : From PA2 of PPC valve
P2 : From PB2 of PPC valve
T : Drain port (to hydraulic tank)
10-138
10-138 WA800-3
(6)
FUNCTION
• The two main control valves control the ac- • There are two safety valves (with suction
tuation of the boom and the bucket in the valves) (10) to protect the circuit if abnormal
hydraulic system. It has a tandem circuit pressure is generated in the bucket circuit. If
which gives priority to the bucket circuit. one of the two safety valves is acting as a
• The oil from the pump enters port P. The relief valve, the other valve acts as a suction
maximum pressure is set by main relief valve valve to make up any lack of oil.
(1). The oil passes through the bypass cir-
cuit of bucket spool (5) and boom spool (4).
It then flows from port T to the drain circuit,
passes through the filter and returns to the
tank. If the bucket and boom spools are ac-
tuated, the oil flows to the bucket and boom
cylinders.
However, the circuit gives priority to the
bucket, so when the bucket spool is being
operated, even if the boom spool is operated,
the boom will not move.
WA800-3 10-139
10-139
(6)
1. Main relief valve PA1 : From PA1 of PPC valve

2. Bucket spool return spring PA2 : From PB2 of PPC valve
3. Boom spool return spring PB1 : From PB1 of PPC valve
4. Boom spool PB2 : From PA2 of PPC valve
5. Bucket spool A1 : To bucket cylinder bottom side
6. Body A2 : To boom cylinder bottom side
7. Suction valve B1 : To bucket cylinder rod side
8. Unloader valve B2 : To boom cylinder rod side
9. Float selector valve P : Pump port
10. Safety valve (with suction) P1 : From PA2 of PPC valve
P2 : From PB2 of PPC valve
T : Drain port (to hydraulic tank)
10-139-1 WA800-3
(6)
FUNCTION
• The two main control valves control the ac- • There are two safety valves (with suction
tuation of the boom and the bucket in the valves) (10) to protect the circuit if abnormal
hydraulic system. It has a tandem circuit pressure is generated in the bucket circuit. If
which gives priority to the bucket circuit. one of the two safety valves is acting as a
• The oil from the pump enters port P. The relief valve, the other valve acts as a suction
maximum pressure is set by main relief valve valve to make up any lack of oil.
(1). The oil passes through the bypass cir-
cuit of bucket spool (5) and boom spool (4).
It then flows from port T to the drain circuit,
passes through the filter and returns to the
tank. If the bucket and boom spools are ac-
tuated, the oil flows to the bucket and boom
cylinders.
However, the circuit gives priority to the
bucket, so when the bucket spool is being
operated, even if the boom spool is oper-
ated, the boom will not move.
WA800-3 10-139-2
(6)
RELIEF VALVE
Serial No.: 50001 – 50014
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut
FUNCTION
• The relief valve is installed at the inlet of the
main control valve. When the oil goes above
the set pressure, the relief valve drains the
oil to the tank. In this way, it sets the maxi-
mum pressure in the hydraulic circuit and
protects the circuit.
OPERATION
• Port A is connected to the pump circuit, and
port C is connected to the drain circuit. The
oil passes through the orifice of main valve
(1) and flows to port B. Pilot poppet (3) is in
close contact with valve seat (2).
• When the hydraulic pressure in the circuit
inside port A and port B reaches the set
pressure of pilot poppet spring (4), pilot pop-
pet (3) opens, and the pressurized oil from
port B flows from port D to port C, so the
pressure at port B drops.
• When the pressure at port B drops, the ori-
fice effect of main valve (1) generates a dif-
ference in pressure between port A and port
B. The main valve is pushed open and the
oil from port A passes through port C and
flows to the drain circuit to release the ab-
normal pressure.
10-140
10-140 WA800-3
(6)

1. Main valve
2. Piston
3. Piston spring
4. Poppet
5. Poppet spring
6. Plug with valve seat
7. Sleeve
8. Adjustment screw
9. Lock nut
10. Orifice
FUNCTION
• The relief valve is installed at the inlet of the
work equipment valve. When the oil pres-
sure rises above the specified level, this valve
drains the oil into the hydraulic tank to limit
the maximum pressure of the work equip-
ment circuit and protect the circuit.
OPERATION
• Ports A and B are connected to the pump
circuit and drain circuit respectively. The oil
pressure in port A is applied through the
hole of piston (3) to port C.
• When the oil pressure is below the set relief
pressure, poppet (4) is in contact with the
seat of plug (6) and the oil does not flow
from chamber C into the drain circuit. Ac-
cordingly, the oil pressure in port A is equal
to that in chamber C.
• Since d2 < d3, main valve (2) is in contact
with the left side. The sectional areas are set
in the following order; d5 > d4 > d1 > d3 >
d2.
• If the pump pressure is raised by spring (5)

to the relief pressure poppet (4) opens and
the oil in chamber C is drained through
chamber D.
• If poppet (4) opens, the oil flows from A
through C to D.
• As the oil flows from A → C [hole through

piston (2)]. its pressure lowers. As a result,
the pressure in chamber C is lower than that
in port A, thus main valve (1) moves to the
right.
• Then, the oil flows from port A to port B and
limits the maximum pressure to protect the
circuit.
WA800-3 10-140-1
(6)
SAFETY VALVE (with suction valve)
1 2 3 4 5 6
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
SEW00166
FUNCTION
• The safety valve (with suction valve) is in
the bucket cylinder circuit in the main valve.
If shock causes any abnormally high pres-
sure in the cylinder when the main valve is
at neutral, the safety valve (with suction
valve) releases the abnormal pressure and
protects the cylinder from damage.
• This valve prevents generation of negative
pressure in the circuit.
OPERATION
AS A SAFETY VALVE A B C 2 4 D
• Port A is the cylinder circuit and port B is
the drain circuit.
The pressure oil in port A flows to port D
through a hole in pilot piston (4). It also
flows to port C through an orifice consisting
of the main valve and pilot piston (4).
Pilot piston (4) is secured to the suction valve
by lock nut. The diameter of the cross sec-
tion (cross sectional area) gives a relation- d1 d3 d4 d2
SEW00167
ship of d2 > d1 > d3 > d4.
• If abnormally high oil pressure occurs in port A B 1 2 3 D

A, suction valve (1) is not actuated because
of the relationship d2 > d1.
However, because of the relationship d3 > d4
in port A and C, the hydraulic pressure on
main valve (2) is equivalent to the area dif-
ference between d3 and d4. If this pressure
goes up to the main valve spring force (set
pressure), main valve (2) is actuated, and
the oil in port A flows into port B. SEW00168
WA800-3 10-141
10-141
(6)
AS A SUCTION VALVE
If negative pressure is generated in port A,
port D also has negative pressure, because
port D and A are connected with each other.
The tank pressure in port B is applied to
port E.
Hydraulic pressure “a” equivalent to the area
difference between d2 and dr is applied to
the safety valve because of the tank pres-
sure in port E. Therefore, hydraulic pressure
d”! ‘e’ d’2

I’e fl acts to open the valve and hydraulic
pressure “a” acts to close suction valve (I).
SEWO: I502
If the pressure in port A drops, (approaching
negative pressure) hydraulic pressure “a”
becomes smaller than oil pressure “e”.
When oil pressure “e” becomes larger than
oil pressure Na” + valve spring (5) force,
suction valve (I) opens, causing the oil to
flow from port B into port A. This prevents
negative pressure from building up in port
A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
SEW00170
OPERATION
. If negative pressure is generated in port A
(boom cylinder rod end) (if the pressure is
lower than in port B in the tank circuit), main
poppet (I) opens because oil then flows from
port B at the tank end to port A at the cylin-
der port end.
dl d'2
SEW01503
lo-142 WA800-3
FLOAT SELECTOR VALVE AND UNLOADER VALVE

Serial No.: 50001 – 50021
FUNCTION
• The float selector valve and the unloader
valve are inside the main control valve. When
the boom control lever is moved to the float
position, the float selector valve detects this.
When it is actuated, it actuates the unloader
valve and sets the boom in the FLOAT
position.
OPERATION
1. LOWER position
This shows the condition with the boom con-
trol lever in the LOWER position.
2. FLOAT position
When the boom control lever is pushed for-
ward from the LOWER position, it enters the
FLOAT position.
Boom spool (1) of the main control valve is
in the same condition as at the LOWER posi-
tion.
The hydraulic pressure at port A is higher
than at the LOWER position, so float selec-
tor valve (2) moves in the direction of the
rightward. The back pressure of unloader
valve (3) is drained, so unloader valve (3)
opens to give the FLOAT condition.
WA800-3 10-143
10-143
(6)
3. FLOAT position (pushed up1

If the machine moves in reverse and the
boom is pushed up, the pressure at the cyl-
inder rod end becomes high. It passes
through port B and is drained through
unloader valve (3).
A vacuum is formed at the cylinder bottom
end, so oil flows in from port C.
From steering valve SDWOl728
4. FLOAT position (lowering under own weight)

When the machine is moving in reverse and
the boom comes down under its own weight,
the pressure at the cylinder bottom end is
high, and it is drained from port C.
A vacuum is formed at the cylinder rod end,
so oil flows in from port B.
From steerlna valve SDW017'29
10-144 WA800-3
FUNCTION
• The float selector valve (2) and the unloader
valve (3) are inside the main control valve.
When the boom control lever is moved to
the float position, the float selector valve (2)
detects this. When it is actuated, it actuates
the unloader valve (3) and sets the boom in
the FLOAT position.
OPERATION
1. LOWER position
This shows the condition with the boom con-
trol lever in the LOWER position.
2. FLOAT position
When the boom control lever is pushed for-
ward from the LOWER position, it enters the
FLOAT position.
Boom spool (1) of the main control valve is
in the same condition as at the LOWER posi-
tion.
The hydraulic pressure at port A is higher
than at the LOWER position, so float selec-
tor valve (2) moves in the direction of the
rightward. The back pressure of unloader
valve (3) is drained, so unloader valve (3)
opens to give the FLOAT condition.
WA800-3 10-144-1
(6)
3. FLOAT position (pushed up)

If the machine moves in reverse and the
boom is pushed up, the pressure at the cyl-
inder rod end becomes high. It passes
through port B and is drained through
unloader valve (3).
A vacuum is formed at the cylinder bottom
end, so oil flows in from port C.
4. FLOAT position (lowering under own weight)

When the machine is moving in reverse and
the boom comes down under its own weight,
the pressure at the cylinder bottom end is
high, and it is drained from port C.
A vacuum is formed at the cylinder rod end,
so oil flows in from port B.
10-144-2 WA800-3
(6)
OPERATION OF HYDRAULIC CIRCUIT

Serial No.: 50001 – 50021
BOOM AND BUCKET SPOOLS IN “HOLD”
OPERATION
• The oil enters port A from the steering valve, • The oil from the PPC pump passes through
and the maximum pressure is set by relief check valve (13), and enters port L of the
valve (11). PPC valve. However, the boom and bucket
• Bucket spool (1) is at the HOLD position, so levers are at the HOLD position, so the oil
the bypass circuit is open and the oil at port returns to the hydraulic tank from PPC relief
A passes around the spool and flows to port valve (12).
B. Boom spool (2) is also at HOLD, so the
bypass circuit is open and the oil at port B
passes around the spool, enters port C of
the drain circuit, passes through the filter in
the hydraulic tank, and returns to the tank.
WA800-3 10-145
10-145
(6)
Serial No.: 50001 – 50021

BOOM SPOOL IN “RAISE”
OPERATION
• When boom lever (3) is pulled, the oil flows and flows to the bypass circuit of boom
from port L of the PPC valve to port N and spool (2). The bypass circuit is closed by the
port S. In addition, the oil at port T passes spool, so the oil pushes open check valve
through port M and flows to the drain cir- (10). The oil flows from port H to port I, and
cuit. The oil pressure at port S pushes boom flows to the cylinder bottom.
spool (2) and moves it to the RAISE posi- • At the same time, the oil at the cylinder rod
tion. end enters drain port C from port K and
• The oil from the steering valve passes returns to the tank. Therefore, the boom
through the bypass circuit of the bucket spool rises.
10-146
10-146 WA800-3
(6)
Serial No.: 50001 – 50021

BOOM SPOOL IN “LOWER”
OPERATION
• When boom lever (3) is pushed, the oil flows (2). The bypass circuit is closed by the spool,
from port L of the PPC valve to port M and so the oil pushes open check valve (10). The
port T. In addition, the oil at port S flows to oil flows from port J to port K, and flows to
the drain circuit. the cylinder rod end.
The oil pressure at port T pushes boom spool • At the same time, the oil at the cylinder
(2) and moves it to the LOWER position. bottom enters drain port C from port I and
• The oil from the steering valve passes returns to the tank. Therefore, the boom goes
through the bypass circuit of the bucket spool down.
and flows to the bypass circuit of boom spool
WA800-3 10-147
10-147
(6)
Serial No.: 50001 – 50021

BOOM SPOOL IN “FLOAT”
OPERATION
• When boom lever (3) is pushed to the FLOAT opens port C1 and port C, and connects to
position, the PPC valve spool moves beyond the drain circuit. When port C1 is connected
the LOWER position to the FLOAT position. to the drain circuit, unload valve (8) moves
The pressure oil at port L flows to port M, up and the oil from the pump flows to the
and at the same time, it also flows to port T drain circuit.
and port W. In addition, the pressurized oil • Therefore, the oil at the cylinder rod end
at port S flows to port N. passes from port K through unload valve (8)
• The pressurized oil at port T pushes boom and flows to the drain circuit. The oil at the
spool (2) to the LOWER position. cylinder bottom flows from port I to port C,
• If a difference in pressure greater than the and then flows to the drain circuit. There-
specified pressure is generated at port W fore, the boom is set to the FLOAT condi-
and port X, valve (7) moves to the right, tion.
10-148
10-148 WA800-3
(6)
Serial No.: 50001 – 50021

BUCKET SPOOL IN “DUMP”
OPERATION
• When bucket lever (4) is pushed, the pres- valve (10). The oil from check valve (10) flows
sure oil at port L of the PPC valve flows from port F to port G, and then flows to the
from port Q to port V. In addition, the oil at cylinder rod end.
port R flows to the drain circuit. The pres- • At the same time, the oil at the cylinder
sure oil at port V moves bucket spool (1) to bottom flows from port D to drain port C,
the DUMP position. and returns to the tank, so the bucket is
• The bypass circuit is closed by bucket spool dumped.
(1), so the oil from port A pushes open check
WA800-3 10-149
10-149
(6)
Serial No.: 50001 – 50021

BUCKET SPOOL IN “TILT BACK”
OPERATION
• When bucket lever (4) is pulled, the pressure (1), so the oil from port A pushes open check
oil at port L of the PPC valve flows from port valve (10). The oil from check valve (10) flows
P to port R. In addition, the oil at port V from port E to port D, and then flows to the
flows to the drain circuit. The pressure oil at cylinder bottom.
port R moves bucket spool (1) to the TILT • At the same time, the oil at the cylinder rod
position. end flows from port G to drain port C, and
• The bypass circuit is closed by bucket spool returns to the tank, so the bucket is tilted.
10-150
10-150 WA800-3
(6)

BOOM AND BUCKET SPOOLS IN “HOLD”
OPERATION
• The oil enters port A from the steering valve, • The oil from the PPC pump passes through
and the maximum pressure is set by relief check valve (13), and enters port L of the
valve (11). PPC valve. However, the boom and bucket
• Bucket spool (1) is at the HOLD position, so levers are at the HOLD position, so the oil
the bypass circuit is open and the oil at port returns to the hydraulic tank from PPC relief
A passes around the spool and flows to port valve (12).
B. Boom spool (2) is also at HOLD, so the
bypass circuit is open and the oil at port B
passes around the spool, enters port C of
the drain circuit, passes through the filter in
the hydraulic tank, and returns to the tank.
WA800-3 10-150-1
(6)

BOOM SPOOL IN “RAISE”
OPERATION
• When boom lever (3) is pulled, the oil flows (1) and flows to the bypass circuit of boom
from port L of the PPC valve to port N and spool (2). The bypass circuit is closed by the
port T. In addition, the oil at port S passes spool, so the oil pushes open check valve
through port M and flows to the drain cir- (10). The oil flows from port H to port I, and
cuit. The oil pressure at port T pushes boom flows to the cylinder bottom.
spool (2) and moves it to the RAISE posi- • At the same time, the oil at the cylinder rod
tion. end enters drain port C from port K and
• The oil from the steering valve passes returns to the tank. Therefore, the boom
through the bypass circuit of the bucket spool rises.
10-150-2 WA800-3
(6)

BOOM SPOOL IN “LOWER”
OPERATION
• When boom lever (3) is pushed, the oil flows spool (2). The bypass circuit is closed by the
from port L of the PPC valve to port M and spool, so the oil pushes open check valve
port S. In addition, the oil at port T flows to (10). The oil flows from port J to port K, and
the drain circuit. flows to the cylinder rod end.
The oil pressure at port S pushes boom spool • At the same time, the oil at the cylinder
(2) and moves it to the LOWER position. bottom enters drain port C from port I and
• The oil from the steering valve passes returns to the tank. Therefore, the boom goes
through the bypass circuit of the bucket spool down.
(1) and flows to the bypass circuit of boom
WA800-3 10-150-3
(6)

BOOM SPOOL IN “FLOAT”
OPERATION
• When boom lever (3) is pushed to the FLOAT opens port C1 and port C, and connects to
position, the PPC valve spool moves beyond the drain circuit. When port C1 is connected
the LOWER position to the FLOAT position. to the drain circuit, unload valve (8) moves
The pressure oil at port L flows to port M, up and the oil from the pump flows to the
and at the same time, it also flows to port S drain circuit.
and port W. In addition, the pressurized oil • Therefore, the oil at the cylinder rod end
at port T flows to port N. passes from port K through unload valve (8)
• The pressurized oil at port S pushes boom and flows to the drain circuit. The oil at the
spool (2) to the LOWER position. cylinder bottom flows from port I to port C,
• If a difference in pressure greater than the and then flows to the drain circuit. There-
specified pressure is generated at port W fore, the boom is set to the FLOAT condi-
and port X, valve (7) moves to the right, tion.
10-150-4 WA800-3
(6)

BUCKET SPOOL IN “DUMP”
OPERATION
• When bucket lever (4) is pushed, the pres- valve (10). The oil from check valve (10) flows
sure oil at port L of the PPC valve flows from port F to port G, and then flows to the
from port Q to port V. In addition, the oil at cylinder rod end.
port R flows to the drain circuit. The pres- • At the same time, the oil at the cylinder
sure oil at port V moves bucket spool (1) to bottom flows from port D to drain port C,
the DUMP position. and returns to the tank, so the bucket is
• The bypass circuit is closed by bucket spool dumped.
(1), so the oil from port A pushes open check
WA800-3 10-150-5
(6)

BUCKET SPOOL IN “TILT BACK”
OPERATION
• When bucket lever (4) is pulled, the pressure (1), so the oil from port A pushes open check
oil at port L of the PPC valve flows from port valve (10). The oil from check valve (10) flows
P to port R. In addition, the oil at port V from port E to port D, and then flows to the
flows to the drain circuit. The pressure oil at cylinder bottom.
port R moves bucket spool (1) to the TILT • At the same time, the oil at the cylinder rod
position. end flows from port G to drain port C, and
• The bypass circuit is closed by bucket spool returns to the tank, so the bucket is tilted.
10-150-6 WA800-3
(6)
STRUCTURE AND FUNCTION LUBRICATION OF WORK EQUIPMENT
LUBRICATION OF WORK EQUIPMENT
SEW01514
1. Bucket cylinder 5. Transmission A. Upper hinge pin

2. Front frame 6. Torque converter B. Bucket cylinder bottom pin
3. Steering cylinder 7. Damper C. Boom pin (left)
4. Boom cylinder 8. Bellcrank D. Boom pin (right)
E. Steering cylinder pin (left)
F. Steering cylinder pin (right)
10-152 WA800-3
STRUCTURE AND FUNCTION LUBRICATION OF WORK EQUIPMENT
Y
u
G. Front axle support
H. Transmission trunnion
I. Rear axle support
J. Rear axle support
WA800-3 10-153
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
1. Bucket 7. Boom
2. Bucket hinge pin (grease filled type) 8. Boom cylinder
3. Bucket link pin (grease filled type) 9. Cord ring
4. Bucket link 10. Tooth with tip
5. Bellcrank 11. Sweeper wing
6. Bucket cylinder
10-154 WA800-3
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
iw
A-A
E-E F-F
D-D
J-J
G-G H-H swwo3713
WA800-3
1o-1 55
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
:_.._\
..-..
__.
----A-
--I
____._’
__.____.___.___
/ ‘.
_._..__._..~
_.__.._
_:,--_._ _._..
._-..-._ ..-.._
- .-..-..-..C ..-..-
__._ ._.. ___._‘;‘,__.~_~.~~____’ _.._
‘-------r;:.c::l.__
I
3/
svwo3714
I. Proximity switch (dump)

2. Lever
3. Proximity switch (boom)
4. Plate
lo-156 WA%OO-3
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER
The bucket positioner is an electrically actu-

ated system which is used to set the bucket
to the desired angle when the bucket is
moved from the DUMP position to the TILT
position. When the bucket reaches the de-
sired position, the bucket lever is returned
from the TILT position to the HOLD position,
and the bucket is automatically set to the
suitable digging angle.
Bar (2) is secured to bucket cylinder rod (5)
by bolts. In addition, proximity switch (I) is
fixed to the cylinder by bolts.
When the bucket is moved from the DUMP
SEW01519
position to the TILT position, the bucket cyl-
inder rod moves to the left, and at the same
time, bar (2) also moves to the left. Bar (2)
separates from proximity switch (I) at the
desired position, and the bucket lever is re-
turned to neutral.
BOOM KICK-OUT
The boom kick-out is electrically operated

and acts to stop the boom. When the boom
reaches the desired position before the
maximum height, the boom lever is returned
to neutral.
Plate (4) is secured to the boom. A proximity
switch (3) is fixed to the frame. When the
boom is moved from the LOWER position to
the RAISE position, the boom rises. When it
reaches the desired position, the proximity
switch and plate come into contact and the
boom lever is returned to neutral.
WASOO-3 10-157
STRUCTURE AND FUNCTION OPERATION OF PROXIMITY SWITCH
OPERATION OF PROXIMITY SWITCH

BOOM RAISE
Proximltv switch for
. When the boom is lower than the set position boom kick-out
To battery
for the kick-out, the detector (steel plate) is relay
not above the detection surface of the
proximity switch, so the proximity switch
load circuit is shut off.
The relay switch is turned OFF and the Kick-out relay
current for the solenoid is shut off. Kick-out solenoid
SVW03367
Cam
Boom Proximity switch
\ Solenoid
YrYPC valve
SEW02324
. When the boom lever is moved to the RAISE

Proximity switch for
position, the boom spool is held at the RAISE boom kick-out
To battery
position by the cam follower and cam on relay
the lever, and the boom rises.
1 1 Kick-out relay
Kick-out solenoid
SVW03367
Boom lever
Boom , Proximity switch
noid
Detector
I_-& PPC valve

SEW02325
lo-158 WAKIQ-3
. When the boom rises and reaches the set

Proxlmitv switch for
position for the kick-out, in other words, the boom kick-out
detector (steel plate) is in position on the relay

detection surface of the proximity switch, an
electric current is sent to the solenoid by the
action of the proximity switch and relay
circuit. As a result, the solenoid is actuated,
and the cam is pulled away from the cam
detent, so the boom spool is returned to the
HOLD position by the return spring.
SVWO3368
Cam
Boom , Boom lever
Proximity
switch
aid
+PPC valve
SEW02326
Action of proximity switch
When detector is in position When detector is separated

Position at detection surface of from detection surface of
oroximitv switch proximity switch
Proximity switch
Lights up Goes out
actuation display
Proximity switch load circuit

Current flows Current is shut off
(relay switch circuit)
Relay switch load circuit

Current flows Current is shut off
(solenoid circuit)
WA800-3 10-159
BUCKET TILT
Proxlmitv switch for
l When the bucket is dumped beyond the set bucket positioner
Z o battery
position for the auto-leveler, the sensor (steel elan
5
plate) is above the detection surface of the
bucket proximity switch, so electric current
flows in the proximity switch load circuit.
The positioner relay is turned ON and the
current for the solenoid is shut off. Positioner solenoid
Cam
Bucket lever
I
\ Solenoid
Detector Proximi;Y switch

+PPC valve
SEW02327
. When the bucket lever is moved to the TILT Proximity switch for
bucket posl t loner
position, the bucket spool is held at the TILT Z
position by the cam follower and cam on
the lever, and the bucket tilts.
Bucket lever
Ier
!noid
Detector Proximity switch

+PPC valve
SEW02328
lo-160 WA800-3
. When the bucket tilts and reaches the set

Proximity switch for
position for the bucket leveler, in other bucket positioner
To battery
words, the sensor (steel plate) separates from relay
the detection surface of the proximity switch,
electric current is sent to the solenoid by the
action of the proximity switch and relay cir-
cuit. II Positioner relay
As a result, the solenoid is actuated, and the
cam is pulled away from the cam detent, so
the bucket spool is returned to the HOLD
position by the return spring.
Cam
Bucket lever
\ Solenoid
Detector Proximity switch
Action of proximity switch
Position
Proximity switch
actuation display
Positioner relay Current flows Current is shut off
Solenoid (for bucket) Current is shut off Current flows
WAgOO-3 10-161
STRUCTURE AND FUNCTION CAB
CAB
\
3
swwo3371
1. Front glass
2. Front wiper
3. Door
10-162 WA800-3
STRUCTURE AND FUNCTION ROPS CANOPY
ROPS CANOPY
1. ROPS canopy
2. Cab
WA800-3 10-163
10-163
(6)
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
SWWO3840
1. Air vent
2. Air vent
3. Condenser
4. Dry reservoir
5. Compressor
6. Air conditioner unit
lo-164 WA800-3
AIR CONDITIONER CONDENSER
1. Electric wiring
2. Fan
3. Refrigerant gas inlet port
4. Refrigerant gas outlet port
AIR CONDITIONER COMPRESSOR
1. Refrigerant outlet port

2. Refrigerant inlet port
3. Charge port on suction side
4. Clutch
5. Relief valve
Specifications
Type: Piston pump type
Refrigerant used: R134a
WA800-3 10-165
10-165
(6)
1. Body
2. Drier
3. Filter
SDW01536
10-166 WA800-3
STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM

fl For the electric circuit diagram, see Chapter 90 (The following electric circuit diagrams of A2 size
are shown in Chapter 90).
Electric circuit diagram [1/16]
Steering wheel specification, steering wheel and joystick steering specification (1/5)
[For mechanical governor engine]
[For electronic governor engine]
AJSS (Advanced Joystick Steering System) specification (1/5)
Electric circuit diagram (Remote boom positioner)
WA800-3 10-167
10-167
4
(6)
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
REMOTE BOOM POSITIONER SPECIFICATION
10-168
10-168 WA800-3
(6)
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
OUTLINE
• The machine monitor system uses the sen- • There are also various switches built into the
sors and other devices installed to various monitor panel which function to operate the
parts of the machine to observe the condition machine.
of the machine. It processes this information
swiftly and displays it on the monitor panel ª The main monitor uses the network wiring to
to inform the operator of the condition of the send signals to the controller, and functions
machine. to display the following information.
• The machine monitor system consists of the 1 Shift indicator: 1st – 3rd, N, F, R (F, R are
main monitor, maintenance monitor, sensors, optional) (When auto shift, joystick steer-
switches, relays, alarm buzzer, and power ing are installed)
source. 2 HOLD (option)
• The displays can be broadly divided into the 3 Failure action code, failure code, time
following: Cautions displayed on the moni- elapsed since failure (failure data display
tors (abnormalities in the machine where an mode)
alarm is given) and normal conditions which
are always displayed on the instrument panel
(pilot lamps and readings for the gauges,
speedometer, and service meter).
WA800-3 10-169
10-169
5
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
10-170
10-170 WA800-3
5
1. Check lamp 4E. Shift hold 5B. Engine low idling switch
2. Caution lamp 4F. Parking brake 5C. Working lamp (front)
3. Caution items 4G. Emergency steering switch
3A. Emergency steering actuated normal 5D. Working lamp (rear)
4. Pilot items 4H. Monitor pilop lamp switch
4A. Turn signal (left) (preheating, afterheating) 5E. Transmission cut-off
4B. Turn signal (right) 4I. Failure action code switch
4C. Shift indicator 5. Switches 5F. Auto shift, manual
4D. Speedometer 5A. Auto grease switch selector switch
OUTLINE
• The main motor has display function for the installed internally, and this processes the sig-
speedometer and other gauges and a switch- nals from the sensors and outputs the display.
ing function to control the electric compo- • A liquid crystal display and LEDs are used for
nents and controllers. the display. The switches are embossed sheet
• There is one CPU (Central Processing Unit) switches.
WA800-3 10-171
10-171
5
MAIN MONITOR DISPLAY FUNCTION
Display
Symbol Display item Display range Display method
category
When there is Display flashes (for details, see

Check
c3 CHECK Check abnormality
maintenance
display on
monitor
MAINTENANCE
DISPLAY FUNCTION)
MONITOR
Emergency steering
Lr
actuated (when
When actuated Display flashes
equipped with
emergency steering
Parking brake actuated,

Display flashes and buzzer
Caution transmission not at
sounds
neutral
c3
CAUTION Caution
When there is
Display flashes (buzzer may
also sound) (for details, see
abnormality display on
MAINTENANCE MONITOR
maintenance monitor
DISPLAY FUNCTION)
Turn signal
When operated Display lights up
(left, right)
Display lights up
Buzzer sounds when parking
Parking brake When operated
brake is applied and shift lever
is not at N
Emergency steering
normal (when When normal (oil is
Display lights up
equipped with flowing in hydraulic circuit]
Pilot emergency steering
Lights up
Lighting up time changes
according to engine water
Preheating When preheating temperature when starting
switch is turned ON (for details,
see PREHEATING CIRCUIT)
Shift hold
(Machine equipped When shift is held Display lights up
SDW02341 with auto shift)
Digital display (display switches

Speedo- 0 - 99 km/h between tachometer and
Travel speed
meter speedometer)
Shift I-3N Digital display

Shift indicator
indicator
When controller detects

failure and action by Digital display
Failure operator is needed, Buzzer sounds
action l@ Failure action code CALL is displayed,
or CALL and E 0 0
(For details of the travel data
display mode, see TROUBLE
code
(action code) are DATA DISPLAY MODE)
displayed in turn
F, R, display (when
Shift Digital display
I- F/P dislllr equipped with F, R
indicator
SOW02342 joystick steering)
WA800-3 10-173
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
Lights up (goes out Auto-greasing control actuated

momentarily when (automatic greasing carried out
switch is turned ON) at fixed internal)
Forced greasing is carried out Flashes (slowly) Grease empty

Auto-greasing while switch is being pressed
when display is lighted up Abnormality in auto-greasing
Flashes (rapidly)
controller system
Auto-greasing controller not

Goes out
installed
Low idling speed set to approx.

Lights up
Engine low idling speed is 850 rpm
Engine low idling changed between two stages
each time switch is pressed Low idling speed set to approx.
Goes out
650 rpm
Front working lamp lights up or

Working lamp goes out each time switch is
(front) pressed when side lamps are
lighted up
Rear working lamp lights up or Lights up Rear working lamp lights up

Working lamp goes out each time switch is
(rear) pressed when side lamps are
lighted up
Transmission Transmission cut-off function is

cut-off actuated or stopped each time
switch is pressed
Goes out Cut-off function stopped
Lights up Manual mode

Auto shift mode switches to
Manual manual mode when switch is
pressed
Goes out Auto shift mode
10-174 WA800-3
TROUBLE DATA DISPLAY MODE
Item Switch operation Actuation
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and
trouble data display switch turned ON, press 2nd switch failure code is displayed on speedometer
mode from top on left side of main display and time elapsed since failure is
monitor (switch below emergency displayed on failure action code display.
steering display) and working lamp (I) Failure code is a two-digit display
(front) switch simultaneously given in numbers or letters.
for at least 5 seconds. The display for the failure no-w
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
SOW00241 999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item.
SOW01254
SOW00242
Clearing failure code Press working lamp (rear) switch Failure code and time elapsed since
for at least 2 seconds failure being displayed are cleared.
Failure code for problem now occurring
(flashing display) cannot be cleared.
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch
simultaneously for at least
5 seconds, or start the engine.
WA8003 10-175
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
3A 38 3C
Id, IB 2A 2B 2.F iC i0 iE iA iB
0
-
SWWO3847
1. Check items (Checks 2D. Air cleaner (L.H.) 4. Service meter

before starting) 2E. Air cleaner (R.H.) 4A. Service meter numeric
IA. Engine water level 2F. Transmission oil filter display
IB. Engine oil level 3. Gauge items 4B. Service meter RUN
2. Caution items (warning 3A. Fuel level pilot lamp
items) 3B. Engine water tempera- 5. Monitor module
2A. Engine oil pressure ture 6. Switch module
2B. Brake oil pressure 3C. Torque converter oil
2C. Battery charge temperature
OUTLINE
. The maintenance monitor has a displayfunc- l A liquid crystal display and LEDs are used for
tion for the caution items and gauges. the display portions. The switches are em-
. The maintenance monitor consists of the bossed sheet switches.
monitor module, switch module, service
meter, case, and other mechanisms.
l The monitor module has a built-in CPU (Cen-
tral Processing Unit). It processes the signal
from the sensors, and carries out the display
and output.
lo-176 WA800-3
MAINTENANCE MONITOR DISPLAY FUNCTION
Display
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
Check CHECK lamp flashes
Transmission oil Above specified Displays when engine is running

filter differential pressure Display when normal: OFF
Dispplay when abnormal: Flashes
Engine water level Below low level Displays when engine is running
Display when abnormal: Flashes
Engine oil pressure Below specified CAUTION lamp flashes
pressure Buzzer sounds
Brake oil pressure Below specified

pressure
––––––––––––––––––––-
Engine water temperature Above 102°C Buzzer sounds if above 105°C
––––––––––––––––––––-
Caution Torque converter oil Above 120°C Buzzer sounds if above 130°C
temperature
Fuel level Below low level Displays when engine is running

CAUTION lamp flashes
Battery charge When charge is Displays when engine is running

defective Display when normal: OFF
Air cleaner Above specified CHECK lamp flashes
negative pressure
Service meter 0 – 9999.9h Actuated when charge is normal

Advances 1 for every hour
Service
meter Service meter indicator Lights up when service meter is
running
Fuel level All lamps light up below applicable

EMPTY FULL
level
1 2 3 4 5 6 7
Flashes when level is 1
E F
Red Green
Engine water temperature One place lights up to show

67 80 90 97 102 105˚C
applicable level
Gauges Flashes when level is 6 or 7
1 2 3 4 5 6 7
C H
White Green Red
Torque converter oil One place lights up to show

50 70 90 110 120 130˚C
temperature applicable level
Flashes when level is 6 or 7
1 2 3 4 5 6 7
C H
Green Red
WA800-3 10-176-1
(6)
REMOTE BOOM POSITIONER SPECIFICATION
1. Check items (Checks 3. Gauge items 4C. Remote boom

before starting) 3A. Fuel level positioner RAISE/
1A. Engine water level 3B. Engine water temperature LOWER selector switch
1B. Engine oil level 3C. Torque converter oil tem- 5. Service meter
2. Caution items (warning perature 5A. Service meter numeric
items) 4. Work equipment control display
2A. Engine oil pressure switches 5B. Service meter RUN
2B. Brake oil pressure 4A. Remote boom positioner pilot lamp
2C. Battery charge LOWER position set switch 6. Monitor module
2D. Air cleaner (L.H.) 4B. Remote boom positioner 7. Switch module
2E. Air cleaner (R.H.) RAISE position set switch
2F. Transmission oil filter
OUTLINE
• The maintenance monitor has a display func- • A liquid crystal display and LEDs are used for
tion for the caution items and gauges. the display portions. The switches are em-
• The maintenance monitor consists of the bossed sheet switches.
monitor module, switch module, service
meter, case, and other mechanisms.
• The monitor module has a built-in CPU (Cen-
tral Processing Unit). It processes the signal
from the sensors, and carries out the display
and output.
WA800-3 10-176-3
(6)
MAINTENANCE MONITOR DISPLAY FUNCTION
Display
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Engine oil level Below low level Display when abnormal: Flashes
Check CHECK lamp flashes
Transmission oil Above specified Displays when engine is running

filter differential pressure Display when normal: OFF
Dispplay when abnormal: Flashes
Engine water level Below low level Displays when engine is running
Engine oil pressure Below specified CAUTION lamp flashes
pressure Buzzer sounds
Brake oil pressure Below specified

pressure
––––––––––––––––––––-
Engine water temperature Above 102°C Buzzer sounds if above 105°C
––––––––––––––––––––-
Caution Torque converter oil Above 120°C Buzzer sounds if above 130°C
temperature
Fuel level Below low level Displays when engine is running

Battery charge When charge is Displays when engine is running

defective Display when normal: OFF
Air cleaner Above specified CHECK lamp flashes
negative pressure
Service meter 0 – 9999.9h Actuated when charge is normal

Advances 1 for every hour
Service
meter Service meter indicator Lights up when service meter is
running
Fuel level All lamps light up below applicable

EMPTY FULL
level
1 2 3 4 5 6 7
Flashes when level is 1
E F
Red Green
Engine water temperature One place lights up to show

67 80 90 97 102 105˚C
applicable level
Gauges Flashes when level is 6 or 7
1 2 3 4 5 6 7
C H
White Green Red
Torque converter oil One place lights up to show

50 70 90 110 120 130˚C
temperature applicable level
Flashes when level is 6 or 7
1 2 3 4 5 6 7
C H
Green Red
10-176-4 WA800-3
(6)
MAINTENANCE MONITOR SWITCH FUNCTION
Item Function Display Actuation
Remote boom Sets stopping position in LOWER

Flashes (2.5 sec) Sets stopping position
positioner LOWER direction for remote boom
position setting positioner (boom position when
switch is pressed is recorded) Goes out –
Remote boom Sets stopping position in RAISE

Flashes (2.5 sec) Sets stopping position
positioner RAISE direction for remote boom
position setting positioner (boom position when
switch is pressed is recorded) Goes out –
Section of remote Sets remote boom positioner in Remote boom positioner

Goes out
boom positioner stopping direction (switches function OFF
RAISE/LOWER function each time switch is
pressed) Remote boom positioner
RAISE lights up
RAISE stop function ON
Remote boom positioner

LOWER lights up
LOWER stop function ON
Remote boom positioner

RAISE, LOWER
RAISE/LOWER stop function
lights up
ON
WA800-3 10-177
10-177
(6)
STRUCTURE AND FUNCTION MULTI MONITOR SYSTEM (IF EQUIPPED)
MULTI MONITOR SYSTEM (IF EQUIPPED)

MULTI MONITOR SYSTEM
OUTLINE
• The multi monitor system consists of a con- • The multi monitor is a color liquid crystal
troller, a control monitor, various sensors, display. The display has the following op-
switches, relays, a caution buzzer, and a eration modes.
power supply unit. 1) Abnormality caution display mode to dis-
• The multi monitor system monitors the ve- play cautions when the vehicle has ab-
hicle condition with the sensors installed to normality.
various parts of the vehicle, processes the 2) Monitor mode to display the engine
signals from those sensors with the control- speed, time, and various gauges.
ler immediately, and displays them on the 3) Load meter mode to measure, save, and
multi monitor to notify the operator of the display the bucket load.
condition and current operation of the vehi- 4) Maintenance mode to count and display
cle. the using hours of various oils and fil-
• The controller sends the image information ters.
in the form of digital RGB signals to the 5) Oil and water adding mode to input,
multi monitor. save, and display the quantity of added
oil and water.
6) Operation record mode to count and dis-
play the operating hours of the vehicle
and load on the vehicle.
• The multi monitor has various switches for
the work equipment controller in it and works
as an operating section of the work equip-
ment controller.
10-177-1 WA800-3
4
MULTI MONITOR
• The multi monitor consists of a color liquid nals and display the images on the color
crystal display, an image signal conversion/ liquid crystal display.
selector circuit, switches, and a service me- • There are 2 switches for operations of the
ter. multi monitor system and work equipment
• The multi monitor converts the RGB image controller.
signals sent from the controller into TV sig-
1. Display unit
2. Switch for operation of work
equipment controller
3. Switch for operation of multi
monitor
4. Service meter
WA800-3 10-177-2
4
CONTROLLER
• The controller has 2 CPU’s (Central Process- for control of the lamps, buzzer, printer, and
ing Units) in it, which are used to control image.
input/output and images respectively. • The CPU for image control converts the data
• The CPU for input/output control receives sent from the CPU for input/output control
signals from the sensors and switches in- into image data and outputs them in the
stalled to various parts of the vehicle body, form of RGB image signals.
calculates them, and sends data to the CPU
Connector signals table

CN1 (040 16-pole) CN2 (040 8-pole) CN3 (MIC 21-pole) CN4 (MIC 5-pole) CN5 (040 12-pole) CN6 (040 20-pole)
No. Signal name No. Signal name No. Signal name No. Signal name No. Signal name No. Signal name
1 Power source 24 V 1 Start signal 1 Engine oil filter 1 RS232C (TXD) 1 Strobe 1 Power source 12 V
2 Power source 24 V 2 Check lamp output 2 Hydraulic oil filter 2 RS232C (RXD) 2 DATA 1 2 GND
3 GND 3 Caution lamp output 3 Battery fluid level 3 RS232C (RTS) 3 DATA 2 3 —
4 Coolant temperature 4 Caution buzzer output 4 — 4 RS232C (CTS) 4 DATA 3 4 —
5 Torque converter oil temperature 5 Flashing synchronization 5 Parking brake 5 GND 5 DATA 4 5 VIDEO R
6 Fuel level 6 Model selection (Spare) 6 — 6 DATA 5 6 VIDEO G
7 — 7 — 7 Subtotal switch 7 DATA 6 7 VIDEO B
8 Coolant level 8 GND 8 Cancel switch 8 DATA 7 8 H. SYNC
9 Brake line failure 2 9 Position of boom 9 DATA 8 9 V. SYNC
10 Engine oil pressure 10 Boom cylinder pressure (+) 10 — 10 C. SYNC
11 Brake oil pressure 11 Boom cylinder pressure (–) 11 BUSY 11 Shield ground
12 Charge level 12 Engine speed (+) 12 GND 12 —
13 Engine oil level 13 Engine speed (–) 13 Monitor switch
14 Transmission oil filter 14 Network input/output (+) 14 Load meter switch
15 Air cleaner 15 Network input/output (–) 15 Maintenance switch
16 Brake line failure 1 16 Network input/output (+) 16 Oil/Water addition switch
17 Network input/output (–) 17 Operation record switch
18 Pressure sensor power source (+15 V) 18 Feed/Update switch
19 Starting switch ACC 19 Numeral/Subtotal switch
20 Battery (+) 20 GND
21 GND
10-177-3 WA800-3
4
DISPLAY FUNCTION OF MULTI MONITOR
1. Display modes
The display modes of the multi monitor are 2) Modes displayed by operation of
classified into ones displayed automatically switches
(flow of time and occurrence of abnormal- • Monitor mode (Displayed automati-
ity) and the other ones selected and dis- cally only after warm-up inspection)
played by operation of the switches. • Load meter mode
1) Modes displayed automatically • Maintenance mode
• Self-check mode • Oil/Water addition mode
• Check-before-starting mode • Operation record mode
• Warm-up inspection mode
• Abnormality alarm mode
2. Change of display mode
Dotted line (···): Automatic change

1Passing of time
2Start of engine
3Occurrence of abnormality
Solid line (–): Change by operation of switches
WA800-3 10-177-4
4
FUNCTION AND DISPLAY IN EACH MODE
1. Self-check mode
1) Function
When the starting switch is turned on,
the “KOMATSU” logo is displayed and
the caution lamp and buzzer are turned
on.
2) Display
2. Check-before-starting mode
1) Function
After the self-check, the following items
are checked without starting the engine.
If any abnormality is found, the abnor-
mality display screen appears and an
alarm is output.
• Fluid level check:
Engine oil level, coolant level, fuel
level, and battery fluid level
• Electric circuit troubleshooting:
Engine oil pressure, brake oil pres-
sure, and coolant temperature
• Maintenance periods of various oils,
filters, and pins
10-177-5 WA800-3
4
2) Display (Example)
CHECKED LEVELS FILTER MAINTENANCE

ENG. OIL CHECKING INTVL LEFT
COOLANT CHECKING ENGINE 250H 220H
FUEL CHECKING T/M 500H 320H
BATTERY CHECKING HYDRAU 2000H 670H
FUEL 500H 320H
CHECKED LEVELS LUBRICATION 1

ENG. OIL GOOD INTVL LEFT
AXLE
COOLANT GOOD PIVOT 100H 50H
WORK
FUEL GOOD EQUIPM 250H 200H
S/T
BATTERY GOOD CYLND 250H 200H
LUBRICATION 2
CONNECTION OF LINES 1 INTVL LEFT
CNTR
TO SENSORS HINGE 1000H 650H
DRIVE
P ENG. OIL CHECKING SHAFT 1000H 650H
CNTR
P BRAKE CHECKING SPPRT 1000H 650H
L COOLANT CHECKING
START OK
YOU CAN NOW START

CONNECTION OF LINES 1 ENGINE
TO SENSORS NO ERROR DETECTED
P ENG. OIL GOOD
P BRAKE GOOD
L COOLANT GOOD
OIL MAINTENANCE
INTVL LEFT
ENGINE 250H 220H
T/M 1000H 670H
HYDRAU 2000H 1670H
AXLES 2000H 1670H
WA800-3 10-177-6
4
3. Warm-up inspection mode

1) Function
After the engine is started, the following
items are inspected. If any abnormality
is found, the abnormality display screen
appears and an alarm is output.
• Pressure inspection:
Engine oil pressure, brake oil
pressure, and charge voltage
Note) For 30 seconds after the en-
gine is started, the brake oil
pressure is lower than the
normal level. This is not ab-
normal, however. The pres-
sure is heightened in this pe-
riod.
• Filter clogging inspection: Air cleaner
PRESSURES OF CHECK FILTER

ENGINE OIL CHECKING AIR CLN. GOOD
BRAKES CHECKING
BATTERY V CHECKING
PRESSURES OF WORK LOW IDLE

ENGINE OIL GOOD UNTIL ENGINE
BRAKES GOOD WATER AND T/C
BATTERY GOOD OIL TEMPERATURE
ARE IN GREEN
CHECK FILTER
AIR CLN. CHECKING
10-177-7 WA800-3
4
4. Abnormality display mode

1) Function
If any abnormality occurs, the abnormal- The abnormality display screen can be
ity display screen appears and an alarm canceled by holding the Feed/Update
is output. The abnormality display screen switch and Numeral/Subtotal switch for
is classified by items. If abnormality 2 seconds. If it is canceled, the screen
shown in another screen occurs, that before it appears. The external alarms of
screen appears automatically to display lamps and buzzers keep operating, how-
the abnormality. ever.
Displayed abnormal items
Method of display
Condition
Screen Displayed items Display range Display on Check Caution
Buzzer for display
monitor lamp lamp
Engine oil level Below low level Abnormal Flashing OFF OFF
Starting
Check before Coolant level Below low level Abnormal Flashing OFF OFF switch is ON.
starting Fuel level Below set level Insufficient Flashing OFF OFF Engine is
stopped.
Battery fluid level Below low level Abnormal Flashing OFF OFF
Fluid level Coolant level Below low level Abnormal OFF Flashing ON
check Fuel level Below set level Insufficient OFF Flashing OFF
Engine oil pressure Below set pressure Abnormal OFF Flashing ON
Below set pressure Abnormal OFF Flashing ON
Pressure Brake oil pressure Below set pressure
inspection For 30 sec after Heightening OFF Flashing OFF
engine is started
When charging is Engine is
Charge voltage abnormal Abnormal Flashing OFF OFF running.
Coolant 102 – 105°C Abnormal OFF Flashing OFF

temperature Above 105°C Abnormal OFF Flashing ON
Temperature
inspection Torque converter 120 – 130°C Abnormal OFF Flashing OFF
oil temperature Above 130°C Abnormal OFF Flashing ON
Filter clogging When filter is
Air cleaner clogged Abnormal Flashing OFF OFF
inspection
When relay circuit is
disconnected Disconnection Flashing OFF OFF
Engine oil When relay circuit is

pressure line ª2 shorted with ground Short circuit Flashing OFF OFF
When sensor circuit Starting

Electric system is disconnected Abnormal Flashing OFF OFF switch is ON.
troubleshooting Engine is
1 ª1 Brake oil pressure When disconnected Disconnection Flashing OFF OFF stopped.
When shorted with Engine is
line Short circuit Flashing OFF OFF running.
ground
When disconnected Disconnection Flashing OFF OFF
Coolant level line When shorted with
ground Short circuit Flashing OFF OFF
WA800-3 10-177-8
4
Method of display
Condition
Screen Displayed items Display range Display on Check Caution
Buzzer for display
monitor lamp lamp
Engine coolant When shorted with
temperature line ground Short circuit Flashing OFF OFF
Electric system Torque converter When shorted with

troubleshooting oil temperature line ground Short circuit Flashing OFF OFF
2 Fuel level line When disconnected Disconnection Flashing OFF OFF
Starting
Boom pressure line When disconnected Disconnection Flashing OFF OFF switch is ON.
Output circuit Sensor power When shorted with Engine is
ground Abnormal Flashing OFF OFF stopped.
inspection source
Engine is
When shorted with
Check lamp Abnormal Flashing OFF OFF running.
power source
Output circuit When shorted with
inspection Caution lamp power source Abnormal Flashing OFF OFF
When shorted with

Caution buzzer power source Abnormal Flashing OFF OFF
ª1) Resistors are installed in series and in paral-

lel with the sensor wiring harness of electric
circuit troubleshooting 1 to check for dis-
connection and short circuit.
ª2) The engine oil pressure signal is reversed
by a relay and a resistor is installed to the
relay circuit.
10-177-9 WA800-3
4
CHECKED LEVELS CONNECTION OF LINES 1

ENG. OIL GOOD TO SENSORS
COOLANT NOT GOOD P ENG. OIL SHRT CIR
FUEL NOT GOOD P BRAKE SHRT CIR
BATTERY NOT GOOD L COOLANT SHRT CIR
LEVEL OF CONNECTION OF LINES 1

TO SENSORS
COOLANT NOT GOOD P ENG. OIL NOT GOOD
FUEL NOT GOOD P BRAKE GOOD
L COOLANT GOOD
PRESSURES OF CONNECTION OF LINES 2

ENGINE OIL NOT GOOD TO SENSORS
BRAKES NOT GOOD T COOLANT SHRT CIR
BATTERY V NOT GOOD T T/C OIL SHRT CIR
L FUEL OPEN CIR
P LIFT CY OPEN CIR
CHECK FILTER MONITOR LAMP/BUZZER

AIR CLN. NOT GOOD CHECK L NOT GOOD
CAUTION L NOT GOOD
CAUTION B NOT GOOD
CONNECTION OF LINES 1
TO SENSORS
P ENG. OIL OPEN CIR
P BRAKE OPEN CIR
L COOLANT SHRT CIR
WA800-3 10-177-10
4
5. Monitor mode
1) Function
The present time, engine speed, coolant
temperature gauge, torque converter oil
temperature gauge, and fuel level gauge
are displayed.
Present time:
Year, Month, Day, Hour, and Minute
Engine speed: 0 to 9999 rpm by 1 rpm
Various gauges: 7-level gauges
6. Load meter mode

1) Function
• Outline
There are the integration mode, sub-
traction mode, calibration mode, and
pressure display mode in the load
meter mode, each of which is se-
lected with switches.
The measured data can be printed.
Change of mode in load meter mode
10-177-11 WA800-3
4
• Calibration mode • Subtraction mode

The no-load pressure of the bucket is In this mode, the load measured each
measured in this mode. If the boom is time is subtracted from a target value
raised from the bottom to the top with which is set in advance. When the load
no load on it, the no-load pressure (cali- is measured and the remainder becomes
bration pressure) is measured and saved negative, the following subtraction is per-
when the boom is horizontal. (The saved formed to attain the target work accu-
data is not deleted even after the power rately.
is turned off.) (1) The remainder becomes red (to indi-
When measuring, warm up the machine cate that it is negative) for 3 seconds
sufficiently and set the accelerator to the and the buzzer sounds intermittently
ratio for normal measurement. (at intervals of 0.8 seconds) during
this period.
• Integration mode (2) Then, the remainder becomes yellow
The every measured load is added in and changes to the weight up to the
this mode. The loads measured until target value (it changes to the value
printing are added up. If the integrated before measuring the weight of the
load is printed, it is cleared. last 1 bucket).
(3) Under this condition, adjust the load
in the bucket for the target value,
Measured Integrated
load load Remarks
and then raise and lower the boom
(ton) (ton) again to measure the load. Repeat
this operation until the remainder
3.0 3.0
Printed becomes 0 or negative (red).
2.0 5.0 integrated (4) If the remainder becomes 0 or nega-
3.5 8.5 data: 8.5
tive, the buzzer sounds intermittently
0.0 0.0
(at intervals of 0.4 seconds). Then,
the data is printed. The data must be
printed since the load cannot be
measured while the buzzer is sound-
ing intermittently.
(5) After the data is printed, the load left
in the bucket is subtracted from the
next target value.
The above sequence is shown below
concretely by using the work of pour-
ing material in a hopper up to target
quantity as an example.
Unit of load: ton

Load on Measured Total in Display of
Remarks
bucket load hopper remainder
0.0 — 0.0 12.0 (Sky blue) Initial target value
5.1 5.1 5.1 6.9 (Sky blue) 1st loading and dumping (5.1 t)
4.9 4.9 10.0 2.0 (Sky blue) 2nd loading and dumping (4.5 t)
5.0 5.0 10.0 3.0 (Red) 3rd loading and dumping, buzzer ON (Period: 0.8 sec)
5.0 — 10.0 2.0 (Yellow) After 3 sec
4.0 4.0 11.0 1.0 (Yellow) Dumping by 1.0 t and measurement
2.8 2.8 12.2 0.2 (Red) Dumping by 1.2 t and measurement, buzzer ON (Period: 0.4 sec)
2.8 — 12.2 9.2 (Sky blue) Printing (12.2 t), 2.8 t left in bucket
WA800-3 10-177-12
4
The target data are set by the following The measured load is saved after 15 sec-
method. onds. At this time, the measured load is
(1) Hold the feed/update switch for 2 sec- displayed as 0.0.
onds, and the alphabet letter of the
type flash in yellow. Measured After 15 sec Measured
load (ton) load (ton)
(2) Each time the feed/update switch is
pressed, the flashing point moves in 3.0 → 0.0
the following order. Make the figure
to be set flash.
• Cancellation of measured value
1st figure to left
Type → → 2nd figure If the cancel switch is held for 2 seconds
of target data
↑ ↓ within 15 seconds after measurement,
5th figure ← 4th figure ← 3rd figure the measured data is cancelled.
(3) Press the numeral/subtotal switch to Measured load (ton) Integrated load (ton)
set the flashing figure. 3.0 3.0
(4) Set the target data by steps (2) and 2.0 5.0
(3). 0.0 3.0
(5) Hold the feed/update switch for 2 sec- Cancel switch ON
onds to finish setting.
• Pressure display mode
The current pressure, pressure at the • Subtotal and total of measured data
time of measurement, pressure at the The subtotal and total, which are the in-
time of calibration, and theoretical no- tegrated values of the measured data,
load pressure in the boom cylinder are can be saved.
displayed. These data can be printed. If The subtotal is the value integrated until
they are printed, measured weight is it is printed in the load meter mode. It is
printed, too. cleared after it is printed. Accordingly, it
• Load measurement mechanism is used to measure the load on each
The load on the bucket is measured with dump truck, etc.
the pressure sensor installed to the bot- The total is the value integrated until it
tom of the boom cylinder and the prox- is printed in the operation record mode.
imity switch of the boom. It is cleared after it is printed. Accord-
The proximity switch is set to the almost ingly, it is used to measure the produc-
horizontal position of the boom. When tion in each day, etc.
the boom is raised from the bottom and Up to 600 subtotals can be saved for
the proximity switch operates, the pres- each type. When 600 subtotals are saved,
sure is measured. The pressure at the they are printed automatically.
loaded time is subtracted from the meas-
ured pressure and the remainder is con-
verted into the no-load pressure. The
pressure-load characteristics are decided
for each model and set in the controller.
Printing in operation record mode.
10-177-13 WA800-3
4
• Type Mode A: Only the subtotal data of each

Integration and subtraction can be per- type is printed.
formed for up to 5 types of measured Mode B: Each measured data of each
objects respectively. type and the subtotal are
The type is changed by the following printed.
method. (1) How to print subtotal data and pres-
(1) Hold the feed/update switch for 2 sure display
seconds. In each mode, hold the numeral/sub-
(2) The alphabet letter of the type flash total switch or subtotal switch of the
in yellow. lever for 2 seconds.
(3) Each time the numeral/subtotal (2) How to print total data
switch is pressed, the alphabet letter In the integration mode or subtrac-
changes in the following order. tion mode, hold the numeral/subto-
tal switch and operation record
A → B → C switch simultaneously for 2 seconds.
↑ ↓
E ← D Print format of subtotal
(4) After selecting the type, hold the Mode A

feed/update switch for 2 seconds to
finish selection.
• Clearing data
The subtotals and totals of the all types
can be cleared, or only the subtotal of
the currently measured type can be
cleared. Each subtotal cannot be cleared
for 15 seconds after it is measured, how-
ever.
(1) How to clear data of all types
Hold the feed/update switch, nu-
meral/subtotal switch, and load me-
ter switch simultaneously for 2 sec-
onds. Mode B
(2) How to clear subtotal
Hold the numeral/subtotal switch and
load meter switch simultaneously for
2 seconds.
• Printing
The subtotal data, total data, and pres-
sure display data can be printed.
If the subtotal data is printed, it is cleared.
It is printed in 2 modes.
WA800-3 10-177-14
4
Print format of total Print format of pressure display
2) Display
Integration mode screen Subtraction mode screen
Pressure display mode screen
PRESSURES AT LOAD
CALIBRATION SEQ.
MODEL WA800-3
1. TILT EMPTY BUCKET ACTUAL 55.35 kg/cm2

COMPLETE BACK MEASURED 103.20 kg/cm2
2. LIFT BOOM UP CALIBRAT 38.12 kg/cm2
EMPTY 37.70 kg/cm2
7. Maintenance mode
1) Function
• Outline The abnormality display screen can be
The replacement periods of various oils canceled by holding the Feed/Update
and filters and the greasing periods of switch and Numeral/Subtotal switch for
the pins are counted. At each replace- 2 seconds. If it is canceled, the screen
ment/greasing period, the number be- before it appears. At this time, the check
comes red and the check lamp lights up. lamp goes off. If the starting switch is
The replacement period is indicated by turned off and on without repairing the
subtraction method (The remaining pe- abnormality, the abnormality display
riod is reduced by 1 hour by 1). When screen appears first. In this case, cancel
the remaining period become 0 or nega- the abnormality display screen and re-
tive, the warning is turned on. turn to the maintenance mode, and then
reset the replacement time.
10-177-15 WA800-3
4
(4) Hold the feed/update switch for 2 sec-

Specified
Item onds, and the replacement period is
time (h)
set to the specified value. To return
Engine 250 the changed period to the value be-
fore changing, hold the feed/update
Transmission 1000
Oil switch for 2 seconds again.
Hydraulic 2000 (5) Hold the feed/update switch for 2 sec-
onds to finish resetting.
Axle 2000
(6) If the numeral/subtotal switch and
Engine 250 maintenance switch are held simul-
taneously for 2 seconds under the
Transmission 500
Filter condition of step (2), all the data can
Hydraulic 2000 be reset.
Fuel 500
• Prohibition of counting of replacement
Axle pivot 100 period
Counting of the replacement/greasing pe-
Pin 1 Work equipment 250
riod of each item can be prohibited by
Steering cylinder 250 the following method. The replacement
period of the prohibited item is displayed
Center hinge 1000
in white.
Pin 2 Drive shaft 1000 (1) Press the maintenance switch to se-
lect the screen of an item to be pro-
Center support 1000
hibited.
onds, and the replacement period of
• Selection of screen the top item flashes in yellow.
There are 4 screens in the maintenance (3) Press the feed/update switch to se-
mode. Those screens appear in the fol- lect the item to be prohibited (Make
lowing order each time the maintenance that item flash).
switch is pressed. (4) Hold the numeral/subtotal switch for
10 seconds, and the replacement
Oil maintenance → Filter maintenance period becomes white. To reset the
↑ ↓ prohibition, hold the numeral/subto-
Pin 2 maintenance ← Pin 1 maintenance tal switch for 10 seconds again.
onds to finish setting prohibition.
• Resetting of replacement period
The time of an item which is replaced or
greased can be reset to the specified
period by the following method.
(1) Press the maintenance switch to se-
lect the screen of the item to be re-
set.
onds, and the replacement period of
the top item flashes in yellow.
(3) Press the feed/update switch to se-
lect the item to be reset (Make that
item flash).
WA800-3 10-177-16
4
2) Display
OIL MAINTENANCE FILTER MAINTENANCE

INTVL LEFT INTVL LEFT
ENGINE 250H 250H ENGINE 250H 250H
T/M 1000H 1000H T/M 500H 500H
HYDRAU 2000H 2000H HYDRAU 2000H 2000H
AXLES 2000H 2000H FUEL 500H 500H
LUBRICATION 2 LUBRICATION 1
INTVL LEFT INTVL LEFT
CNTR AXLE
HINGE 1000H 1000H PIVOT 100H 100H
DRIVE WORK
SHAFT 1000H 1000H EQUIPM 250H 250H
CNTR S/T
SPPRT 1000H 1000H CYLND 250H 250H
8. Oil/Water addition mode

1) Function Item Item
added oil/water 1
added oil/water 2
• Outline Fuel Transmission oil
Quantity of
Quantity of
If the quantity of added oil or water is
input, it is saved. Each item can be input Grease Hydraulic oil
from 0 to 999 (liters). If the saved data Engine oil Axle oil
are printed in the operation record mode,
they are cleared. Coolant
There are 7 items saved in this mode,
which are displayed on 2 screens. The
screen is changed by holding the oil/
water addition switch for 2 seconds.
• How to input data Feed/Update switch
(1) Select the screen of the item to be
input.
onds, and the first figure from the
right in the top item flashes in yel-
low.
(3) Press the oil/water addition switch
to select the item to be input. (The
first figure from the right in the se-
lected item flashes.) Numeral/Subtotal switch
(4) Press the feed/update switch to se-
lect the figure to be input. (The se-
lected figure flashes.)
(5) Press the numeral/subtotal switch to
set the data.
(6) To select the other screen, hold the
oil/water addition switch for 2 sec-
onds.
(7) Press the feed/update switch to fin-
ish inputting.
10-177-17 WA800-3
4
2) Display
9. Operation record mode

1) Function • Number of loading times and integrated
• Outline weight
The starting and finishing times of work, Number of the loading times and inte-
operating hours, number of loading grated weight of each type measured in
times, and integrated weight can be the load meter mode are displayed.
saved and displayed in this mode. They Only the data of the types set in the load
can be printed, too. In addition, the date, meter mode are displayed.
time, and serial No. of each vehicle can The number of the loading times and
be set and the print mode of the load integrated weight of the types which
meter can be selected. have loaded and the totals of those val-
• Starting and finishing times of work and ues are printed.
operating hours • Selection of screen
Starting time of work: Hold the operation record switch for 2
The time when the engine is started seconds, and the screen changes in the
for the first time after the data is following order.
printed Operation record Date, time, and serial
Finishing time: screen → No. setting screen
The time when the data are printed. ↑ ↓
If the data are printed when the en- Load meter printer mode setting screen
gine is stopped, however, the time
when the engine is stopped is dis- • Setting of date, time, and serial No.
played. Select the date, time, and serial No. set-
Operating hours: ting screen and set the date, time, and
The integrated running hours of the serial No. according to the following pro-
engine (Service meter). cedure.
• Setting of serial No.
onds, and the first figure from the
right in the serial No. flashes in yel-
low.
(2) Press the feed/update switch to make
the figure to be set flash.
(3) Press the numeral/subtotal switch to
set the serial No.
WA800-3 10-177-18
4
• Setting of date (3) Press the feed/update switch to se-

(1) Press the operation record switch to lect a figure to be changed. At this
select the item to be set (Serial No., time, the 2nd and upper 3 figures
minute, hour, day, month, or year). become yellow. If the upper figure(s)
(2) Press the numeral/subtotal switch to is (are) 0, it (they) is (are) not dis-
set a value. At this time, if the switch played.
is held for 2 seconds or more, the ( _ _ 100) “_” is blank.
number increases by 2 automatically. These 4 figures become yellow.
(3) Hold the feed/update switch for 2 sec- (4) Press the numeral/subtotal switch to
onds to finish setting. change the data.
(5) Hold the feed/update switch and op-
Operation record switch eration record switch for 2 seconds
to finish setting.
• Printing
Hold the numeral/subtotal switch or the
subtotal switch of the lever for 2 sec-
onds in the operation record screen, and
the operation record data are printed.
Printed data
Feed/Update switch (1) Operating day and operating hours:
Starting time and finishing time of
Numeral/Subtotal switch work, service meter: Operating hours
(2) Load meter data:
Number of loading times and inte-
grated weight of all types and totals
of those values
(3) Maintenance period:
Time up to next replacement/greas-
• Setting of load meter printer mode ing of each item
Select the load meter printer mode set- (4) Quantity of added oil/water
ting screen and set the mode according Data of each input item. Items which
to the following procedure. have not been input are printed as
(1) Hold the feed/update switch for 2 sec- “None”.
onds, and the mode selection dis- (5) Abnormal item:
play (A or B) flashes in yellow. Date and time when abnormality oc-
(2) Press the numeral/subtotal switch to curs. If any abnormality has not oc-
select a mode (A or B). curred, “None” is printed.
onds to finish setting.
• Setting of operating hours
The operating hours can be changed ac-
cording to the following procedure.
(1) Stop the engine and select the op-
eration record screen.
(2) Hold the feed/update switch and op-
eration record switch for 2 seconds,
and the 1st figure from right in the
operation record flashes in yellow.
10-177-19 WA800-3
4
Print format
2) Display
WORKING DATA CHANGE DATE & TIME Selecting load meter print
START TIME 9 : 15 Y M D A: Each individual weighed
END TIME 17 : 30 load is printed out
H M B: Only the sub total load
WORK HOURS 2150
SET UP SERIAL NO and total number of loads
NUM. DUMPS 50 TIMES are printed out
TTL WEIGHT 185.6 TON SERIAL NO Mode selection:
WA800-3 10-177-20
4
SELECTION OF MODEL
Since the load meter data are different from a

model to another, select the model with the dip Switch position Model
switches of the controller. 0 WA200-3
Procedure for selection 1 WA300-3

• Remove the rubber cap from the surface of 2 WA350-3
the controller.
• There is a rotary switch under the rubber 3 WA400-3
cap. Rotate that switch with a small plastic 4 WA450-3
cross-head screwdriver (or a small flat-head
screwdriver) to set the model. 5 WA500-3
6 WA600-3
7 WA700-3
8 WA800-3
9 WA900-3
A —
B —
• The correspondence between the switch po- C WA300-3 m/c
sitions and models is shown at right.
D WA350-3 m/c
E WA400-3 m/c
FUNCTION OF CLEARING ALL DATA IN
MEMORY F WA450-3 m/c
The controller of the control monitor has a

memory (storage) in it. The data of the load
meter, operation record, etc. are saved in that
memory even if the starting switch is turned off.
While the starting switch is off, the memory is
powered with the battery in the controller and
the battery on the vehicle. Accordingly, if the
battery on the vehicle is removed for replace-
ment, etc., the data in the memory are broken.
In this case, all the data in the memory must be
cleared. If the data in the memory are broken,
when the power is turned on, the “KOMATSU”
logo screen is kept displayed or the data of the
load meter and operation record become abnor-
mal. If the internal battery is charged fully at
this time, however, the data are kept about 1
week, even if the battery on the vehicle is re-
moved.
• Method of clearing all data in memory

Hold the feed/update switch, numeral/subto-
tal switch, and load meter switch simultane-
ously and turn the starting switch on, and
then keep holding those switches while the
“KOMATSU” logo screen is displayed.
10-177-21 WA800-3
4
Pressure sensor
1. Voltage amplifier
2. Lead wire
3. Connector
4. Flange
5. Pressure sensor module
6. Pressure receiving pipe
Function
The pressure sensor is installed to the bottom
side of the boom cylinder and used to measure
the cylinder bottom pressure. The relationship
between the pressure and voltage is shown be-
low.
Battery fluid level sensor
1. Body Function
2. Connector • The battery fluid level sensor is installed to
3. Filter the battery. When the battery fluid lowers
4. Packing below the specified level, the sensor tip is
5. Pin exposed to air and the voltage applied to it
changes. The signal of the voltage change is
sent to the control monitor (controller), and
then the control monitor displays lowering
of the battery fluid level.
WA800-3 10-177-22
4
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL SYSTEM
WORK EQUIPMENT CONTROL SYSTEM

System diagram
Input signals Output signals
Bucket cylinder proximity switch D D Magnet detent boom RAISE

Safety lock lever switch D D Magnet detent boom FLOAT
Remote positioner RAISE set switch D D Magnet detent bucket TILT
Work equipment controller

Remote positioner LOWER set switch D D Remote positioner RAISE
Remote positioner RAISE/LOWER stop indication
selector switch D D Remote positioner LOWER
Lever potentiometer boom 1 A stop indication
Lever potentiometer boom 2 A D Work equipment neutral lock
Lever potentiometer bucket 1 A solenoid
Lever potentiometer bucket 2 A A Boom RAISE EPC
Boom angle sensor A A Boom LOWER EPC
Engine speed output signal P A Bucket TILT EPC
A Bucket DUMP EPC
D Buzzer output
Control function
Remote positioner function

Stopping boom at RAISE and LOWER positions
Setting boom RAISE and LOWER stop positions
Sensor adjustment function
Troubleshooting function
OUTLINE
• With the remote positioner control, the op-
erator can set the boom stop (lever kick-out)
position freely to start and stop the boom
smoothly. As a result, the operator can con-
trol the machine safely and easily during
reverse travel, digging work, and approach
to a dump truck.
10-177-23 WA800-3
(6)
Configuration of work equipment control system circuit
WA800-3 10-177-24
(6)
OUTLINE OF REMOTE POSITIONER Raise ‡

Raise fi Raise ‡ Raise fi
1. Stopping boom at RAISE and LOWER posi- 1 → 2 → 3 → 4
tions Lower fi Lower ‡ Lower ‡ Lower fi
The controller constantly senses the lever
operating direction sent from the boom le- Lamp is turned ON: ‡
ver potentiometer and the boom angle (po- Lamp is turned OFF: fi
sition) sent from the boom angle
potentiometer. 2. Setting remote positioner to RAISE stop po-
1) Boom RAISE stop (When RAISE selector sition
switch is turned ON) While the RAISE lamp is turned ON, set the
If the boom control lever is set in the stop position freely.
RAISE DETENT position and the boom The set position is saved even if the key
rises to just before the set position, the switch is turned OFF.
boom raise detent is reset and the boom 1) Setting stop position
stop modulation control is performed. i) Raise the boom to a position to be
When the boom is not in the RAISE set.
DETENT position, the boom rises accord- ii) Press and release the remote
ing to the operator’s operation. positioner raise position set switch.
When RAISE is not selected (When the iii) If the remote positioner raise posi-
selector switch is turned OFF), only the tion set switch was released in the
RAISE KICK-OUT operates. When the settable range, the angle at which
boom is in the DETENT position, if the the switch was released is saved tem-
boom angle is larger than the level, only porarily and the setting completion
the RAISE KICK-OUT operates. buzzer makes 2 pips. If the switch is
2) Boom LOWER stop (When LOWER se- released out of the settable range,
lector switch is turned ON) the setting cancel buzzer sounds.
If the boom control lever is set in the iv) The raise indicator flashes (for 2.5
FLOAT DETENT position and the boom seconds).
lowers to 10° before the set position, v) After the raise indicator stops flash-
deceleration starts and the float detent ing, the setting is saved.
is reset and the boom stop modulation 2) Resetting stop position
control is performed. If the boom con- i) While the raise indicator is flashing
trol lever is set in the LOWER CONTROL (for 2.5 seconds) in step iv) for set-
position at this time, the boom starts ting the stop position, press and re-
lowering again. lease the remote positioner raise set
When LOWER is not selected (When the switch again.
selector switch is turned OFF), only the ii) After the raise indicator stops flash-
FLOAT DETENT operates. When the ing, set the raise stop position point
boom is in the DETENT position, if the to 0° (level).
boom angle is larger than the level, only iii) The set (default) value is saved.
the FLOAT DETENT operates.
3. Setting remote positioner to LOWER stop
Table 1 position
While the LOWER lamp is turned ON, set
Stop position
Raise Lower the stop position freely.
Model The set position is saved even if the key
switch is turned OFF.
WA800-3 0° – 43.1° 0° – 39.8°
1) Setting stop position
i) Lower the boom to a position to be
The setting of control can be changed in set.
the following order by pressing the ii) Press and release the remote
RAISE/LOWER selector switch of the re- positioner lower position set switch.
mote positioner. The boom stops auto-
matically at the position where the lamp
is lighting.
10-177-25 WA800-3
(6)
iii) If the remote positioner lower posi-

tion set switch was released in the
settable range, the angle at which
the switch was released is saved tem-
porarily and the setting completion
buzzer makes 2 pips. If the switch is
released out of the settable range,
the setting cancel buzzer sounds.
iv) The lower indicator flashes (for 2.5
seconds).
v) After the lower indicator stops flash-
ing, the setting is saved.
2) Resetting stop position
i) While the lower indicator is flashing
(for 2.5 seconds) in step iv) for set-
ting the stop position, press and re-
lease the remote positioner lower set
switch again.
ii) After the lower indicator stops flash-
ing, set the lower stop position point
to 0° (level).
iii) The set (default) value is saved.
4. Conditions for outputting buzzer and indi-

cator lamp signals
The buzzer and indicator lamp signals are
output under the same conditions for rais-
ing and lowering.
Output condition Indicator lamp Buzzer output Stop position
Remote positioner selection switch = On Comes on None Controlled with the

value saved previously
Remote positioner selection switch = On; Controlled with the

Position setting switch = On. Blinks Setting completion value saved previously.
Output for 2.5 seconds or until reset (for 2.5 seconds buzzer beeps upon Value attained when
(When the sensor is operating normally) or until reset) releasing setting switch. setting switch was
released is saved
Remote positioner selection switch = On; Setting cancellation Controlled with the
Position setting switch = On; Comes on. buzzer beeps upon value saved previously.
Boom angle = Outside the setting range. releasing setting switch. The value stored is not
altered.
Remote positioner selection switch = On; Not controlled.

When the sensor is not operating normally. Goes off. None The value stored is not
altered.
Controlled with the

Remote positioner selection switch = On; Comes on. None value saved previously.
When the sensor is not operating normally. The value stored is not
altered.
Remote positioner selection switch = On; Setting cancellation Controlled with the
Position setting switch = On. Comes on. buzzer beeps upon value saved previously.
Reset during 2.5-seconds blinking releasing setting switch. The default value is
(Position setting switch = On again) saved.
Not controlled.
Remote positioner selection switch = Off Goes off. None RAISE/FLOAT detent is
controlled.
WA800-3 10-177-26
(6)
SENSOR ADJUSTMENT FUNCTION

• With this function, errors made when the
potentiometers are installed can be offset
and the correct position data of the work
equipment can be obtained.
Be sure to use this function after the con-
troller, a potentiometer, or the work equip-
ment is replaced.
TROUBLESHOOTING FUNCTION
• The controller constantly monitors the elec-
tronic parts of each potentiometer which re-
ceives input signals, each solenoid valve
which receives output signals, etc. to see if
they are functioning normally.
• If any one of the above parts has trouble,
the controller detects it and notifies the op-
erator of the trouble by flashing the LED of
the remote positioner switch.
10-177-27 WA800-3
(6)
POTENTIOMETER
1. Connector
2. Case
3. Shaft
4. Element
5. Bearing
6. Contact
7. Mold
Function
The boom angle potentiometer is installed to The hatched area in the diagram above is the
the front frame boom mount, and detects the abnormality detection area, and if the controller
boom angle. receives this signal, it judges that there is a dis-
Inside the potentiometer, the 5 V power source connection, short circuit, or other abnormality in
voltage from the angle is converted by the re- the potentiometer system.
sistance value of a variable resistor to a signal
voltage, and this is sent to the controller.
WA800-3 10-177-28
(6)
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROLLER
WORK EQUIPMENT CONTROLLER
10-177-29 WA800-3
(6)
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROLLER
CONNECTOR SIGNALS
CN1 (CN P01) CN2 (CN P02) CN3 (CN P03)

Pin Signal name Input/ Pin Name of signal Input/ Pin Name of signal Input/
No. output No. output No. output
1 Bucket control lever potentiometer B Input 1 — — 1 Power source, +24 V, unswitched Input
2 — — 2 Remote positioner raise/lower select Input 2 Power source, +24 V Input
3 — — 3 Remote positioner lower set Input 3 Solenoid, common GND GND
4 — — 4 — — 4 Buzzer OUT Output

5 — — 5 — — 5 Bucket tilt EPC A Output
6 — — 6 — — 6 Boom raise EPC A Output
7 Bucket control lever potentiometer A Input 7 — — 7 — —

8 Boom angle potentiometer Input 8 — — 8 Remote positioner raise set indicator Output
9 — — 9 Remote positioner lower stop indicator Output 9 — —
10 — — 10 Engine speed signal Input 10 — —

11 — — 11 — — 11 Power source, +24 V, unswitched Input
12 — — 12 — — 12 Power source, +24 V Input
13 Boom control lever potentiometer B Output 13 Remote positioner raise set Input 13 Solenoid, common GND GND
14 — — 14 — — 14 Starting switch BR Input
15 — — 15 — — 15 Bucket dump EPC A Output
16 — — 16 — — 16 Boom lower EPC A Output

17 Safety lock level switch Input 17 — — 17 Boom lever rise detent Output
18 — — 18 — — 18 Remote positioner lower set indicator Output
19 Boom control lever potentiometer A Input 19 Remote positioner raise stop indicator Output 19 — —
20 — — 20 — — 20 Bucket cylinder proximity switch Input
21 SENSOR GND GND 21 — — 21 POWER GND GND
22 Potentiometer power source, +5 V Output 22 — — 22 Power source, +24 V Input

23 — — 23 — — 23 — —
24 — — 24 — — 24 Starting switch BR Input
25 BOOM ANGLE CAL MODE Input 25 Bucket tilt EPC B Output
26 — — 26 Boom raise EPC B Output
27 — — 27 Boom lever float detent Output
28 — — 28 Work equipment neutral lock solenoid A Output
29 — — 29 — —
30 — — 30 — —
31 — — 31 Controller GND GND
34 — — 34 — —
35 EPC LEVER CAL MODE Input 35 Bucket dump EPC B Output
36 — — 36 Boom lower EPC B Output
37 — — 37 Bucket lever tilt detent Output
38 — — 38 Work equipment neutral lock solenoid B Output
39 — — 39 — —
40 — — 40 — —
WA800-3 10-177-30
(6)
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
Alternator StartIne motor
Joystick steering
Neutral relay switch relay Engine stop relay
Starting switch
Enolna stop motor
L_77fT____-______.__J 7+&r m-
FUNCTION
. There is a neutral safety circuit which prevents At the same time, electric current flows from
the engine from being started if the directional starting switch terminal BR + battery relay coil
lever is not at the N portion. This is to ensure --+ ground, and the switch of the battery relay
safety when starting the engine. coil is closed.
. It is possible to start or stop the engine by Electric current flows from the battery (+) +
turning the starting switch ON or OFF. An elec- starting switch terminal B + starting switch
trical fuel-cut device (stop motor) is installed terminal BR --t engine stop motor relay coil -t
which improves the ease of operation. ground. Electricity then flows in engine stop
motor relay contacts (5) and (3).
OPERATION When this happens, electricity flows from the
. When the directional lever is placed at N po- battery (+) --t engine stop motor terminal B +
sition, the neutral contacts of the directional engine stop motor terminal P2 + engine stop
lever switch are closed. In this condition, if motor relay + engine stop motor terminal A
the starting switch is turned to the START + ground. The engine stop motor.is actuated,
position, electric current flows as follows. and the fuel cut-off is canceled. A circuit is
. Electric current flows from the battery (+I + formed from the battery (+) -* battery relay m+
starting switch terminal B + starting switch starting motor terminal B, so the engine starts.
terminal C + neutral relay terminals 5 - 3 + If the directional lever is not at the N position,
starting motor terminal C --+starting motor ter- the neutral relay is not actuated, so the circuit
minal E + ground. is not formed and the engine does not start.
lo-178 WA800-3
FUNCTION OPERATION
• The neutral safety circuit is employed to se- • If the forward-reverse switch is set in the N
cure safety when the engine is started. This (Neutral) position, the neutral contacts of the
circuit allows the engine to start only when forward-reverse lever are closed and neutral
the forward-reverse switch and the joystick relay contacts 3 and 5 are connected. On the
steering lever are in the N (Neutral) position. other hand, when the joystick steering lever
• It is possible to start or stop the engine by is in the N (Neutral) position, steering lever
turning the starting switch ON or OFF. An elec- neutral safety relay contacts 3 and 5 are con-
trical fuel-cut device (stop motor) is installed nected. If the starting switch is turned to the
which improves the ease of operation. START position, a current flows as shown
below.
• A current flows in the following route: Bat-
tery (+) terminal → Starting switch terminal B
→ Starting switch terminal C → Neutral relay
terminals 5 – 3 → Steering lever neutral safety
relay terminals 6 – 3 → Starting motor termi-
nal C → Starting motor terminal E → Ground.
WA800-3 10-178-1
(6)
• At the same time, electric current flows from

starting switch terminal BR → battery relay coil
→ ground, and the switch of the battery relay
coil is closed.
• Electric current flows from the battery (+) →
starting switch terminal B → starting switch ter-
minal BR → engine stop motor relay coil →
ground. Electricity then flows in engine stop
motor relay contacts 5 and 3.
When this happens, electricity flows from the
battery (+) → engine stop motor terminal B →
engine stop motor terminal P2 → engine stop
motor relay → engine stop motor terminal A
→ ground. The engine stop motor is actuated,
and the fuel cut-off is canceled. A circuit is
formed from the battery (+) → battery relay →
starting motor terminal B, so the engine starts.
• When the forward-reverse switch is not in the
N (Neutral) position, the neutral relay does not
operate. Accordingly, the steering circuit is not
formed and the engine does not start. When
the joystick steering lever is not in the N (Neu-
tral) position, the steering lever neutral safety
relay operates to break the steering circuit,
thus the engine does not start.
10-178-2 WA800-3
(6)
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT
Alternator Startino motor
I Startino switch Ii I
Engine stop motor
I B,]
0
/
t
M I- 1 120A 1
Slowblowfuse
J
II I/II + -11 IIll

Battery
OPERATION
. When the starting switch is turned OFF, cur-
rent stops flowing to the coil of the engine
stop motor relay. No electric current flows,
so the continuity between engine stop relay
contact (3) and (5) is shut off, and the circuit
between contacts (3) and (6) becomes con-
tinuous.
When this happens, current flows from bat-
tery (+) + engine stop motor terminal B + en-
gine stop motor terminal PI + engine stop
motor relay (contact 3 and 6) + engine stop
motor terminal A -+ ground connection. When
current flows in the above circuit, the fuel sup-
ply is cut, and the engine stops.
WA800-3 10-179
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
PREHEATING CIRCUIT
(AUTOMATIC PREHEATING SYSTEM)
Preheating relay
Startlna switch
Enain water Slow blow fuse

temperature sensor
_]*I
77kv
Battery relay
Main monitor
OUTLINE OPERATION
l To improve the ease of starting in cold areas, . When the starting switch is turned to the ON
an automatic preheating system is installed. (ACC) position, a circuit is formed from start-
This system helps to reduce the preheating ing switch terminal BR + controller inside
time and also automatically sets the preheat- main monitor + preheating output + ground.
ing time to match the engine water tempera- The preheating relay coil is excited, so the
ture when the starting switch is operated. preheating relay is actuated to actuate the
. When the starting switch is turned to the ON heater relay.
(ACC) position, the preheating pilot lamp on . Current flow from the battery + battery relay
the main monitor lights up and preheating is + heater relay + electrical intake air heater
carried out on the intake air for the electric to carry out preheating. When the preheating
intake air heater. completion signal is sent from the controller,
The engine water temperature is detected by the preheating relay and heater relay are
the water temperature sensor, and the pre- turned OFF and the preheating is completed.
heating time is set by the controller built into
the main monitor.
. While the pilot lamp is lighted up, preheating
is being carried out, so the starting switch
must be kept at the ON position. If the star-t-
ing switch is turned to the START position
while the pilot lamp is ON, the preheating is
canceled.
lo-180 WASOO-3
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL
ELECTRICAL TRANSMISSION CONTROL
1. Transmission cut-off selector switch 9. Transmission controller

2. Parking brake switch (Model with auto shift system)
3. Directional lever 10. Transmission control valve
4. Speed lever 11. Speed sensor
5. Kick-down switch 12. Transmission cut-off switch
6. Maintenance monitor 13. Brake valve (left)
7. Relays 14. Brake valve (right)
8. Fuse boxes
Function
1 Selection of F, R, and N positions Using directional lever
2 Selection of speed range Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch
3 Kick-down switch without using the speed lever. If directional lever is operated to R or N,
speed range automatically returned to 2nd.
Transmission is shifted to neutral when brake is operated.
4 Transmission cut-off function (Serial No.: 50001 – 50025: Right and left brake pedals)
(Serial No.: 50026 and up: Left brake pedal)
It is possible to select whether to actuate or not actuate the transmission
cut-off function. In this way, it is possible to obtain the same or greater
5 Transmission cut-off selector function ease of operation as on conventional loaders with the left brake when
carrying out scooping work or when loading or unloading the machine
from a trailer.
To prevent seizure of the parking brake when traveling with the parking
6 Neutralizer brake applied, the transmission is shifted to neutral when the parking brake
is applied.
If the directional lever is not at the N position, the engine will not start
7 Neutral safety function when the starting switch is turned. This prevents the machine from starting
suddenly. (For details, see STARTING CIRCUIT.)
8 Warning function When traveling in reverse, the backup lamp lights up and the backup horn
sounds to warn people in the area.
WA800-3 10-181
10-181
(6)
COMBINATION SWITCH
swwo3727
OUTLINE
. The directional lever has three positions and body by three screws. When each lever is
the speed lever switch has three positions. As operated to the desired position, the switch,
an individual part, the switch does not have a which is interconnected by a shaft, acts to
detent mechanism; the detent mechanism is allow electric current to flow to that circuit
in the combination switch. Each switch is only.
positioned by two pins, and is secured to the
General locations, function

1 Directional lever switch Switches between F, R, and N
2 Speed lever switch Selects speed range
Stopper used to prevent speed lever from entering 3rd during
3 Speed lever stopper
operations
’
1
4 1 Turn sianal indicators

1
1 Direction indicator lamps used when turning left or right
Turn signal indicator lever automatically returns to central position
5 Self cancel
after machines turns left or right
6 Lamp switch Switches on clearance lamp, head lamp, parking lamp, etc.
7 Dimmer switch Selects high beam for travel and low beam for passing
Makes both left and right turn signal indicator lamps flash at the
8 Hazard switch
same time
/ I
9 1 Emeraencv flashina oilot lame / Flashes at the same time as the emeraencv flashina lamp flashes
10 / Parkina brake switch / Aoolies or releases parking brake
lo-182 WAND-3
OPERATION
Directional lever (I) and shaft (2) of the speed le-
ver of the combination switch form one unit with
magnet (3), and magnet (3) also moves together
with lever (1).
Control switch (5) with built-in hole IC (4) is in-
stalled at the bottom of magnet (31, and hole IC
(4) is positioned on the board to match each po-
sition.
When directional lever (I) is operated to the F
position, magnet (3) is immediately above hole
IC (4) for the F position of the control switch. The
magnetism from magnet (3) passes through the
gap and case (6), and magnetism is applied to
hole IC (4).
When this happens, hole IC (4) is inside a magne-
tism detection circuit, so it detects the magnetism
of magnet (3) and sends the F position signal to
the electric current amplification circuit. In the
electric current amplification circuit, a signal is
output to actuate the transmission.
SEW00302
WA800-3 1O-l 83
STRUCTURE AND FUNCTION KICK-DOWN, HOLD SWITCH
KICK-DOWN, HOLD SWITCH
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
SOW02107
KICK-DOWN SWITCH HOLD SWITCH

OPERATION . The hold switch is installed to the boom
l The kick-down (shifting down from 2nd + lever, and when the hold switch is pressed,
1st) is actuated only when traveling in F2. the speed range displayed on the main
. When traveling in F2, if it is desired to shift monitor transmission indicator is held (when
down to 1st without operating the speed equipped with auto shift).
lever, operate the kick-down switch on the . Press the hold switch again to cancel (when
boom lever to ON to shift down to Fl. equipped with auto shift).
. After this, even if the kick-down switch is
pressed, the transmission is kept at Fl.
CANCELLATION (or not actuated)

. When directional lever is at N
. When directional lever is at R
. When speed lever is not at 2nd
. When starting switch is OFF
lo-184 WASOO-3
STRUCTURE AND FUNCTION JOYSTICK STEERING SYSTEM
JOYSTICK STEERING SYSTEM
1. Joystick
2. Transmission and joystick steering controller
3. Proportional solenoid valve
4. Control pump
5. Stop valve
WA800-3 10-184-1
5
1. Combination of joystick steering, transmission control functions

fi: Function is employed
Steering wheel Joystick
Boom lever switch
Automatic Manual Automatic Manual
Kick-down function fi fi fi —
Hold function fi — fi
Up/down function — — — fi
CN C5-5 input signal Kick-down Kick-down Kick-down Shift down
CN C5-13 input signal Hold Hold Shift up
2. Controller input signals 4. Main monitor display

• Common signal input for kick-down/shift
down switch (CN C5-5 terminal)
• Common signal input for hold/shift up
switch (CN C5-13 terminal)
Whether the joystick or the steering
wheel is in use is indicated by the above
signals.
3. Up/down shift switch function

• Shift up switch: Normal shift up is out-
put by signal input
• Shift down switch: Normal shift down is
output by signal input
• Judgement of the input of the switch
uses the change in the ON/OFF condi-
tion of the signal.
(When the switch is pushed, it becomes
ON (GND).)
In addition, it always uses the latest sig-
nal to judge shift up or down.
• The maximum speed range is set by the
transmission lever.
Range lever position Speed range used
3 3–1
2 2, 1
1 1
10-184-2 WA800-3
5
TRANSMISSION AND JOYSTICK STEERING CONTROLLER
10-184-4 WA800-3
5
(6)
Connector signal
C1 C3A C4
Pin Name of signal Input/ Pin Name of signal Input/ Pin Name of signal Input/
1 S/T SOL. cut relay Output 1 NC — 1 NC —
2 T/M F SOL. Output 2 NC — 2 Engine revolution sensor (+) Input
3 T/M 1 SOL. Output 3 S/T lever potentio meter Input 3 RS232C TXD Input
4 Engine revolution output Output 4 NC — 4 RS232C RXD Input
5 T/M 3 SOL. Output 5 NC — 5 NC —
6 GND Input 6 Pressure sensor power supply Output 6 NC —
7 Power supply (+24V) Input 7 Potentio power supply Output 7 NC —
8 Back lamp relay Output 8 NC — 8 Flash write sig. Input
9 T/M R SOL. Output 9 NC — 9 Engine rev./speed sensor (–) Output
10 T/M 2 SOL. Output 10 Engine select Input 10 RS232C GND Input
11 NC — 11 NC — 11 NC —
12 GND Input 12 NC — 12 NC —
13 Power supply (+24V) Input 13 NC —
C5
14 NC —
C2 Pin Name of signal Input/
15 NC — No. output
Pin Name of signal Input/
No. output 16 GND (for pressure sensor) Output 1 GND (for Plus) Output
1 SOL. power supply (+24V) Input 17 GND (for potentio) Output 2 Speed sensor (+) Input
2 S/T RH SOL. (+) Output 18 NC — 3 GND Output
3 S/T LH SOL. (+) Output 19 Neutralizer relay Input 4 GND Output
4 F LED (S/T) Output 20 Auto shift T/M Input 5 Kick down SW/Shift down SW Input
5 R LED (S/T) Output 6 T/M cut off switch Input
C3B
6 NC — 7 Joystick N (NC) Input
7 N LED (S/T) Output No. output 8 Joystick F (NC) Input
8 Neutral safety output (+) Output 1 Joystick S/T Input 9 Joystick R (NC) Input
9 Caution relay (S/T) (+) Output 2 Machine select 1 Input 10 GND (for Plus) Output
10 Caution (monitor) (+) Output 3 Machine select (EVEN parity) Input 11 S/T lever neutral switch Input
11 PGND Input 4 S-NET + Input 12 NC —
12 SOL. power supply (+24V) Input 5 Direction F Input 13 Hold SW/ Shift up SW Input
13 S/T RH SOL. (–) Output 6 Direction R Input 14 Manual SW Input
14 S/T LH SOL. (–) Output 7 Range SW1 Input 15 Joystick N (NO) Input
15 NC — 8 Range SW3 Input 16 Joystick F (NO) Input
16 NC — 9 NC — 17 Joystick R (NO) Input
17 NC — 10 Machine select 2 Input
18 Neutral safety output (–) Output 11 NC —
19 Caution relay (S/T) (–) Output 12 S-NET + Input Joystick System Functional
20 NC — 13 Direction N Input
Selection Table
21 PGND Input 14 Joystick ON/OFF switch Input OFF ON
Pin
15 Range SW2 Input C3B-1 OPEN GND
Machine Select Table 16 Range SW4 Input GND: Connect GND.

Machine OPEN: Disconnect GND.
WA800-3
Pin
C3B-2 OPEN
Automatic T/M Functional Engine Selection Table
Selection Table Engine
C3B-10 GND KOMATSU CUMMINS
OFF ON Pin
C3B-3 OPEN Pin C3A-10 OPEN GND
C3A-20 OPEN GND
GND: Connect GND. GND: Connect GND.
OPEN: Disconnect GND. GND: Connect GND. OPEN: Disconnect GND.
OPEN: Disconnect GND.
WA800-3 10-184-5
5
STRUCTURE AND FUNCTION AJSS (ADVANCED JOYSTICK STEERING SYSTEM)
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)

System configuration diagram
Control circuit configuration diagram
10-184-6 WA800-3
5
(6)
Control function Outline

• Potentiometer calibration function • The flow rate gain of the steering hydraulic
• Neutral interlock function system is controlled according to the differ-
• Troubleshooting function ence between the joystick steering lever an-
gle and the frame angle to improve the nar-
row steering angle characteristics and re-
sponse in quick counter steering. As a re-
sult, the controllability of the vehicle is im-
proved.
Potentiometer calibration function

• The angle difference (offset angle) between the steering lever and frame angle detecting
potentiometer is read and corrected automatically.
Neutral interlock function

• Interlock relays are installed to the engine and the starting line of the starting motor so that the
frame will not be bent and the vehicle will not start when the engine is started.
When the difference between the steering lever angle and frame angle is 6 degrees or more, the
interlock prevents the engine from starting. At this time, the buzzer sounds.
If the steering lever is set in the neutral position and the FNR switch is set in the “N” position, the
interlock is reset and the engine can start.
• When the FNR switch is not in the “N” position, the neutral safety function prevents the engine
from starting.
WA800-3 10-184-7
5
Troubleshooting function
The controller constantly checks that the electronic devices composing each potentiometer which
collects input signals, each solenoid valve which receives output signals, etc. are operating normally.
If any of those devices becomes abnormal, the controller detects it and indicate it by the “Failure
code” on the main monitor to notify the operator of it.
Failure codes table
System Main monitor

Code Item
Short circuit Disconnection action code
55 Travel speed sensor fi fi E00
56 Joystick caution buzzer relay fi fi None
57 Steering lever angle sensor fi fi E01 + CALL
Shifting of steering lever angle sensor,
58 — — E01 + CALL
frame angle sensor, or potentiometer signal
59 Frame angle sensor fi fi E01 + CALL
60 Steering lever lock switch fi fi E01 + CALL
62 Joystick neutral interlock relay fi fi E00
63 Joystick basic pressure control EPC solenoid fi fi E01 + CALL
10-184-8 WA800-3
5
POTENTIOMETER
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Function
The potentiometer senses the operating angle. the above signal in this area, it judges that the
In the potentiometer, the source voltage of 5 V potentiometer system has a trouble such as wire
is converted with a variable resistor into a sig- breakage, short circuit, etc. Since the correct po-
nal voltage according to the angle, then sent to sition cannot be sensed in this case, the control
the controller. output is turned off and the failure code is dis-
The hatched area in the above figure is the ab- played on the main monitor.
normality detection area. If the controller receives
WA800-3 10-184-9
5
TRANSMISSION AND JOYSTICK STEERING CONTROLLER
10-184-10 WA800-3
5
(6)
Connector signal
C1 C3A C4
Pin Name of signal Input/ Pin Name of signal Input/ Pin Name of signal Input/
1 NC — 1 NC — 1 NC —
2 T/M F SOL. Output 2 NC — 2 Engine revolution sensor (+) Input
3 T/M 1 SOL. Output 3 S/T lever potentiometer Input 3 RS232C TXD Input
4 Engine revolution output Output 4 NC — 4 RS232C RXD Input
5 T/M 3 SOL. Output 5 NC — 5 NC —
6 GND Input 6 Pressure sensor power supply (+24V) Output 6 NC —
7 Power supply (+24V) Input 7 Potentio power supply (+5V) Output 7 NC —
8 Back lamp relay Output 8 NC — 8 Flash write switch. Input
9 T/M R SOL. Output 9 NC — 9 Puls GND Output
10 T/M 2 SOL. Output 10 Engine select Input 10 RS232C GND Input
11 NC — 11 NC — 11 NC —
12 GND Input 12 NC — 12 NC —
13 Power supply (+24V) Input 13 Frame angle potentiometer Input
C5
14 NC —
C2 Pin Name of signal Input/
15 NC — No. output
No. output 16 GND (for pressure sensor) Output 1 GND (for Plus) Output
1 SOL. power supply (+24V) Input 17 GND (for potentio) Output 2 Speed sensor (+) Input
2 Auto 1 range LED (+) Output 18 NC — 3 GND Output
3 Auto 3 range LED (+) Output 19 Potentiometer CAL switch Input 4 GND Output
4 Auto 2 range LED Output 20 NC — 5 Kick down switch Input
5 NC — 6 T/M cut off switch Input
C3B
6 NC — 7 NC —
7 S/T EPC SOL (+) Output No. output 8 NC —
8 J/S lever neutral safety relay (+) Output 1 NC — 9 NC —
9 J/S caution buzzer relay (+) Output 2 Machine select 1 Input 10 GND (for Plus) Output
10 Caution (monitor) (+) Output 3 Machine select (EVEN parity) Input 11 NC —
11 PGND Input 4 S-NET (+) Input 12 NC —
12 SOL. power supply (+24V) Input 5 Direction F Input 13 Hold switch Input
13 NC — 6 Direction R Input 14 Auto/manual switch Input
14 NC — 7 Shift up switch (N. O.) Input 15 NC —
15 NC — 8 Shift down switch (N. O.) Input 16 NC —
16 NC — 9 S/T lever lock pressure switch Input 17 NC —
17 S/T EPC SOL (–) Output 10 Machine select 2 Input
18 NC — 11 NC —
19 J/S caution buzzer relay (–) Output 12 S-NET (+) Input
20 NC — 13 Direction N Input
21 PGND Input 14 Neutralizer relay Input
15 Shift up switch (N. C.) Input
Machine Select Table 16 Shift down switch (N. C.) Input

Machine
Pin
WA800-3 Engine Selection Table
C3B-2 OPEN Engine
KOMATSU CUMMINS
Pin
C3B-10 GND
C3A-10 OPEN GND
C3B-3 OPEN
GND: Connect GND.
GND: Connect GND. OPEN: Disconnect GND.
OPEN: Disconnect GND.
WA800-3 10-184-11
5
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
ELECTRIC PARKING BRAKE CONTROL
SWW03728
OUTLINE
l When electric current flows to the parking 1. Parking brake display switch
brake valve (solenoid valve), the hydraulic 2. Parking brake switch
pressure from the accumulator is applied to 3. Accumulators
the spring cylinder to release the parking 4. Emergency brake switch
brake. 5. Low pressure switch
On the other hand, if the electric current is 6. Spring cylinders
turned off, the oil pressure from the accumu- 7. Parking brake solenoid valve
lator is cut off, so the oil pressure inside the 8. Neutralizer relay
spring cylinder passes through the parking 9. Parking safety relay
brake valve and is drained, the parking brake
is actuated by the force of the spring.
WA800-3
lo-185
FUNCTION
1. Applying and releasing parking brake : The parking brake is applied or released by using
the parking brake switch (combination switch).
2. Emergency brake If there is damage to the hydraulic circuit, and the
pressure inside the accumulator drops and it is
impossible to guarantee the braking force of the
brake, the parking brake is automatically applied
to act as an emergency brake.
3. Parking brake safety It is dangerous if the parking brake can be released
simply by turning the starting switch ON after the
automatic parking brake has been applied.
Therefore, to ensure safety, the system is designed
so the brake cannot be released unless the starting
switch is turned ON and then the parking brake
switch is also turned ON.
4. Neutralizer : The parking brake may seize if the machine is
driven with the parking brake still applied. To
prevent this problem, the caution lamp lights up
and the alarm buzzer sounds to warn the operator
of the mistaken operation. In addition to this, when
the parking brake is applied, the transmission is
forcibly shifted to neutral to make it impossible to
driven the machine. However, the braking distance
will become longer if the transmission is shifted to
neutral when the emergency brake is applied. It
may also be necessary to move the machine if it
stops in places where it is prohibited to stop (such
as on railway crossings). To overcome this, the
circuits is designed so that the transmission is not
shifted to neutral when the emergency brake is
applied.
PARKING BRAKE SWITCH
Parklna brake switch
\ Parkins brake
10-186 WA800-3
PARKING BRAKE SOLENOID VALVE
PARKING SAFETY RELAY

NEUTRALIZER RELAY
Relay actuation table

Terminal
Electricity No. 3 6 5
between 1 and 2
OFF
ON
EMERGENCY BRAKE SWITCH
WA800-3 10-187
10-187
(6)
OPERATION
1. STARTING SWITCH OFF
Battery
Parkin@ brake
Neutralizer relay safety relay - III _-IL
Parking brake
switch Start ins
OFF switch
ADDEd - Released
h \/ \
Battery relay I I
I I
n
I I
To transmission controller
Emagr brak;tch’_i
SW4
-
Parking brake \ 424 I I Battery relay

solenoid valve
‘I ‘/‘I ‘I
Battery
SWWO3852
. When the starting switch is turned OFF, the

battery relay is opened, so electricity does not
flow to the parking brake circuit. For this rea-
son, if the starting switch is at the OFF posi-
tion, no electric current flows to the parking
brake solenoid valve, regardless of whether
the parking brake switch is ON (applied) or
OFF (released), so the parking brake is actu-
ated.
10-188 WAgOO-3
2. STARTING SWITCH ON
2-l When parking brake switch is ON (actuated) before starting switch is turned ON
Elat terv
Parking brake
Neutraltzer relay safety relay - /II _-IL
Parking brake
7n 1 switch
FF
Start ina
switch
eased
To transmission controller Slow blow fuse / /

-
Emergency brake switch
SW3 SW2 SW1
Battery relay I
Battery
. The electric current flows in circuit 0 from relay terminal 5 - 3 + parking safety relay
the battery 4 starting switch + battery relay terminal 1 - 2 + ground. From this point,
coil + ground, so the battery relay is closed. the parking safety relay is in the condition of
When this happens, electric current flows in circuit @ until the starting switch is turned
circuit @ from the battery + battery relay + OFF.
parking brake switch terminal 1 - 3 -+ parking . In this condition, electric current does not
brake safety relay terminal 1 - 2 + ground. flow to the parking brake solenoid valve, so
In this way, the parking safety relay is the parking brake is actuated.
actuated and safety relay terminals 3 - 5 are . In addition, in this condition, the trans-
closed. mission is shifted to neutral by transmission
. When this happens, circuit @ is formed from controller.
the battery + battery relay + parking safety
WA800-3 lo-189
2-2 When parking brake switch is OFF (released) before starting switch is turned ON
Parking brake Battery

Neutralfzer relay safety relay
I I Parktns brake
Parking brake
solenoid valve
I\ /I
. Electric current flows in circuit @Ifrom the bat- l In addition, the electric current does not flow
tery -+ starting switch -+ battery relay coil + to the transmission controller, so the machine
ground, so the battery relay is closed. How- does not move.
ever, in this case, the parking brake switch is
OFF (released), so the parking safety relay is
not actuated. For this reason, the electric cur-
rent does not flow to the parking brake sole-
noid valve, so after the automatic parking
brake is applied, the parking brake is not re-
leased automatically even when the starting
switch is turned ON.
10-190 VVA800-3
3. PARKING BRAKE SWITCH OFF (RELEASED)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
Battery
Parking brake
arkina brake
To transmlsslon controller
Parking brake Battery relay

solenoid valve
I/ //II + -11 ,1,12
Battery
SWWO3855
. If the parking brake switch is turned from Q This circuit is formed from the emergency
ON (actuated) to OFF (released), the circuit brake switch + parking brake solenoid valve
for terminals 2 and 3 of the parking brake + ground, and the parking brake is released.
switch is connected, and the parking brake l In addition, a signal is sent at the same time
safety relay is also actuated. For this reason, from terminal 3 of the neutralizer relay to the
electric current flows in circuit @ from the transmission controller to make it possible to
battery (+) + battery relay + parking brake travel.
safety relay + parking brake switch, and then
flows to circuit 0.
WA800-3 10-191
4. Parking brake switch ON (actuated)
Parkins brake
Neutralizer rela safety relay
Parking brake
-- switch
i Start ins
T
..”
Battery relay
t t I
Emergency brake swtch
’I ’I’I
Battery
SWW03856
. If the parking brake switch is turned ON (ap- . In addition, at the same time, the neutralizer
plied) after carrying out operations with the relay is reset, so the circuit between termi-
parking brake switch OFF (released), the cir- nals 3 and 5 is opened, and no electricity flows
cuit in the diagram above is formed. to the transmission directional circuit, so the
. Electric current does not flow to the parking transmission is shifted to neutral.
brake solenoid valve, so the oil pressure from As a result, the signal from terminal 3 to the
the accumulator to the spring cylinder is shut transmission controller is cut and the trans-
off. At the same time, the oil pressure inside mission is shifted to neutral.
the spring cylinder passes through the park- In this way, the transmission is shifted to neu-
ing brake valve and is drained, so the parking tral when the parking brake is applied. This
brake is applied by the force of the spring. makes it impossible for the machine to travel
with the parking brake applied, and prevents
the parking brake from seizing.
lo-192 WA8003
5. When main brake oil pressure drops (emergency brake actuated)
Parklna brake
Neutralizer relay safety relay
ParkIns bra
n n I Ire n I switch
t t
To transmlsslon controller
Parkina
solenoid
brake
valve
7 Battery relay
Battery
SWWO3851
OPERATION
. If the accumulator pressure drops, the emer- . For this reason, a signal is sent to the trans-
gency brake switch installed to the accumu- mission controller, and it is possible to engage
lator is opened. the transmission clutch. In this way, it is pos-
Forthis reason, the electric current stops flow- sible to use the engine brake when the emer-
ing to the parking brake solenoid valve, so the gency brake is applied, so the braking distance
oil pressure inside the spring cylinder is becomes shorter. At the same time, if the
drained and the parking brake is applied. emergency brake has been applied and it is
However, in this case, the condition is differ- necessary to move the machine (for example,
ent from the case where the parking brake if the emergency brake is applied when the
switch is ON (applied), because there is elec- machine is on a railway crossing), it is pos-
tric current flowing to the neutralizer relay coil. sible to move the machine by operating the
transmission lever.
WA800-3 10-193
20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine.. ...................................................................................................... 20- 2
Standard value table for chassis.. ..................................................................................................... 20- 3
Standard value table for electrical parts .......................................................................................... 20- 9
Testing and adjusting ............................................................................................................................. 20-I 01
Troubleshooting ...................................................................................................................................... 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
The service limit value given in the tables is the estimated value for the shipped machine based on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
These standard values are not the standards used in dealing with claims.
a When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
g When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
a When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
A Be careful not to get caught in the fan, fan belt or other rotating parts.
WA800-3 20-l
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Engine SA12V140-1
f
Cats?- Standard value Service limit
Item Measurement conditions Unit
gonV
-.-
for new machine value
High idling 2,220 YL50 2,220 * 50
Engine speed Low idling vm 650':' 650+:'
Rated speed 2,000 2,000
Air supply pressure kPa

At rated output 133 {1,000~ 106 {800)
(boost pressure) {mmHgl
Whole speed range

Exhaust temperature (ambient temperature: “C Max.650 700
20°C)
At sudden acceleration Max. 4.0 6.0

Bosch
Exhaust gas color
index
At high idling Max. 2.0 3.0
Intake valve 0.43 -

Valve clearance
mm
(normal temperature) 0.80 -
Exhaust valve
Oil temperature: 40 - 60°C

Compression pressurf 3
MPa Min. 3.14
(Engine speed:
(SAE30 oil) {kg/cm21 {Min. 32) :i2:
160 - 200 rpm
(Water temperature:
.-? Blow-by pressure kPa 1.47 2.94
Operating range)
(SAE30 oil) ImmHzO} 11501 (300)
P Rated output
w ---- ---__
(Water temperature:
0.25 - 0.39 0.18
Operating range]
(2.5 - 4.0) 11.8)
At high idling (SAE30)
MPa Min. 0.12 0.07

Oil pressure At low idling (SAE30)
Ikg/cmzI {Min. 1.2) IO.71
Min. 0.10 0.07

At low idling (SAEIOW)
{Min. 1.0) IO.71
I
Whole speed range
Oil temperature “C 80- 110 120
(oil pan)
Fuel injection timing Before top dead center deg. 30 * 1 30 + 1
Deflection of one belt

Alternator belt when pressed with finger
tension force of approx. 59 N mm 20 20 - 22
{approx. 6 kg}
Air conditioner Deflection when pressed

compressor with finger force of 9 - 12.5 16.5
belt tension approx. 98 N {approx. 10 kg}
20-2 WA800-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Machine model
T WA800-3
Standard value Senjctimit

Item Measurement conditions Unit
or new machinr
w b Engine stopped
Wg: 16.7 Il.71
_ * Hook push-pull scale to point a
and measure.
Travel N-FORWARD,
REVERSE mm 35 f 20
a
5.9 1::;(0.62:: 1 16.7 (1.7)
NIkg:
5.91::; {0.6$;) 16.7 (1.7)
35klO 35 ?I20
Travel mm
BWWOOfl71 35+ 10 35 + 20
HOLD-+FiAISE . Low idling Max. 23.5 (2.41 35.3 13.61

. Hydraulic oil temperature:
’ RAISE+HOLD 45- 55°C Max. 15.7 Il.61 23.5 (2.41
k Hook push-pull scale to center
HOLD+LOWER Max. 24.5 (2.5) 37.2 (3.81
of lever knob and measure.
Lift arn
LOWER+HOLD l Measure maximum value. - -
LOWER-tFLOAT Max. 34.3 (3.51 51.9 (5.3)
FLOAT+HOLD Max. 14.7 (1.5} 23.5 (2.31
HOLD+DUMP Max. 23.5 (2.4) 35.3 (3.61
Max. 23.5 (2.41 35.3 (3.61
Max. 14.7 {1.5} 23.5 (2.31
1 Low idling 67 + 15 67 k 30
1Hydraulic oil temperature:
Lift arm t”““-“-
HOLD+LOWER 45 - 55°C 53k15 53 f 30
---Es
* Hook push-pull scale to center
of lever knob and measure. mm 67i. 15 67 + 30
bMeasure maximum value.
t--izx-
60& 15 60 f 30
Bucket 60+ 15 60 * 30
1 Engine stopped
Play mm Max. 20 20
1Play in direction of turning
bFlat, horizontal,straight, dry
paved road surface
bHydraulic oil temperature:
45 - 55°C
9.8 - 14.7 9.8 - 14.7
Operating effort pHook push-pull scale to steering (1.0 - 1.5) (1.0 - I.51
wheel knob and measure.
pMeasure effort taken to turn
steering wheel.
Hydraulic oil temperature:

45 - 55°C Max. 6.8 6.8
Operating Flat, horizontal, straight, dry
time paved road surface
sec.
Left lock - right lock Max. 5.0 5.0
WA800-3 20-3
Cab standard value

Item Measurement conditions Jnit 3r new machine
gcr
l Put push-pull scale in contact at

point 150 mm from pedal fulcrum
a, and measure maximum value
Operating effort to end of stroke. ~{@I 59 16.01 88 19.01
l Low idling
l Engine water temperature:
Within operating range
l Engine stopped
Low idling (al) 52 -

Measuring Point A
deg.
High idling b2) 35
Stopper height (L) mm 58 -

TWW0184. 2
l Put push-pull scale in contact at

point 150 mm from pedal ful-
crum a, and measure maximum
294 k 29
Operating effort value to end of stroke. Wgl
I 421 1431
(30 f 3)
l Engine started
l Hydraulic oil temperature:
45 - 55%
0,
l Engine stopped
p Neutral (al) 45
m
deg.
15
Play 5 * 0.5
!
Bwwolol
mm
l Tire inflation pressure:

Specified value Max. 2.5
A
Insertion of wheel -
lock ring
B mm Max. 4.0
- TEW00004
TEW00003
Clearance of
C 20 - 35
wheel lock ring
20-4 WA800-3
Cate- Standard value Service limit

gory Item Measurement conditions Unit for new machine value
• Engine water temperature:
2,040 ± 50 2,040 ± 50
Engine speed
Torque converter stall

• Torque converter oil
Hydraulic stall temperature: 60 – 80°C rpm 2,080 ± 100 2,080 ± 200
• Hydraulic oil temperature:
Torque converter stall 45 – 55°C
• Speed control lever: F3 1,660 ± 100 1,660 ± 200
+ hydraulic stall (full stall)
Transmission main • Torque converter oil
relief valve pressure temperature: 60 – 80°C 2.75+ 0.29
0 {28 + 30 } 2.75+ 0.29
0 {28 + 30 }
Transmission, torque converter
• Engine: High idling 1.03 ± 0.10 1.03 ± 0.10

Pilot reducing pressure
• Torque converter oil {10.5 ± 1.0} {10.5 ± 1.0}
temperature: 60 – 80°C
Modulate pressure
(excluding F3, R3) 2.45 + 0.29
0 {25 + 30 } 2.45 + 0.29
0 {25 + 30 }
Torque converter inlet MPa

(kg/ 0.79 – 0.94 0.59 – 0.94
port pressure cm2} {8.0 – 9.5} {6.0 – 9.5}
Torque converter outlet 0.59 ± 0.10 0.59 ± 0.10
port pressure {6 ± 1} {6 ± 1}
0.14 ± 0.06 0.14 ± 0.06
Lubrication valve pressure {1.4 ± 0.6} {1.4 ± 0.6}
Reducing valve pressure 1.96 ± 0.10 1.96 ± 0.10
(for F3, R3) {20 ± 1} {20 ± 1}
• Hydraulic oil temperature:
MPa + 0.49 + 0.98
45 – 55°C (kg/ 31.36 – 0.39 31.36 – 0.78
Steering relief pressure • Engine full +5 +10
cm2} {320 – 4 } {320 – 8 }
Steering
• Steering is relieved.
• Engine started
Emergency steering • Hydraulic oil temperature: MPa 20.58 ± 0.49 20.58 ± 0.98
(kg/
relief pressure 45 – 55°C cm2} {210 ± 5} {210 ± 10}
• Machine speed: 24 km/h
• Brake oil pres- + 0.49 + 0.98

sure warning 5.88 0 5.88– 0.49
Accumulator
• Engine +5 +10
Charge cut-in pressure lamp: When {60 0 } {60 – 5 }
speed: Low goes out MPa
idling (kg/
• Brake oil cm2}
• When oil pres-
temperature: sure turns from 9.8 + 0.98 9.8+– 1.47
0 0.49
Charge cut-out pressure 45 – 55°C increasing to +10 +15
{100 0 } {100 – 5 }
decreasing
PPC valve source pressure • Hydraulic oil temperature: + 0.2 + 0.2

45 – 55°C 3.72 0 3.72– 0.2
(Orbit-roll source pressure) +2 +2
• Engine speed: High idling {38 0 } {38 – 2 }
Boom RAISE, • Hydraulic oil temperature: MPa

PPC
+ 0.2 + 0.2
FLOAT, 45 – 55°C (kg/ 3.72 0 3.72– 0.2
PPC valve bucket • Engine speed: High idling cm2} +2 +2
{38 0 } {38 – 2 }
output DUMP, TILT • Work equipment control lever:
pressure Full operating
Boom 2.54 ± 0.05 2.54 ± 0.05
LOWER {26 ± 0.5} {26 ± 0.5}
WA800-3 20-5
(8)
Cate- Standard value Service limit

gory Item Measurement conditions Unit for new machine value
• Tire inflation pressure:
Specified pressure
• Flat, horizontal, straight, dry
paved road surface
• Speed when applying brake:
Performance 20 km/h, braking delay: 0.1 m Max. 7.5 —
second
• Brake pedal operating effort:
Specified operating effort
Wheel brake
(373 N {38 kg})

• Transmission cut-off switch: ON
• Measure stopping distance.
• Engine stopped
• Compress by pump to 4.2 – 5.2
MPa {43 – 53 kg/cm2} MPa Max. 0.49
Drop in brake pressure (kg/ —
—
• Measure drop in brake pressure {Max. 5.0}
cm2}
after 5 minutes
Disc wear • Measure piston stroke mm 40.7 ± 1.4 Max. 46.3
• Tire inflation pressure:

Specified pressure
• Flat dry paved road with
Performance 1/5(11°20‘) grade — Stopped —
Parking brake
• Machine at operating
condition
Pad thickness • Including back metal 31.7 12.7

mm
Pad clearance • Total of each end 1.06 ± 0.18 Max. 2.1
20-6 WA800-3
(9)

-
Cat’ Standard value Se;ic;imit
Item Measurement conditions Unit i or new machint
90’
l High idling 3 1.36 _’::;: 31.36%

Hydraulic oil temperature:
1320 :;‘I
l
MPa 1320 :::I

45 - 55°C
(kg/
Relieve only measuring circuit
cm21
l
31.36% 31.36 %
+lO
I320 -‘:“I 1320 -131
Clearance between bucket

positioner and proximity 3-5
switch
mm
Clearance between boom
kick-out and proximity 3-5
switch
- -
l High idling
45 - 55°C
Engine water temperature:
ks
l

10.4 * 0.5 13.3
x
E l
l
No load
Steering: Straight
:
z
E
.-a
Boom speed - sec.
?
%
2” E
3 4.8 + 0.5 6.4
9
TWWOl857
- -
WA800-3 20-7
Item
Machine model
Measurement conditions
-r WA800-3
standard value Se;ic;imit

Uni
)r new machin’
l Full throttle
45 - 55°C
l Engine water temperature:
l No load 2.5 f 0.3 3.7
When fully operated
Bucket speed set 3.8 * 0.3 4.9
Horizontal
-
TWWO171
2.0 * 0.3 2.9

45 - 55°C
l Stop engine, leave for 5 minutes,
then measure for next 15 min-
utes.
detraction of boom
- Bucket empty, boom, bucket Max. 40 40
:ylinder rod
horizontal
Work equipment Posture

mn
detraction of bucket
:ylinder rod Max. 20 20
TWWOl714
20-8 WA800-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Name of Connector Inspection Measurement

System Judgement table
component No. method conditions
If the condition is as shown in the table 1) Turn starting
Measure voltage
below, it is normal. switch OFF.
Between C1(7), (13) – chassis 2) Insert T-
adapter.
Power supply C1 3) Turn starting
Between C2(1), (12) – chassis
C2 switch ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
Measure voltage

2) Insert T-
Power supply Between (6) – (17) adapter.
C3A 20 – 30 V
(for signal) 3) Turn starting
Between (6) – chassis switch ON.
4) Turn parking
brake switch ON

Measure
voltage
Turn parking brake 2) Insert T-

Parking L01 20 – 30 V adapter.
brake switch switch ON Between
3) Turn starting
Transmission & Joystick steering controller
Turn parking brake (1) – (3) Max. 1 V switch ON.

switch OFF

resistance
Measure

Solenoid TR1 2) Disconnect
(1st) (male) Between (1) – (6) 5 – 15 Ω connectors.
Between (1), (6) – chassis Max. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

(2nd) (male) Between (2) – (6) 5 – 15 Ω connectors.
adapter.

resistance
Measure

(3rd) (male) Between (3) – (6) 5 – 15 Ω connectors.
adapter.

resistance
Measure

Between (4) – (6) 5 – 15 Ω connectors.
(F) (male)
adapter.

resistance
Measure

(R) (male) Between (5) – (6) 5 – 15 Ω connectors.
adapter.

resistance
Measure

Engine speed E03 2) Disconnect
sensor (male) Between (1) – (2) 500 – 1000 Ω connectors.
adapter.
WA800-3 20-9
5

Measure in AC range 1) Turn starting
Controller
Measure
switch OFF.
voltage
Engine
Between (2) – (9) Min. 0.5 V 2) Insert T-
speed C4 adapter.
sensor 3) Start engine.
Adjust
1) Screw in the engine speed sensor until it
Engine speed — contacts the ring gear, then turn it back 1 turn. —
sensor
2) It works normally by adjustment above.

resistance
Measure

BC01 2) Disconnect
Speed sensor Between (1) – (2) 500 – 1000 Ω connectors.
(male)
adapter.
1) Screw in until the tip of sensor contact

Adjust
Speed sensor — gear, then turn back 3/4 –1 turn.

—
2) Sensor should work normally when
adjusted as above.

Measure
Speed
voltage
control Speed control lever 2) Insert T-

at 1st Between 20 – 30 V adapter.
lever (7) – 3) Turn starting
(1st) Speed control lever chassis switch ON.
Max. 1 V
not at 1st

Measure
Speed
voltage
control Speed control lever Between 2) Insert T-

at 2nd 20 – 30 V adapter.
(2nd) Speed control lever chassis switch ON.
Max. 1 V
not at 2nd

Measure
Speed
voltage

at 3rd Between 20 – 30 V adapter.
(3rd) Speed control lever chassis
Controller
Max. 1 V switch ON.

not at 3rd
C3B
Measure
voltage
Directional Directional lever 2) Insert T-

lever Between 20 – 30 V adapter.
at F (5) –
(F) 3) Turn starting
Directional lever chassis Max. 1 V switch ON.
not at F

Measure
voltage
Directional 2) Insert T-
lever Directional lever
at R Between 20 – 30 V adapter.
(R) (6) – 3) Turn starting
not at R

Measure
Directional
voltage
lever Directional lever 2) Insert T-

Between 20 – 30 V adapter.
(N) at N (13) – 3) Turn starting
not at N
20-10 WA800-3
5

Measure
voltage
Neutralizer Parking brake is 2) Insert T-
relay C3A released 20 – 30 V adapter.
Between 3) Start engine.
Parking brake is (19) – (17)
Controller
applied Max. 1 V
System
network If the condition is as shown in the table 1) Turn starting
Measure
voltage
(S-NET)
(Between T/M 2) Insert T-
C3B adapter.
controller and Between (4), (12) – chassis 4–8V
main 3) Turn starting
monitor) switch ON.

resistance
Measure
Kick-down 2) Disconnect
Kick-down switch
switch & shift- at ON Max. 1 Ω connectors.
down switch Between 3) Connect T-
Kick-down switch (1) – (2) adapter.
Min. 1 MΩ
at OFF
L15
(male)
resistance

Measure
Shift-up switch 2) Disconnect

Shift-up switch at ON Max. 1 Ω connectors.
Between 3) Connect T-
Shift-up switch (3) – (4) adapter.
at OFF Min. 1 MΩ

resistance
Measure
Transmission L12 2) Disconnect

cut-off switch (male) Normal condition Max. 1 Ω connectors.
L.H. brake pedal (1) – (2) adapter.
Min. 1 MΩ
is depressed

Controller
Measure
voltage
Manual switch 2) Insert T-

Manual Between Max. 1 V adapter.
C5 at ON
switch (14) – 3) Turn starting
Manual switch chassis switch ON.
at OFF 20 – 30 V
WA800-3 20-11
5

Measure voltage
adapter.
C2 switch ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
Measure voltage

2) Insert T-
C3A 20 – 30 V
4) Turn parking
brake switch ON

Measure
voltage

3) Turn starting
Turn parking brake (1) – (3)

Max. 1 V switch ON.
switch OFF

resistance
Measure

adapter.

resistance
Measure

adapter.

resistance
Measure

(3rd) (male)
adapter.

resistance
Measure

(F) (male)
adapter.

resistance
Measure

adapter.

resistance
Measure

adapter.
20-12 WA800-3
5

Controller
Measure
switch OFF.
voltage
Engine
speed Between (2) – (9) Min. 0.5 V 2) Insert T-
C4 adapter.
Adjust
Engine speed
— contacts the ring gear, then turn it back 1 turn. —
sensor
2) It works normally by adjustment above.

resistance
Measure

Speed sensor BC01 2) Disconnect
(male) Between (1) – (2) 500 – 1000 Ω connectors.
adapter.

Adjust

—
adjusted as above.

Measure
Speed
voltage

Max. 1 V
not at 1st

Measure
Speed
voltage

Max. 1 V
not at 2nd

Measure
Speed
voltage

Controller
Max. 1 V switch ON.

not at 3rd
C3B
Measure
voltage

at F (5) –
not at F

Measure
voltage
not at R

Measure
Directional
voltage

not at N
WA800-3 20-13
5

resistance
JS3 below, it is normal. switch OFF.
Measure
System cut-off (male) System cut-off 2) Disconnect
switch JS4 switch ON Between Max. 1 Ω connectors.
JS3(1) – 3) Connect T-
(female) System cut-off JS4(1) adapter.
Min. 1 MΩ
switch OFF
resistance
Measure
Joystick R.H. L27 2) Disconnect
solenoid (male) Between (1) – (2) 10 – 20 Ω connectors.
Between (1), (2) – chassis Min. 1 MΩ 3) Connect T-
adapter.

resistance
Measure

Joystick L.H. L26 2) Disconnect
solenoid (male) Between (1) – (2) 10 – 20 Ω connectors.
adapter.

resistance
Between (1) – (3) of joystick N switch 2) Disconnect

Measure
Joystick connectors.
JS5 Not at N Max. 1 Ω
neutral (N) 3) Connect T-
(male)
switch At N adapter.
Min. 1 MΩ
Between (1) – chassis

resistance
Measure
2) Disconnect
Joystick JS2 Between (1) – (2) 0 – 2 kΩ ± 20% connectors.
potentiometer (male) Between (2) – (3) 2 kΩ ± 20% 3) Connect T-
adapter.
Between (3) – (1) 0 – 2 kΩ ± 20%

2) Set joystick
Between column to
Continue (7) – (3) 20 – 30 V
joystick
Measure
Joystick pushing
voltage
N switch Between position.

lever Max. 1 V 3) Turn joystick
C5 (15) – (3)
neutral (N) ON/OFF switch
switch Between ON.
(7) – (3) Max. 1 V 4) Insert T-
Not to push
N switch adapter.
Between 5) Turn starting
20 – 30 V
Controller
(15) – (3) switch ON.

2) Set joystick
Between column to
Continue (8) – (3) 20 – 30 V
joystick
Measure
pushing
voltage
Joystick F switch Between position.

lever C5 (16) – (3) Max. 1 V 3) Turn joystick
F switch ON/OFF switch
Between ON.
(8) – (3) Max. 1 V 4) Insert T-
Not to push
F switch adapter.
(16) – (3) 20 – 30 V
switch ON.
20-14 WA800-3
5

2) Set joystick
Measure voltage
Between column to
Continue (9) – (3) 20 – 30 V
pushing joystick
Joystick R switch Between position.
lever C5 (17) – (3) Max. 1 V 3) Turn joystick
R switch ON/OFF switch
Between ON.
(9) – (3) Max. 1 V
Not to push 4) Insert T-
R switch adapter.
(17) – (3) 20 – 30 V
switch ON.
Controller

Measure
voltage
Neutralizer Parking brake is 2) Insert T-

relay C3A released 20 – 30 V adapter.
Parking brake is (19) – (17)
applied Max. 1 V
System
Measure

voltage
(S-NET)
C3B adapter.
monitor) switch ON.

resistance
Measure
Kick-down switch
Min. 1 MΩ
at OFF
L15
(male)
resistance
Measure

at OFF Min. 1 MΩ

resistance
Measure

Min. 1 MΩ
is depressed

Controller
Measure
voltage

Manual C5 Between Max. 1 V adapter.
switch at ON
(14) – 3) Turn starting
at OFF 20 – 30 V
WA800-3 20-15
5
System Name of Connector Inspection Judgement table Measurement

Measure voltage
adapter.
C2 switch ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
Measure voltage

2) Insert T-
C3A 20 – 30 V
4) Turn parking
brake switch ON

Measure
voltage

3) Turn starting
Turn parking brake (1) – (3)

Max. 1 V switch ON.
switch OFF

resistance
Measure

adapter.

resistance
Measure

adapter.

resistance
Measure

(3rd) (male)
adapter.

resistance
Measure

(F) (male)
adapter.

resistance
Measure

adapter.

resistance
Measure

adapter.
20-16 WA800-3
5

Controller
Measure
switch OFF.
voltage
Engine
Between (2) – (9) Min. 0.5 V 2) Insert T-
speed C4 adapter.
Adjust
Engine speed — contacts the ring gear, then turn it back 1 turn. —
sensor 2) It works normally by adjustment above.

resistance
Measure

BC01 2) Disconnect
Speed sensor Between (1) – (2) 500 – 1000 Ω connectors.
(male)
adapter.

Adjust

—
adjusted as above.

Measure
Speed
voltage

Max. 1 V
not at 1st

Measure
Speed
voltage

Max. 1 V
not at 2nd

Measure
Speed
voltage

Controller
Max. 1 V switch ON.

not at 3rd
C3B
Measure
voltage

at F (5) –
not at F

Measure
voltage
not at R

Measure
Directional
voltage

not at N
WA800-3 20-17
5

System
Controller
Measure
voltage
(S-NET)
C3B adapter.
monitor) switch ON.

resistance
Measure
Kick-down switch
Min. 1 MΩ
at OFF
L15
(male)
resistance
Measure

at OFF Min. 1 MΩ

resistance
Measure

Min. 1 MΩ
is depressed

Measure
voltage

Manual C5 Between Max. 1 V adapter.
switch at ON
at OFF 20 – 30 V

Measure
voltage
Joystick When joystick FNR 2) Insert T-

FNR button switch is in “F” Between 17 –30 V adapter.
switch “F” (5) – 3) Turn starting
When joystick FNR chassis switch ON.
switch is not in “F” Max. 1 V

below, it is normal.
Controller
switch OFF.
Measure
voltage

FNR button switch is in “N” Between 17 –30 V adapter.
switch “N” (13) – 3) Turn starting
switch is not in “N” Max. 1 V
C3B
Measure
voltage

gear shift switch is in “R” Between 17 –30 V adapter.
switch R (6) – 3) Turn starting
switch is not in “R” Max. 1 V

Measure
voltage
Neutralizer When joystick FNR 2) Insert T-

relay signal switch is in “N” Between 17 –30 V adapter.
switch is not in “N” Max. 1 V
20-18 WA800-3
5

Measure
voltage
Joystick When joystick shift- 2) Insert T-
shift-up up switch is “ON” Between Max. 1 V adapter.
switch (N.O) (7) – 3) Turn starting
When joystick shift- chassis switch ON.
up switch is “OFF” 17 – 30 V

Measure
voltage
shift-down down switch is “ON” Between Max. 1 V adapter.
switch (N.O) (8) – 3) Turn starting
down switch is “OFF” 17 – 30 V

Measure
voltage

shift-up C3B up switch is “ON” Between 17 –30 V adapter.

switch (N.C) (15) – 3) Turn starting
up switch is “OFF” Max. 1 V

Measure
voltage

Controller
shift-down down switch is “ON” Between 17 –30 V adapter.

switch (N.C) (16) – 3) Turn starting
down switch is “OFF” Max. 1 V

Measure
voltage
Steering When steering lock 2) Insert T-

lever is in “LOCK” Between 17 –30 V adapter.
lock signal
When steering lock chassis switch ON.
lever is in “FREE” Max. 1 V

Measure
2) Insert T-
voltage
Steering When steering

lever angle 3.5 – 4.5 V adapter.
angle is RIGHT. Between 3) Start engine.
sensor
When steering (3) – (16) 4) Move joystick
angle is LEFT. 0.5 – 1.5 V to left or right
stoke end.
C3A
Measure
2) Insert T-
voltage
Frame angle When frame angle adapter.

is RIGHT. 0.5 – 1.5 V
sensor Between 3) Start engine.
When frame angle (13) – (16) 4) Move joystick
is LEFT. 3.5 – 4.5 V to left or right
stoke end.
WA800-3 20-19
5

2) Insert T-
When joystick
Controller
Measure
Joystick
voltage
adapter.
lever neutral steering lever is in Max. 1 V 3) Turn starting
C2 neutral Between
interlock (8) – switch ON.
relay When joystick chassis
steering lever is 17 – 30 V
not in neutral
fl Set machine in straight travel position.

2) Insert T-
Measure
voltage
When steering lever adapter.

3.5 – 4.5 V 3) Start engine.
angle is RIGHT. Between
When steering lever (1) – (3) 4) Move joystick
0.5 – 1.5 V to left or right
Steering lever angle is LEFT.
JS2 stoke end.
angle sensor
resistance
Measure

2) Disconnect
Between (1) – (2) 0 – 5 kΩ connector.
3) Connect T-
Between (3) – (2) 4 – 5 kΩ adapter.

2) Insert T-
Measure
voltage
When frame angle adapter.

is RIGHT. 0.5 – 1.5 V
When frame angle (1) – (3) 4) Move joystick
is LEFT. 3.5 – 4.5 V to left or right
Frame angle stoke end.
sensor L27

resistance
Measure

2) Disconnect
Between (1) – (2) 0 – 5 kΩ connector.
3) Connect T-
Between (3) – (2) 4 – 5 kΩ adapter.
20-20 WA800-3
5
ALL SPECIFICATIONS
System Name of Connector Inspection Judgement table Measurement

Measure
voltage
Power supply L05 2) Insert T-
Between (1), (2) – chassis adapter.
20 – 30 V
Between (1), (2) – (3) 3) Turn starting
switch ON.

2) Insert T-
Measure
Engine running (At
voltage
Charge above 1/2 throttle) Between 28 ± 2 V adapter.
L05 (5) – (3)
(Alternator) Starting switch Max 1 V
ON
ª If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.

resistance

Measure
Engine water 2) Disconnect

E05 Normal Approx.
temperature connectors.
(male) temperature (25°C) Between 2 kΩ
sensor (1) – 3) Connect T-
5°C chassis Approx. adapter.
4 kΩ

Measure
voltage

switch (N) L05 at N Between 20 – 30 V adapter.
(8) – (3) 3) Turn starting
Directional lever Max 1 V switch ON.
not at N
Main monitor

Measure
voltage
Starting switch L09 Starting switch 2) Insert T-

START Between 20 – 30 V adapter.
C terminal (male) (3) –
Starting switch chassis Max 1 V
OFF or ON

Measure
voltage
2) Insert T-
Starting switch Start engine 20 – 30 V adapter.
C terminal Between
Starting switch (4) – (3)
Max. 1 V
OFF or ON

L05 below, it is normal. switch OFF.
Starting switch ª 20 – 30V 2) Insert T-
Measure
adapter.
voltage
ON Between →1V
Preheating
switch ON Max. 1 V
OFF
ª Voltage changes only when water temperature
is below 0°C, and time taken to change differs
according to water temperature.

Starting switch ª 1V→ 2) Insert T-
Measure
adapter.
voltage
ON Between 20 – 30 V
Preheating (4) – (16)
L06 Starting switch
output Max. 1 V
OFF
ª Voltage changes only when water temperature
is below 0°C, and time taken to change differs
according to water temperature.
WA800-3 20-21
5

Measure
voltage
Starting switch L09 Starting switch 2) Insert T-
BR terminal (male) ON Between 20 – 30 V adapter.
(2) –
Starting switch chassis Max. 1 V
OFF

Measure
voltage
Starting switch Starting switch 2) Insert T-
L07 adapter.
BR terminal ON Between 20 – 30 V
Max. 1 V
OFF

resistance

Measure
Parking brake 2) Disconnect

F13 Parking brake
Between Max. 1 Ω
indicator connectors.
(male) switch ON
Main monitor
switch 3) Connect T-
Parking brake (1) – (2) adapter.
Min. 1 MΩ
switch OFF

resistance
Measure

Low idling B01 2) Disconnect
select solenoid (male) Between (1) – (2) 19 – 23 Ω connectors.
adapter.

Measure
voltage
Directional lever Between adapter.
switch (F) at F 20 – 30 V
not at F
L08
Measure
voltage
2) Insert T-
Directional Directional lever Between adapter.
at R 20 – 30 V
switch (R) (8) – 3) Turn starting
not at R
20-22 WA800-3
5

System component No. method Judgement table conditions
Measure
voltage
Power supply L18 2) Insert T-
Between (1), (2) – chassis adapter.
20 – 30 V
Between (1), (2) – (3) 3) Turn starting
switch ON.
resistance
Measure
Engine water E04 Normal Approx. 2) Disconnect
temperature (male) temperature (25°C) Between 40 kΩ connectors.
sensor (1) – (2) 3) Connect T-
130°C Approx. adapter.
1.7 kΩ

resistance
Measure
Torque
2) Disconnect
converter oil T02 Normal Approx. connectors.
temperature (male) temperature (25°C) Between 40 kΩ 3) Connect T-
sensor (1) – (2) Approx. adapter.
130°C
1.7 kΩ

2) Disconnect
Float connectors.
raised to 3) Drain fuel.
Maintenance monitor
stopper 4) Remove fuel

Approx. level sensor.
4Ω 5) Connect T-
resistance
Measure
adapter.
Fuel level R05
sensor (male)
Float
lowered to
stopper Approx.
85 Ω

resistance

Measure
Radiator water G06 2) Disconnect

level sensor (male) Water level normal Max. 1 Ω connectors.
(1) – (2) adapter.
Water level low Min. 1 MΩ

2) Disconnect
Engine oil pressure terminal.
when engine 3) Start engine.
resistance
running: Min. 1 MΩ
Measure
Engine oil above 0.07 MPa

pressure E09 {0.7 kg/cm2} Between
sensor (1) – (3)
Engine oil pressure
when starting
switch ON: Max. 1 Ω
above 0.03 MPa
{0.3 kg/cm2}
WA800-3 20-23
5

2) Disconnect
Measure resistance
BC04 Accumulator
pressure: connectors.
(male) 3) Connect T-
Brake Min. 5.39 ± 0.49 MPa Max. 1 Ω
BC05 {55 ± 5 kg/cm2} adapter.
accumulator (male)
low pressure BC06 Between
switch (male) Depress brake and (1) – (2)
lower accumulator
BC07 pressure to below
(male Min. 1 MΩ
4.41 ± 0.49 MPa
{45 ± 5 kg/cm2}

below, it is normal.
Measure voltage
switch OFF.
Engine running 2) Insert T-
(above half throttle) Between 28 ± 2 V adapter.
Charge (12) – (3) 3) Start engine.
L18 Starting switch ON
(Alternator) Max. 1 V
ª If the battery is old, or after starting in

cold areas, the voltage may not rise for
some time.

resistance
Measure
Maintenance monitor
Engine oil level R02 Engine oil level 2) Disconnect

normal Between Max. 1 Ω terminal.
sensor (male) (1) –
Engine oil level chassis Min. 1 MΩ
abnormal
B08 If the condition is as shown in the table 1) Turn starting

R.H.
(female) below, it is normal. switch OFF.

B09 2) Disconnect
continuity
Between
Air cleaner (male) Air cleaner normal B09(1) – B08(1) Continuity connectors.
Check
clogging 3) Start engine.

sensor B06 Air cleaner clogged Between No 4) Check sensor
(female) or engine stopped B07(1) – B06(1) Continuity side connector
L.H.
B07 by using
(male) tester.
If the condition is as shown in the table below, monitor panel 1) Connect T-

is normal. adapter.
Table 1 (CHECK lamp & CAUTION lamp)

Connector Monitor item Measurement Display Sensor
No. (input connector) conditions signal input
Engine water level Engine stopped Flashing 15 – 20 V
((8) – (3)) Starting switch ON Lighted off Max. 1 V
Engine oil level Engine stopped Flashing 15 – 20 V
CHECK lamp ((13) – (3)) Starting switch ON Lighted off Max. 1 V
& Engine oil pressure Flashing 15 – 20 V
CAUTION lamp Engine start
((10) – (3)) Lighted off Max. 1 V
L18 Brake oil pressure Flashing 15 – 20 V
Engine start
(male) ((11) – (3)) Lighted off Max. 1 V
Transmission oil filter Flashing 15 – 20 V
Engine start
((16) – (3)) Lighted off Max. 1 V
Battery charge Flashing Max. 10 V
Engine start
((12) – (3)) Lighted off Min. 12 V
Air cleaner Flashing 15 – 20 V
Engine start
((14), (15) – (3)) Lighted off Max. 1 V
20-24 WA800-3
5

Table 2 (Gauge) 1) Turn starting
Display level resistance switch OFF,
Gauge display position (monitor panel input then insert
resistance) dummy
Starting switch ON Starting switch OFF resistance or
measure
Min. Green 6 0 – 15.7 resistance of
1
2
3
4
5
6
sensor.
Green
Green
Green
Green
Green
Green
Fuel level Green 5 12.6 – 24.0 2) Turn starting
Red
gauge Green 4 20.5 – 30.6 switch ON and
L18 (male) check display.
Measure Green 3 26.7 – 39.6
E F
resistance Green 2 35.2 – 51.6
between Red Green
(6) – (3) Flash-←→ Green 1 46.5 – 80.6
ON ← Max.
ing
(kΩ) Red 73.8 – 80.6
67 102130°C
Min. Red 2 0.24 – 3.47
Engine
Red 1 3.13 – 3.75
1
2
3
4
water
Green
Green
Green
Green
White
Red 1
Red 2
tempera- Green 4 3.39 – 4.26
Maintenance monitor
Gauge ture gauge

L18 (male) Green 3 3.85 – 5.14
resistance E F
between Green 1 6.27 – 10.26
White Green Red Max.
(4) – (3)
→ ON ←→ Flashing (kΩ) White 9.19 – 10.26
(1 place) (1 place)
50 120130°C
Torque Min. Red 2 0.24 – 1.90
converter Red 1 1.68 – 2.40
1
2
3
4
5
oil
Green
Green
Green
Green
Green
Red 1
Red 2
tempera- Green 5 2.15 – 3.05

ture gauge Green 4 2.74 – 5.14
L18 (male)
resistance E F
Green 2 8.43 – 18.18
between Green Red Max.
(5) – (3) → ON ←→ Flashing (kΩ) Green 1 15.88 – 10.26
(1 place) (1 place)

resistance
BC02
Measure
2) Disconnect
Transmission (male) Filter normal Max. 1 Ω connectors.
oil filter sensor BC03 (1) – (2)
Filter clogged Min. 1 MΩ adapter.
(male)
WA800-3 20-25
5

2) Disconnect
Measure resistance
BC08 Accumulator
pressure: Between connectors.
(male) BC08 3) Connect T-
Min. 3.92 ± 0.49 MPa Max. 1 Ω
BC09 {40 ± 5 kg/cm2} (1) – (2), adapter.
Emergency (male) BC09
brake switch BC10 (1) – (2),
(male) Depress brake and BC10
lower accumulator (1) – (2),
BC11 pressure to below
(male BC11 Min. 1 MΩ
3.63 ± 0.49 MPa (1) – (2)
{37 ± 5 kg/cm2}

Accumulator 2) Insert T-
Measure voltage
pressure: adapter.
Min. 3.92 ± 0.49 MPa 20 – 30 V 3) Turn starting
{40 ± 5 kg/cm2} switch ON.
Emergency
brake switch CBL1 Between
Depress brake and (3) – (4)
lower accumulator
pressure to below Max. 1 V
3.63 ± 0.49 MPa
{37 ± 5 kg/cm }
2

Others
Bucket 2) Insert T-
Measure
voltage
Between (1) – (3) 20 – 30 V adapter.

positioner 3) Turn starting
proximity F05 Bucket fully Between
Max. 1 V switch ON.
switch dumped (2) – (3)
Bucket fully tilted Betwen
(2) – (3) 20 – 30 V

2) Insert T-
Measure
voltage
Bucket kick-out Between (1) – (3) 20 – 30 V adapter.

proximity F06 3) Turn starting
Bucket fully Between switch ON.
switch dumped (2) – (3) Max. 1 V
Bucket fully tilted Betwen

(2) – (3) 20 – 30 V

resistance
Measure
2) Disconnect
Bucket kick-out
solenoid L16 Between (1) – (2) 19 – 23 Ω connectors.
3) Connect T-
Between (1), (2) – chassis Min. 1 MΩ adapter.

resistance
Measure
Bucket 2) Disconnect
positioner L17 Between (1) – (2) 19 – 23 Ω connectors.
solenoid 3) Connect T-
Between (1), (2) – chassis Min. 1 MΩ adapter.
20-26 WA800-3
5
Table of tools for testing, adjusting, and troubleshooting .................................................................................. 20-102
Measuring engine speed .......................................................................................................................................... 20-103
Measuring exhaust gas color .................................................................................................................................. 20-105
Adjusting valve clearance ........................................................................................................................................ 20-106
Measuring compression pressure ........................................................................................................................... 20-107
Measuring blow-by pressure ................................................................................................................................... 20-108
Testing and adjusting fuel injection timing ........................................................................................................... 20-109
Measuring engine oil pressure ............................................................................................................................... 20-111
Measuring exhaust temperature ............................................................................................................................. 20-112
Measuring air supply pressure (Boost pressure) .................................................................................................. 20-113
Testing and adjusting alternator belt tension ....................................................................................................... 20-114
Testing and adjusting belt tension for air conditioner compressor ................................................................... 20-115
Measuring accelerator pedal operating effort ....................................................................................................... 20-116
Measuring accelerator pedal operating angle ....................................................................................................... 20-117
Adjusting fuel control cable, linkage, and servo cylinder .................................................................................... 20-118
Adjusting engine stopping motor cable ................................................................................................................. 20-120
Testing and adjusting torque converter and transmission oil pressure ............................................................ 20-122
Procedure for operating emergency steering spool when transmission valve fails ........................................ 20-125
Testing and adjusting steering oil pressure .......................................................................................................... 20-127
Testing and adjusting emergency steering oil pressure ...................................................................................... 20-128
Bleeding air from steering circuit ........................................................................................................................... 20-130
Testing and adjusting steering stop valve ............................................................................................................. 20-131
Testing and adjusting steering stopper bolt ...................................................................................................... 20-131-1
Testing and adjusting steering lever angle sensor and frame angle sensor ................................................. 20-131-2
Testing wheel brake performance .......................................................................................................................... 20-132
Testing wheel brake oil pressure drop .................................................................................................................. 20-133
Measuring wear of wheel brake disc ..................................................................................................................... 20-135
Testing and adjusting accumulator charge cut-in and cut-out pressure ........................................................... 20-136
Bleeding air from wheel brake circuit .................................................................................................................... 20-138
Testing parking brake performance ........................................................................................................................ 20-139
Measuring parking brake solenoid output pressure ............................................................................................. 20-140
Checking and adjusting parking brake pad ........................................................................................................... 20-141
Testing and adjusting PPC pressure ....................................................................................................................... 20-143
Adjusting PPC valve linkage .................................................................................................................................... 20-145
Testing and adjusting work equipment hydraulic pressure ................................................................................ 20-146
Bleeding air from piston pump ............................................................................................................................... 20-148
Bleeding air from work equipment circuit ............................................................................................................. 20-149
Adjusting work equipment lever linkage ............................................................................................................... 20-150
Releasing remaining pressure in hydraulic circuit ............................................................................................... 20-152
Testing and adjusting bucket proximity switch .................................................................................................... 20-153
Testing and adjusting boom proximity switch ..................................................................................................... 20-154
Testing proximity actuation pilot lamp .................................................................................................................. 20-155
Adjusting speedometer module of main monitor ................................................................................................ 20-156
Adjusting joystick lever potentiometer .................................................................................................................. 20-157
Adjusting joystick lever neutral detection switch ................................................................................................. 20-158
Adjusting work equipment control lever ............................................................................................................... 20-159
Adjusting work equipment boom angle ................................................................................................................ 20-163
WA800-3 20-101
(7)
TABLE OF TOOLS FOR TESTING, ADJUSTING,
TESTING AND ADJUSTING AND TROUBLESHOOTING
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND

TROUBLESHOOTING
Check or measurement item iymbol 1 Part No. 1 Part Name Remarks
Digital L: 60 - 2,000 rpm

1 799-203-8001 Multi-tachometer display H: 60 - 19,999 rpm
Kit part No.: 799-203-9000
Engine speed A
2 6210-81-4111 Gear box
1 3 ) 6215-81-3500 ITachometer drive I

Water, oil, exhaust B 1 799-101-1502 1 Digital temperature gauge I-99.9 to +1,299%
temperatures
Pressure gauge:
799-101-5002 Hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm*)
,
Pressure gauge:
Oil pressure C 790-261-1203 Digital hydraulic tester
68.6 MPa I700 kg/cm*}
: 2 l 799-101-5160 l Nipple PT l/8
I 3 I 799-401-2320 1 Hydraulic gauge II.0 MPa {IO kg/cm*}
1 795-502-1590 Compression gauge 0 - 6.9 MPa IO - 70 kg/cm*)

Compression pressure D
2 795-502-I 500 Adapter Kit part No.: 795-502-1205
1 799-201-1504 Blow-by checker -

Blow-by pressure E
2 799-201-1590 Gauae 0 - 9.8 kPa IO - 1,000 mmHzO1
I I I I
Commercially
Valve clearance F available Feeler gauge
1 799-201-9000 Handy smoke checker Discoloration 0 - 70%

(with standard color)
Exhaust color G Commercially (Discoloration x1/10 + Bosch index)
2 available Smoke meter
-.
Air supply pressure H 799-201-2201 Pressure -101.3 - 199.9 kPa
(boost pressure) _ gauge I-760 - 1,500 mmHg1
1 793-605-1001 Brake tester kit
Brake oil pressure J 2 790-101-1430 Coupler
3 790-101-I 102 Pump
Operating effort K E] Push-pull scale
Commercially
Operating angle of pedal L available Angle gauge
Commercially
Stroke, hydraulic drift M available Scale
Commercially -
Work equipment speed N available Stop watch
Commercially -
Measuring brake disc wear P available Caliper gauge
-
Moving machine when there
Q 1 793T-685-11 IO 1Plate I -
is failure in transmission valve
Measuring voltage, resistance
value --;64-0211 1Tester I -
III - -
799 601 7400 I-T adapter assembly I -
SWPIPP
SWPIGP
Troubleshooting of wirin&
harness, sensors
2 M8P
799-601-7380 JFCPP
799-601-3460 MSIOP
20-l 02 WA800-3
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
A When removing
equipment,
or installing
be careful not to
the measuring
touch any high
temperature parts.
ABefore starting measurement, check that there
is no one in the surrounding area.
A Put blocks under the wheel to stop the machine
from moving.
* Measure the engine speed under the following
conditions.
l Water temperature: Within operating range
. Hydraulic temperature: 45 - 55°C
. Power train oil temperature: 60 - 80°C
1. Measuring low idling speed and high idling speed

1) Remove cap (1)-f&m the revolution take-out
port of engine.
2) Install gear box A2 and tachometer drive
A3.
3) Connect multi-tachometer Al.
4) Start the engine and measure the engine
speed at low idling and high idling.
* Check that the engine speed is in the standard

range. If it is out of the standard range, check I
the fuel control linkage for looseness, play, etc. A3 A2 BWWOO837
2. Measuring torque converter stall speed

1) Start the engine.
2) Turn the transmission cut-off switch OFF and
depress the left brake pedal fully. Check that
the transmission cut-off pilot lamp goes out.
3) Turn speed control lever to 3rd.
Turn directional lever not at N.
4) Release the parking brake.
5) Run the engine at full throttle and measure
the engine speed when the torque converter
stalls.
BWWOO838
WA800-3 20- 103

TESTING AND ADJUSTING MEASURING ENGINE SPEED
3. Measuring hydraulic stall speed

I) Start the engine.
2) Run the engine at full throttle and extend
the boom cylinder or bucket cylinder fully,
and measure the engine speed when the
circuit is relieved.
4. Measuring torque converter stall and hydraulic

stall (full stall) speed
I) Start the engine.
2) Turn the transmission cut-off switch OFF and
depress the left brake pedal fully. Check that
the transmission cut-off pilot lamp goes out.
3) Turn speed control lever to 3rd.
Turn directional lever not at N.
4) Release the parking brake.
5) Run the engine at full throttle and stall the
torque converter, and at the same time, ex-
tend the boom cylinder or bucket cylinder
fully and measure the engine speed when
the circuit is relieved.
20-104 WA8003
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS

COLOR
. When measuring in the field when there is no
air or power supply, use handy smoke checker
Gl; when recording official data, use smoke
meter G2.
Ir Raise the coolant temperature to the operating
range before measuring.
A When removing
equipment,
or installing the measuring
be careful not to touch any high
temperature part.
1. Measuring with handy smoke checker Gl

1) Fit filter paper in tool Gl.
2) Insert the exhaust gas intake port of tool Gl
into the exhaust pipe, accelerate the engine
suddenly, and at the same time operate the
handle of tool Gl to catch the exhaust gas
on the filter paper.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter G2

1) Insert probe @ into exhaust pipe, then
tighten the clip to secure it to the exhaust
pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
* The pressure of the air supply should be
less than 1.5 MPa {I5 kg/cm2}_
3) Connect the power cord to the power sup-
PlY.
* When connecting the port, check first that
the power switch of tool G2 is OFF. TWWOI991
4) Loosen the cap nut of the suction pump,

then fit the filter paper.
Ir Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool G2 and catch the exhaust gas color on
the filter paper.
7) Lay the filter paper used to catch the ex-
haust gas color on top of unused filter pa-
pers (IO sheets or more) inside the filter pa-
per holder, and read the indicated value.
TLD00140
WA800-3 20- 105

TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE
CLEARANCE
1. Remove the cylinder head cover.
2. Rotate the crankshaft in the normal direction.

While watching the movement of the intake valve
of the R6 cylinder, bring the RI cylinder into the
top dead center position of the compression
stroke and align the “RI.6 TOP” line on vibra-
tion damper (2) with pointer (I).
Ir When the RI cylinder comes near the top
dead center of the compression stroke, the
R6 intake valve will start to open.
TKWOIOGI
3. Loosen locknut (6) of adjustment screw (5) of RI

cylinder, insert the feeler gauge F correspond-
ing to the specified clearance between crosshead
(4) and rocker arm (31, and adjust the clearance
with the adjustment screw until the thickness
gauge can slide lightly.
4. Tighten locknut in position to secure adjustment

screw.
w Locknut 58.8 + 5.9 Nm 16 f 0.6 kgm}
5. Follow the same procedure to align the line with

-
the pointer and adjust the valve clearance of
each cylinder according to the firing order.
* Firing order:
RI - Ll - R5 - L5 - R3 - L3 - R6 - L6 - R2 -
L2 - R4 - L4
20-106 WA800-3
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
* When carrying out performance test or trouble-

shooting, if it is thought that the piston, piston
ring, or cylinder liner are worn, measure the
compression pressure.
A When measuring the compression pressure, be

careful not to touch the exhaust manifold or
other hot parts, or to get caught in rotating parts,
such as the fan or fan belt.
1. Adjust the valve clearance.

-k For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up the engine so that the oil temperature

rises to 40 - 60°C.
3. Disconnect wiring connector (I 1.
4. Remove nozzle holder of cylinder to be meas-

ured.
5. Install adapter D2 and plate D3 of tool D on the

mount of the nozzle holder, then connect the
pressure gauge Dl.
6. Set multi-tachometer A in position.
7. Disconnect the wiring of the engine stopping

motor, crank the engine with the starting motor
and measure the compression pressure.
* Measure the compression pressure at the

point where the pressure gauge indicator
remains steady.
* When measuring the compression pressure,
measure the engine speed to confirm that it
is within the specified range.
WA8003 20-107
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
* Raise the water temperature to the operating

range before measuring.
1. Install blow-by checker El to the end of engine

blow-by hose (I) and (2), then connect gauge E2
(0 - 9.8 kPa (0 - 1,000 mmHz01).
Ir Since there are blow-by hoses respectively
on the right bank and left bank of the en-
gine, measure the blow-by pressure for each
of them.
2. Run the engine at high idling and relieve the

bucket, and measure the blow-by pressure. E2
4I When measuring, be careful not to touch

any hot parts or rotating parts.
CAUTION FOR MEASURING BLOW-BY

* Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
problems concerning defective blow-by, such
as excessive oil consumption, defective ex-
haust gas color, or prematurely dirty or de-
teriorated oil.
20-l 08 WA800-3
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
TESTING FUEL INJECTION TIMING
1. Disconnect fuel injection pipe (1) of RI cylinder.
2. Remove delivery valve holder (21, then remove

delivery valve (3) and spring (4), and install only
delivery valve holder (2).
3. Place accelerator pedal at FULL position.
4. Operate priming pump and rotate crankshaft

slowly in normal direction. Check point where
fuel stops flowing from delivery valve holder
(2).
TEW01066
5. Check that the fuel injection line on damper (5)

is aligned with pointer (6) at the position where
the fuel stops flowing:
* BEYOND injection timing line:
Timing RETARDED
* BEFORE injection timing line:
Timing ADVANCED
* If the test shows that the fuel injection timing is
incorrect, adjust as follows.
WA800-3 20-109
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
ADJUSTING FUEL INJECTION TIMING BY

DELIVERY CHECK
1. Turn crankshaft back for 30” to 40” from top

dead center.
2. Rotate the crankshaft in the normal direction,

and align the fuel injection line on damper (5)
with pointer (6).
3. Loosen bolts (7) on the injection pump coupling

flange bolt.
- -
TEW01068
4. Rotate the flange on the pump side little by little

while operating the priming pump (8) until no
fuel flows out of the delivery valve holder.
5. Tighten bolts (7) in oblong hole of coupling

flange of fuel injection pump.
Ir Check again that the fuel stops flowing from
the delivery valve holder at the point where
the pointer is aligned with the line on the
damper.
6. Remove delivery valve holder (21, assembly de-

livery valve (3) and spring (4), then install deliv- TEW01069
ery valve holder (2) and fuel injection pipe (I)
again.
w Delivery holder:
32.4 + 2.0 Nm (3.3 + 0.2 kgm)
7. Connect fuel injection pipe (I).
w Sleeve nut: 23.5 f 1.0 Nm 12.4 f 0.1 kgm}
20-110 WA800-3
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
Ir Measure the engine oil pressure under the fol-

lowing conditions.
. Water temperature: Within operating range
1. Remove engine oil pressure switch (I) from the

left bank of the engine (right side of the ma-
chine).
2. Install nipple C2 and oil pressure gauge C3 (1.0

MPa {IO kg/cm*}).
3. Start engine, and measure the oil pressure at

low idling and high idling.
WA800-3 20-111
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST
TEMPERATURE
4L The temperature sensor must be installed to the

exhaust system, so if the machine has been op-
erated, wait for the manifold temperature to drop
before installing the sensor.
* Raise water temperature to operating range.
1. Remove measuring plugs (3) and (4) (PT l/8)

from right bank connector (I) and left bank con-
nector (2) between the turbocharger and exhaust
muffler.
* The right bank and left bank have two plugs
respectively. Remove either one from each
side.
2. Install temperature sensors of digital tempera-

ture gauge B to both banks of engine.
. Temperature sensor
: 6215-11-8180 (Cable length 610 mm)
or
: 6215-11-8170 (Cable length 490 mm) X type connector (2Dins. female) Temcerature
/ sensor
3. Connect to digital temperature gauge B with the
wiring harness (799-201-I 1 IO).
MEASUREMENT PROCEDURE
799-201-1110
TWWOl826
1. When measuring the maximum value during
troubleshooting
Carry out actual work and measure the maxi-
mum value during operation.
* Use the PEAK mode (it can store the maxi-
mum value in memory) of the temperature
gauge function.
Note:
The exhaust temperature varies greatly accord-
ing to the ambient temperature (temperature of
the engine intake air), so if any abnormal value
is obtained, carry out temperature compensa-
tion.
* Compensation = Measured value + 2 x
(standard ambient temperature - actual am-
bient temperature)
* The standard ambient temperature is
taken as 20°C.
Exhaust aas Value is stable
2. When measuring periodically (during preventive temperature
t h
maintenance, etc.) I i
*--
1) Raise the exhaust temperature to approx.
700°C by using full stall (torque converter Exhaust aas
temDerature
Measured when only
stall and hydraulic pump relief). at torque
torque converter stall
2) In the above condition, cancel the hydraulic converter
relief, and carry out only torque converter

stall.
3) Note the stable temperature.
-Time
+ If only torque converter stall is used
converter stall
when measuring the exhaust tempera-
ture, torque converter will overheat be- TWWOl827
fore a stable value is obtained.
20-l 12 WA800-3
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY

PRESSURE (BOOST PRESSURE)
A Be careful not to touch any hot or rotating parts

when measuring or when removing or install-
ing the measuring tools.
1. Remove measuring plugs (3) and (4) (PT l/8)

from air intake connector (I) for the right bank
air intake connector (2) for the left bank.
* The right bank and left bank have two plugs
respectively. Remove either one from each
side.
2. Install nipples C2 to both sides, then connect

pressure gauges H (-101.3 - 199.9 kPa I-760 -
1,500 mmHg1).
Note: Operate the engine at midrange speed or

above, and push to open the self-seal por-
tion of the hose to bleed the oil inside the
hose.
. Insert the hose into gauge then discon-
nect, repeat the action to open the self-
seal portion to bleed the oil.
Sr If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
3. Carry out the torque converter stall operation at

engine full and read the gauge.
Jr The air supply pressure (boost pressure) should

be measured with the engine running at rated
output. However, when measuring in the field, a
similar value can be obtained by operating at
torque converter stall.
WA800-3
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION

ALTERNATOR BELT TENSION
TESTING
. Measure deflection a of the belt when each belt
is pushed with a force of approx. 59 N {approx.
6 kg) at a point midway between the alternator
pulley and the drive pulley.
* Deflection a of belt (standard value):
approx. 20 mm
ADJUSTING
1. Loosen the alternator assembly mounting bolts ElWWOO849
and nuts (I), (21, (3) and lock nut (4).

2. Turn adjustment nut (5) to adjust the tension of
belt (6).
3. After positioning the alternator, secure it by tight-
ening lock nut (41, mounting bolts and nuts (I),
(2) and (3).
4. After adjusting the belt tension, check that de-
flection is the standard value according to the
above procedure.
BWWOO850
20-114 WA800-3
TESTING AND ADJUSTING BELT TENSION
TESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
TESTING
. Measure deflection b of the belt when it is pushed
with a force of approx. 98 N {approx. 10 kg} at a
point midway between the drive pulley and the
air conditioner compressor pulley.
Ir Deflection b of belt (standard value):
9 - 12.5 mm
BWWO0985
ADJUSTING
1. Loosen mount bolts and nuts (11, (21, (3), locknut
(4).
2. Turn adjustment nut (5) to adjust the tension of
air conditioner compressor belt (6).
3. When the position of the air conditioner com-
pressor is correct, tighten locknut (4), mounting
bolts and nuts (I), (21, (3) to secure it in posi-
4.
tion.
After adjusting the belt tension, repeat the test-
5’
ing procedure above to check that the deflection
is adjusted within the standard range. BWWOO847
WA800-3 20-115
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL OPERATING EFFORT
MEASURING ACCELERATOR
PEDAL OPERATING EFFORT
MEASURING
1. Put push-pull gauge K in contact with the accel-

erator pedal at point 150 mm from pedal ful-
crum “a”.
2. Start the engine, push the pedal and measure

the maximum value when pushing from idling
to the end of the pedal travel (high idling).
TLW01071
ADJUSTING
‘I . Stop the engine.
2. Disconnect cable (I) at bottom of the accelera-

tor pedal, and check that the linkage move
smoothly.
3. Connect the cable (I) at the bottom of the pedal,

then disconnect at the connection for lever (21,
and check that cable (I) moves smoothly.
TEW01073
4. Leave cable (I) disconnect, and check that lever

(2) moves smoothly.
20-116 WABOO-3
MEASURING ACCELERATOR PEDAL OPERATING EFFORT
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL OPERATING ANGLE
5. Disconnect cable (3) from servo cylinder (4) and

lever (51, and check that cable (3) and lever (5)
move smoothly.
Ir When carrying out this inspection, adjust or

replace parts if necessary. Measure the op-
erating force again and check that it is within
the standard range.
Sr When operating force is heavy in spite of
there is no abnormality in this inspection,
check operation of servo cylinder (4).
/----vlz- TEW01075
MEASURING ACCELERATOR
PEDAL OPERATING ANGLE
MEASURING
1. Stop the engine.
2. Apply angle meter L to measure angle cxl for

low idling and o2 for high idling.
ADJUSTMENT
Referring to “ADJUSTING FUEL CONTROL CA-
BLE, LINKAGE, AND SERVO CYLINDER”, adjust
the angle of the accelerator pedal.
WA800-3
ADJUSTING FUEL CONTROL CABLE, LINKAGE,
TESTING AND ADJUSTING AND SERVO CYLINDER
ADJUSTING FUEL CONTROL

CABLE, LINKAGE, AND SERVO
CYLINDER
1. Remove the cover at the bottom of the cab,

then open the inspection cover at the rear of the
cab and the engine inspection cover.
2. With the accelerator pedal at the low idling po-

sition, loosen nut (2) and adjust so that the length
a is as shown below.
. Standard value: a = 148.4 mm La TWWO1828
3. Adjust joint (4) of the servo cylinder spool so

that the length of servo return spring (3) is b at
b
low idling. (When low idling)
l Standard value: b = 256 mm
I TWW01829
4. Remove rod (5) at the engine end, and adjust

the overall length to c.
l Standard value: c = 405.4 mm
5. Temporarily install rod (5), to governor lever (61,

then adjust the length of rod (5) so that engine
governor lever (6) contacts low idling stop bolt
(7) lightly, and tighten locknut (8).
Ir Install so that water drain hole d of the rod
is at the bottom.
I TWWOI830
6. Start the engine, gradually depress accelerator

pedal (IO), adjust length e of stopper (11) so
that accelerator pedal (IO) and stopper (II) are
in contact at the position where governor lever
(6) contacts high idling stopper bolt (9), then
secure with locknut (12).
. Reference value: e = Approx. 56 mm
TWWOl83l
20-l 18 WA800-3
ADJUSTING FUEL CONTROL CABLE, LINKAGE,
TESTING AND ADJUSTING AND SERVO CYLINDER
7. Loosen locknut (13) and adjust the secondary

low idling by turning yoke (12) so that the clear-
ance f between lever (I I) at the engine end and
air cylinder yoke (12) is as shown below when
the engine is topped.
. Standard value: f = 6.3 mm
* After completing the adjustment, check that
the engine speed is 850+z” rpm when the
low idling speed is switched to secondary
low idling speed.
Detail P TWW01843
WA8003 20-119
TESTING AND ADJUSTING ADJUSTING ENGINE STOPPING MOTOR CABLE
ADJUSTING ENGINE STOPPING

MOTOR CABLE
1. Temporarily install ball joint (3) to cable (2) of

engine stop motor (1) (screw in fully, then turn
back approx. l/2 turns), then install the ball joint
to the stop lever of the injection pump.
2. Pull stop lever (4) of the injection pump by hand

to the engine stop position (no injection of fuel),
and temporarily assemble the cable to the
bracket. When this is done, secure the cable at a
point where stop lever (4) contacts engine STOP
stopper (51, and temporarily assemble to the
bracket (7) with locknut (6).
Ir Engine stop motor (1) is at the engine STOP
position with cable (2) pulled.
3. Adjust stop lever (4) of the injection pump and

STOP stopper (5) at the stop end so that clear-
ance a is 1.0 - 2.0 mm.
Adjust with nut (6) which secures the cable to
the bracket or carry out fine adjustment by
changing the depth that ball joint (3) is screwed
in.
4. Tighten all nuts and bolts.
5. Turn the engine starting switch repeatedly to

the ON and OFF positions, and check that the
engine stop motor and cable work smoothly,
then carry out the following checks again.
I) Check visually that there is slack in the en-
gine stop motor cable when the engine is
running, and that the stop lever of the fuel
injection pump has returned fully to the RUN
position.
20- 120 WA800-3

TESTING AND ADJUSTING ADJUSTING ENGINE STOPPING MOTOR CABLE
2) Check that the clearance between the stop

lever and stopper at the STOP end is 1.0 -
2.0 mm when the engine is stopped.
Ir With the engine stop motor, there are built-
in limit switches at both ends of the cable
stroke.
* Engine stop motor stroke: 35 mm
Fuel injection pump stop lever stroke:
30 mm
* When the engine is running, there is slack in
the engine stop motor cable, and the RUN
position is maintained by the action of a
spring (this is frequently built into the fuel
injection pump).
* There is a loose spring inside the engine
stop motor, and this absorbs the error in the
stop motor when the engine is stopped.
However, if this is absorbed by the loose
spring in the engine stop motor, force is
brought to bear on the injection pump, so
depending on the machine model, this sys-
tem may not be possible to use.
With such models, there is a danger of prob-
lems arising with the injection pump if the
clearance between the stop lever and the
stopper at the STOP end is set to 0 when the
engine is stopped.
* Problems caused by improper adjustment of

engine stop motor cable
l When engine stop l Engine does not stop

motor cable is pulled
and clearance be-
tween stop lever and
STOP stopper is too
large.
l When cable is free and l Engine does not give
clearance between full output because of
stop lever and RUN drop in amount of fuel
stopper is too large injected
WA800-3 20-l 21
TESTING AND ADJUSTING TORQUE CONVERTER AND
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE

TORQUE CONVERTER AND
TRANSMISSION OIL PRESSURE
MEASUREMENT CONDITIONS
. Coolant temperature: Inside operating range
. Torque converter oil temperature: 60 to 80°C
A Apply the parking brake and block the tires.
MEASURING PROCEDURE
* The following preparatory work is necessary
before measuring any oil pressure.
. Remove cover on upper side of the trans-
mission.
l Turn transmission cut-off selector switch (2)
to OFF and use the left brake. (Check that
the pilot lamp is OFF).
. Remove the plug (P5) (PT l/8) from the meas-
uring port of the transmission valve.
. Install nipple C2 and hydraulic tester Cl (2.5
MPa 125 kg/cm*})to the measuring port, pull
the gauge to the operator’s compartment,
then start the engine and measure the pres-
sure. ' 'TLW01097
* Check that there is no leakage of oil from any

joints.
1. Transmission main relief valve pressure

1) Remove plug (PO) (PT l/8), and install nipple
C2 and hydraulic tester Cl (5.9 MPa (60 kg/
cm*)).
2) Start the engine and measure the pressure
at 2000 rpm.
2. Measuring pilot reducing pressure

1) Remove plug (P5) (PT l/8), and install nipple
C2 and hydraulic tester Cl (2.5 MPa (25 kg/
cm*)).
2) Run the engine at engine full and put the di-
rectional lever in neutral, and measure the
pressure when the speed control lever is op-
erated.
20- 122 WA800-3

3. Measuring modulating pressure

1) Remove plug (P2) (PT 1/8), and install nipple
C2 and hydraulic tester C1 (5.9 MPa {60 kg/
cm2}).
2) Run the engine at engine full and put the di-
rectional lever in neutral, and measure the
pressure when the speed control lever is op-
erated.
fl Measure pressure except F3 and R3.
4. Measuring torque converter inlet pressure

1) Remove plug (P10) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (2.5 MPa {25
kg/cm2}).
at engine full.
5. Measuring torque converter outlet pressure

1) Remove plug (P11) (PT 1/8), and install nip-
ple C2 and hydraulic tester C1 (2.5 MPa {25
kg/cm2}).
at engine full.
6. Measuring lubrication valve pressure

cm2}).
at engine full.
7. Measuring reducing valve pressure

cm2}).
at engine full.
WA800-3 20-123
(8)
ADJUSTING PROCEDURE
AAlways stop engine before adjusting hydraulic

pressure.
+ If it is impossible to measure relief pressure

acculately, do not try to adjust pressure.
* If the main relief pressure is out of the standard
range, adjust it according to the following pro-
cedure.
1. Adjusting of transmission main relief pressure

1) Loosen cap (I) to reduce spring tension.
2) Remove cover (21, and pull out plunger (3),
then increase or decrease shims (4) to ad-
just oil pressure.
* Standard shim thickness: 6.0 mm
* Amount of adjustment for one shim (t =
0.5 mm): approx. 11.8 kPa IO.12 kg/cm?
Ir To increase pressure, increase shims.
To decrease pressure, decrease shims.
20-124 WA800-3
PROCEDURE FOR OPERATING EMERGENCY
TESTING AND ADJUSTING STEERING SPOOL WHEN TRANSMISSION VALVE FAILS
PROCEDURE FOR OPERATING

EMERGENCY STEERING
SPOOL WHEN TRANSMISSION
VALVE FAILS
OUTLINE
. The transmission valve is controlled electrically.
Therefore, the emergency manual spool is in-
stalled to enable the machine to be moved if
there is any failure in the electrical system, or in
the solenoid valve and spool.
BWWOO876
AL The emergency manual spool is for use when
failure in the transmission control prevents the
machine from being moved. It allows the ma-
REVERSE FORWERD 2nd 1st 3rd
chine to be moved from a dangerous place to a
place where repairs can be carried out safety.
The emergency manual spool must never be
used except when the transmission control has
broken down.
A When operating the emergency manual spool,

follow the correct order of operation exactly,
and pay full attention to safety when moving
the machine.
TWW01832
A To prevent the machine from moving, lower the
bucket to the ground, apply the parking brake,
and block the wheels.
LL
OPERATION
1. Open cover on upper side of transmission.
A Always stop the engine before operating spool.
2. Remove lock plate (2) of emergency manual

spool (I) of the transmission valve.
Ir Simply loosen the mounting bolts to remove
the lock plate (2).
3. Decide the direction to move the machine (for-

ward or in reverse), then move the emergency
manual spool to the operating position.
FORWARD: Rotate FORWARD clutch spool and

1st spool counterclockwise, and pull
out approx. 10 mm to the operat-
ing position.
REVERSE: Rotate REVERSE clutch spool and

1st spool counterclockwise, and pull
out approx. IO mm to the operat-
ing position.
WA800-3 20- 125

PROCEDURE FOR OPERATING EMERGENCY
TESTING AND ADJUSTING STEERING SPOOL WHEN TRANSMISSION VALVE FAILS
4. Check that the area around the machine is safe,

remove the blocks from under the wheels.
5. Sit in the operator’s seat, and depress the left

brake pedal fully.
6. Start the engine, release the parking brake, then

release the brake pedal gradually to start the
machine.
a When the engine is started, the transmission

engaged and the machine will start. Therefore,
is
before starting the engine, always check that

the direction of travel is safe, and always keep
the brake pedal depressed.
If the machine does not start, turn the 2nd spool
and 3rd spool clockwise, and screw in approx.
10 mm to the OFF position.
7. After moving the machine, stop the engine, ap-

ply the parking brake, and block the wheels.
8. Return the emergency manual spool to the neu-

tral position, and install the lock plate.
ZO-126 WA800-3
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE

STEERING OIL PRESSURE
MEASURING
Hydraulic oil temperature: 45 - 55°C
a Install the safety bar to lock front frame and rear

frame.
ALoosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then operate
the steering wheel 2 - 3 times to release the
remaining pressure in the hydraulic piping.
1. Remove hydraulic oil pressure measurement

plug (2) (PT l/8) from right-hand steering cylin-
der (I).
2. Install nipple C2, then install oil pressure meas-

urement gauge Cl (39.2 MPa {400 kg/cm21).
3. Start the engine and run it at the full speed.

Turn the steering wheel to the left and measure
the hydraulic pressure when the relief valve ac-
tuates.
* When removing the oil pressure measure- I \ \ BWWOO879
ment plug from left-hand steering cylinder,
turn the steering wheel to the right and
measure the oil pressure.
ADJUSTING
a If the relief pressure is not normal, adjust the

steering relief valve according to the following
procedure.
a Adjust
. the steering relief valve while the engine
is stopped.
Loosen lock nut (3), then turn adjustment screw

(4) to adjust.
* Amount of adjustment for 1 turn of adjust-
ment screw.
1 turn: Approx. 17.8 MPa (181 kg/cm21
* Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
Sr If it is impossible to measure relief pressure
accurately, do not try to adjust the pressure.
TKWOlll
WA800-3 20-127
TESTING AND ADJUSTING TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE

EMERGENCY STEERING OIL
PRESSURE
MEASURING
. Hydraulic oil temperature: 45 - 55°C
A pressure
Loosen the oil filler cap slowly to release the
inside the hydraulic tank. Then operate
the steering wheel 2 - 3 times to release the
remaining pressure in the hydraulic piping.
AFit the safety bar to lock the front frame and

rear frame.
1. Disconnect drive shaft (I) between transmission

and center support at transmission side.
2. Disconnect drive shaft (2) between transmission

and rear axle at transmission side.
3. Disconnect hose (3) to pilot port of diverter valve,

replace elbow (4) by oil passage shut off elbow
(for details, see next page), then connect hose
(3).
(As a result of this, oil pressure to pilot port of
diverter valve is shut off, emergency steering is
operating.)
4. Remove plug (5) (PT l/8) between diverter valve

and steering valve, and install nipple C2 and
hydraulic tester Cl (39.2 Mpa {400 kg/cm*}).
5. Start engine, shift transmission gear shift lever

to F3 or R3 raise speedometer until 24 km/h.
Turn the steering wheel to the right or left and
measure the pressure when the relief valve is
actuated.
20- 128 WA800-3

TESTING AND ADJUSTING TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE
ADJUSTING
A Always stop the engine before adjusting the

hydraulic pressure.
1. Remove capnut (6) of the relief valve.
2. Loosen locknut (7), then turn adjustment screw

(8) to adjust.
Amount of adjustment for 1 turn of adjust-
ment screw.
1 turn: Approx. 3.5 MPa (35.7 kg/cm?
Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
If it is impossible to measure relief pressure
accurately, do not try to adjust the pressure.
TKWO1118
* Preparatory of oil passage shut off elbow

Prepare elbow (07236-10210), insert pin (dia.: 5
mm) in drilled hole, then weld pin and elbow to
shut off passage.
WA800-3 20-129
TESTING AND ADJUSTING BLEEDING AIR FROM STEERING CIRCUIT
BLEEDING AIR FROM

STEERING CIRCUIT
1
* Bleed the air from the circuit as follows if the
steering valve or steering cylinder have been
removed and installed again.
1. Start the engine and run at idling for approx. 5

minutes.
2. Run the engine at low idling and turn 4 - 5

times to the left and right in turn.
BWWOO883
* Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not to
relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at engine slow and operate the

piston to the end of its stroke to relieve the
circuit.
20- 130 WA8003

TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING STOP VALVE

STEERING STOP VALVE
STEERING WHEEL SPECIFICATION,
STEERING WHEEL AND JOYSTICK STEERING
SPECIFICATION
TESTING
1. Set the front frame and rear frame facing
straight.
2. Check that locknut (2) of stopper bolt (1) is not
loose.
3. Start the engine, and check that there is a clear-
ance between the front frame stopper and rear
frame stopper when the steering is turned to
the right or left.
¤ Measure the clearance with the engine
stopped.
4. Before adjusting stopper bolt, check front frame
stopper does not come into contact with rear
frame stopper at steering end. If they come into
contact, adjust as shown below.
fl If they do not come into contact because of
lack of stopper, repair and then check above
for each steering end.
ADJUSTING
fl If the clearance between the front frame and
rear frame is not within the standard value, ad-
just as follows.
1. Loosen locknut (2), tighten stopper bolt (1), and
make sure that there is no contact with the steer-
ing stop valve (3).
2. Start the engine, run at engine slow, then turn
the steering wheel slowly to bring the front frame
and rear frame into contact.
¤ When turning, be extremely careful not to
get your arm or any other part of your body
caught between the front frame and rear
frame.
3. Stop the engine, then loosen the stopper bolt
until it contacts the steering stop valve contact
surface.
4. Start the engine and run it at engine solw. Re-
turn the steering wheel slowly. When distance b
between stop valve (3) and head of stopper bolt
(1) becomes about 20 – 30 mm, stop the engine.
5. Loosen stopper bolt (1) 8.5 – 9 turns (length c:
14.9 – 15.8 mm), then tighten locknut (2).
fl Carry out the procedure in Steps 1 – 5 to
adjust both the left and right sides.
6. Start the engine, turn the machine, and check
that clearance between the front frame and rear
frame is within the standard value for both the
left and right and that the steering stopper valve
and stopper bolt come into contact and the steer-
ing is stopped.
WA800-3 20-131
5
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING STOPPER BOLT
TESTING AND ADJUSTING STEERING STOPPER BOLT

TESTING ADJUSTING
1. Start the engine and set steering lock lever (1) fl If clearance a is abnormal, adjust it ac-
in the free position. cording to the following procedure.
2. Run the engine at low idling and move joystick 1. Set the steering lock lever in the free po-
steering lever (2) to the right or left stroke end sition and return the steering lever to the
and keep it at that position. neutral position.
¤ Operate the steering lever slowly and take
care not to catch your body or arm between 2. Set the steering lock lever in the lock po-
the front frame and rear frame. sition.
3. Set steering lock lever (1) in the lock position. 3. Adjust projection b of adjustment bolt (5)
on the side where clearance a is abnor-
4. Check that clearance a between the end stop- mal.
pers of the front frame (3) and rear frame (4) is fl If projection b is increased, clearance
normal. a is increased, too. If the former is
fl Clearance a: 20 – 30 mm decreased, the latter is decreased, too.
fl Perform the above test at the right and left fl Standard projection b (Reference): 15
steering ends separately. mm
3 Locknut:
8.8 – 10.8 Nm {0.9 – 1.1 kgm}
fl After adjusting, check clearance a again

according to the procedure explained
above.
20-131-1 WA800-3
5
TESTING AND ADJUSTING STEERING LEVER ANGLE
TESTING AND ADJUSTING SENSOR AND FRAME ANGLE SENSOR
TESTING AND ADJUSTING STEERING LEVER ANGLE

SENSOR AND FRAME ANGLE SENSOR
TESTING
1. Start the engine and set steering lock lever (1) 5. Set steering lock lever (1) in the free posi-
in the free position. tion and check that the caution buzzer
sounds.
2. Run the engine at low idling and operate joy- fl If the system is normal, the caution
stick steering lever (2) to set the steering system buzzer makes pips 1 second after the
in the neutral position (position for straight steering lock lever is operated.
travel).
fl When the front frame can be locked with the ADJUSTING
safety bar, the steering system is in the neu- fl If the caution buzzer does not sound, ad-
tral position (straight travel position). just the sensors according to the follow-
ing procedure.
3. Set steering lock lever (1) in the lock position
and run the engine at low idling. 1. Loosen the mounting bolt of steering le-
fl Do not move the joystick steering lever dur- ver angle sensor (4) or frame angle sen-
ing steps 3 through 5. sor (5) and adjust the position of the sen-
sor.
4. Slide left armrest (3) to the storage position (rear fl Standard position (Reference):
end). Position at which bolt is at center
fl At this position, the console switch for test- of oblong hole
ing is turned on.
fl After adjusting, check the operation of the
caution buzzer according to the procedure
explained above.
WA800-3 20-131-2
5
TESTING AND ADJUSTING TESTING WHEEL BRAKE PERFORMANCE
TESTING WHEEL BRAKE PERFORMANCE
A A A
Stooping Point Point where braking Paint where o~eretor out
eifect started foot on brake oedei
I (oDerat ion Point)
StoPPins distance Run-up path
TWW01715
* Test the performance of the wheel brake under 3. Measure the distance from the point
the following conditions. where the brakes were applied to the point
. Road surface: Flat, horizontal, dry paved sur- where the machine stopped.
face. + Repeat this measurement three times
. Travel speed: 20 km/h when brakes are ap- and take the average.
plied
. Tire inflation pressure: Specified pressure
(235.4 kPa (2.4 kg/cm*})
. Operating effort of pedal: 373 N {38 kg}
. Operation delay time: 0.1 sec.
1. Start the engine, operate the directional lever to

F and the speed lever to 3rd, and drive the ma-
chine.
2. Maintain the travel speed at 20 km/h, and de-

press the brake pedal with the specified operat-
ing force.
* Before carrying out this operation, determine
the run-up path and the point for applying
the brakes, then travel at 20 km/h and apply
the brakes when the machine reaches the
braking point.
Sr Switch the transmission cut-off switch ON
when carrying out this operation.
20-132 WA800-3
TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE DROP
TESTING WHEEL BRAKE OIL

PRESSURE DROP
A Apply the parking brake and put blocks securely

under the tires.
1. Remove the brake hose cover (I).
2. Remove hose (2) and nipple (3) from the brake

system to be measured.
If the brake pedal is depressed when the
g
hose is disconnected, high-pressure oil will
spurt out. Never depress the brake pedal in
this condition.
3. Set brake tester kit Jl in position and connect

coupler 52 and pump J3.
4. Loosen bleeder (4), operate pump J3 to bleed

the air, then tighten bleeder (4).
5. Operate the pump to raise the oil pressure to

the specified pressure, then close the stop valve.
* Specified oil pressure:
4.2 - 5.2 MPa I43 - 53 kg/cm*)
6. Leave in this condition for 5 minutes, then check

the drop in pressure over the next 5 minutes.
* If the hose is moved during the inspection,
the pressure will change, so be careful not
to move the hose.
t After completion of the inspection, operate
the pump to release the oil pressure, then
remove the brake tester kit.
WA800-3 20- 133

TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE DROP
Brake tester kit J
J
P
TWW01716
20-134 WA&IO-3
TESTING AND ADJUSTING MEASURING WEAR OF WHEEL BRAKE DISC
MEASURING WEAR OF WHEEL

BRAKE DISC
AStop the machine on level ground and block the

tires.
1. Remove plug (I).
2. Depress the brake pedal fully to the end of its

stroke.
3. Measure depth a from the end face of the hous-

ing to the spring guide by using caliper gauge
P.
* Keep the brake pedal depressed while meas-
uring.
Wear limit: a = 46.3 mm

(Reference: When machine is new, a = 40.7
+ 1.4 mm)
* When the disc is near the wear limit, carry

out inspection frequently, regardless of the
maintenance interval.
TKW01142
WA800-3 zo- 135

TESTING AND ADJUSTING ACCUMULATOR
TESTING AND ADJUSTING CHARGE CUT-IN AND CUT-OUT PRESSURE

ACCUMULATOR CHARGE CUT-
IN AND CUT-OUT PRESSURE
MEASURING
* Brake oil temperature: 45 - 55°C
ADepress the brake pedal at least 100 times with
the engine stopped to release the pressure in-
side the accumulator circuit.
1. Remove the brake oil tank side cover (on the

front side of the machine body).
2. Disconnect hose (PP port) (2) from accumulator

charge valve (I) on the accumulator distribution
tube (3) side.
3. Install adapter and nipple C2, then connect oil

pressure gauge Cl (39.2 MPa (400 kg/cm*}) .
4. Measure the accumulator charge cut-in pressure.

Start the engine, run the engine at engine slow,
and measure the oil pressure when the brake oil
pressure warning pilot lamp on the maintenance
monitor goes out and buzzer stops.
5. Measure the accumulator charge cut-out pres-

sure.
After the accumulator charge cut-in is actuated, / TWWOl992
measure the oil pressure when the indicator of

the oil pressure gauge rises and becomes going
down.
20-136 WA800-3
TESTING AND ADJUSTING ACCUMULATOR
TESTING AND ADJUSTING CHARGE CUT-IN AND CUT-OUT PRESSURE
ADJUSTING
Accumulator charge cut-out pressure
When the accumulator charge cut-out pressure
is adjusted, the cut-in pressure also changes in
proportion to the ratio of the valve area. For this
reason, there is no adjustment screw for the
cut-in pressure.
Loosen locknut (5) of cut-out valve (4) and ad-

just cut-out pressure with the adjustment screw
(6) as follows.
Adjustment screw BDW00701
. To INCREASE cut-out pressure, turn CLOCK-
WISE
. To DECREASE cut-out pressure, turn
COUNTERCLOCKWISE
Pressure adjustment for one turn of adjustment
screw: 5.59 MPa 157 kg/cm?
w Locknut: 9.8 - 11.8 Nm il.0 - 1.2 kgml
After adjustment, check again the cut-in and cut-
out pressure according to the procedure men-
tioned in the previous page.
I BDW00702
I
WA800-3 20-137
TESTING AND ADJUSTING BLEEDING AIR FROM WHEEL BRAKE CIRCUIT
BLEEDING AIR FROM WHEEL

BRAKE CIRCUIT
-)r If brake circuit hoses were disconnected because

of removing brake valve or axle, bleed air as
follows.
A Apply the parking brake and put blocks securely
under the tires.
g When engine is running, never bleed air from
slack adjuster because drive shift is rotating.
1. Start the engine and accumulate the pressure in

the accumulator (about 30 seconds at the high
idling speed).
2. Stop the engine and insert either end of vinyl

hoses @ in bleeders (2) of slack adjuster (I),
then insert the other end in the container.
3. Depress the brake pedal, loosen the bleeder

screw, and bleed the air. Tighten the screw,
then release the brake pedal slowly.
* Carry out this operation with two workers:
one worker depresses the brake pedal, and
the other worker bleeds the air from the
bleeder screw.
* Use L.H. brake pedal.
j, If brake oil level goes down, refill oil to keep
full.
Repeat this operation until no more bubbles

come out with the fluid from the vinyl hose,
then depress the pedal fully and tighten the
bleeder screw while the oil is flowing out.
Similarly, bleed air from the slack adjuster on

the opposite side and bleeder (3) of each wheel.
If the accumulator pressure goes down, start
the engine and charge the accumulator.
After completion of the air bleed operation,
run the engine at low idling, check the hy-
draulic oil level, and add oil if necessary.
After bleeding air, perform “TESTING WHEEL
BRAKE PERFORMANCE”.
20- 138 WA800-3

TESTING AND ADJUSTING TESTING PARKING BRAKE PERFORMANCE
TESTING PARKING BRAKE

PERFORMANCE
* Measurement condition
l Tire inflation pressure: Specified pressure
. Road surface: Flat, dry, paved surface with l/5
(11’20’) gradient.
. Machine: In operating condition
1. Start the engine and drive the machine straight

up a l/5 gradient with the bucket unloaded.
2. Depress the brake, place the directional lever in

neutral, then stop the engine.
3. Turn the parking brake switch ON, then slowly

release the brake pedal and keep the machine
must be kept stopped.
* The measurement must be made with the
machine facing either up or down the slope.
I TWW01837
WA800-3 20- 139

TESTING AND ADJUSTING MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE
MEASURING PARKING BRAKE

SOLENOID OUTPUT PRESSURE
Ir Brake oil temperature: 45 - 55°C
a Put blocks securely under the tires.
A the
Depress the brake pedal at least 100 times with
engine stopped to release the pressure in-
side the accumulator circuit.
1. Turn starting switch ON, then parking brake

switch OFF to release brake.
2. Remove front frame right sidecover.
3. Disconnect parking brake spring cylinder output

hose (I) from parking brake solenoid valve.
4. Connect nipple C2 and oil pressure gauge Cl

(39.2 MPa {400 kg/cm2}).
5. Start engine and after accumulator charged, turn

parking brake switch ON.
6. Measure oil pressure with the engine slow.
A After measuring parking brake oil pressure, de-

press the brake pedal at least 100 times with the
engine stopped to release the pressure inside
the accumulator circuit, and remove measuring
tools after turning parking brake switch OFF.
20-140 WA8003
TESTING AND ADJUSTING CHECKING AND ADJUSTING PARKING BRAKE PAD
CHECKING AND ADJUSTING

PARKING BRAKE PAD
A Block the tires securely.
MEASURING
1. Turn the starting switch ON, and turn the park-
ing brake switch (I) OFF to release the brake.
2. Measure the thickness of the parking brake pad.

Measure the thickness of the parking brake pad
with slide calipers N.
a When the starting switch is turned OFF, the
parking brake is applied, so be careful not to
turn it OFF.
+ Measure 4 pads.
+ If the thickness is not within the standard
value, replace the 2 parking brake pads as
one set.
+ For details of removing the parking brake
pad, see “DISASSEMBLY AND ASSEMBLY”.
3. Measure the parking brake pad clearance. Insert

thickness gauge F between disc (I) and pad (21,
then measure the clearances.
Ir The clearance value mentioned above indi-
cates the total value of both sides. (a + b)
4L Note that the parking brake is actuated if the
starting switch is turned OFF.
WABOO-3 20-141
TESTING AND ADJUSTING CHECKING AND ADJUSTING PARKING BRAKE PAD
ADJUSTING
* If the measured value is not within the standard
value, adjust as follows.
1. Turn the starting switch ON, then turn the park-

ing brake switch OFF to release the brake.
* If the main switch is turned OFF, so be care-
ful the parking brake will be actuated.
2. Turn adjustment bolt (4) of parking brake slack

adjuster (3) clockwise until parking brake pad
(2) is lightly in contact with disc (3).
* If the adjustment bolt is tightened too much
and parking brake pad (2) and disc (3) are
brought strongly into contact, it may cause
the brake to squeak or the discs to overheat.
BWWOO896
3. Return adjustment bolt (‘I) 180” 5 30” (three notch)

counterclockwise. This will adjust the total clear-
ance on the left and right between pad (2) and
disc (I) to 1.06 f 0.18 mm.
* After adjusting, measure the brake performance

again and check that it is within the standard
value.
20-l 42 WA8003
TESTING AND ADJUSTING TESTING AND ADJUSTING PPC PRESSURE

PPC PRESSURE
Ir Hydraulic oil temperature: 45 - 55°C
ALoosen the oil filler cap slowly to release the

pressure inside the hydraulic tank.
g Operate the control levers 2 - 3 times to release
the pressure in the PPC accumulator circuit.
MEASURING
1. Measuring PPC relief pressure
1) Remove plug (PT l/8) (I) for P port oil pres-
sure measuring from bottom of PPC valve
assembly.
2) Install nipple C2 and oil pressure gauge Cl
(5.9 MPa 160 kg/cm*}).
3) Start engine and measure oil pressure with
the engine full throttle.
2. Measuring PPC valve output pressure

1) Remove work equipment valve cover.
2) Remove plug (PT l/8) (2) for bucket DUMP
circuit oil pressure measuring, and install
nipple C2 and oil pressure gauge Cl (5.9
MPa 160 kg/cm*}).
3) Start the engine and raise the boom. Dump
the bucket with the engine at the full speed
and measure the hydraulic pressure when
the relief valve operates.
WA800-3 20-143
TESTING AND ADJUSTING TESTING AND ADJUSTING PPC PRESSURE
ADJUSTING
1. Adjusting PPC relief valve
AAdjust the hydraulic pressure while the engine
is stopped.
AGradually loosen the oil filler cap of the hydrau-
lic tank to release the pressure from the tank.
g Operate the work equipment control lever two -
three times to release the pressure from the
accumulator circuit for PPC.
1) Remove the upper cover of the transmis-
sion.
2) Remove cap nut (3) of the PPC relief valve BWWOO914
beside the accumulator charge valve for PPC.
3) Loosen locknut (4) and adjust with the ad-
justment screw (5).
* Adjustment screw
. To INCREASE, turn CLOCKWISE
. To DECREASE, turn COUNTERCLOCK-
WISE
* Pressure adjustment for one turn of adjust-
ment screw: 0.96 MPa (9.8 kg/cm*}
BWWO0915
20- 144 WA8003

TESTING AND ADJUSTING ADJUSTING PPC VALVE LINKAGE
ADJUSTING PPC VALVE

LINKAGE
1. Remove cover at the bottom of the work equip-

ment control lever.
2. Adjust dimension a from nut (I) of the PPC valve

linkage to the top surface of the floor.
. Dimension a (target value): 54 mm
3. Loosen nuts (2) and (3), then adjust the installed

height of trunnion (5) so that there is no play in
lever (4).
4. After adjusting, tighten nuts (2) and (3).
WA800-3 zo- 145

TESTING AND ADJUSTING WORK
TESTING AND ADJUSTING EQUIPMENT HYDRAULIC PRESSURE

WORK EQUIPMENT
HYDRAULIC PRESSURE
* Hydraulic oil temperature: 45 - 55°C
A pressure
Loosen the oil
inside
filler cap slowly to release
the hydraulic tank.
the
MEASUREMENT
1. Measuring work equipment relief pressure
a
1) Raise-bucket portion a approx. 30 - 50 mm TEW00149
and set portion b in contact with the ground.

2) Stop the engine, then operate the work
equipment control lever and check that the
bottom surface of the bucket (both portion a
and portion b) is in contact with the ground.
AAfter lowering the bucket to the ground,
operate the work equipment control le-
ver 2 - 3 times to release the remaining
pressure in the piping.
3) Remove plug (PT l/8) (I) for bucket DUMP
circuit hydraulic pressure measuring, and
install nipple C2 and oil pressure gauge Cl
(39.2 MPa (40 kg/cm21).
4) Start the engine and raise the boom, then
dump the bucket with the engine at the full
speed and measure the hydraulic pressure
when the relief valve operates.
AAfter measuring, repeat the procedure
used when installing the oil pressure
gauge to release the pressure inside the
circuit, then remove the oil pressure
gauge.
20-146 WA800-3
TESTING AND ADJUSTING WORK
TESTING AND ADJUSTING EQUIPMENT HYDRAULIC PRESSURE
ADJUSTING
1. Adjusting work equipment relief valve
A Adjust the hydraulic pressure while the en-
gine is stopped.
Loosen locknut (3) of work equipment relief valve
(21, then turn adjustment screw (4) to adjust.
* Turn the adjustment screw to adjust as fol-
lows.
l To INCREASE the pressure, turn CLOCK-
WISE.
l To DECREASE the pressure, turn
COUNTERCLOCKWISE. TEW01163
j, Amount of adjustment for one turn of ad-

justment screw: 12.6 MPa (128 kg/cm?
* After completion of the adjustment, repeat
the above procedure to measure the work
equipment relief pressure again.
I TLW01164
WASOO-3 20-147
TESTING AND ADJUSTING BLEEDING AIR FROM PISTON PUMP
BLEEDING AIR FROM PISTON

PUMP
* When replacing oil inside hydraulic tank or re-

moving piston pump or hydraulic pipings of pis-
ton pump, bleed air from piston pump to pre-
vent pump inner parts seizing as follows.
1. Check that the hydraulic tank is filled with hy-

draulic oil.
* The cap of the hydraulic tank remains re-
moving, until the air bleeding of the piston
pump finishes.
2. Loosen plugs (I), (2) and (3) of piston pump

suction tube.
3. When oil overflows from plugs (I), (2) and (3) in

turn, and tighten plugs under air is bled com-
pletely. After that, in order to fill the inside of
the pump with the hydraulic oil, leave it for IO
minutes.
+ Since the oil level in the hydraulic tank is higher

than positions (I), (2) and (3) above, air is bled
easily.
4. Loosen the mouthpiece of the case drain hose

(41, starting an engine at the condition of low
idling. Tighten the mouthpiece, confirming that
hydraulic oil flows from the mouthpiece.
20-l 48
0
TESTING AND ADJUSTING BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
BLEEDING AIR FROM WORK

EQUIPMENT CIRCUIT
* Bleed the air from the circuit as follows if the

work equipment control valve or work equip-
ment cylinders have been removed and installed
again.
1. Start the engine and run at idling for approx. 5

minutes.
2. Run the engine at engine slow and raise and

BWWO0993
lower the boom 4 - 5 times in turn.
* Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not to
relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at engine slow and operate the

piston to the end of its stroke to relieve the
circuit.
5. Repeat Steps 2 to 3 for the bucket cylinder also.
\ ,
'--- BWWOO918
WA800-3 20-149
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LEVER LINKAGE
ADJUSTING WORK
EQUIPMENT LEVER LINKAGE
If the operating effort or travel of the work equip-

ment control lever is not within the standard value,
or the work equipment control lever, PPC valve as-
sembly, or boom or bucket solenoids have been
removed, adjust as follows.
ACarry out the adjustment with the engine

stopped.
* Check if the operating effort of the work equip-

ment lever is within the standard value.
1. Remove the side cover from the work equip-

ment control lever.
2. Operate boom lever (I) and adjust rod (4) so

that boom lever cam follower (2) enters the
detent portion at both ends of cam (3) uniformly
and clearance a is 0 - 1 mm.
* Distance b between pins on both ends of
rod (4): 337 mm (for reference)
3. Operate bucket lever (5) and adjust rod (8) so

that bucket lever cam follower (6) enters the
detent portion of cam (7) uniformly and clear-
ance c is 0 - 1 mm.
* Distance b between pins on both ends of
rod (8): 337 mm (for reference)
“:-5Ti
a
3 7
+ OO
‘1
go 0
\ C
‘\ a
+
; 6
1 Eww00903 BWWOO904
20-150
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LEVER LINKAGE
4. Do as follows to set boom kickout solenoid (9)

and bucket positioner solenoid (IO) at the pulled
(electricity flowing) condition.
1) Disconnect wiring connectors (FO5) (11) and
(FO6) (12).
Ir F05 (11) : Proximity switch for bucket
positioner
F06 (12) : Proximity switch for boom
kickout
2) Connect T-adapter and short circuit between
terminals (I) and (2).
* Check that the solenoid is pulled in full
stroke 12 mm.
5. Set with boom kickout solenoid (9) pulled, then

move to adjust the solenoid so that clearance d
between boom lever cam (3) and cam follower 3 7
(2) is 0 - 0.5 mm.
OO
* When adjusting, hold boom lever at HOLD. go 0
+ +
6. Set with bucket positioner solenoid (IO) pulled, 2 e
d 6
then move to adjust the solenoid so that clear-
q %
ance e between bucket lever cam (7) and cam
follower (6) is 0 - 0.5 mm.
* When adjusting, hold bucket lever at HOLD. BWWOO907 1 BWWOO908
7. If the operating effort for releasing the boom

lever is not 19.6 N (2 kg} and the operating
effort for releasing the bucket lever is not 9.8 N
{I kg}, change the position of the mounting holes
(4 places) of spring (13) to adjust the release
effort.
Ir When the machine is shipped from the fac-
tory, the spring is hooked to the 2nd mount-
ing hole from the top.
8. After the adjustment, operate the bucket control

lever and boom control lever to check that those
levers are held at the TILT, DUMP, RAISE and TWWOlB38
FLOAT positions.
WA8003 20-151
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE

IN HYDRAULIC CIRCUIT
1. Releasing remaining pressure between each

hydraulic cylinder and control valve
* If the piping between the hydraulic cylinder
and the control valve is to be disconnected,
release the remaining pressure from the cir-
cuit as follows.
1) Stop the engine.
2) Loosen the oil filler cap slowly to release the
pressure inside the tank.
3) Operate the control levers.
* When the levers are operated 2 - 3 times,
the pressure stored in the PPC accumu-
lator is removed. Start the engine, run at
low idling for approx. 5 minutes, then
stop the engine and operate the control
levers.
* Repeat the above operation 2 - 3 times
to release all the remaining pressure.
2. Releasing remaining pressure in brake accumu-

lator circuit
* If the piping between the accumulator and
accumulator check valve, and between the
accumulator and brake valve is to be dis-
connected, release the remaining pressure
from the circuit as follows.
I) Stop the engine.
2) Depress the brake pedal at least 100 times
to release the pressure inside the brake ac-
cumulator circuit.
3. Releasing remaining pressure PPC accumulator

circuit
* If the piping between the PPC accumulator
and PPC valve is to be disconnected, release
the remaining pressure from the circuit as
follows.
. Operate the control lever 2 - 3 times to re-
lease all the remaining pressure.
20-152 WA800-3
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH

BUCKET PROXIMITY SWITCH
TESTING
1. With the engine stopped, check that the clear-

ance between switch (I) and angle (2) is within
the standard value.
2. Start the engine, run at high idling and check

the actuating position. (Measure three times and
take the average.)
ADJUSTING
Lower the bucket to the ground and operate the

bucket to the desired digging angle. Return the
lever to the hold position and stop the engine.
Fix support (3) to the bucket cylinder bracket so

that the tip of angle (2) align the center of the
proximity switch (1).
Adjust and fix nut (4) of switch so that the clear-

ance a between the proximity switch sensing
surface and the angle is within the standard
value.
Standard clearance a : 3 - 5 mm
&M oun t’g
In nut of proximity switch:
14.7 + 19.6 Nm Il.5 f 2.0 kgm}
* After adjusting, operate the bucket lever and
check that the buckrt is actuated at the de-
sired position.
WA800-3 20-153
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM PROXIMITY SWITCH

BOOM PROXIMITY SWITCH
TESTING
1. With the engine stopped, check that the clear-

ance a between switch (I) and plate (2) is within
the standard value.
2. Start the engine, run at high idling and check

the actuating position. (Measure three times and
take the average.)
BWWOO92
I
ADJUSTING
1. Raise the boom to the desired position, stop the

engine, then lock the control lever.
2. Loosen mounting bolt (3), then adjust and fix

the plate so that the clearance b between center
of proximity switch (I) and end of plate (2) is
within the standard value.
3. Adjust and fix nut (4) of proximity switch (I) SO

that the clearance a between the proximity
switch (I) sensing surface and plate (2) is 3 - 5
mm.
l Standard clearance a : 3 - 5 mm
w Mounting nut of proximity switch:
14.7 + 19.6 Nm Il.5 f 2.0 kgm1
Ir After adjusting, operate the boom lever and
check that the boom is actuated at the de-
sired position.
20- 154 WA800-3

TESTING AND ADJUSTING TESTING PROXIMITY ACTUATION PILOT LAMP
TESTING PROXIMITY
ACTUATION PILOT LAMP
Proximity switch actuation pilot lamp (red)

The proximity switch is equipped with a pilot lamp
which shows when it is being actuated, so use this
when adjusting.
Proximity switch
actuation Lights up Goes out
pilot lamp
Detector When detector is positioned at When detector has moved away from
position detection surface of proximity switch detection surface of proximity switch
Bucket
positioner
Boom
kick-out
WA800-3 20-155
TESTING AND ADJUSTING ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR
ADJUSTING SPEEDOMETER
MODULE OF MAIN MONITOR
• The speedometer on the main monitor is a com-

mon part for all machines, and the input signal
for the travel speed differs according to the
machine, so it is necessary to adjust the moni-
tor for use with the particular model.
ADJUSTMENT PROCEDURE
• Turn off the power, then remove the machine
monitor and adjust the switches at the back of
the speedometer.
1. Setting machine model

1) Remove the rubber caps from dipswitches
1, 2 and 3 at the back of the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen inside. Using a flat-
headed screwdriver, turn this switch to ad-
just it to the settings in the table below.
Switch 1 Switch 2 Switch 3

(speedo- (tacho-
Tire size (model
selection) meter meter input
correction) selection)
45/65-45-46PR 0 7 0
3) After completing adjustment, fit the rubber

caps securely and install the main monitor.
Correction amount of switch 2 (for reference)

Switch position 0 1 2 3 4 5 6 7
Correction amount
+14 +12 +10 +8 +6 +4 +2 0
(%)
Switch position 8 9 A B C D E F
Correction amount
0 –2 –4 –6 –8 –10 –12 –14
(%)
fl DIP switch 4 is set as shown in the figure at

right when delivered. If it is changed, the ma-
chine will not function normally. Accordingly,
do not change it. When the main monitor is
replaced, check the setting of DIP switch 4.
DIP switch 4
Specification
1 2 3 4
Without auto shift
ON ON OFF ON
system
With auto shift
ON ON OFF OFF
system
20-156 WA800-3
(9)
TESTING AND ADJUSTING ADJUSTING JOYSTICK LEVER POTENTIOMETER
ADJUSTING JOYSTICK LEVER

POTENTIOMETER
SPECIFICATION
PREPARATORY WORK
Loosen the potentiometer mounting screws, remove
potentiometer connector CNJS2, then connect a T-
adapter (X type 3-pin).
fl Turn the starting switch OFF before doing this.
1. Adjusting neutral position

1) Set the joystick selector switch to the OFF
position and set the joystick lever to the N
position.
2) Turn the starting switch ON.

fl Turn only to the ON position. Do not
start the engine.
3) Check the voltage between pins 2 and 3 of

the T-adapter.
• Voltage between pins: DC 5V ± 0.05V
Adjust the voltage by turning the
potentiometer slowly so that the voltage
between pins 1 and 3 of the T-adapter
become the standard value.
• Voltage between pins: DC 2.5V ± 0.1V
(set value)
After adjusting the voltage, tighten the
potentiometer mounting screws.
WA800-3 20-157
5
ADJUSTING JOYSTICK LEVER POTENTIOMETER
TESTING AND ADJUSTING ADJUSTING JOYSTICK LEVER NEUTRAL DETECTION SWITCH
2. Adjusting left and right turning position

1) Operate the potentiometer to adjust the volt-
age at the left and right turn positions.
Lever position Voltage between

pins (1) and (3)
Left turn DC 0.83V ± 0.1V
Right turn DC 4.17V ± 0.1V
2) After adjusting the voltage, lock the stopper

bolt in position.
ADJUSTING JOYSTICK LEVER

NEUTRAL DETECTION SWITCH
SPECIFICATION
PREPARATORY WORK
After adjusting the neutral position with the
potentiometer, set the lever to the neutral posi-
tion and loosen the nut of the cam plate.
ADJUSTING
1) Set so that the tip of the roller of the neutral
detection switch contacts the concave portion
of the cam plate, then tighten the switch mount-
ing bolts.
fl Never make the roller of the neutral detec-
tion switch push into the concave portion of
the cam plate.
2) Tighten the nut so that the cam plate is not at

an angle.
20-158 WA800-3
5
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT CONTROL LEVER
ADJUSTING WORK
EQUIPMENT CONTROL LEVER
SPECIFICATIONS OF EPC WORK EQUIPMENT
CONTROL LEVER
CALIBRATION OF STARTING POINT
Preparation
Connect a T-adapter to calibration connector CNP05
(1) and short-circuit pins [1] and [3], and then start
the engine.
Adjusting
1. Lowering boom
1) Press the remote positioner RAISE/LOWER
selector switch so that only LOWER will be
selected.
2) Set the boom on the level without applying
any load, and then lower it gradually, run-
ning the engine at high idling.
3) Return the boom control lever in the fine
control mode. When the boom stops, hold
the boom control lever at the current posi-
tion.
4) Hold the remote positioner RAISE position
set switch for 0.5 seconds, and the work
equipment controller reads the EPC com-
mand value and saves the difference be-
tween the read value and standard value as
the offset value.
5) The buzzer makes a pip twice, and setting is
completed.
6) If the remote positioner LOWER position set
switch is pressed, the buzzer sounds for 1
second and the adjustment value is cleared
(and the default values are set).
7) Remove the short-circuit wire from pins [1]
and [3] of calibration connector CNP05 (1),
and the adjustment mode is turned OFF.
2. Raising boom
selector switch so that only RAISE will be
selected.
2) Dump the bucket and lower the boom to
raise the front tires.
3) Running the engine at high idling, raise the
boom (Lower the chassis).
4) Return the boom control lever in the fine
control mode. When the boom stops (while
the tires are floated), hold the boom control
lever at the current position.
WA800-3 20-159
(7)

the offset value.
completed.
3. Dumping bucket
selector switch so that either of RAISE and
LOWER will not be selected (so that the
boom RAISE lamp and boom LOWER lamp
will go off).
2) Set the bucket on the level without applying
any load, and then dump it gradually, run-
ning the engine at high idling.
3) Return the bucket control lever in the fine
control mode. When the bucket stops, hold
the bucket control lever at the current posi-
tion.
the offset value.
completed.
20-160 WA800-3
(7)
4. Tilting bucket
selector switch so that both of RAISE and
LOWER will be selected (so that the boom
RAISE lamp and boom LOWER lamp will
light up).
2) Dump the bucket and lower the boom to
raise the front tires.
3) Running the engine at high idling, tilt the
bucket gradually (lower the chassis).
4) Return the bucket control lever in the fine
control mode. When the bucket stops (while
the tires are floated), hold the bucket control
lever at the current position.
the offset value.
completed.
CALIBRATION OF LEVER DETENT POSITION
Preparation
Connect a T-adapter to calibration connector CNP05
(1) and short-circuit pins [1] and [3], and then turn
the starting switch to the ON position (but do not
start the engine).
Adjusting
1. Floating (Lowering) boom

selector switch so that only LOWER will be
selected.
WA800-3 20-161
(7)
2) Stop and hold the boom control lever 3. Tilting bucket

just before the float detent position. 1) Press the remote positioner RAISE/
3) Hold the remote positioner RAISE posi- LOWER selector switch so that both of
tion set switch for 0.5 seconds, and the RAISE and LOWER will be selected (so
work equipment controller reads the le- that the boom RAISE lamp and boom
ver output voltage and changes and LOWER lamp will light up).
saves the standard value. 2) Stop and hold the bucket control lever
4) The buzzer makes a pip twice, and set- just before the tilt detent position.
ting is completed. 3) Hold the remote positioner RAISE posi-
5) If the remote positioner RAISE position tion set switch for 0.5 seconds, and the
set switch is pressed while the lever out- work equipment controller reads the le-
put voltage is above the standard value ver output voltage and changes and
(1.3 V), the buzzer sounds for 1 second saves the standard value.
and the adjustment is canceled. 4) The buzzer makes a pip twice, and set-
6) Remove the short-circuit wire from pins ting is completed.
[1] and [3] of calibration connector CNP05 5) If the remote positioner RAISE position
(1), and the adjustment mode is turned set switch is pressed while the lever out-
OFF. put voltage is below the standard value
(3.7 V), the buzzer sounds for 1 second
2. Raising boom and the adjustment is canceled.
1) Press the remote positioner RAISE/ 6) Remove the short-circuit wire from pins
LOWER selector switch so that only [1] and [3] of calibration connector CNP05
RAISE will be selected. (1), and the adjustment mode is turned
2) Stop and hold the boom control lever OFF.
just before the float detent position.
3) Hold the remote positioner RAISE posi-
tion set switch for 0.5 seconds, and the
work equipment controller reads the le-
ver output voltage and changes and
saves the standard value.
4) The buzzer makes a pip twice, and set-
ting is completed.
5) If the remote positioner RAISE position
set switch is pressed while the lever out-
put voltage is below the standard value
(3.7 V), the buzzer sounds for 1 second
and the adjustment is canceled.
6) Remove the short-circuit wire from pins
[1] and [3] of calibration connector CNP05
(1), and the adjustment mode is turned
OFF.
20-162 WA800-3
(7)
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT BOOM ANGLE
ADJUSTING WORK
EQUIPMENT BOOM ANGLE
SPECIFICATIONS OF EPC WORK EQUIPMENT
CONTROL LEVER
1. Run the engine and raise the boom to the maxi-

mum lifting height (to the stroke end of the cyl-
inder).
2. Connect a T-adapter to calibration connector

CNP05 (1) and short-circuit pins [2] and [3].
3. The buzzer makes a pip twice, and setting is

completed.
4. Remove the short-circuit wire from pins [2] and

[3] of calibration connector CNP05 (1), and the
adjustment mode is turned OFF.
WA800-3 20-163
(7)
TROUBLESHOOTING
Points to remember when troubleshooting ....................................................................................... 20-202

Sequence of events in troubleshooting .............................................................................................. 20-203
Points to remember when carrying out maintenance ...................................................................... 20-204
Checks before troubleshooting ............................................................................................................ 20-212
Types and locations of connectors ..................................................................................................... 20-213
Connector arrangement diagram ........................................................................................................ 20-216
Connection table for connector pin numbers .................................................................................... 20-221
T-adapter table ................................................................................................................................. 20-230-13
Explanation of functions of electric control mechanism .................................................................. 20-231
Method of displaying action code and failure code .......................................................................... 20-236
Chart of action codes and failure codes, and re-enaction ............................................................. 20-236-2
Transmission controller LED display .................................................................................................. 20-239
Method of using judgement table ....................................................................................................... 20-241
Method of using troubleshooting charts ............................................................................................. 20-242
Method of using matrix troubleshooting tables ................................................................................. 20-244
Troubleshooting of engine system (S mode) .................................................................................... 20-301
Troubleshooting of transmission control system (T mode) ............................................................. 20-401
Troubleshooting of main monitor system (M mode) ....................................................................... 20-501
Troubleshooting of maintenance monitor system (K mode) ........................................................... 20-601
Troubleshooting of electrical system (E mode) ................................................................................. 20-701
Troubleshooting of hydraulic and mechanical system (H mode) .................................................... 20-801
Troubleshooting of joystick steering control system (J mode) ....................................................... 20-851
Troubleshooting of AJSS (advanced joystick steering system) control system (A mode) .......... 20-901
Troubleshooting of work equipment control system (WRK mode) ............................................... 20-1001
WA800-3 20-201
(7)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
A If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
. It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. t When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 - 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from t The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202 WA800-3
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180 @ TEW00181 Jobsi*e

\
step 1
IExamination, confirmation of symptoms
I,
I ---_--
11 When a request for repairs is received, first Ring f Ring I
ask the following points. ------
- Name of cuStomer
- Type. serial number of machine
- Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
- Condition of failure TEW00182
- Work beina carried out at the time of the
failure -
- Operating environment
. Past history, details of maintenance, etc.
I
step 2
\I TEW00183
Determining probable location of cause] a
1) Look at the troubleshooting section of the

shop manual to find locations of possible ::%!;:” :
F
M”SSS.
/ 1 Repairatjobslte 1 \
TEW00184
Step 3
IPreparation of troubleshooting tools\
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
tools.
. T-adapter
. Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the nec-
essaiy replacement parts. II Before starting troubleshooting, locate and
repair simple failures.
- Check before starting items
* Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
-step 6
[Re-enacting failure
- Drive and operate the machine to confirm

the condition and judge if there is really a
TEWOO188
step 4
Ask operator questions to confirm details of
- Was there anything strange about the ma-

chine before the failure occurred?
- Did the failure occur suddenly?
. Had anv repairs been carried out before the
TEW00189
Ill failure?’
TEW00190
WA800-3 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to improper insertion
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
I TEW00192
Defective crimping or soldering of connec-

tors
The pins of the male and female connectors Crimped portion
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
correction or breakage.
TEW00193
20-204 WA800-3
@ Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
\ TEW00194
@I High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be short- TEW00195
circuited by the water, so if any water gets

in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
@ Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
Ir When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
* If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
WA800-3 20-205
2) Removing, installing, and drying connectors and

wiring harnesses
l Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con- TEW00197
nectors apart.
* Never pull with one hand.
When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down
or to the left or right, the housing may
break.
TEW00212
TEW002 13
Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
Ir If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEW00198
20-206 WA8003
0 Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de- Cliks into position
fective contact, corrosion, or damage to
the connector pins.
ri
3) Check that there is no damage or break-
age to the outside of the connector.
* If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth. TEW00199
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
* If there is any damage or breakage, re-
place the connector.
Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
* If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. I TBW00487
WA800-3 20-207
l Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
Ir If the connector is blown dry with com- TEW00196
pressed air, there is the risk that oil in

the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer
to dry the connector.
Ir Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
\ \ TFW”“,“?
Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
* After completely drying the connector,
blow it with contact restorer and reas-
T-adapter
semble.
TEW00203
20-208 WA8003
3) Handling control box

The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
Do not open the cover of the control box
unless necessary.
I TEW00204
Do not place objects on top of the control

box.
Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand)
Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
// TEW00206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
* If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
* If there is any change, there is probably defective contact in that circuit.
WA800-3 20-209
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating environment.

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

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
F TEW00207
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
TEW00208
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to Flushing oil
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
TEW00210
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEW00211
WA800-3 20-211
3
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
-r ludgement
Item Remedy
standard
1. Check fuel level, type of fuel Add fuel
2. Check for impurities in fuel Clean, drain
3. Check hydraulic oil level Add oil
4. Check hydraulic filter - Clean, drain

(Torque converte, Transmission hydraulic oil)
5. Check brake oil level - Add oil
6. Check engine oil level Add oil
7. Check coolant level Add water
8. Check dust indicator for clogging - Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace
IO. Check for looseness, corrosion of alternator terminal, wiring Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring Tighten or replace
12. Check operation of instruments Repair or replace
13. Check for abnormal noise, smell - Repair
14. Check for oil leakage Repair
15. Carry out air bleeding Bleed air
16. Check effect of parking brake, wheel brake Repair or replace
17. Check battery voltage (engine stopped) 24 - 26 V Replace
18. Check battery electrolyte level - Add or replace
19. Check for discolored. burnt, exposed wiring - Replace
20. Check for missing wiring clamps, hanging wiring Repair
21. Check for water leaking on wiring (be particularly careful attentior - Disconnect
to water leaking on connectors or terminals) :onnector and dry
22. Check for blown, corroded fuses Replace
23. Check alternator voltage (engine running at l/2 throttle or above)

(If the battery charge is low, the voltage may be approx. 25V 28.5 - 29.5 \ Replace
immediately after starting.)
24. Sound of actuation of battery relay - -

(when starting switch is turned ON, OFF)
20-212 WA800-3
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
TYPES AND LOCATIONS OF CONNECTORS

fl The addresses in the following table refer to approximate locations in the connector arrangement
drawing.
Connector Number
Type Device name Address
No. of pins
A4 X 2 Air conditioner REC & FRE air servomotor U-9
A5 M 2 Air conditioner thermistor X-6
A6 SWP 6 Air conditioner air mix servomotor X-7
A7 M 6 Air conditioner blower motor & resistor X-6
A8A S 10 Intermediate connector (Air conditioner) X-6
A8B S 8 Intermediate connector (Air conditioner) X-5
A9 YAZAKI 4 Air conditioner blower relay (MAIN) X-4
A10 YAZAKI 4 Air conditioner blower relay (Hi) X-4
A11 YAZAKI 4 Air conditioner blower relay (M2) X-4
A12 YAZAKI 4 Air conditioner condenser relay X-3
A13 YAZAKI 4 Air conditioner blower relay (M1) X-5
A14 YAZAKI 4 Air conditioner condenser Hi (1) relay W-3
A15 YAZAKI 4 Air conditioner condenser Hi (2) relay W-2
A16 YAZAKI 4 Air conditioner magnetic clutch relay X-3
A16 AMP 12 Air conditioner control amplifier R-1
A17 AMP 16 Air conditioner control amplifier Q-1
A18 SWP 8 Air conditioner left air flow servomotor S-1
A19 SWP 8 Air conditioner right air flow servomotor N-5
A21 X 2 Air conditioner condenser Hi-Lo switch X-7
A22 YAZAKI 2 Air conditioner condenser Me switch X-8
AL01 One-pin connector 1 Battery relay L-5
AL02 Terminal 1 Battery relay L-5
AR01 One-pin connector 1 Battery relay L-7
AR02 Terminal 1 Battery relay K-9
AR03 Terminal 1 Battery relay K-9
ASS X 2 Air suspension seat W-8
B01 KES1 2 Low idling selector switch F-9
B02 KES1 2 Front windshield washer I-9
B03 KES1 2 Diode L-5
B04 KES1 2 Rear windshield washer I-9
B05 KES1 2 Diode I-9
B06 One-pin connector 1 Left dust indicator L-4
B07 One-pin connector 1 Left dust indicator L-4
B08 One-pin connector 1 Right dust indicator G-9
B09 One-pin connector 1 Right dust indicator G-9
B10 X 2 Air conditioner left condenser L-6
B11 X 1 Air conditioner left condenser L-6
B12 X 2 Air conditioner right condenser H-9
B13 X 1 Air conditioner right condenser H-9
BC01 X 2 Speed sensor F-1
BC02 X 2 Torque converter oil filter sensor I-2
BC03 X 2 Torque converter oil filter sensor H-1
BC04 X 2 Brake accumulator low pressure switch G-1
BC05 X 2 Brake accumulator low pressure switch H-1
BC06 X 2 Brake accumulator low pressure switch J-3
BC07 X 2 Brake accumulator low pressure switch J-2
WA800-3 20-213
20-213
5
Connector Number
No. of pins
BC08 X 2 Emergency brake switch G-1
BC09 X 2 Emergency brake switch H-1
BC10 X 2 Emergency brake switch I-2
BC11 X 2 Emergency brake switch J-2
BR1 SWP 12 Intermediate connector K-3
C1 MIC 13 Transmission & joystick steering controller P-7
C2 MIC 21 Transmission & joystick steering controller N-6
C3A AMP040 20 Transmission & joystick steering controller O-7
C3B AMP040 16 Transmission & joystick steering controller P-7
C4 AMP040 12 Transmission & joystick steering controller O-6
C5 MIC 17 Transmission & joystick steering controller N-6
C01 M 6 Front wiper motor C-7
C02 YAZAKI 9 Cassette stereo & radio C-7
C03 M 2 Right front working lamp D-8
C04 M 2 Left front working lamp D-8
C05 KYORITSU 4 Warning lamp (Beacon) switch D-8
C06 KES1 2 Room lamp E-9
C07 M 4 Rear wiper motor K-3
C08 One-pin connector 1 Cigarette lighter C-7
C09 Terminal 1 Cigarette lighter D-8
C10 M 1 Power supply C-7
C11 One-pin connector 1 Right room lamp door switch —
C12 One-pin connector 1 Left room lamp door switch —
C13 KES0 2 Left speaker G-9
C14 KES0 2 Right speaker F-9
C15 One-pin connector 1 Warning lamp (Beacon) E-8
C16 M 2 Left side working lamp G-9
C17 M 2 Right side working lamp E-8
CBL1 SWP 8 Intermediate connector U-1
CL1 S 12 Intermediate connector N-4
CL2 S 10 Intermediate connector (Air conditioner) N-3
CL3 M 6 Intermediate connector (Air conditioner) N-3
CL4 M 6 Intermediate connector N-3
CL18 YAZAKI 1 Left power window regulator —
CL19 YAZAKI 1 Left power window regulator —
CL20 YAZAKI 1 Right power window regulator —
CL21 YAZAKI 1 Right power window regulator —
D01 KES 2 Diode [Steering wheel and joystick specification] —
D02 KES 2 Diode [Steering wheel and joystick specification] —
E02 Terminal 1 Starting motor Z-3
E03 X 2 Engine speed sensor Z-3
E03 SWP 8 Engine stop motor L-5
E04 X 2 Engine water temperature sensor (For monitor) b-7
E05 AMP250 1 Engine water temperature sensor (For timer) b-7
E06 X 2 Starting motor Y-3
E07 X 2 Starting motor Y-3
20-214 WA800-3
5
Connector Number
No. of pins
E08 X 1 Air compressor magnetic clutch c-7
E09 Terminal 1 Engine oil pressure switch Z-3
E10 Terminal 1 Right heater relay Z-7
E11 Terminal 1 Right heater relay Z-7
E12 Terminal 1 Left heater relay c-3
E13 Terminal 1 Left heater relay d-4
E14 KES 2 Diode Y-5
E15 KES 2 Diode Y-4
E16 KES 2 Diode Y-5
E17 KES 2 Diode Y-4
E18 KES 2 Diode d-5
E19 KES 2 Diode b-2
E20 Terminal 1 Alternator d-6
ER1 SWP 12 Intermediate connector Y-6
ER2 L 2 Intermediate connector Y-4
ER3 L 2 Intermediate connector a-2
F01 M 4 Intermediate connector A-5
F05 X 3 Proximity switch for bucket positioner A-3
F06 X 3 Proximity switch for boom kick-out A-4
F07 Terminal 1 Horn C-1
F08 Terminal 1 Horn D-1
F09 Terminal 1 Horn A-5
F10 Terminal 1 Horn A-4
F11 X 2 Parking brake solenoid B-1
F13 X 2 Parking brake indicator switch B-1
FL1 S 12 Intermediate connector X-5
FL2 SWP 6 Intermediate connector W-2
FL3 One-pin connector 1 Intermediate connector [AJSS specification] —
FS1 L 2 Intermediate connector (Fuse box) W-8
FS2 S 12 Intermediate connector (Fuse box) W-8
FS2A S 12 Intermediate connector (Fuse box) —
FS3 M 6 Intermediate connector (Fuse box) V-9
FS4 L 2 Intermediate connector (Fuse box) V-9
FS5 M 6 Intermediate connector (Fuse box) V-9
FS6 M 4 Intermediate connector (Fuse box) U-9
G01 M 6 Right rear combination lamp I-9
G02 M 2 Right working lamp K-9
G03 M 2 Right working lamp J-9
G04 Terminal 1 Backup buzzer L-6
G05 Terminal 1 Backup buzzer L-6
G06 X 2 Radiator water level sensor J-9
G07 M 2 Left working lamp K-8
WA800-3 20-215
20-215
(7)
Connector Number
No. of pins
G08 M 2 Left working lamp L-6
G09 M 6 Left combination lamp L-8
GND M 1 Right front combination lamp B-6
GND M 1 Left front combination lamp D-1
GND One-pin connector 1 Intermediate connector (GND) —
GND One-pin connector 1 Intermediate connector (GND) —
GR1 SWP 12 Intermediate connector K-8
GRE SWP 6 Auto grease connector T-1
H01 Terminal 1 Additional horn [AJSS specification] —
HEAD M 2 Right head lamp A-6
HEAD M 2 Left head lamp A-1
IL1 One-pin connector 1 Joystick F indicator LED [Steering wheel and joystick specification] —
IL1 One-pin connector 1 Joystick 3 indicator LED [AJSS specification] f-2
IL2 One-pin connector 1 Joystick F indicator LED [Steering wheel and joystick specification] —
IL2 One-pin connector 1 Joystick 3 indicator LED [AJSS specification] f-2
IL3 One-pin connector 1 Joystick R indicator LED [Steering wheel and joystick specification] —
IL3 One-pin connector 1 Joystick 1 indicator LED [AJSS specification] e-3
IL4 One-pin connector 1 Joystick R indicator LED [Steering wheel and joystick specification] —
IL5 One-pin connector 1 Joystick N indicator LED [Steering wheel and joystick specification] —
IL6 One-pin connector 1 Joystick N indicator LED [Steering wheel and joystick specification] —
IL7 KES 2 Diode [Steering wheel and joystick specification] [AJSS specification] —
IL10 YAZAKI 2 Diode [Steering wheel and joystick specification] [AJSS specification] —
IL11 Relay 5 LED dimmer relay [Steering wheel and joystick specification] [AJSS specification] —
JL1 S 8 Intermediate connector [Steering wheel and joystick specification] —
JL1 SWP 6 Intermediate connector [AJSS specification] j-3
JL2 S 8 Intermediate connector [Steering wheel and joystick specification] —
JL2 S 10 Intermediate connector [AJSS specification] i-2
JS1 SWP 12 Joystick lever [AJSS specification] j-8
JS2 X 3 Steering angle potentiometer [AJSS specification] j-8
JS3 One-pin connector 1 Joystick console switch [AJSS specification] j-7
JS4 One-pin connector 1 Joystick console switch [AJSS specification] j-6
L01 M 6 Parking brake switch [Steering wheel specification] [Steering wheel and joystick specification] O-2
L01 M 3 Parking brake switch [AJSS specification] e-6
L02 SWP 6 Lighting & dimmer switch [Steering wheel specification] [Steering wheel and joystick specification] P-1
L02 SWP 4 Lighting switch [AJSS specification] e-6
L03 SWP 6 Turn signal & hazard switch [Steering steering specification] [Steering wheel and joystick specification] O-2
L03 SWP 2 Hazard switch [AJSS specification] e-6
L04 SWP 14 Forward-Reverse & Gear shift switch P-1
20-215-1 WA800-3
5
Connector Number
No. of pins
L05 AMP040 20 Main monitor N-5
L08 AMP040 8 Main monitor O-2
L09 M 4 Starting switch O-2
L10 S 10 Front & rear wiper switch P-1
L12 X 2 Transmission cut-off switch R-1
L15 M 4 Kickdown switch & shift-up switch P-7
L16 KES1 2 Boom kick-out solenoid O-6
L17 KES1 2 Bucket positioner solenoid N-5
L18 AMP040 16 Maintenance monitor Q-8
L19 AMP040 8 Maintenance monitor Q-8
L21 KES1 2 Maintenance monitor R-8
L22 KES1 2 Maintenance monitor R-9
L26 X 2 Joystick steering left solenoid [Steering wheel and joystick specification] S-1
L26 DT2 2 Joystick EPC solenoid [AJSS specification] h-2
L27 X 2 Joystick steering right solenoid [Steering wheel and joystick specification] S-1
L27 DT2 3 Frame angle potentiometer [AJSS specification] h-1
L31 One-pin connector 1 Turn signal switch [AJSS specification] f-8
L32 One-pin connector 1 Turn signal switch [AJSS specification] f-8
L33 One-pin connector 1 Turn signal switch [AJSS specification] e-7
L39 KES1 6 Joystick steering ON/OFF solenoid [Steering wheel and joystick specification] R-8
L39 DT2 2 Steering lock oil pressure switch [AJSS specification] i-2
L40 YAZAKI 7 Right power window switch Q-8
L41 YAZAKI 7 Left power window switch P-8
L42 One-pin connector 1 Caution buzzer S-9
L43 One-pin connector 1 Caution buzzer S-9
L44 KES 6 Wiper relay T-9
L46 KES 4 Flasher unit T-9
L48 Relay 5 Bucket relay M-7
L49 Relay 5 Boom relay N-7
L50 Relay 5 Low idling selector relay P-8
L51 Relay 6 Side working lamp N-9
L52 Relay 5 Hazard relay M-7
L53 Relay 5 Stop lamp relay M-7
L54 Relay 5 Backup lamp relay N-9
L55 Relay 5 Horn relay [Steering wheel specification] [Steering wheel and joystick specification] N-7
L55 Relay 6 Horn relay [AJSS specification] g-9
L56 Relay 5 Preheater relay O-9
L57 Relay 5 Neutral relay M-7
L58 Relay 5 Neutralizer relay M-8
L59 Relay 5 Parking brake safety relay M-9
L60 Relay 6 Front working lamp relay N-9
L61 Relay 6 Rear working lamp relay O-9
L62 Relay 5 Engine stop relay M-9
L63 One-pin connector 1 Horn switch P-1
WA800-3 20-215-2
5
Connector Number
No. of pins
L64 Relay 5 Engine oil pressure relay M-8
L65 Relay 5 Joystick steering caution relay [Steering wheel and joystick specification] N-7
L66 Relay 5 Joystick steering selector relay [Steering wheel and joystick specification] P-7
L66 Relay 6 Head lamp relay [AJSS specification] g-9
L67 Relay 5 Joystick steering cut-out solenoid relay [Steering wheel and joystick specification] P-8
L67 Relay 5 Small lamp relay [AJSS specification] —
L68 Relay 6 Turn signal and hazard relay [AJSS specification] h-9
L71 Relay 5 Left power window RAISE relay P-9
L72 Relay 5 Left power window LOWER relay P-8
L73 Relay 5 Right power window RAISE relay O-9
L74 Relay 5 Right power window LOWER relay P-9
L79 Relay 5 Left dust indicator relay M-9
L80 Relay 5 Right dust indicator relay M-8
L81 X 2 Stop lamp switch Q-1
L95 Relay 5 Steering lever neutral lock relay [Steering wheel and joystick specification] [AJSS specification] —
LM1 S 10 Control monitor X-8
LR1 SWP 14 Intermediate connector V-1
LR2 SWP 12 Intermediate connector V-2
LR3 SWP 16 Intermediate connector T-1
LR4 M 4 Intermediate connector U-1
LR5 L 2 Intermediate connector U-1
OP1 One-pin connector 1 Intermediate connector (Fuse box) —
P01 DRC 24 Work equipment controller —
P04 AMP040 16 Maintenance monitor —
P05 M 3 Calibration —
P10 DT-T 2 Boom N lock switch —
P11 DT 2 Boom and bucket EPC lever —
P14 DT-T 4 Boom and bucket EPC lever —
P15 DT-T 4 Boom and bucket EPC lever —
P17 Relay 5 Caution relay —
P18 Relay 5 RAISE stop indicator relay —
P19 Relay 5 LOWER stop indicator relay —
P30 DT-T 2 Boom RAISE EPC A —
P31 DT-T 2 Boom LOWER EPC A —
P32 DT-T 2 Bucket TILT EPC A —
P33 DT-T 2 Bucket DUMP EPC A —
P34 DT-T 2 Boom RAISE EPC B —
P35 DT-T 2 Boom LOWER EPC B —
20-215-3 WA800-3
(7)
Connector Number
No. of pins
P36 DT-T 2 Bucket TILT EPC B —
P37 DT-T 2 Bucket DUMP EPC B —
P38 DT-T 2 Boom EPC cut-off solenoid —
P39 X 3 Boom angle sensor (For boom EPC) —
P40 DT-T 3 Bucket positioner proximity switch (bucket EPC) —
P41 DT 2 Diode (For boom EPC cut-off solenoid) —
P42 DT-T 2 Boom EPC cut-off solenoid —
P43 DT 2 Diode (For boom EPC cut-off solenoid) —
PJ1 DT-T 12 Intermediate connector (Work equipment solenoid) —
PJ2 DT-T 12 Intermediate connector (Work equipment solenoid) —
PJ3 DT-T 8 Intermediate connector (Work equipment sensor) —
R01 X 2 Emergency steering indicator switch G-1
R02 X 1 Engine oil level sensor L-4
R03 KES 2 Diode L-5
R04 KES 2 Diode L-4
R05 X 2 Fuel level sensor L-5
R06 Terminal 1 Slow-blow fuse a-2
R07 Terminal 1 Slow-blow fuse b-2
R08 Terminal 1 Slow-blow fuse c-3
R09 Terminal 1 Slow-blow fuse c-3
R11 Terminal 1 Battery L-6
RA1 X 3 Battery relay L-6
RA2 X 2 Battery relay L-5
RPM One-pin connector 1 Intermediate connector —
SEL1 M 4 Model selector connector Q-1
SEL2 M 2 Engine selector connector —
SEL3 M 2 Option selector connector [Steering wheel specification] [Steering wheel and joystick specification] —
SEL4 M 2 Option selector connector [Steering wheel specification] [Steering wheel and joystick specification] —
SL1 2 Intermediate connector (Rear step light) —
SL2 M 2 Rear step light switch j-6
SL3 Relay 5 Rear step light relay —
SL4 M 6 Rear step light timer —
SL5 2 Rear step light —
SMALL M 1 Right front combination B-7
SMALL M 1 Left front combination lamp E-1
T01 MS 10 Transmission solenoid J-3
T02 X 2 Torque converter oil temperature sensor F-9
TR1 SWP 8 Intermediate connector H-9
TURN M 1 Right front combination lamp B-6
TURN M 1 Left front combination lamp F-1
WORK M 2 Right working lamp A-6
WORK M 2 Left working lamp A-1
WA800-3 20-215-4
(7)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM
B
TO2
Cl4
CO6
Cl7
Cl6
I I \ \\
/
WORK FH' F13 ' F07 FOS GND SMALL TURN Bcol ,
20-216 WA800-3
WA800-3 20-217
20-217
5
20-218 WA800-3
5
LRl
\
Li7
Ill
Ai L26
I I
GRE LR3
\
LR6
\
CBLI
LR4
+ z Bwwoloo4
WA800-3 20-219
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
El 1 E04 EOS EOB
/ E2 1
, E22
E20
El6 c
El3
ER3 R06 R07 El9
WA800-3
WA800-3 20-220-1
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

fl The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No. X-type connector

of
Male (female housing) Female (male housing) T-adapter
pins Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20

— • Electric wire size: 2.0 • Electric wire size: 2.0 —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
WA800-3 20-221
(7)
No. SWP-type connector

of
pins Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
20-222 WA800-3
(7)
No. SWP-type connector

of
pins Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691
Terminal part No.: Terminal part No.:

• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:

• Electric wire size: 1.25 • Electric wire size : 1.25
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
WA800-3 20-223
(7)
No. M-type connector

of
T-adapter
pins Male (female housing) Female (male housing)
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7390
Part No.: 08056-00871 Part No.: 08056-00881
20-224 WA800-3
(7)
No. S-type connector

of
pins Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10 799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12 799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
WA800-3 20-225
(7)
No. S-type connector

of
pins Part No.
10 —
(Blue)
— —
12 799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16 799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
20-226 WA800-3
(7)
No. MIC-type connector

of
T-adapter
Part No.
Body part No.: 79A-222-2640 Body part No.: 79A-222-2630

7 —
(Q’ty: 5) (Q’ty: 5)

11 —
(Q’ty: 5) (Q’ty: 5)
5 799-601-2710

(Q’ty: 5) (Q’ty: 5)
9 799-601-2950

(Q’ty: 5) (Q’ty: 5)
13 799-601-2720

(Q’ty: 2) (Q’ty: 2)
WA800-3 20-227
(7)
No. MIC-type connector

of
pins Part No.
17 799-601-2730

(Q’ty: 2) (Q’ty: 2)
21 799-601-2740

(Q’ty: 2) (Q’ty: 2)
—
(Q’ty: 50) (Q’ty: 50)
20-228 WA800-3
(7)
No. AMP040-type connector

of
pins Part No.
8 799-601-7180
— Housing part No.: 79A-222-3430

(Q’ty: 5)
12 799-601-7190

(Q’ty: 5)
16 799-601-7210

(Q’ty: 5)
20 799-601-7220

(Q’ty: 5)
fl Terminal part No.: 79A-222-3470 (No relation with number of pins)
WA800-3 20-229
(7)
No. AMP070-type connector

of
pins Part No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
20-230 WA800-3
(7)
No. L-type connector

of
pins
Part No.
2 —
— —
No. Connector for PA

of
pins Part No.
9 —
— —
No. Bendix MS connector

of
T-adapter
Part No.
10 799-601-3460
— —
WA800-3 20-230-1
(7)
No. KES 1 (Automobile) connector

of
pins Part No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.: 08027-10310 Part No.: 08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
20-230-2 WA800-3
(7)
No. KES 1 (Automobile) connector

of
pins
Part No.
8 —
08027-10820 (Black) 08027-10870 (Black)
No. Connector for relay (Socket type)

of
T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
WA800-3 20-230-3
(7)
No. F-type connector

of
pins Part No.
4 —
— —
20-230-4 WA800-3
(7)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9230
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
WA800-3 20-230-5
(7)

(shell
size T-adapter
Part No.
799-601-9230
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

799-601-9240
18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
20-230-6 WA800-3
(7)
(shell
size T-adapter
Part No.
799-601-9250
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
WA800-3 20-230-7
(7)

(shell
size T-adapter
Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202, 08191-81203, Part No.: 08191-84101, 08191-84102, 08191-84103,
24-22 08191-81204, 08191-81205, 08191-80206 08191-84104, 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202, 08191-82203, Part No.: 08191-83101, 08191-83102, 08191-83103,
08191-82204, 08191-82205, 08191-82206 08191-83104, 08191-83105, 08191-83106
20-230-8 WA800-3
(7)
(shell
size T-adapter
Part No.
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
WA800-3 20-230-9
(7)
No. DT Series connector

of T-adapter
pins Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
20-230-10 WA800-3
(7)
No. DT Series connector

of T-adapter
pins Body (plug) Body (receptacle)
Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR:799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12BR:799-601-9140
WA800-3 20-230-11
(7)
No. DTM Series connector

of
Body (plug) Body (receptacle) T-adapter
pins Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
No. DTHD Series connector

of
Body (plug) Body (receptacle) T-adapter
pins Part No.
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-230-12 WA800-3
(7)
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
fl The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the
wiring harness checker assemblies are shown in the lines.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Part No. Type of connector No. of pins
799-601-2600 Box for measurement Econo-21P fi fi fi fi fi fi

799-601-3100 Box for measurement MS-37P fi
799-601-3200 Box for measurement MS-37P fi
799-601-3300 Box for measurement Econo-24P fi
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P fi fi
799-601-3420 BENDIX (MS) 24P fi fi
799-601-3430 BENDIX (MS) 17P fi fi
799-601-3440 BENDIX (MS) 17P fi fi
799-601-3450 BENDIX (MS) 5P fi fi
799-601-3460 BENDIX (MS) 10P fi fi
799-601-3510 BENDIX (MS) 5P fi fi
799-601-3520 BENDIX (MS) 14P fi fi
799-601-3530 BENDIX (MS) 19P fi fi
799-601-2910 BENDIX (MS) 14P fi fi
799-601-3470 Case fi
799-601-2710 MIC 5P fi fi fi fi
799-601-2720 MIC 13P fi fi fi fi
799-601-2730 MIC 17P fi fi fi fi fi fi fi
799-601-2740 MIC 21P fi fi fi fi fi fi fi
799-601-2950 MIC 9P fi fi fi fi
799-601-2750 ECONO 2P fi fi
799-601-2760 ECONO 3P fi fi
799-601-2770 ECONO 4P fi fi
799-601-2780 ECONO 8P fi fi
799-601-2790 ECONO 12P fi fi
799-601-2810 DLI 8P fi fi
799-601-2820 DLI 12P fi fi
799-601-2830 DLI 16P fi fi
799-601-2840 Extension cable fi fi fi
799-601-2850 Case fi
799-601-7010 X 1P fi fi
799-601-7020 X 2P fi fi fi fi
799-601-7030 X 3P fi fi fi fi
799-601-7040 X 4P fi fi fi fi
799-601-7050 SWP 6P fi fi fi
799-601-7060 SWP 8P fi fi fi
799-601-7310 SWP 12P fi
799-601-7070 SWP 14P fi fi
799-601-7320 SWP 16P fi
WA800-3 20-230-13
(7)
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7080 M 1P fi fi
799-601-7090 M 2P fi fi fi fi
799-601-7110 M 3P fi fi fi fi
799-601-7120 M 4P fi fi fi fi
799-601-7130 M 6P fi fi fi fi
799-601-7340 M 8P fi
799-601-7140 S 8P fi fi fi fi
799-601-7150 S 10P-White fi fi fi fi
799-601-7160 S 12P-Blue fi fi fi
799-601-7170 S 16P-Blue fi fi fi fi
799-601-7330 S 16P-White fi
799-601-7350 S 12P-White fi
799-601-7180 AMP040 8P fi
799-601-7190 AMP040 12P fi fi
799-601-7210 AMP040 16P fi fi fi fi
799-601-7220 AMP040 20P fi fi fi fi
799-601-7230 Short connector X-2 fi fi fi fi
799-601-7240 Case fi fi
799-601-7270 Case fi
799-601-7510 070 10P fi
799-601-7520 070 12P fi
799-601-7530 070 14P fi
799-601-7540 070 18P fi
799-601-7550 070 20P fi
799-601-7360 Relay connector 5P fi
799-601-7370 Relay connector 6P fi
799-601-7380 JFC connector 2P fi
799-601-9010 DTM 2P fi fi
799-601-9020 DT 2P fi fi
799-601-9030 DT 3P fi fi
799-601-9040 DT 4P fi fi
799-601-9050 DT 6P fi fi
799-601-9060 DT 8P-Gray fi fi
799-601-9070 DT 8P-Black fi fi
799-601-9080 DT 8P-Green fi fi
799-601-9090 DT 8P-Brown fi fi
799-601-9110 DT 12P-Gray fi fi
799-601-9120 DT 12P-Black fi fi
799-601-9130 DT 12P-Green fi fi
799-601-9140 DT 12P-Brown fi fi
799-601-9210 HD30 18-8 fi fi
799-601-9220 HD30 18-14 fi fi
20-230-14 WA800-3
(7)
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 fi fi

799-601-9240 HD30 18-21 fi fi
799-601-9250 HD24 24-9 fi fi
799-601-9260 HD30 24-16 fi fi
799-601-9270 HD30 24-21 fi fi
799-601-9280 HD30 24-23 fi fi
799-601-9290 HD30 24-31 fi fi
799-601-9310 Plate For HD30 fi fi fi
799-601-9320 Box for measurement For DT, HD fi fi fi
799-601-9330 Case fi
799-601-9340 Case fi
799-601-9350 DEUTSCH 40P fi
799-601-9360 DEUTSCH 24P fi
799-601-9410 For NE, G sensor 2P fi
799-601-9420 For fuel, boost pressure 3P fi
799-601-9430 PVC Socket 2P fi
WA800-3 20-230-15
(7)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL

MECHANISM
TRANSMISSION CONTROL SYSTEM
WA800-3 20-231
20-231
5
WORK EQUIPMENT CONTROL SYSTEM
20-231-1 WA800-3
(7)
MAIN MONITOR SYSTEM
20-232 WA800-3
5
MAINTENANCE MONITOR SYSTEM
WA800-3 20-233
20-233
5
JOYSTICK STEERING CONTROL SYSTEM
20-234 WA800-3
5
AJSS (ADVANCED JOYSTICK STEERING SYSTEM) CONTROL SYSTEM
WA800-3 20-235
20-235
5
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
METHOD OF DISPLAYING ACTION

CODE AND FAILURE CODE
1. Outline
The speedometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are three types of action code: E00, E01 +
CALL (E01 and CALL are displayed alternately),
and CALL. If a failure occurs suddenly, one of
these codes is shown on the speedometer dis-
play.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which
controller has failed, so carry out troubleshoot-
ing for the applicable controller.
4. Saving failure code

The transmission and joystick steering control-
ler writes the failure codes to memory.
1) A total of 9 failure codes can be saved in
memory.
2) The data that is saved to memory is as fol-
lows: (1) Failure code
(2) Time elapsed since failure
(up to 1000 hours)
3) The failures are saved in the order that they
occur. If a failure code already exists in the
memory, the repeat failure code is not saved.
4) If there are already 9 items in memory, and
a 10th failure occurs, the oldest item is de-
leted and the new item is saved.
fl It is possible to display the failure code and
time elapsed since failure for items saved in
memory by operating the main monitor set
switch.
20-236 WA800-3
5
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
5. Switch operation procedure and actuation

Switch operation Actuation
Trouble data memory

mode display
1) Stop engine. • The failure code is
2) Turn starting displayed on the
switch ON. speedometer dis-
3) Push operation play and the time
mode switch (1) elapsed since failure
and head lamp is displayed on the
switch (2) simulta- action code display.
neously and keep • If there is no failure,
pressed for at least the speedometer dis-
5 seconds. play shows [CC] and
the action code dis-
play shows [0000].
Going to nest failure
code
4) Press head lamp • The failure code and
switch (2). time elapsed since
failure are displayed
in turn (when this is
done, the failure code
for the latest failure
is displayed first).
• If the failure still ex-
ists, the display
flashes; if the failure
has been restored,
the display lights up.
Clearing failure code

5) Keep rear lamp • The failure code and
switch (3) pressed elapsed time on the
for at least 2 display are cleared.
seconds. • If the failure still ex-
ists, the failure code
is not cleared.
Quitting trouble data
memory display mode
6) Push operation • The display returns
mode switch (1) to the normal dis-
and head lamp play.
switch (2) simulta-
neously and keep
pressed for at least
5 seconds. Or start
the engine.
WA800-3 20-236-1
5
TROUBLESHOOTING CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION
CHART OF ACTION CODES AND FAILURE CODES, AND

RE-ENACTION
1. Transmission control system codes table
Failed system Re-enaction
Action Failure Alarm
code code Item Short Discon- Short Discon- Memory buzzer
circuit nection circuit nection
— 10 Back lamp relay fi fi ■ fl fi ×
12 F solenoid fi fi ■ fl fi fi
13 R solenoid fi fi ■ fl fi fi
14 1st solenoid fi fi ■ fl fi fi
CALL
15 2nd solenoid fi fi ■ fl fi fi
16 3rd solenoid fi fi ■ fl fi fi
20 Directional switch signal fi fi fl fl fi fi
— 21 Range switch signal fi fi fl fl fi fi
22 Speed sensor × fi × fl fi fi
E00
23 Engine speed sensor × fi × fl fi ×
• After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-
enact the problem as follows.
• Re-enaction marks.
fl : Turn stating switch ON (with engine stopped)
: Start engine
■ : Carry out operation to actuate actuator.
2. Action code table
Action Transmission control system Joystick steering control system Action Action by
code Problem system Action of machine Problem system Action of machine buzzer operator
Disconnection in Automatic
speed sensor gearshifting not
system carried out Normal opera-
(changes to — — tion possible at
manual manual
E00 No
gearshifting)(OP)
Disconnection in Gearshifting not Normal opera-

engine speed carried out in — — tion possible at
sensor system Auto mode. (OP) manual
Shift lever Become neutral

system discon- and cannot
nection, short travel — —
circuit with GND, (Judges control-
short circuit ler input as N)
F, R solenoid Become neutral

signal system and cannot Stop travelling
disconnection, travel immediately,
short circuit with (Output off) — — Turn starting
CALL Yes switch OFF,
GND, short
circuit Call service
after action
1st, 2nd, 3rd Become neutral above.
solenoid system and cannot
disconnection, travel
short circuit with (Output off) — —
GND, short
circuit
20-236-2 WA800-3
5

Action Failure Alarm
code code
Item Short Discon- Short Discon- Memory buzzer
— 10 Back lamp relay fi fi ■ fl fi ×
CALL 14 1st solenoid fi fi ■ fl fi fi
E00 19 Joystick directional switch signal fi fi fl fl fi fi
CALL 20 Directional switch signal fi fi fl fl fi fi
— 21 Range switch signal fi fi fl fl fi fi
E00
: Start engine
2. Joystick steering control system codes table

Action Failure Item Alarm
code code Short Discon- Short Discon- Memory buzzer
None 56 Caution relay output fi × fl ■ fi ×
57 Steering right solenoid fi fi ■ ■ fi fi
58 Steering left solenoid fi fi ■ ■ fi fi
59 Steering right solenoid fi × fl fl fi fi
E00 60 Steering left solenoid fi × fl fl fi fi
61 Steering solenoid cut relay output fi fi fl ■ fi fi
62 Joystick steering neutral signal fi fi fl fl fi fi
63 Joystick steering lever potentiometer fi fi fl fl fi fi
: Start engine
• If any abnormality is detected, the joystick caution system operates.
• Send E59 and E60 signals at a same time because monitor cannot distinguish E59 and E60.
• For E56, monitor cannot detect disconnection because E56 is normally closed.
WA800-3 20-237
20-237
5
Action Transmission control system Joystick steering control system Action Action by
code Problem system Action of machine Problem system Action of machine buzzer operator
Normal opera-
system carried out
manual manual
gearshifting)(OP)
Disconnection in Gearshifting not

engine speed carried out in
sensor system Auto mode. (OP) Normal opera-
E00 — — No tion possible at
manual
Breakage, short Set to neutral

circuit with position. (Can Normal opera-
chassis ground be changed to tion possible at
— — steering wheel
or short circuit steering wheel
of joystick FNR mode.) mode
signal line

nection, short travel
circuit with GND, (Judges control- — —
F, R solenoid Become neutral Stop travelling

immediately,
signal system and cannot
Turn starting
CALL short circuit with (Output off) — — Yes switch OFF,
Call service
GND, short
after action
circuit
above.
1st, 2nd, 3rd Become neutral
GND, short
circuit
20-238 WA800-3
5

Action Failure Caution
code code Item Saving buzzer
Short Discon- Short Discon-
— 10 Backup lamp relay fi fi ■ fl fi ×
CALL 14 1st solenoid fi fi ■ fl fi fi
CALL 20 Joystick forward-reverse switch fi fi fl fl fi fi
— 21 Joystick shift-up/down switch fi fi fl fl fi fi
E00
: Start engine
2. AJSS (Advanced Joystick Steering System) control system codes table

Action Failure Item Caution
code code Saving buzzer
Short Discon- Short Discon-
— 56 Caution buzzer relay output fi × fl ■ fi ×
57 Steering lever angle sensor fi fi fl fl fi fi
58 Shifting of steering lever angle sensor or frame angle sensor fi fi fl fl fi fi
59 Frame angle sensor fi fi fl fl fi fi
E00
60 Steering lock pressure switch fi fi fl ■ fi fi
62 Steering neutral interlock relay fi fi fl fl fi fi
63 Steering basic pressure control EPC solenoid fi fi fl fl fi fi
: Start engine
• If any abnormality is detected, the joystick caution system operates.
• For E56, monitor cannot detect disconnection because E56 is normally closed.
WA900-3 20-238-1
5
AJSS (Advanced Joystick steering system)

Action Transmission control system control system Action Action by
code buzzer operator
Problem system Action of machine Problem system Action of machine
system carried out Normal opera-
manual manual
gearshifting)(OP)
E00 No
sensor system Auto mode. (OP) Normal opera-
— — tion possible at
manual

circuit with GND, (Judges control- — —
F, R solenoid Become neutral Stop travelling

signal system and cannot immediately,
disconnection, travel Turn starting
CALL short circuit with (Output off) — — Yes switch OFF,
GND, short Call service
circuit after action
above.
1st, 2nd, 3rd Become neutral
GND, short
circuit
20-238-2 WA900-3
5
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DISPLAY
TRANSMISSION CONTROLLER LED DISPLAY

The transmission controller uses two 7segment LEDs to display the internal condition of the controller
and input/output errors. The display shows two characters at the same time, and changes these in turn
to give the display.
Ir When the engine is started, “Program part No.. display mode” appears, follwed by “Output speed
range display mode”. If there is any abnormality in the controller, it changes to “Troubleshooting
mode”.
* The failure mode is saved to memory by the main monitor.
Method of displaying failure codes for transmissron controller

Condition of
When normal
machrne
Prosram nart Ncdisnlav mode Outnut speed ranne disnlay modelTable I)

Startis switch
OFF-ON
*When nnwar is ON,disnlav chances every second * LEO disnlau chanaes according to transmissran speed ranae
h
r \
Self-draanostrc
display
~1~1~~1~~1~
Display time -1 sec.--I sec.-- 1 sec. --I sec.-- I sec.-- 1 sec. -
When abnormal
Troubleshootinn display mode
* When there is one abnormal item *When there are two abnormal items
Abnormality occurs Failure code Abnormality occurs:Failure code
Self-diaonastrc
disblay
Display time - 2 sec. -- 2 sec. -- 2 sec. -- 2 set -- 2 set -- 2 sec. --2 set -- 2 sec. -
TwW01844
Table 1 (Output speed range display mode)
Display Content Display Content
0. lo Neutral, 1st F. 3, FORWARD, 3rd
0. 2, Neutral, 2nd A. 1, REVERSE, 1st
0. 3, Neutral, 3rd A. 2, REVERSE, 2nd
F. 1, FORWARD, 1st Neutral safety condition or

E. 0, abnormality in selection signal
F. 2, FORWARD, 2nd
WAX03 20-239
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormal-
ity in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms
are then used to decide which troubleshooting table
(E-00, H-00, etc.) matches the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which
troubleshooting table to go to.
* The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor
system (M-00, K-00).
(See troubleshooting of the machine monitor system)
[Method of using judgement table1

. A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check
if an error code is displayed on the graphic display portion of the monitor panel.
. If an error code is displayed:
Go to the troubleshooting code at the bottom of the judgement table (E-00, etc.).
. If there is a problem but no error code is displayed:
Go to the troubleshooting code on the right of the judgement table (H-00).
. For failure modes where no 0 mark is given, go directly to the troubleshooting code on the
right of the judgement table.
WA800-3 20-241
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component

S-fifi Troubleshooting of engine system
T-fifi Troubleshooting of transmission control system
M-fifi Troubleshooting of main monitor system
K-fifi Troubleshooting of maintenance monitor system
E-fifi Troubleshooting of electrical systems
H-fifi Troubleshooting of hydraulic, mechanical system
J-fifi Troubleshooting of joystick steering control system
A-fifi Troubleshooting of AJSS (Advanced Joystick Steering System) control system
WRK-fifi Troubleshooting of work equipment control system
2. Method of using troubleshooting table

1 Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the
problem with the machine.
2 General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top
of the page and marked with fl.
The precautions marked fl are not given in the , but must always be followed when
carrying out the check inside the .
3 Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the
model, component, or problem. In such cases, the troubleshooting chart is further divided into
sections marked with small letters (for example, a), b)), so go to the appropriate section to
carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first
check item.
4 Method of following troubleshooting chart
YES
• Check or measure the item inside NO
, and according to the answer follow either the
YES line or the NO line to go to the next . (Note: The number written at the top right
corner of the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column. Check the cause and take the action given in the Remedy
column on the right.
• Below the there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the are correct or the answer to the question
inside the is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and
the judgement values. If this preparatory work is neglected, or the method of operation or
handling is mistaken, there is danger that it may cause mistaken judgement, or the equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
5 Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6 Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart.
20-242 WA800-3
(7)
<Example>
@ M-6 Turn signal display does not light up
0* Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
Ir Always connect any disconnected connectors before going on to the next step.
* Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on
the monitor is not blown.
a) L.H. turn signal display does not light up

0 a) Divided into sections a) and b)
I b) R.H. turn signal display does not light up
@ Flow chart a) L.H. turn signal display does not light up
Y=
Remedy
1 YES
Defective main monitor Replace
Is voltage
between LO6 I141
Defective contact or
and chassis
disconnection in wiring
ground normal?
harness between LO6
. Reheats 0 V and NO (female) (14) and LO3
zo- 30 v. (female) (4)
*Turn starting switch ON.
*Turn L.H. turn signal ON.
b) R.H. turn signal display does not light up
Repair or
replace
M-6 Related electrical circuit diagram
R.H. turn SIgnal

LO6 (04Oi6) LRI (S12) FRl (SlO) F02 (M3)
Turn s~onal and - I I

hazard switch
F03 (M3)
LR5 (X4)
jq
WA800-3 20-243
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to
locate the causes of failures in the machine. The troubleshooting tables are divided broadly into
categories for the main components, such as the steering system and work equipment hydraulic
system. Follow the procedure given below and carry out troubleshooting to locate the problems
accurately and swiftly.
Step 1. Questioning the operator 1. Steering does not work t Symptom [Example]
The questions to ask the operator are given
below the failure symptom. If the answers Ask the operator about the following points.
to the questions match the information given, l Did the steering suddenly stop working +
follow the arrow to reach the probable cause Breakage in steering equipment
of the failure. . Had the steering gradually been becoming
heavy? -+ Internal wear of steering equipment,
Consider the contents of the questions and
defective seal
consult the table while proceeding to Steps
2 and 3 to grasp the true cause.
Step 2. Checks before troubleshooting Checks before starting [Example]

Before starting the main troubleshooting and
measuring the hydraulic pressure, first check l Is the oil level in the hydraulic tank correct?
the Checks before Starting items, and check Is the type of oil correct?
for oil leakage and loose bolts. These checks - Is there any leakage of oil from the steering
valve or Orbit-roll?
may avoid time wasted on unnecessary trou-
- Has the safety bar been removed from the
bleshooting.
frame?
The items given under Checks before Start-
ing are items which must be considered par-
ticularly for that symptom before starting
troubleshooting.
[Example 1I
Step 3. Using cross-reference table

I) Operate the machine to carry out the
checks in the troubleshooting item col-
umn.
Mark the items where the results match
the symptom. Steering can only be operated to one side.
* It is not necessary to follow the trou-
bleshooting checks in order; follow
an order which is easiest to carry
out troubleshooting.
2) Find the appropriate cause from the [Example 21

cause column. If the symptom appears,
the 0 marks on that line indicate the
possible causes. (For item No. 2 in the
table on the right, the possible causes
are c or e.)
If there is only one 0:
Carry out the other troubleshooting items
(where the same cause is marked with
01, check if the symptom appears, then
repair.
If there are two 0:
Go on to Step 3) to narrow down the
possible causes.
20-244 WA800-3
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
3) Operate the machine and check the trouble-

shooting items other than those in I).
Operate the machine and check the items in
the same way as in I), and if the symptom
appears, mark that item. (In the chart on the
right, the symptom appears again for item
5).
4) Find the appropriate cause from the cause

column. In the same way as in Step 21, if the
symptom appears, the 0 marks on that line
indicate the possible causes. (For item No. 5
in the table on the right, the possible causes
are b or e.)
Applicable troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
5) Narrow down the possible causes.
There is one common cause among the
causes located in Steps 2) and 4). (One cause hese causes
marked 0 appears on the line for both items.)
This cause is common to both the symp-
toms in troubleshooting Steps I) and 3). Common causes
* The causes which are not common to
both troubleshooting items (items which
are not marked 0 for both symptoms)
are unlikely causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting Item 2 are c
or e, and the cause for Troubleshooting
Item 5 are b or e, so cause e is common
to both.)
6) Repeat the operations in Steps 3), 4) and 5)

until one cause (one common cause) re-
mains.
* If the causes cannot be narrowed down
to one cause, narrow the causes down
as far as possible. to take
7) Remedy
If the causes are narrowed down to one com-
mon cause, take the aciton given in the rem-
edy column.
The symbols given in the remedy column
indicate the following:
X: Replace, a: Repair, A; Adjust, C: Clean
WA800-3 20-245
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts .. . . .. . . . . .. .. . . . . .. . . . . . .. . . . . . . . .. . . . . . . .. . . . . .._.......................................... 20-302

s- 1 Starting performance is poor (Starting always takes time). ................................................ .20-306
s- 2 Engine does not start ............................................................................................................... 20-307
(1) Engine does not turn.. ........................................................................................................ 20-307
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected) .................. 20-308
(3) Exhaust gas comes out but engine does not start (Fuel is being injected). ............... 20-309
s- 3 Engine does not pick up smoothly (Follow-up is poor). ....................................................... 20-310
s- 4 Engine stops during operations .............................................................................................. 20-31 1
s- 5 Engine does not rotate smoothly (hunting) ........................................................................... 20-312

S- 6 Engine lacks output (no power). .............................................................................................. 20-313
s- 7 Exhaust gas is black (incomplete combustion). ..................................................................... 20-314
S- 8 Oil consumption is excessive (or exhaust gas is blue). ....................................................... .20-315
s- 9 Oil becomes contaminated quickly ......................................................................................... 20-316
S-IO Fuel consumption is excessive ................................................................................................ 20-317
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down .......................... 20-318
S-l 2 Oil pressure lamp lights up (drop in oil pressure) ................................................................ 20-319
s-13 Oil level rises.. ........................................................................................................................... 20-320
S-l 4 Water temperature becomes too high (overheating) ............................................................ 20-321
s-15 Abnormal noise is made .......................................................................................................... 20-322
S-l 6 Vibration is excessive ............................................................................................................... 20-323
WA8003 20-301
METHOD OF USING TROUBLESHOOTING CHARTS

Using troubleshooting chart for engine-related
failure
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the user’s level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-302 WA8003
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items1 that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with 0.
Check each of the [Questions] and [Check items1 in
turn, and marked the 0 or 0 in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
the most probable cause, so start troubleshooting
for that item to make final confirmation of the cause.
(%I. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with D to use as reference
3 for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
<%2. Use the A in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
WA800-3 20-303
. Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three
symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power
slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with
five causes. Let us explain here the method of using this causal relationship to pinpoint the most
probable cause.
s-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
PISpeed of some cylinders

on reduced cviinders
does not change when operating
When check is made “smg deltvery method. ,“jecr,o” t,mi”(

IS found to be incorrect
Remedy
20-304 WA800-3
P Five causes
Clarify the relationship between the three

Step 1
symptoms in the [Questions] and [Check items1

section and the five Cause items in the vertical
column.
7 SteD 2
Add up the total of 0 and 0 marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(I) Clogged air cleaner element: 000
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA8003 20-305
TROUBLESHOOTING S-l
S-l Starting performance is poor (Starting always takes time)

General causes why starting performance is poor
. Defective electrical system
. Insufficient supply of fuel
. Improper selection of fuel
(At ambient temperature of -10°C [-14”F] or below, use ASTM D975
No. 1, and -10°C [-14”Fl or above, use ASTM D975 No. 2 diesel fuel.)
t Battery charging rate.
. The specific gravity should exceed the value for the charging
rate of 70% in the above table.
. In cold weather the specific gravity must exceed the value for
the charging rate of 75% in the above table.
Legend
0 :Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
e to length of use (used for a long period)
1) Little fuel comes out even when injection pump sleeve

I I I I I I I I I I PI I I I
Whencompression pressureismeasured, it isfoundto below 10101 1j 1I I I I I I j I

When air element is inspected directly, it is found to be
0
cloaaed
% Refer to TESTING AND ADJUSTING.
20-306 WA800-3
TROUBLESHOOTING s-2
S-2 Engine does not start Causes
@ Engine does not turn

General causes why engine does not turn
. Internal parts of engine seized
t If internal parts of the engine are
seized, carry out troubleshooting for
“Engine stops during operations”.
. Failure in power train
. Defective electrical system
Legend
0 : Possible causes (judging from Questions and check items)
a : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Confirm recent repair history
Condition of horn when starting
When starting switch is turned to

START, pinion moves out, but
Makes rattling noise and

does not turn
When starting switch is turned to START, pinion does not

move out
When starting switch is turned to ON, there is no clicking sounc
Battery terminal is loose
When starting switch is turned to ON, linkage does not move
[ When battery is checked, battery electrolyte is found to be low
jpecific gravity of electrolyte, voltage of battery is low
:or the following conditions 1) - 5). turn the starting switch

IFF, connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are

connected, engine starts
2) Even when terminal B and terminal C of starting motor

are connected, engine does not start
3) When terminal B and terminal C of safety relay are

connected, engine starts
4) When terminal of safety switch and terminal B of

starting motor are connected, engine starts
5) There is no 24V voltage between battey relay terminal B

and terminal E
Nhen ring gear is inspected directly, tooth surface is found

o be chipped
Ioes not move even when engine stop motor linkage is

Gsconnected
B Carry out troubleshooting for electrical system E.

Remedy
WA800-3 20-307
TROUBLESHOOTING s-2
@ Engine turns but no exhaust gas comes out (Fuel is not being injected)
(including cases with V-type engine where there is no fuel injection for the bank on one side)
General causes why engine turns but no exhaust gas comes out
l Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particularly in winter)
Standards for use of fuel
Legend
A : Possible causes
.
due to length of use (used for a long period)
Degree of use Operated for long period
Exhaust gas suddenly (when starting again) stops coming out
Replacement of filters has not been carried out according to

operation manual
Fuel tank is found to be empty
There is leakage from fuel piping
Mud is stuck to fuel tank cap
When fuel filter is drained, fuel does not come out
plug is loosened
Inspect injection pump directly
When push the control rack, it is heavy and no return
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
When priming pump strainer is inspected directly, it is found

to be clogged
I I 1 I I*/ I I I I I
When fuel cap is inspected directly, it is found to be clogged 0
Inspect fuel cut solenoid directly I I I I I I I I I.1
20-308 WA800-3
TROUBLESHOOTING s-2
@ Exhaust gas comes out but engine does Causes

not start
(Fuel is being injected)
General causes why exhaust gas comes out

but engine does not start
. Lack of rotating force due to defective
electrical system
. Improper selection of fuel
Legend
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
Degree of use 1Operatedforlong period 1 1 lA/AlAl 1 Ial 1

Suddenly failed to start lalal I I I I I I I I I
When engine is cranked, abnormal noise is heard from
around head 0
Engine oil must be added more frequently 0

Non-svecified fuel has been used 0 n

operation manual I I I I I I I I I
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve 0

nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
and injection pump air bleed plug are loosened 00 0 0
There is leakage from fuel piping 0
When exhaust manifold is touched immediately after

starting engine, temperature of some cylinder is low I I I I I I I I I I0 I I I
When fuel filter is drained, no fuel comes out
WA800-3 20-309
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick
up smoothly
. Improper fuel used
ions and check items)

estions and Check items)
(used for a long period)
Degree of use 1Operated for long period n n a n n
Replacement of filters has not been carried out according to 0 0 0

operation manual
d fuel has been used
l-i%st and water are found when fuel is drained
Dust indicator caution lights up 0
Noise of interference is heard from around turbocharger
/ Engine pick-up suddenly became poor 0

Blue under light load
Color of exhaust gas
Black 0 B
Clanging sound is heard from around cylinder head I I I I I I I PI I I

There is leakage from fuel piping
When air element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directry, they are

found to be clogged
When feed pump strainer is inspected directly, it is found to

be clogged
Stop fuel injection to one cylinder at a time. If there is no

change in engine speed, that cylinder is not working
When control rack is pushed, it is found to be heavy, or

does not return
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be

outside standard value
When fuel cap is inspected directly, it is found to be clogged

When feed pump is operated, operation is too light or too heavy
Link connecting left and right injection pumps is stiff
Boost compensator does not work
Remedy
20-310 WA800-3
TROUBLESHOOTING s-4
S-4 Engine stops during operations

(For V type engine, including cases where one bank stops)
General causes why engine stops during
operations
. Seized parts inside engine
. Overheating
* If there is overheating and insuffi-
cient output, carry out troubleshoot-
ing for overheating.
. Failure in power train
Jr If the engine stops because of a fail-
ure in the power train, carry out trou-
bleshooting for the chassis.
Legend
: Possible cau th of use (used for a long period)
ICondition when engine

:mnnz=d
L.“,,.._
engine sroppeo
VVY
! I / I ( I j I ! ! ! (-1 ! 1
Non-specified fuel hasbeenused

When feed owno ic nwrat4
_I “r-. _.__,
there is no response
. .
or it is heavy
-
dud is stuck to fuel tank cap
rns, but stops when power train control lever is
Try to turn by hand using

barring tool
When fuel filter, strainer are inspected directly, they are

6 found to be clogged
5 -
: When feed pump strainer is inspected directly, it is found to
t be clogged
WA&IO-3 20-311
TROUBLESHOOTING s-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
. Air in fuel system
. Defective governor mechanism
Legend
: Items to confirm the cause.
Ocuurs even when speed is
I Governor lever (solenoid olunoer) is stiff
Spool valve is stiff

does not return
When fuel cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is found to

be clogged
When fuel filter, strainer are inspected directly, they are

found to be clogged
Remedy
20-312 WA800-3
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

(With V-type engine, for cases where there
is injection for only one bank, go to
troubleshooting S-2-0 or S-4.)
G leneral causes why engine lacks output
. improper condition of fuel injection
. Improper fuel used
(if non-specified fuel is used, output
drops)
. Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for
overheating.
Legend
IEnqlne
: pickup is poor and combustion is irreaular I 161 I I
When exhaust manifold is touched immediately after I I I I I lhlAl I I Trl
found to be clogged

0

dose not return 0

outside standard value 0
When feed pump is operated, operation is too light or too heavy 0

When fuel cap is inspected directly, it is found to be clogged 0
When injection pump boost compensator is inspected, it

does not work 0
WA800-3 20-3 13
TROUBLESHOOTING s-7
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
I Causes I
Legend
0 : Moss probable causes (judging from Questions and Check items)
D : Possible causes due to length of use fused for a long period)
When exhaust manifold is touched immediately after

starting engine, temperature of some cylinders is low I I I I I I I
Match marks on fuel injection pump are out of alignment 0
Clanging sound is heard from around cylinder head 0
Exhaust noise is abnormal 0 0 0
/
Muffler is crushed
I I I I I I IQI I I
Leakage of air between turbocharger and head, loose clamp 1 ICI,1 1
I When muffler is removed. exhaustaascolor returnsto normal 1 I / / I 1 101 l I

When control rack is pushed, it is found to be heavy, or does
0
not return
I I I I / I I I I I I
I Refer to TESTING AND ADJUSTING
Remedy
20-314 WA800-3
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)

+ Do not run the engine at idling for more
than 20 minutes continuously. (Both low
and high idling)
General causes why oil consumption is ex-
cessive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system
* Judge the oil consumption by compar- Causes
ing it with the fuel consumption during

the same period.
More than 0.5%: Check the engine
More than 1.0%: There is some abnor-
mality
Legend
0 : Most probable causes (judging from Quesrions and Check items)
D : Possible causes due to length of use (used for a long period)
0 : Items to confirm the ca
Confirm recent repair

F? I Dearee of use I Ooeratedforlonaoeriod I I I I I I IAIAI I InI I
Honormarry ex
Amount of blow-by gas
None
Area around engine is dirty with oil
1 There is nil in enoine coolina water
When exhaust pipe is removed, inside is found to be dirty

with oil
Inside of turbocharger intake pipe is dirty with oil
Oil level in clutch or TORQFLOW transmission damper

chamber rises
Clamps
for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Check rear seal directly
i When intake manifold is removed, dust is found inside
v
ti;,en;ntake manifold is removed, inside is found to be dirty
Oil is above H level on oil level gauge
WA800-3 20-315
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper combustion Causes
. Improper oil used
. Operation under excessive load
Legend
0 : Possible causes (judging from Questions and check items.1
n : Possible causes due to length of use (used for a long period)
Confirm recent repair history I I I I I I I I I II
Degree of use Operated for long period a n n
Engine oil must be added more frequently I I I I I I lo

I Non-specified fuel has been used
Blue under light load

Color of exhaust gas
Black
Abnormally exe
Amount of blow-by gas
None
Oil filter caution lamp stays on even when oil pressure rises 0
When oil filter is inspected, metal particles are found 0 00

When exhaust pipe is removed, inside is found to be dirty with oil 0
Engine oil temperature rises quickly 0
er e ement IS lnspecte
20-316 WA800-3
TROUBLESHOOTING S-IO
S-IO Fuel consumption is excessive

General causes why fuel consumption is ex-
cessive
. Leakage of fuel I Causes
I
. improper condition of fuel injection
Legend
n : Possible causes due to length of use (used for a long period)
1 Confirm recent repair history
l;_Ir Operated for long period
More than for other machines of 0

nn
same model
0
Condition of fuel consumption
Gradually increased
Suddenly increased
/I Exhaust gas color

Black
White
loloi loI
1 lo
1
There is irregular combustion 0
When exhaust manifold is touched immediately after starting engine,

temperature of some cylinders is low
00
Match mark on injection pump is misaligned 0

There is external leakage of fuel from engine 0
Engine oil level rises and smells of diesel fuel 0 0
Engine low idling speed is high 0
Injection pump test shows that injection amount is excessive

F I I I I I I
Stop fuel injection to one cylinder at a time. If there is no change in engine
0
speed, that cylinder is not working
When control rack is pushed, it is found to be heavy, or does not return 0

When check fuel injection timing, injection timing is found to be incorrect I 0
Remove head cover and check directly 0
% Refer to TESTING AND ADJUSTING.
WA8CX.J3 20-3 17
TROUBLESHOOTING S-l 1
S-11 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
. internal leakage in lubrication system
. Internal leakage in cooling system
I Causes I
Legend
Engine oil level has risen, oil is cloudy white

‘In I ,
Excessive air bubbles inside radiator, spurts back 00

i
C
Hydraulic oil, torque converter transmission oil is cloudy white 0
%
al
When hydraulic oil, torque converter, transmission oil is drained, water is
6 0
found
Pressure-tightness test of oil cooler shows there is leakage

I.1 ! p ! !
Pressure-tightness test of cylinder head shows there is leakage 0
Remove cylinder head and check directly 0
Remove oil pan and check directly 00

Check water seal and oil seal of water pump
20-318 WA800-3
TROUBLESHOOTING s-12
S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights
up
. Leakage, clogging, wear of lubricating
system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
* Standards for use of oil

Selection of oil SAE number according
to ambient temperature
Type of oil Causes
Engine oil
I I I I I
Legend
lacement of filter has not been carried out according to
Condition when oil pressure
When oil level sensor is replaced, oil pressure sensor lamp

goes out
When oil pressure is measured. it is found to be within

standard value
WA800-3 20-3 19
S-13 Oil level rises

+ If there is oil in the cooling water, carry
out troubleshooting for “Oil is in cooling
water”.
General causes why oil level rises
. Water in oil (cloudy white)
. Fuel in oil (diluted, and smells of diesel
fuel) Cause
. Entry of oil from other component
Legend
0 : Possible causes (judging from Questions and check items1
0: to confirm the cause.
-
I
.2 Degree of use Operated for long period n arm
;;
2 There is oil in radiator cooling water 000
u
Exhaust gas is white 0
When engine is first started, drops of water come from muffler 0
Leave radiator cap open. When engine is run at idling, an

0
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud 0
When water pump breather hole is clean, water comes out 0
Oil level goes down in clutch, TORQFLOW transmission, or

damper chamber
I I I m
1 Oil level goes down in hydraulic tank I I I I I 7G
Engine oil smells of diesel fuel I I I I I I
Fuel is added more frequently
I I I I I I
Pressure-tightness test of oil cooler shows there is leakage I.1 I I I I I I 1I I” I
! ! ! ! ! ! !
Pressure-tiahtness test of cvlinder head shows there is leakaae I I.1 I I I I I I I I
Remove water pump and check directly I I I.1 I I I I I I

Check rear seal directly 01
I I I I I I I I I I
When pump auxiliary equipment is removed, seal is found
to be broken
Remove head cover and check directly
Remove injection pump and check directly
There is improper contact of thermostat seat valve
Remove oil pan and check directly
L Remedy
20-320 WA800-3
S-14 Water temperature becomes too high

(overheating)
General causes why water temperature becomes too high
. Lack of cooling water (deformation, damage of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
. Rise in oil temperature of power train
* Carry out troubleshooting for chassis.
* Check that the maintenance monitor panel cool-
ant level caution lamp is not lighted up.
* When the maintenance monitor panel water tem-
perature gauge is normal, go to troubleshooting
of machine monitor system (M mode).
Questions and check items)

I I I I I I I I
Degree of use Operated for long period I lnlnl I I I I
Condition of overheating
IS
1 Rises quickly I I I Ial lol I

Water temperatut .e gauge
Does not go down from red
range
Radiator water level sensor lights up
I
Fan belt whines under sudden load
I I I I I I IQI I
Cloudy white oil is floating on cooling water 0
Water is leaking because of cracks in hose or loose clamps 0
Belt tension is found to be slack 0
Power train oil temperature enters red range before engine

water temperature 0
l#l
Temperature difference between top and bottom radiator
0
tank is excessive
Temperature difference between top and bottom radiator

tank is slight
0
When water filler port is inspected, the core is found to be clogged 0
When a function test is carried out on the thermostat, it does

0
not open even at the cracking temperature
When water temperature is measured, it is found to be normal I I I i--m

I When oil cooler is inspected directly, it is found to be clogged I I I I I I I-Ii
When measurement is made with radiator cap tester, set
pressure is found to be low
I
I
I
I
1 I
/ I
I
I
I
I
I
I
I
I
Remove oil pan and check directly
WA800-3 20-32 1
S-15 Abnormal noise is made

Sr Judge if the noise is an internal noise or
an external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion noise
. Air sucked in from intake system
Legend
0: Possible causes (judging from Questions and check items1
0: Most probable causes (judging from Questions and Check items)
Condition of abnormal noise

Sudden1 , “”
Non-specified fuel has been used oo,, /, ,
Engine oil must be added more frequently
Metal particles are found in oil filter
Blow-by gas is excessive
I Noise of interference is heard from around turbocharger I lot I I I I I I I I I I1

I Engine pickup is poor and combustion is irregular I I I 101 I I I I I I I I I
When exhaust manifold is touched immediately
starting engine, temperature of some cylinders
after
is low
I I lH”lI I I
- -
I I I I I I
When comoression oressure is measured. it is found to be low 0 I I I I I I -
When turbocharger is rotated by hand, it is found to be heaw 0
I I I I I - -
Remove gear cover and check directly I I.1
- -
- -
When control rack is pushed, it is found to be heavy or does not return
- -
lniection oumo test shows that iniection amount is incorrect
- -
Fan is deformed, or belt is loose
- -
outside standard value
- -
Remove cylinder head cover and check directly
-
When muffer is removed, abnormal noise disappers c-
Metal particles are found in oil pan, oil filter
- s-
Remedy
: :
m 9
E LTE
@z
- -
20-322 WA800-3
TROUBLESHOOTING S-16
S-16 Vibration is excessive

* If there is abnormal noise together with
the vibration, carry out troubleshooting
for “Abnormal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, break-
age)
. Improper alignment
. Abnormal combustion
Legend
0 : Possible causes (judging from Questions and check items1
Ca~ Vibration occurs at mid-range speed 00

%
al Vibration follows engine speed 00000 0
6 Exhaust gas is black 00
Remove oil pan and check directly 0
Remove side cover and check directly 0
Check directly for worn support pilot, play 0
Check directly for loose engine mounting bolts, broken cushion
Check inside of output shaft (damper) directly
When radial runout, face runout are measured, they are

found to be outside standard value
Remove front cover and check directly
Remove head cover and check directly
Injection pump test shows that injection amount is incorrect
WA800-3 20-323
TROUBLESHOOTING OF TRANSMISSION
CONTROL SYSTEM (T MODE)
Judgement table for transmission control system related parts ......................................................20-402

Action taken by controller when abnormality occurs and problems on machine ..........................20-404
Electrical circuit diagram for transmission control system ...............................................................20-408
T- 1 Failure code [10] (Short circuit, disconnection, short circuit with power source
in backup lamp relay) is displayed ..........................................................................................20-410
Steering wheel specification, Steering wheel and joystick steering specification
in backup lamp relay) is displayed ..........................................................................................20-411
AJSS (Advanced Joystick Steering System) specification
in F solenoid) is displayed ........................................................................................................20-412
in R solenoid) is displayed .......................................................................................................20-413
T- 5 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st
solenoid) is displayed ................................................................................................................20-414
T- 6 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd
T- 7 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd
T- 8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is
displayed ..................................................................................................................................20-417
Steering wheel and joystick steering specification
T- 9 Failure code [20] (Short circuit, disconnection in directional switch system) is
displayed ..................................................................................................................................20-418
T-10 Failure code [20] (Short circuit or disconnection in joystick lever switch system)
is displayed .................................................................................................................................20-421
T-11 Failure code [21] (Short circuit, disconnection in range switch system) is displayed ......20-422
Steering wheel specification and Steering wheel and joystick steering specification
T-12 Failure code [21] (Short circuit or disconnection in joystick shift-up/shift-down
switch system) is displayed ......................................................................................................20-425
T-13 Failure code [22] (Disconnection in travel speed sensor system) is displayed ..................20-426
T-14 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is
displayed ..................................................................................................................................20-427
T-15 Kickdown switch signal system and hold switch signal system .........................................20-428
Steering wheel specification
T-16 Shift-down switch signal system and shift-up switch signal system .................................. 20-429
T-17 Transmission cut-off signal system .........................................................................................20-430
T-18 Neutralizer signal system ..........................................................................................................20-431
T-19 Buzzer signal system .................................................................................................................20-432
T-20 Network system .........................................................................................................................20-433
T-21 Transmission controller power source system ......................................................................20-434
T-22 Short circuit in travel speed sensor system ...........................................................................20-435
T-23 Abnormality in machine selection wiring harness ................................................................20-436
WA800-3 20-401
5
JUDGEMENT TABLE FOR TRANSMISSION CONTROL
TROUBLESHOOTING SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM

RELATED PARTS
STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION
Self-diagnostic display (abnormality display)
Short circuit, disconnection in directional switch signal system
Short circuit, disconnection in engine speed sensor system

Short circuit, disconnection in shift switch signal system
Short circuit, disconnection in joystick directional switch system
Abnormality in network signal system or main monitor

Short circuit, disconnection in back lamp relay system
Location of failure
Short circuit, disconnection in 2nd solenoid system

Short circuit, disconnection in 3rd solenoid system
Short circuit, disconnection in 1st solenoid system
Abnormality in transmission cut-off signal system

Short circuit, disconnection in R solenoid system
Short circuit, disconnection in F solenoid system
Abnormality in kickdown switch signal system
Abnormality in alarm buzzer signal system

Trouble-
Abnormality in neutralizer signal system

Disconnection in speed sensor system
Abnormality in network signal system

shooting
code when
no abnor-
mality
display is
given
Failure
Failure mode code
Transmission control error
10 12 13 14 15 16 19 20 21 22 23 — — — — — —
1 Travel is impossible fififififi E-1, H-1
2 Directional lever and direction of travel are fi

different
3 Machine travels forward when directional lever is

not at F
fi fi
4 Machine travels in reverse when directional lever
is not at R.
fi fi
5 There is excessive gearshifting shock fifi H-2, H-3
6 There is shift hunting when traveling fi

7 There is shift hunting when shifting gear fi
8 Speed range cannot be controlled with speed
lever fi
9 Back lamp and buzzer do not work fi
10 Kickdown does not work fi T-15, E-9
11 Transmission is not cut off with left brake fi T-17, E-14
12 It is possible to travel even when parking brake is

applied
fi T-18, E-5
13 If F-R lever is operated when traveling at high fi T-19

speed, alarm buzzer does not sound
14 Alarm buzzer continues to sound fi T-19, J-1
15 Main monitor does not display transmission control- fi T-20

ler information (alarm buzzer, failure code, etc.)
Troubleshooting code when error code is displayed T-1 T-3 T-4 T-5 T-6 T-7 T-8 T-9 T-11 T-13 T-14 — — — — — —
20-402 WA800-3
5
JUDGEMENT TABLE FOR TRANSMISSION CONTROL
TROUBLESHOOTING SYSTEM RELATED PARTS

Short circuit, disconnection in Joystick forward-reverse switch

Short circuit, disconnection in Joystick shift-up/down switch
Short circuit, disconnection in engine speed sensor system
Abnormality in network signal system or main monitor

Short circuit, disconnection in back lamp relay system
Location of failure
Short circuit, disconnection in 2nd solenoid system

Short circuit, disconnection in 3rd solenoid system
Short circuit, disconnection in 1st solenoid system
Abnormality in transmission cut-off signal system

Short circuit, disconnection in R solenoid system
Short circuit, disconnection in F solenoid system
Abnormality in kickdown switch signal system
Abnormality in alarm buzzer signal system

Trouble-
Abnormality in neutralizer signal system

Disconnection in speed sensor system
Abnormality in network signal system

shooting
code when
no abnor-
mality
display is
given
Failure
Failure mode code
Transmission control error
10 12 13 14 15 16 20 21 22 23 — — — — — —
1 Travel is impossible fififififi E-1, H-1
2 Directional switch and direction of travel are fi

different
3 Machine travels forward when directional switch

is not at F
fi fi
4 Machine travels in reverse when directional
switch is not at R.
fi fi
5 There is excessive gearshifting shock fifi H-2, H-3
6 There is shift hunting when traveling fi

7 There is shift hunting when shifting gear fi
8 Speed range cannot be controlled with Shift-up/
down switch fi
9 Back lamp and buzzer do not work fi
10 Kickdown does not work fi T-16, E-9
11 Transmission is not cut off with left brake fi T-17, E-14
12 It is possible to travel even when parking brake is

applied
fi T-18, E-5
13 If F-R lever is operated when traveling at high fi T-19

speed, alarm buzzer does not sound
14 Alarm buzzer continues to sound fi T-19, J-1
15 Main monitor does not display transmission control- fi T-20

ler information (alarm buzzer, failure code, etc.)
Troubleshooting code when error code is displayed T-2 T-3 T-4 T-5 T-6 T-7 T-10 T-12 T-13 T-14 — — — — — —
WA800-3 20-403
5
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
Failure code Abnormal system Nature of abnormality
1) Defective back lamp relay

2) Short circuit with power source, short circuit with chassis
ground, defective contact, disconnection in wiring harness
between transmission & joystick controller C1 (female) (8)
Short circuit, disconnection and L54 (1)
10
in back lamp relay system 3) Defective contact or disconnection in wiring harness
between back lamp relay L54 (female) (2) and chassis
ground
4) Defective transmission & joystick controller
1) Defective F solenoid
12 Short circuit, disconnection – TR1 (4) – T01 (4)
in F solenoid system 3) Short circuit with chassis ground, defective contact,
disconnection in wiring harness between chassis – TR1
(6) – T01 (1)
1) Defective R solenoid
Short circuit, disconnection
13 – TR1 (5) – T01 (3)
in R solenoid system
3) Short circuit with chassis ground, defective contact,
(6) – T01 (1)
1) Defective 1st solenoid

Short circuit, disconnection between transmission & joystick controller C1 (female) (3)
14 – TR1 (1) – T01 (8)
in 1st solenoid system
(6) – T01 (2)
1) Defective 2nd solenoid

Short circuit, disconnection between transmission & joystick controller C1 (female)
15 (10) – TR1 (2) – T01 (7)
in 2nd solenoid system
disconnection in wiring harness between chassis–TR1 (6)–
T01 (2)
1) Defective 3rd solenoid

in 3rd solenoid system 3) Short circuit with chassis ground, defective contact,
(6) – T01 (2)
4) Defective transmission controller
20-404 WA800-3
5
Condition when normal Action by controller Problem that appears Trouble-

when abnormality is on machine when shooting
(voltage, current, resistance) detected there is abnormality code
1) Resistance of relay coil: 200 – 400 Ω Neutral Back lamp is not
2) Voltage between transmission & joystick (F, R, 1st, 2nd, 3rd actuated when driving
controller C1 (8) and chassis ground at neutral: solenoid output: off) in reverse
Less than 1 V
3) Resistance in wiring harness between
transmission & joystick controller C1 (female) T-1
(8) and L54 (female) (1): Max. 1 Ω
4) Resistance in wiring harness between back
lamp relay L54 (female) (2) and chassis ground:
Max. 1 Ω
1) Resistance between transmission & joystick Neutral It is impossible to

controller C1 (female) (2) and chassis ground: 5 (F, R, 1st, 2nd, 3rd travel
– 15 Ω solenoid output: off)
2) Voltage between transmission & joystick
controller C1 (2) and chassis ground at neutral: T-3
Less than 1 V

Less than 1 V

Less than 1 V
1) Resistance between transmission & joystick

controller C1 (female) (10) and chassis ground: Neutral It is impossible to
5 – 15 Ω (F, R, 1st, 2nd, 3rd travel
2) Voltage between transmission & joystick solenoid output: off)
controller C2 (10) and chassis ground at T-6
neutral: Less than 1 V

controller C1 (female) (5) and chassis ground: 5 Neutral It is impossible to
– 15 Ω (F, R, 1st, 2nd, 3rd travel
Less than 1 V
WA800-3 20-405
5
1) Defective joystick directional lever F, N, R switch

2) Disconnection between joystick directional lever connector
JS1 (8) and chassis ground
When the wiring harness is in any of the following
conditions with the switch not pressed
3) Defective contact or disconnection in wiring harness
– JS1 (2) – joystick lever connector (4)
or short circuit with chassis ground in wiring harness
between C5 (female) (16) – JS1 (3) – joystick lever
Short circuit, disconnection connector (3)
19 in joystick directional 4) Defective contact or disconnection in wiring harness
switch system between transmission & joystick controller C5 (female) (7)
connector (5)
connector (7)
1) Defective directional lever

2) Defective combination switch power source
Short circuit with power source, short circuit with chassis
ground, defective contact, disconnection in the following
Short circuit, disconnection wiring harness
20 in directional switch signal 3) Wiring harness between transmission & joystick controller
C3B (female) (5) and L04 (2)
system 4) Wiring harness between transmission & joystick controller
5) Wiring harness between transmission & joystick controller
1) Defective directional lever

2) Defective combination switch power source
Short circuit with power source, short circuit with chassis
ground, defective contact, disconnection in the following
Short circuit, disconnection wiring harness
in shift switch signal 3) Wiring harness between transmission & joystick controller
21 C3B (female) (7) and L04 (5)
system 4) Wiring harness between transmission & joystick controller
5) Wiring harness between transmission & joystick controller
1) Defective speed sensor

2) Defective adjustment of speed sensor mount
Disconnection in speed between transmission & joystick controller C5 (female) (2)
22 sensor system – CBL1 (6) – C01 (1)
between transmission & joystick controller C5 (female)
(10) – CBL1 (7) – C01 (2)
1) Defective engine speed sensor

2) Defective adjustment of engine speed sensor mount
23 in engine speed sensor – LR3 (14) – ER1 (10) – E03 (1)
system 4) Defective contact or disconnection in wiring harness
– LR3 (15) – ER1 (17) – E03 (2)
20-406 WA800-3
5

1) Resistance between joystick directional lever Neutral Cannot travel in
connector (8) and chassis ground: Less than 1 Ω (F, R, 1st, 2nd, 3rd joystick mode (possible
The following conditions are when the switch is solenoid output: off) in steering wheel
not pressed mode)
controller C5 (female) (8) and chassis ground:
Less than 1 Ω
Less than 1 Ω
and resistance between C5 (female) (15) and
chassis ground: Min. 1 MΩ T-8
Less than 1 Ω
and resistance between C5 (female) (17) and
chassis ground: Min. 1 MΩ
1) Voltage between combination switch L04 (1) • Shifts to neutral It is impossible to

and chassis ground: 20 – 30 V immediately when travel
2) Voltage for only 1 system in accordance with short circuit with
position of directional lever: 20 – 30 V (Others: power supply is
Less than 1 V) detected
F: Between transmission & joystick controller • When there is no
C3B (5) – chassis ground signal T-9
N: Between transmission & joystick controller (disconnection),
C3B (13) – chassis ground holds previous signal
R: Between transmission & joystick controller condition for 2
C3B (6) – chassis ground seconds
1) Voltage between combination switch L04 (1) • If 2 signals are input, 1) Auto-shift limit is
and chassis ground: 20 – 30 V it judges speed range different from
2) Voltage for only 1 system in accordance with position in order of range position
position of range lever: 20 – 30 V (Others: Less priority 3←2←1 selected by
than 1 V) • When there is no operator (OP)
1st: Between transmission & joystick controller signal 2) Impossible to shift
C3B (7) – chassis ground (disconnection), gear in manual T-11
2nd: Between transmission & joystick controller holds previous signal mode
C3B (15) – chassis ground condition (speed
3rd: Between transmission & joystick controller range position)
C3B (8) – chassis ground
1) Resistance between travel speed sensor C01 1) Switches to manual 1) Does not carry out
(1) and (2): 500 – 1,000 Ω mode (OP) auto-shift (OP)
2) Voltage between transmission & joystick 2) Shifts gear 2) Switches to
controller C5 (female) (2) and (10): Min. 0.5 V according to manual shift
operation of range T-13
lever
1) Resistance between engine speed sensor E03 1) Switches to manual 1) Does not carry out
(1) and (2): 100 – 500 Ω mode (OP) auto-shift (OP)
controller C4 (female) (2) and (9) according to manual shift
lever
WA800-3 20-407
5
1) Defective back lamp relay

Short circuit, disconnection and L54 (1)
10
in back lamp relay system 3) Defective contact or disconnection in wiring harness
between back lamp relay L54 (female) (2) and chassis
ground
1) Defective F solenoid
in F solenoid system 3) Short circuit with chassis ground, defective contact,
(6) – T01 (1)
1) Defective R solenoid
Short circuit, disconnection
13 – TR1 (5) – T01 (3)
in R solenoid system
(6) – T01 (1)
1) Defective 1st solenoid

14 – TR1 (1) – T01 (8)
in 1st solenoid system
(6) – T01 (2)
1) Defective 2nd solenoid

15 Short circuit, disconnection
in 2nd solenoid system (10) – TR1 (2) – T01 (7)
disconnection in wiring harness between chassis–TR1 (6)–
T01 (2)
1) Defective 3rd solenoid

in 3rd solenoid system 3) Short circuit with chassis ground, defective contact,
(6) – T01 (2)
4) Defective transmission controller
20-407-1 WA800-3
5

1) Resistance of relay coil: 200 – 400 Ω Neutral Back lamp is not
2) Voltage between transmission & joystick (F, R, 1st, 2nd, 3rd actuated when driving
controller C1 (8) and chassis ground at neutral: solenoid output: off) in reverse
Less than 1 V
3) Resistance in wiring harness between
transmission & joystick controller C1 (female) T-2
(8) and L54 (female) (1): Max. 1 Ω
4) Resistance in wiring harness between back
lamp relay L54 (female) (2) and chassis ground:
Max. 1 Ω

Less than 1 V

Less than 1 V

Less than 1 V

controller C1 (female) (10) and chassis ground: Neutral It is impossible to
5 – 15 Ω (F, R, 1st, 2nd, 3rd travel
controller C2 (10) and chassis ground at T-6
neutral: Less than 1 V

controller C1 (female) (5) and chassis ground: 5 Neutral It is impossible to
– 15 Ω (F, R, 1st, 2nd, 3rd travel
Less than 1 V
WA800-3 20-407-2
5
1) Defective joystick forward-reverse switch

2) Disconnection or defective contact in wiring harness
between fuse – JS1 (female) (1)
3) Disconnection, defective contact, short circuit with chassis
ground, or short circuit in wiring harness between
transmission & joystick controller C3B (female) (5) – JS1
(female) (2)
Short circuit or 4) Disconnection, defective contact, short circuit with chassis
disconnection in joystick ground, or short circuit in wiring harness between
20 forward-reverse switch transmission & joystick controller C3B (female) (13) – JS1
signal system (female) (3)
(female) (4)
1) Defective joystick shift-up/down switch

between fuse – JS1 (female) (1)
(female) (5)
Short circuit or ground, or short circuit in wiring harness between
21 disconnection in joystick transmission & joystick controller C3B (female) (8) – JS1
shift-up/down switch signal (female) (6)
system 5) Disconnection, defective contact, short circuit with chassis
(female) (7)
(female) (8)
1) Defective speed sensor

2) Defective adjustment of speed sensor mount
Disconnection in speed between transmission & joystick controller C5 (female) (2)
22 sensor system – CBL1 (6) – C01 (1)
(10) – CBL1 (7) – C01 (2)
1) Defective engine speed sensor

2) Defective adjustment of engine speed sensor mount
23 in engine speed sensor – LR3 (14) – ER1 (10) – E03 (1)
system 4) Defective contact or disconnection in wiring harness
– LR3 (15) – ER1 (17) – E03 (2)
20-407-3 WA800-3
5

1) Voltage between transmission & joystick 1) When N signal is 1) When in F: Stops.
controller C3B (5) and chassis ground input: Shifts to N 2) When in N or R:
When joystick forward-reverse switch is in “F”: immediately. Starts moving
17 – 30 V 2) When F/R signal is forward suddenly.
When joystick forward-reverse switch is not in input: Shifts to N 3) When in N: N
“F”: Max. 1 V immediately. signal is not
2) Voltage between transmission & joystick 3) When there is no output.
controller C3B (13) and chassis ground signal: Holds 4) When in F or R:
When joystick forward-reverse switch is in “N”: previous signal Sets to neutral
17 – 30 V condition for 2 suddenly. T-10
When joystick forward-reverse switch is not in seconds, then shifts 5) When in R: Stops.
“N”: Max. 1 V to N. 6) When in N or F:
3) Voltage between transmission & joystick Starts moving in
controller C3B (6) and chassis ground reverse suddenly.
When joystick forward-reverse switch is in “R”:
17 – 30 V
When joystick forward-reverse switch is not in
“R”: Max. 1 V
1) Voltage between transmission & joystick 1) Holds current gear 1) Cannot shift gear
controller C3B (7) and chassis ground (Shift-up speed. up.
NO) 2) Cannot shift gear
When joystick shift-up switch is ON: Max. 1 V down.
When joystick shift-up switch is OFF: 17 – 30 V
controller C3B (8) and chassis ground (Shift-
down NO)
When joystick shift-down switch is ON: Max. 1 V
When joystick shift-down switch is OFF: 17 – 30 V
3) Voltage between transmission & joystick T-12
controller C3B (15) and chassis ground (Shift-up
NC)
When joystick shift-up switch is ON: 17 – 30 V
When joystick shift-up switch is OFF: Max. 1 V
controller C3B (16) and chassis ground (Shift-
down NC)
When joystick shift-down switch is ON: 17 – 30 V
When joystick shift-down switch is OFF: Max. 1 V
1) Resistance between speed sensor C01 (1) and 1) Switches to manual 1) Does not carry out
(2): 500 – 1,000 Ω mode (OP) auto-shift (OP)
controller C5 (female) (2) and (10): Min. 0.5 V according to manual shift
lever
1) Resistance between engine speed sensor E03 1) Switches to manual 1) Does not carry out
(1) and (2): 100 – 500 Ω mode (OP) auto-shift (OP)
controller C4 (female) (2) and (9) according to manual shift
lever
WA800-3 20-407-4
5
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TROUBLESHOOTING CONTROL SYSTEM

CONTROL SYSTEM
20-408 WA800-3
5
fl This circuit diagram is made by extracting the part of the transmission & joystick steering controller
system from the general circuit diagram.
WA800-3 20-409
5
20-409-1 WA800-3
5
system from the general circuit diagram.
WA800-3 20-409-2
5
TROUBLESHOOTING T-1
T-1 Failure code [10] (Short circuit, disconnection, short circuit with
power source in backup lamp relay) is displayed
fl This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the
problem has been removed.
fl Before carrying out troubleshooting, check that all the related connectors are properly inserted.
fl Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between L54
(female) (2) and Defective contact or
3 chassis ground disconnection in wiring
Is resistance normal? Repair or
between C1 harness between C2
YES • Max. 1 Ω NO (female) (17) and L54 replace
(female) (8) and • Turn starting
2 chassis ground switch OFF. (female) (2)
normal? • Disconnect C1 Short circuit with chassis
Is resistance
• Min. 1 MΩ and L54. ground in harness Repair or
YES between C1
(female) (8) and L54 • Turn starting NO between C1 (female) (8) replace
1 (female) (1) normal? switch OFF. and L54 (female) (1)
Is failure code 10 • Disconnect C1 Defective contact or
displayed when
• Max. 1 Ω and L54. disconnection in wiring Repair or
backup relay is • Turn starting
NO harness between C1 replace
replaced with other switch OFF.
(female) (8) and L54
relay of same type? • Disconnect C1
(female) (1)
• Turn starting and L54.
switch OFF. Defective backup lamp
Repair
• Replace backup NO relay
relay with other relay of same type.
• Turn starting switch ON.
• Set directional lever to R. 5 YES Defective transmission &
joystick steering Repair
Is voltage between controller
C1 (female) (8) and
From A
chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Turn starting NO between C1 (female) (8) replace
switch ON. and L54 (female) (1)
• Disconnect C1
and L54.
• Max. 1 V
T-1 Related electrical circuit diagram
20-410 WA800-3
5
TROUBLESHOOTING T-2
power source in backup lamp relay) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between L54
between C1 harness between L54
YES • Max. 1 Ω NO (female) (2) and chassis replace
(female) (8) and • Turn starting
2 chassis ground switch OFF. ground
normal? • Disconnect C1 Short circuit with chassis
Is resistance
• Min. 1 MΩ and L54. ground in harness Repair or
YES between C1
(female) (8) and L54 • Turn starting NO between C1 (female) (8) replace
1 (female) (1) normal? switch OFF. and L54 (female) (1)
Is failure code 10 • Disconnect C1 Defective contact or
displayed when
• Max. 1 Ω and L54. disconnection in wiring Repair or
backup relay is • Turn starting
replaced with other switch OFF.
relay of same type? • Disconnect C1
(female) (1)
• Turn starting and L54.
switch OFF. Defective backup lamp
Repair
• Replace backup NO relay
relay with other relay of same type.
• Turn starting switch ON.
• Set directional lever to R. 5 YES Defective transmission &
joystick steering Repair
C1 (female) (8) and
From A
• Disconnect C1
and L54.
• Max. 1 V
WA800-3 20-411
5
TROUBLESHOOTING T-3
power source in F solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (1) and disconnection in wiring
3 chassis ground
Is resistance harness between T01 Repair or
normal?
between C1 (female) (1) and chassis replace
YES • Max. 1 Ω NO
(female) (2) and ground
• Turn starting
2 chassis ground
switch OFF. Short circuit with chassis
normal?
Is resistance • Disconnect T01. ground or another part in
• Min. 1 MΩ Repair or
YES between C1 harness between C1
(female) (2) and T01
• Turn starting NO replace
1 (female) (4) normal? switch OFF.
(female) (4)
• Disconnect C1
Is resistance between
• Max. 1 Ω and T01. Defective contact or
T01 (male) (1) and (4)
disconnection in wiring Repair or
and between (1), (4)
• Turn starting
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (2) and T01
• Between (1) and and T01. (female) (4)
(4): 5 – 15 Ω Defective F solenoid Replace
• Between (1), (4) NO
and chassis ground: Min. 1 MΩ
• Turn starting switch OFF.
• Disconnect T01. Defective transmission &
5 YES
joystick steering Replace
C1 (female) (2) and
From A chassis ground
Short circuit with power
normal?
source in wiring harness Repair or
switch ON. and T01 (female) (4)
• Disconnect C1
and T01.
• Max. 1 V
20-412 WA800-3
5
TROUBLESHOOTING T-4
power source in R solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01
(female) (1) and
3 chassis ground
Is resistance normal? harness between T01 Repair or
YES between C1 • Max. 1 Ω (female) (1) and chassis replace
(female) (9) and
NO
• Turn starting ground
2 chassis ground
normal? switch OFF. Short circuit with chassis
Is resistance • Min. 1 MΩ • Disconnect T01. ground or another part in Repair or
(female) (9) and T01 (female) (9) and T01
(female) (3)
• Disconnect C1
• Max. 1 Ω and T01. Defective contact or
T01 (male) (1) and (3) Repair or
and between (1), (3) • Turn starting disconnection in wiring
NO replace
(3): 5 – 15 Ω Defective R solenoid Replace
and chassis ground:
Min. 1 MΩ
• Turn starting switch OFF. 5 YES Defective transmission &
• Disconnect T01. joystick steering Replace
C1 (female) (9) and
From A chassis ground Short circuit with power
• Max. 1 V NO between C1 (female) (9) replace
• Turn starting and T01 (female) (3)
switch ON.
• Disconnect C1
and T01.
WA800-3 20-413
5
TROUBLESHOOTING T-5
power source in 1st solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
3 chassis ground
Is resistance harness between T01
normal? Repair or
YES between C1 (female) (2) and chassis
• Max. 1 Ω NO replace
chassis ground
• Turn starting
2 switch OFF. Short circuit with chassis
normal?
Is resistance • Disconnect T01. ground or another part in
(female) (8)
• Disconnect C1,
• Max. 1 Ω T01 and L05. Defective contact or
T01 (male) (2) and (8) Repair or
NO replace
(8): 5 – 15 Ω Defective 1st solenoid Replace
• Disconnect T01. 5 YES Defective transmission &
C1 (female) (3)
From A and chassis
ground normal?
switch ON.
• Disconnect C1,
T01 and L05.
20-414 WA800-3
5
TROUBLESHOOTING T-6
power source in 2nd solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
3 chassis ground
Is resistance harness between T01
normal?
(female) (2) and chassis Repair or
YES between C1 • Max. 1 Ω NO replace
chassis ground
• Turn starting
2 switch OFF. Short circuit with chassis
Is resistance normal?
• Disconnect T01. ground or another part in
between C1 • Min. 1 MΩ Repair or
YES harness between C1
(female) (10) and • Turn starting NO replace
T01 (female) (7) switch OFF.
1 normal?
(female) (7)
Is resistance between • Disconnect C1,
T01 (male) (2) and (7)
• Max. 1 Ω T01 and L05. Defective contact or
Repair or
NO replace
(7): 5 – 15 Ω Defective 2nd solenoid Replace
C1 (female) (10) and
From A chassis ground Short circuit with power
switch ON.
• Disconnect C1,
T01 and L05.
WA800-3 20-415
5
TROUBLESHOOTING T-7
power source in 3rd solenoid) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01
(female) (2) and
3 chassis ground
Is resistance normal? harness between T01 Repair or
YES between C1 • Max. 1 Ω NO
(female) (2) and chassis replace
chassis ground
• Turn starting
2 switch OFF.
normal? Short circuit with chassis
Is resistance
• Min. 1 MΩ • Disconnect T01. ground in harness Repair or
YES between C1 between C1 (female) (5)
switch OFF. and T01 (female) (6)
1 (female) (6) normal?
• Disconnect C1,
• Max. 1 Ω Defective contact or
T01 (male) (2) and (6) T01 and L05. Repair or
• Turn starting disconnection in wiring
and between (2), (6) harness between C1 replace
and chassis ground switch OFF. NO
• Disconnect C1 (female) (5) and T01
normal?
and T01. (female) (6)
• Between (2) and
(6): 5 – 15 Ω Defective 3rd solenoid Replace
C1 (female) (5) and
From A chassis ground
normal?
switch ON.
• Disconnect C1,
T01 and L05.
20-416 WA800-3
5
TROUBLESHOOTING T-8
T-8 Failure code [19] (Short circuit, disconnection in joystick

directional switch system) is displayed
Cause Remedy
Defective transmission &

4 YES joystick steering
Is voltage between controller Replace
YES C5 (female) (7), (8), Short circuit, short circuit
(9), (15), (16), (17) with chassis ground,
3 and chassis as defective contact, or
Is resistance disconnection in wiring
shown in table 1?
harness between JS1
Repair or
YES between JS1 • Turn starting NO (female) (2), (3), (4), (5), (7) replace
(female) (8) – switch ON and C5 (female) (7), (8), (9),
2 chassis normal? (15), (16), (17)
Is voltage Defective contact or
YES between JS1 (1) • Max. 1 Ω Repair or
disconnection in wiring replace
• Turn starting NO
and chassis harness between JS1
switch OFF. (female) (8) and chassis
1 normal?
• Disconnect JS1.
Is voltage between • 20 – 30 V Short circuit, short circuit
with chassis ground, Repair or
JS1 (8) and (2), (3), • Turn starting
NO defective contact, or replace
(4), (5), (6), (7) as switch ON.
shown in Table 1? disconnection in wiring
harness between C3A
• Turn starting (male) (6) and chassis
switch ON. Defective joystick lever Replace
NO
Table 1 Voltage on each position of joystick lever

Pushed switch
F N R
Terminal
JS1 (male) (8) – (2) Between C5 (8) and chassis 20 – 30 V Max. 1 V Max. 1 V
JS1 (male) (8) – (3) Between C5 (16) and chassis Max. 1 V 20 – 30 V 20 – 30 V
JS1 (male) (8) – (4) Between C5 (7) and chassis Max. 1 V 20 – 30 V Max. 1 V
JS1 (male) (8) – (5) Between C5 (15) and chassis 20 – 30 V Max. 1 V 20 – 30 V
JS1 (male) (8) – (6) Between C5 (9) and chassis Max. 1 V Max. 1 V 20 – 30 V
JS1 (male) (8) – (7) Between C5 (17) and chassis 20 – 30 V 20 – 30 V Max. 1 V
WA800-3 20-417
5
TROUBLESHOOTING T-9
T-9 Failure code [20] (Short circuit, disconnection in directional switch

system) is displayed
YES
6
YES C3B (female) (6) and
chassis ground and
between C3B (female)
5 (6) and (13) normal
Is voltage • Min. 1 MΩ
YES between C3B (5) • Disconnect L04,
and chassis C3B and L08. NO
4 ground normal? • Turn starting
Is resistance between • 20 – 30 V switch OFF.
YES C3B (female) (5) and • Turn starting
chassis ground and
between C3B (female) switch ON. NO
3 (5) and (6), (13) normal? • Set directional
Is resistance • Min. 1 MΩ lever to F.
YES between L04 • Disconnect L04,
(female) (10) and
chassis ground C3B and L08. NO
2 normal? • Turn starting
Is voltage between • Max. 1 Ω switch OFF.
YES L04 (female) (1) • Turn starting
and chassis switch OFF. NO
1 ground normal? • Disconnect L04.
Is resistance • 20 – 30 V
between L04 • Turn starting
(female) (1) and
switch ON.
chassis ground NO
normal?
• Min. 1 MΩ
• Disconnect FS2
and L04. NO
• Turn starting
switch OFF.
20-418 WA800-3
5
TROUBLESHOOTING T-9
Cause Remedy

10 YES joystick steering
Replace
YES L04 (2), (3), (4) and
9 chassis ground as
Is voltage shown in Table 1? Defective directional Repair or
YES between C3B (13) switch replace
• Turn starting NO
and chassis switch ON. Defective contact or
8 ground normal? disconnection in wiring
Is resistance
harness between L04 Repair or
YES between C3B • 20 – 30 V
(female) (3) and C3B (female) replace
(female) (13) and • Turn starting NO (13), or defective lever
chassis ground switch ON.
7 normal? Short circuit with chassis
• Set directional
Is voltage ground in harness between
• Min. 1 MΩ lever to N. L04 (female) (3) and C3B
between C3B (6) Repair or
• Disconnect L04, (female) (13)
and chassis NO replace
C3B and L08. Defective contact or
ground normal? • Turn starting disconnection in wiring
• 20 – 30 V switch OFF. harness between L04
(female) (4) and C3B (female) Repair or
• Turn starting (6), or defective lever
switch ON. NO replace
Short circuit with chassis ground
• Set directional in harness between L04 (female)
lever to R. (4) and C3B (female) (6), or short
circuit of harness between L04 Repair or
(female) (4) and C3B (female) (6)
and harness between L04 replace
(female) (3) and C3B (female)
(13) with each other
Defective contact or Repair or
harness between L04
(5), or defective lever
Short circuit with chassis ground in
harness between L04 (female) (2) Repair or
and C3B (female) (5), or short circuit
of harness between L04 (female) (2) replace
and C3B (female) (5) and harness
between L04 (female) (3) and C3B
(female) (13) with each other
harness between fuse I (9)
and L04 (female) (1)
harness between L04 replace
(female) (10) and chassis
ground
Short circuit with chassis
ground in harness Repair or
between FS2 (female) (8) replace
Table 1
Directional lever position
F N R
Terminal
Between L04 (2) – chassis 20 – 30 V Max. 1 V Max. 1 V
Between L04 (3) – chassis Max. 1 V 20 – 30 V Max. 1 V
Between L04 (4) – chassis Max. 1 V Max. 1 V 20 – 30 V
WA800-3 20-419
5
TROUBLESHOOTING T-9
20-420 WA800-3
5
TROUBLESHOOTING T-10
T-10 Failure code [20] (Short circuit or disconnection in joystick lever

switch system) is displayed
fl Check that fuse II (6) is normal.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (5), (13), (6) and
chassis ground as Disconnection, defective
2 shown in Table 1? contact, short circuit with
Is voltage chassis ground, or short Repair or
YES between JS1 (1) circuit in wiring harness replace
• Turn starting NO between JS1 (female) (2), (3),
and chassis switch ON. (4) – C3B (female) (5), (13), (6)
1 ground normal?
Is voltage between • 20 – 30 V Disconnection or defective
JS1 (2), (3), (4) and contact in wiring harness Repair or
chassis ground as between fuse II (6) – JS1
shown in Table 1? switch ON.
(female) (1)
• Turn starting
switch ON. Defective joystick lever
Replace
NO switch
Table 1 Voltage measured with joystick lever switch at each position

Position of FNR switch
F N R
Terminals
JS1 (male) (1) – (2) C3B (5) – Chassis ground 20 – 30 V Max. 1 V Max. 1 V
JS1 (male) (1) – (3) C3B (13) – Chassis ground Max. 1 V 20 – 30 V Max. 1 V
JS1 (male) (1) – (4) C3B (6) – Chassis ground Max. 1 V Max. 1 V 20 – 30 V
WA800-3 20-421
5
T-11 Failure code [21] (Short circuit, disconnection in range switch

system) is displayed
YES
6
YES C3B (female) (8) –
chassis and between
C3B (female) (8) and
5 (15) normal?
Is voltage • Min. 1 MΩ
YES between C3B (7) • Disconnect L04,
and chassis C3B. NO
Is resistance between • 20 – 30 V switch OFF.
YES C3B (female) (7) – • Turn starting
chassis and between
C3B (female) (7) – (8), switch ON. NO
3 (15) normal? • Set speed control
Is resistance
• Min. 1 MΩ lever to 1st.
YES between L04 • Disconnect L04,
(female) (10) and
chassis ground C3B. NO
Is voltage • Max. 1 Ω switch OFF.
YES between L04 (1) • Turn starting
and chassis switch OFF. NO
1 ground normal? • Disconnect L04.
Is resistance • 20 – 30 V
(female) (1) and
switch ON.
chassis ground NO
normal?
• Min. 1 MΩ
• Disconnect FS2,
L04. NO
• Turn starting
switch OFF.
20-422 WA800-3
5
Cause Remedy
10 YES Defective transmission &

YES L04 (5), (6), (7) and
9 chassis ground as
Is voltage shown in Table 1? Repair or
Defective lever
YES between C3B (15) • Turn starting NO replace
and chassis switch ON.
8 Defective contact or
normal?
Is resistance disconnection in wiring
• 20 – 30 V Repair or
YES between C3B harness between L04
• Turn starting NO (female) (6) and C3B (female) replace
(female) (15) and
7 chassis normal? switch ON. (15), or defective lever
• Set directional Short circuit to chassis
Is voltage • Min. 1 MΩ lever to 2nd. ground between L04
between C3B (8) Repair or
• Disconnect L04, (female) (6) and C3B (female)
and chassis NO (15)
replace
C3B.
normal? • Turn starting Defective contact or
• 20 – 30 V switch OFF. disconnection between L04
(female) (7) and C3B (female) Repair or
• Turn starting (8), or defective lever
switch ON. NO replace
• Set directional ground in harness between
lever to 3rd. L04 (female) (7) and C3B
(female) (8), or short circuit Repair or
in wiring harness between
L04 (female) (7) and C3B replace
(female) (8) – L04 (female) (6)
and C3B (female) (15)
disconnection between L04
Repair or
(female) (5) and C3B (female) replace
(7), or defective lever
ground in wiring harness
between L04 (female) (5) and
C3B (female) (7), or short circuit Repair or
between L04 (female) (5) and replace
C3B (female) (7), or between L04
(15), or between L04 (female) (7)
and C3B (female) (8)
harness between fuse I (9)
harness between L04
ground in wiring harness Repair or
between FS2 (female) (8) and replace
L04 (female) (1)
Table 1
Directional lever position
1st 2nd 3rd
Terminal
Between L04 (5) – chassis 20 – 30 V Max. 1 V Max. 1 V
Between L04 (6) – chassis Max. 1 V 20 – 30 V Max. 1 V
Between L04 (7) – chassis Max. 1 V Max. 1 V 20 – 30 V
WA800-3 20-423
5
20-424 WA800-3
5
T-12 Failure code [21] (Short circuit or disconnection in joystick shift-

up/shift-down switch system) is displayed
Cause Remedy
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (16), (8), (15), Disconnection, defective
(7) and chassis
2 ground as shown in
contact, short circuit with
chassis ground, or short
Is voltage Table 1? circuit in wiring harness Repair or
YES between JS1 (1) • Turn starting NO between JS1 (female) (5), (6), replace
and chassis (7), (8) – C3B (female) (16),
1 switch ON. (8), (15), (7)
ground normal?
Is voltage between
Disconnection or defective
JS1 (5), (6), (7), (8) • 20 – 30 V Repair or
and chassis ground contact in wiring harness
as shown in Table between fuse II (6) – JS1
switch ON.
1? (female) (1)
• Turn starting
Defective joystick shift-
switch ON. Replace
NO up/shift-down switch
Table 1 Voltage measured with joystick shift-up/shift-down switch at each position

When shift-up/shift-down switch Shift-up Shift-down
Terminals is pressed switch ON switch ON
JS1 (5) – Chassis ground C5 (16) – Chassis ground 20 – 30 V Max. 1 V
JS1 (6) – Chassis ground C5 (8) – Chassis ground Max. 1 V 20 – 30 V
JS1 (7) – Chassis ground C5 (15) – Chassis ground Max. 1 V 20 – 30 V
JS1 (8) – Chassis ground C5 (7) – Chassis ground 20 – 30 V Max. 1 V
WA800-3 20-425
5
T-13 Failure code [22] (Disconnection in travel speed sensor) is

displayed

Is resistance controller
YES between C5 (female)
(10) and BC01 Defective contact or
2
(female) (2) normal? disconnection in wiring
Is resistance
harness between C5 Repair or
between C5
YES (female) (2) and • Max. 1 Ω NO (female) (10) and BC01 replace
BC01 (female) (1) • Disconnect C5, BC01 and (female) (2)
1 normal? L07.
Is resistance between Defective contact or
• Max. 1 Ω • Turn starting switch OFF. Repair or
BC01 (male) (1) and disconnection in wiring
(2) and between (1), • Disconnect BC01, NO harness between C5 replace
(2) and chassis C5 and L07. (female) (2) and BC01
ground normal? • Turn starting (female) (1)
• Between (1) and switch OFF.
Defective speed sensor Replace
(2): 500 – 1000 Ω NO
• Disconnect BC01.
• Turn starting
switch OFF.
20-426 WA800-3
5
T-14 Failure code [23] (Short circuit, disconnection in engine speed

sensor system) is displayed
Cause Remedy
4 YES
Go to A
Is resistance
YES between C4 Defective contact or
3 (female) (9) and E03 disconnection in wiring
(female) (2) normal?
Is resistance harness between C4 Repair or
YES between C4 (female) • Max. 1 Ω NO (female) (9) and E03 replace
2
(2) and chassis • Disconnect C4 and E03. (female) (2)
ground normal? • Turn starting switch
Is resistance
• Min. 1 MΩ OFF. ground in harness Repair or
YES between C4
(female) (2) and E03 • Disconnect C4, NO between C4 (female) (2) replace
1 (female) (1) normal E03 and L07. and E03 (female) (1)
• Turn starting Defective contact or
Is resistance • Max. 1 Ω switch OFF. disconnection in wiring Repair or
between E03 • Disconnect C3,
(male) (1) and (2) E03 and L07. (female) (2) and E03
normal? • Turn starting (female) (1)
• 100 – 500 Ω switch OFF.
• Disconnect E03. Defective engine speed Replace
• Turn starting NO sensor
switch OFF.
6 YES joystick steering Replace
YES between C4 Short circuit of harness
From A 5 (female) (2) and between C4 (female) (2)
(9) normal? and E03 (female) (1) and Repair or
Is resistance harness between C4
between C4 (female) • Min. 1 MΩ NO replace
(female) (9) and E03
(9) and chassis • Disconnect C4, (female) (2) with each
ground normal? E03 and L07. other
• Turn starting switch OFF. Short circuit with chassis Repair or
• Min. 1 MΩ
• Disconnect C4 NO ground in harness replace
and E03. between C4 (female) (9)
• Turn starting and E03 (female) (2)
switch OFF.
WA800-3 20-427
5
T-15 Kickdown switch signal system and hold switch signal system
fl Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Kickdown switch Cause Remedy

YES joystick steering Replace
1 controller
Is resistance Short circuit with chassis
between C5 ground, defective
(female) (5) and 2 YES contact, or disconnection Repair or
chassis normal?
Is resistance in wiring harness replace
• Disconnect C5. between L15 between C5 (female) (5)
• Kick-down (male) (1) and (2) and L15 (female) (1)
NO normal?
switch Defective kick-down
ON: Max. 1 Ω Replace
• Disconnect L15. NO switch
OFF: Min. 1 MΩ • Kick-down switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
Hold switch Cause Remedy

fl Hold switch is applied to only the auto-shift specification.

YES
1 controller
Is resistance
between C5 Short circuit with chassis
(female) (13) and ground, defective
2 YES Repair or
chassis normal? contact, or disconnection
• Hold switch (male) (3) and (4) and L15 (female) (3)
NO normal?
ON: Max. 1 Ω
OFF: Min. 1 MΩ Defective hold switch Replace
• Disconnect L15. NO
• Hold switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
20-428 WA800-3
5
T-16 Shift-down switch signal system and shift-up switch signal

system
Shift-down switch Cause Remedy

1 controller
between C5 ground, defective
(female) (5) and 2 YES contact, or disconnection Repair or
chassis normal?
• Shift-down (male) (1) and (2) and L15 (female) (1)
NO normal?
switch Defective shift-down
ON: Max. 1 Ω Replace
• Disconnect L15. NO switch
OFF: Min. 1 MΩ • Shift-down switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
Shift-up switch Cause Remedy

YES
1 controller
Is resistance
between C5 Short circuit with chassis
(female) (13) and ground, defective
2 YES Repair or
chassis normal? contact, or disconnection
• Shift-up switch NO (male) (3) and (4) and L15 (female) (3)
ON: Max. 1 Ω normal?
OFF: Min. 1 MΩ Defective Shift-up switch Replace
• Disconnect L15. NO
• Shift-up switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
WA800-3 20-429
5
T-17 Transmission cut-off signal system

Cause Remedy

1 controller
• Short circuit with chassis
Is resistance ground, defective contact, or
between C5 disconnection in wiring
(female) (6) and 2 YES harness between C5 (female) Repair or
chassis normal? (6) and L12 (female) (1)
Is resistance • Short circuit with chassis
replace
• Disconnect C5. between L12 ground in wiring harness
• Transmission (male) (1) and (2) between C5 (female) (6) and
NO normal? L06 (female) (3)
cut-off switch
ON: Max. 1 Ω Defective transmission Replace
• Disconnect L12. NO cut-off switch
OFF: Min. 1 MΩ • Transmission
cut-off switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
20-430 WA800-3
5
T-18 Neutralizer signal system

fl Check that the parking brake works normally.
Cause Remedy

YES
controller
1 4 YES Defective neutralizer

Is resistance relay Replace
Is voltage
between C3A (19) YES between C3A Defective contact or
(female) (6) and
and chassis 3 disconnection in wiring
C3A (female) (19)
normal? Is voltage harness between C3A
normal?
(female) (6) – L58 (female) Repair or
YES between L58 • Disconnect C3A and NO (5), L58 (female) (3) – C3A replace
• Turn starting
(female) (1) and L58.
switch ON. (female) (19)
2 chassis normal? • Short circuit L58
• Parking brake (female) (3) and (5) Short circuit with chassis
switch: Is resistance • Disconnect L58. • Max. 1 Ω ground, defective contact, Repair or
ON → OFF between L58 • Turn starting or disconnection in wiring replace
NO harness between L58
• 20 – 30 V NO (female) (2) and switch ON.
chassis normal? • Parking brake switch: ON → OFF (female) (2)
• Disconnect L58. • 20 – 30 V
• Max. 1 Ω NO disconnection in wiring replace
harness between L58
WA800-3 20-431
5
T-19 Buzzer signal system

fl Check that the main monitor and alarm buzzer works normally.
Cause Remedy

Is resistance
between C2 controller
YES
1 L08 (female) (6)
harness between C2
between C2 • Disconnect C1 NO replace
(female) (10) and and L08. (female) (6)
chassis normal? • Max. 1 Ω
• Disconnect C1 Short circuit with chassis
Repair or
and L08. ground in wiring harness
NO replace
• Min. 1 MΩ betwen C2 (female) (10)
20-432 WA800-3
5
T-20 Network system

Cause Remedy

controller
YES C3B (female) (4), (12)
and L08 (female) (1), Defective contact or
1 (3) or LM1 (female) disconnection in wiring
Is resistance (5) normal? harness between C3B Repair or
between C3B (female) (4), (12) and L08
(female) (4), (12)
• Max. 1 Ω NO replace
• Turn starting switch OFF. (female) (1), (3), or LM1
and chassis (male) (5)
normal? • Disconnect C3B, L08 and
LM1. Short circuit with chassis
betwen C3B (female) (4),
switch OFF.
(12) and L08 (female) (1),
• Disconnect C3B, (3), or LM1 (male) (5)
L08 and LM1.
WA800-3 20-433
5
T-21 Transmission controller power source system

Cause Remedy

1 controller
Is voltage between Short circuit with chassis
C1 (7), (13), C2 (1), ground, defective contact or
(12) and C1 (6), (12), disconnection in wiring
C2 (11), (21)
2 YES harness between C1 (female) Repair or
normal? Is resistance between (7), (13) and FS5 (female) (6), replace
C1 (female) (6), (12) and between C2 (female) (1),
• 20 – 30 V
and chassis, and C2 (12) and FS5 (female) (6)
• Turn starting NO (female) (11), (21)
switch ON. Defective contact or
and chassis normal? disconnection in wiring Repair or
• Max. 1 Ω NO harness between C1 (female) replace
• Turn starting (6), (12) and chassis, and
between C2 (female) (1), (12)
switch OFF.
and chassis
• Disconnect C1
and C2.
20-434 WA800-3
5
T-22 Short circuit in travel speed sensor system

Cause Remedy

2 YES Replace
joystick steering
YES between C5 Short circuit in wiring
1 (female) (2) and harness betwen C5 (female)
(10) normal? (2) – L07 (female) (1) – BC01
Is resistance (male) (1) or short circuit in Repair or
between C5 • Min. 1 MΩ NO wiring harness between C5 replace
(female) (2) and • Turn starting switch OFF. (female) (10) – L07 (female)
(2) – BC01 (female) (2)
chassis normal? • Disconnect C5, BC01 and
L07. Short circuit in wiring
• Min. 1 MΩ harness betwen C5 (female) Repair or
• Turn starting NO (2) – TM2 (9) – CN3 (female) replace
switch OFF. (2), or short circuit in
between C5 (female) (2) and
• Disconnect C5, L07 (female) (1)
BC01 and L07.
WA800-3 20-435
5
T-23 Abnormality in machine selection wiring harness

fl Check that machine selection connector is properly selected.
Cause Remedy

Is resistance
controller
between C3B
(female) (2), (3), (10) Defective machine
and C1 (female) (6), selection connector, or
(12) normal? defective contact or Repair or
• Turn starting NO disconnection in wiring replace
switch OFF. harness
• Disconnect C3B
and C1.
Table 1
Machine model
WA800-3
Connector
Between C3B (female) (2) and C1 (female) (6), (12) Min. 1 MΩ
Between C3B (female) (3) and C1 (female) (6), (12) Min. 1 MΩ
Between C3B (female) (10) and C1 (female) (6), (12) Max. 1 Ω
20-436 WA800-3
5
TROUBLESHOOTING OF MAIN MONITOR
SYSTEM
(M MODE)
Trouble data display . . . . . . . . .. . . . .. . . .. . . . . . .. . . . . . . . . .. . . . . . . .. . . . . .. . . . . . . . . . . .. . . . . .. . . . . . .. . . . . .. . .. . .. . . .. . . . .. . . . . . .. . . . . . .. . . . . . .. . . . ...... 20-503

Electrical circuit diagram of machine monitor system . . . . . .. .. . . . . .. . .. . . .. . .. . . . . .. . .. . . .. . . . . . .. . . . . . .. . . . . .. .. . . .. .. . . .. 20-506
M- 1 Main monitor does not work ..................................................................................................... 20-508
M- 2 When starting switch is turned ON (within 3 seconds) and engine is started
immediately, all lamps stay lighted up.. ................................................................................... 20-509
M- 3 Speedometer display does not work properly.. ...................................................................... .20-510
M- 4 Abnormality in shift indicator.. .................................................................................................. 20-511
a) Displays N even when directional lever is at F .. . . . . . .. . . . . . .. .._.............................................. 20-511
b) Displays N even when directional lever is at R .. . . . . . . ..___.._..._............................................. 20-511
c) Does not display N even when directional lever is at N (Displays 1st - 3rd)............... 20-512
d) Does not display 1st even when gear shift lever is at 1st position
(Directional lever is at F or R position) . .. . . .. . . . . . .. . . . .. . . . . . . . .. .. . . .. .. . . . . .. . . . . . . . . .. . . . .. . .. . . . . .. . . .. . . .. . . . . 20-512
e) Does not display 2nd even when gear shift lever is at 2nd position
(Directional lever is at F or R position) . . .. . . .. . . . . . .. . . . . . . . .. . . . . . .. . . . . . .. . . . . . .. . . . . . . . .. . . . . .. . . . . . .. . . . . . .. . . . . 20-512
f) Does not display 3rd even when gear shift lever is at 3rd position
(Directional lever is at F or R position) .. . . . . .. . . .. . .. . .. . . . . . . .. . . . . .._......_...................................... 20-513
M- 5 High beam display does not light up.. ...................................................................................... 20-514
M- 6 Turn signal display does not light up ....................................................................................... 20-515
a) L.H. turn signal display does not light up.. ....................................................................... .20-515
b) R.H. turn signal display does not light up ......................................................................... 20-515
M- 7 Abnormality in parking display.. ................................................................................................ 20-516
a) Parking lamp display does not light up ............................................................................. 20-516
b) Parking lamp display stays lighted up ............................................................................... 20-516
M- 8 Abnormality in preheating system ............................................................................................ 20-517
a) Does not carry out preheating ............................................................................................ 20-517
b) Always carries out preheating for 45 seconds .................................................................. 20-518
c) Preheating stays on .............................................................................................................. 20-518
d) Preheating time becomes shorter, or there is variation.. ................................................. 20-519
M- 9 Night lighting does not light up. ............................................................................................... 20-521
M-10 Abnormality in front working lamp ........................................................................................... 20-522
a) Neither monitor display nor front working lamp light up ................................................ 20-522
b) Working lamp lights up but monitor display does not light up ...................................... 20-522
c) Monitor display lights up but front working lamp does not light up ............................ 20-522
M-l 1 Abnormality in rear working lamp.. .......................................................................................... 20-524
a) Neither monitor display nor rear working lamp light up ................................................. 20-524
b) Rear working lamp lights up but monitor display does not light up ............................ 20-524
c) Monitor display lights up but working lamp does not light up ...................................... 20-524
M-12 Abnormality in transmission cut-off .......................................................................................... 20-526
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change ...................................................................... .20-526
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out
but cut-off function is actuated when pedal is depressed ............................................... 20-526
c) When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated ..................................................................................... 20-526
WA800-3
d) Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF). ........................................................................... 20-526
e) Monitor display lights up (transmission cut-off switch turned ON),
but cut-off function is not actuated .................................................................................... 20-527
M-13 Abnormality in low idling selection .......................................................................................... 20-528
a) When monitor switch (Low idle selector switch) is turned ON, the low idling speed
does not rise and display does not change.. ..................................................................... 20-528
b) When the monitor switch (Low idle selector switch) is turned ON, the monitor
lights up but the low idling speed does not rise .............................................................. 20-528
c) When the monitor switch (Low idle selector switch) is turned OFF, the monitor
goes off but the low idling speed does not lower.. ......................................................... .20-529
M-14 Abnormality in emergency steering normal display ............................................................... 20-530
Emergency steering normal display does not light up.. ......................................................... 20-530
M-15 Abnormality in emergency steering actuation display .......................................................... .20-531
a) Emergency steering actuation display does not light up.. .............................................. .20-531
b) Emergency steering actuation display stays lighted up .................................................. .20-531
M-16 Abnormality in parking brake dragging warning.. ................................................................... 20-532
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp
flashes even when directional lever is at N ....................................................................... 20-532
b) When parking brake is applied, buzzer does not sound and CAUTION lamp
does not light up even when directional lever is at position other than N .................. 20-532
M-17 Abnormality in parking brake dragging warning (When joystick steering model (OP)) .... 20-534
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp
flashes even when directional lever is at N ....................................................................... 20-534
b) When parking brake is applied, buzzer does not sound and CAUTION lamp
does not light up even when directional lever is at position other than N .................. 20-534
M-18 When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated
continuously, or they are not actuated ..................................................................................... 20-536
a) Actuated continuously .......................................................................................................... 20-536
b) Not actuated .......................................................................................................................... 20-536
M-19 Abnormality in buzzer.. ............................................................................................................... 20-537
a) Buzzer does not sound when starting switch is at ON (for 3 seconds)
(during self-check). ................................................................................................................ 20-537
b) Buzzer always sounds .......................................................................................................... 20-537
M-20 Condition of monitor switches is not stored in memory.. ..................................................... .20-538
M-21 Abnormality in failure display mode.. ....................................................................................... 20-539
a) Does not enter failure display mode .................................................................................. 20-539
b) Count for time elapsed since failure in failure display mode does not advance.. ....... 20-539
M-22 Buzzer is not made to sound by transmission & joystick steering controller.. ................... 20-540
M-23 Abnormality in auto-greasing system ....................................................................................... 20-541
a) Forced greasing cannot be carried out .............................................................................. 20-541
b) Monitor display flashes rapidly (2 times/set) .................................................................... 20-541
c) When no more grease remains, monitor display flashes rapidly (2 times/set) ........... 20-541
d) Monitor display flashes slowly (1 time/set). ...................................................................... 20-542
e) Monitor display goes out.. ................................................................................................... 20-542
M-24 Failure code is not sent to main monitor (abnormality in network) (OP) ............................ 20-543
20-502 WA8003
TROUBLESHOOTING TROUBLE DATA DISPLAY
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2. Display of failure action code

This code informs the operator directly of the ExamPle:When action code CALL is
abnormality, and takes action, such as stopping displaied
the machine immediately.
There are three types of action code: EOO, EOI + / SPEED \
CALL (EOI and CALL are displayed alternately),
and CALL. If a failure occurs suddenly, one of
these codes is shown on the speedometer dis-
play.
3. Failure code and time elapsed since failure

TOW01377
The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which
controller has failed, so carry out troubleshoot- ExamDle:When failure code “4l”has
ing for the applicable controller. occurred 27 hours before
For failure that have occurred and been reset, Failure code
the failure code and the time elapsed since fail-
ure are displayed to make it easy to check fail-
ures that are not occurring at present.
The failure codes for failures that are now oc-
curring flash, and the codes for failures that are
not occurring light up.
For details of the method of operating and trans-
ferring data to the trouble data display mode,
see STRUCTURE AND FUNCTION for the main
monitor.
Note: If the engine is not stopped, it is impos-
sible to switch to the trouble data dis-
play mode, so the codes for failures
which can only be detected when the
engine is operating light up.
For the correspondence between the failure
codes for each controller and the failed system,
see Item 4.
WA800-3 20-503
TROUBLESHOOTING TROUBLE DATA DISPLAY
Actior
code
r-r Transmission control system r Joystick control system 4ctior
buzzer
I Action by
operator
Problem system Action of machine Problem system qction of machine
travel speed gearshifting not
Normal opera-
sensor system carried out
tion possible at
(changes to
manual
manual
gearshifting)

Normal opera-
sensor system Auto mode. (OP)
EOO No tion possible at
manual
Breakage, short Set to neutral

Normal opera-
circuit with position. (Can
tion possible at
chassis ground be changed to
- wheel steering
or short circuit steering wheel
mode
of joystick FNR mode.)
signal line

-
circuit with GND, (Judges control-
Stop travelling
F, R solenoid Become neutral
immediately,
signal system and cannot
Turn starting
CALL - Yes switch OFF,
short circuit with (Output off)
Call service
GND, short
after action
circuit
above.
1st. 2nd, 3rd Become neutral
short circuit with (Output off)
GND, short
circuit
20-504 WA800-3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR

SYSTEM
20-506 WA800-3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
fl This circuit diagram is made by extracting the part of the main monitor system from the general
circuit diagram.
WA800-3 20-507
5
TROUBLESHOOTING M-l
M-l Main monitor does not work
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
YES
1
Is voltage Defective contact or

between LO5 (I), - disconnection in wiring
2 YES Repair or
(2) - (3) normal? ~ j harness between LO5
Is resistance replace
~ between LO5 (female) (1). (2) and FS2
*20-30V (female) (9)
- (female) (3) and -
* Turn starting NO chassis ground
normal? Repair or
-Turn starting NO replace
harness between LO5
switch OFF. (female) (3) and LR4
. Disconnect L05.
(male) (3)
* Max. 1 R
M-l Related electrical circuit diagram

Buzzer
L42
Maintenance monitor
I Battery relay
L18 (040 16) I
I \ I
LR3 (SWP16)
I
Main monitor t
FSl (L2)
LR5 (L2)
LO7 (040 12) L

Battery
Slow blow fuse
TWW01760
20-508 WA800-3
TROUBLESHOOTING M-2
M-2 When starting switch is turned ON (within 3 seconds) and engine

is started immediately, all lamps stay lighted up
t Always connect any disconnected connectors before going on to the next step.
Cause Remedy
I YES Defective main monitor

1 When engine is 11
started, is voltage
between LO5 (41 and - Defective contact or
chassis ground disconnection in wiring
Repair or
normal? harness between LO5
replace
.20-30V NO (female) (4) and L57
. Start engine. (female) (3)

El4
Transmission 6 Neutral relay Exchange joystick relay (KES~ 2)
joystick steerlne L57 L66
controller 1 I I ,B
I
c2 (MIC21) ,D
/
El6
(KESl 2)
Maintenance monitor 73
1 I
I Ll9 (0408) --3
LR3 (SWP16)
I -I El6
Main monitor (KES1 2)
I t
73
LR4 (M4) ZI
/’
+
I I El7
E06 (X2) (KESl 2)
DIrectional & shift switch
J
-3
@I
-3
E07 (X2)
Starting swtch
TWW01761
WA800-3 20-509
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly

* When error code is not displayed.
1; Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
* Check that the gap between the speed sensor and gear is normal.
Cause Remedy
1 YES
Is resistance
between LO7
(female) (II- (2)
normal? Repair or
harness between LO7
*500-l kQ NO replace
(female) (I), (2) - BCOI
. Turn starting (female) (1). (2)
switch OFF.
* Disconnect L07.
Transmission &
joystick steering
controller Main monitor
I I
C5 (MIC17) LO7 (04012)
3 Speedometer (+I
3 Speedometer (-1
CBLl
(SWP8) BCOl (X2) Speed sensor
@ 3
a 3
TWW01748
20-5 10 WAND3
TROUBLESHOOTING M-4
M-4 Abnormality in shift indicator
Ir Check that error code is not displayed.

* Check that the transmission shifts.
Ir The steering system must be in the steering wheel mode.
a) Displays N even when directional lever is at F
Cause Remedy
I

Is voltage
between LO8 (7)
and chassis
ground normal? Repair or
harness between LO8
*20-30V NO replace
(female) (7) and LO4
- Turn starting (female) (2)
switch ON.
* Directional lever: F
b) Displays N even when directional lever is at R

Cause Remedy
1 YES
Is voltage
between LO8 (8)
and chassis
_._ harness between LO8
*20-30V NU replace
(female) (81 and LO4
*Turn starting (female) (4)
switch ON.
* Directional lever: R
WA800-3 20-511
TROUBLESHOOTING M-4
c) Does not display N even when directional lever is at N (Display 1st - 3rd).

Is voltage
between LO8 (7)
source in wiring harness
or (8) and chassis
between LO8 (female) (7)
and LO4 (female) (2) or
* Max. 1 V NO replace
harness between LO8
. Turn starting (female) (8) and LO4
* Set directional
lever to N.
d) Does not display 1st even when gear shift lever is at 1st position (Directional lever is at F or R
position).
Cause Remedy
I YES
Is voltage between
LO5 (female) (12)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between LO5
*20-30V NO replace
(female) (12) and Cl
* Turn starting (female) (3)
switch ON.
. Set gear shift lever
to 1st.
* Set directional
lever to F or R.
el Does not display 2nd even when gear shift lever is at 2nd position (Directional lever is at F or R
position).
Cause Remedy
1 YES
Is voltage between
LO5 (female) (12)
Repair or
harness between LO5
* 20 - 30 v NO reolace
. Turn starting (female) (10)
switch ON.
* Set gear shift lever
to 2 nd.
- Set directional
lever to F or R.
20-512 WA800-3
TROUBLESHOOTING M-4
f) Does not display 3rd even when the gear shift lever is at 3 rd position (Directional lever is at F
or R position).
Cause Remedy
1 YES
Is voltage between
LO5 (female) (14)
Repair or
harness between LO5
*20-3ov NO replace
switch ON.
- Set gear shift lever
to 3 rd.
. Set directional
lever to F or R.

Transmission &
Directional 6 shift switch joustlck steering
ControIIer
r
m
Directional F
Directional R
System netnark
Directional N
Main monitor
3rd solenoid
2nd solenoid
LO7 (040 12.1 LR6 (X4)

Eatterv
GND
I II II II iI
LO8 (0408)
Net work (tl
TWW01763
WA8003 20-513
TROUBLESHOOTING M-5
M-5 High beam display does not light up

+ Always connect any disconnected connectors before going on to the next step.
* Before starting troubleshooting, check that the lamp bulb is not blown.
2 YES
Is resistance II I
YES between LO6
- (femalel (131and - Defective contact or
1
~ chassis ground disconnection in wiring
Is voltage normal? Repair or
harness between LO6
between LO6 (12) _ . ~a~, 1Q NO replace
and chassis * Turn starting switch OFF. (female) (3)
ground normal? * Disconnect L06.
* Dimmer switch: Hi beam Defective contact or
- Repair or
*20-30V disconnection in wiring
* Turn starting NO replace
harness between LO6
switch ON. (female) (12) and FS2
(female) (2)
Main monitor Fuse (II
Hiah beam (+)
Hish beam (-)
= I
RH head lamp
FOl HEAD
L H head lamp
TWW01764
20-514 WA800-3
TROUBLESHOOTING M-6
M-6 Turn signal display does not light up

Ir Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the
monitor is not blown.
a) L.H. turn signal display does not light up
v
1 YES Defective main monitor Replace
Is voltage
between LO6 (I 4)
and chassis
harness between LO6
replace
. Repeats 0 V and NO (female) (14) and LO3
20-30V. (female) (4)
*Turn starting switch ON.
*Turn L.H. turn signal ON.
b) R.H. turn signal display
1 YES
does not light up
---I-=
Is voltage
between LO6 (15)
and chassis
harness between LO6
replace
* Repeats 0 V and NO (female) (15) and LO3
20-30V. (female) (3)
-Turn starting switch ON.
- Turn R.H. turn signal ON.
Maln monitor
I I R. H. turn sianal
LO6 (040 16) LRl (S12) FRl (S10) F02 (M3)
@- a- - -3
@--- a--- -3
F03 (M3)
‘31 t_l )d 1 i I la
L. H. turn signal
TWW01765
WA800-3 20-515
TROUBLESHOOTING M-7
M-7 Abnormality in parking display
a) Parking lamp display does not light up Cause Remedy
3 YES
iKHP Defective contact or

harness between F13 Repair or
YE * Max. 1 !A NO (female) (2) and chassis replace
. Turn starting ground
1 ground normal? switch OFF.
LJ
Is resistance . Disconnect F13. Repair or
between F13 . Turn starting replace
NO harness between LO6
(male) (1) and (2) switch ON. (female) (11) - F13
normal? * Turn oarkino (female) (1)
* Max. 1 R switch ON. -
Defective parking brake Replace
* Disconnect F13. VO indicator switch
. Turn starting
switch ON.
* Turn parking
switch ON.
I
b) Parking lamp display stays lighted up Cause Remedy
2 YES
Is voltage
YES between F13 (I)
1 and chassis Short circuit with power
ground normal? source in harness Repair or
between LO6 (female) replace
I * Turn starting (11) - F13 (female) (I)

switch ON.
- Max. 1R
*Turn parking switch OFF. Defective parking brake
. Disconnect F13. NO indicator switch
* Turn starting
switch ON.
*Turn parking
switch OFF.
Main monitor
1 Parking brake
LO6 (04016) FL2 (SWP6) F-13 (X2) indicator switch
Parking brake signal
TWW01766
20-516 WA800-3
TROUBLESHOOTING M-8
M-8 Abnormality in preheating system
j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a) Does not carry out preheating

Sr Check that the water temperature is below 5°C.
(1) Monitor display also does not light up
I Cause Remedy1
2 YES
Is resistance
YES between LO5
~ 1 chassis ground Short circuit with power
source in harness Repair or
Is resistance
2NO between LO5 (female) (7) replace
between E05 (male) _ * Min. 4 kR
(1) and chassis *Turn starting - E05 (female) (1)
ground normal? switch OFF.
- . Disconnect L05. Defective engine water
*Min. 4 kQ Replace
. Turn starting NO temperature sensor
switch OFF.
. Disconnect E05.
(2) Only monitor display lights up
1 Cause Remedy
3 YES harness between Ell, Repair or
Is voltage El3 and terminal B of replace
YES between Ell, El3 _ starter
2 and chassis
- ground normal? Defective preheating
Is voltage between _ ~ Replace
YES terminal of electric .20-30V NO relay
- intake air heater and - . Turn starting
1 chassis ground
switch ON.
P normal?
Defective electric intake
Is voltage *20-30V Replace
NO air heater
between ElO, El2 - * Turn starting
- L56 (3) normal? switch ON.
I
*20-3ov Repair or
. Turn starting replace
switch ON.
WA800-3 20-517
TROUBLESHOOTING M-8
b) Always carries out preheating for 45 seconds

* Check that the water temperature is above - 10°C
I Cause 1 Remedy
Repair or
harness between LO5
reolace
(female) (7) - E05
(1) and chassis
(female) (1)
ground normal?
I I
* Max. 9 kR Defective engine water
Replace
*Turn starting temoerature sensor
switch OFF.
* Disconnect E05.
c) Preheating stays on
Cause Remedy
3 YES Defective preheating

Does preheating Replace
relay
YE
PIP
2 Short circuit with chassis
. Turn starting ground in wiring harness Repair or
switch OFF.
Ioes preheating .20-30V NO between LO6 (female) (4) replace
- Disconnect L06.
* Turn starting - L56 (female) (2)
h
switch ON. Short circuit with power
. Turn starting supply in wiring harness Repair or
switch OFF. IO between L56 (female) (3) replace
* Remove - ElO, El2 or L56
preheating relay. (female) (3) - LO5
(female) (19)
2048 WA800-3
TROUBLESHOOTING M-8
d) Preheating time becomes shorter, or there is variation
Cause Remedy
3 YES
Is voltage
YES between LO5 (3)
I- and chassis
2
Defective contact of
Is resisrance - ground normal?
Repair or
wiring harness between
YES between LO5 . Max. 0.1 V NO replace
- (female) (7) and - LO5 (3) -chassis ground
. Turn starting
1 chassis ground as
switch ON. Short circuit with chassis
shown in Table l?
ground or defective
between E05 (male) * See Table 1. Repair or
contact of wiring harness
(11 and chassis - Turn startina NO replace
ground as shown in 1 switch OFF.- - E05 (female) (1)
(kble1? [
. See Table 1.
Defective engine water Replace
* Turn starting
temperature sensor
switch OFF.
Table 1 (Tolerance + 0.5 kQ)

Temperature PI) -30 -20 0 20 40 60 80 90
Resistance value (kR) 19.5 12.1 5.11 2.39 1.21 0.695 0.381 0.295
WA800-3 20-519
TROUBLESHOOTING M-8
c -
I I
*k
LO7(04012)
piixzyj
R03
IKE91 2) (KESl 2) startinmotor
TWW01767
20-520 WA800-3
TROUBLESHOOTING M-9
M-9 Night lighting does not light up
Sr Always connect any disconnected connectors before going on to the next step.
* Before starting troubleshooting, check that the lamp bulbs are not blown.
j, Check that fuse I-6 is normal. If it is blown, check for a short circuit with the chassis ground in the
wirina harness between FS2 (female) (5) and LO5 (female) (16).
Cause Remedy
1 YES Defective main monitor Replace

Is voltage
between LO5 (16)
and chassis
harness between LO5
.20-30V NO (female) (16) and FS2
switch ON.
*Turn small lamp
switch ON.
Main monitor
Night Ilshtins
R. H. clearance GO1
R. H. sma I I lamp
lamp F02 (M3) GRl (~6)
/
a
@)
E
\
L. H. clearance
TWW01768
WA800-3 20-521
TROUBLESHOOTING M-10
M-10 Abnormality in front working lamp
* Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
* Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor front working lamp light up
Cause Remedy
YES harness between L60 Repair or
(female) (1) - LO5 replace
(female) (17), CL1
(female) (7)
1 YES Defective front working
Replace
Is voltage 3 lamp relay
between L60 (1) _ Is voltage
and chassis YES between L60 (6)
ground normal? and chassis 4 YEI
ground normal? ~ Is voltage - Defective main monitor Replace
- Max. 1 V
2-
* Turn starting ~ -Max. 1 V between LO6 (1)
switch ON. Is voltage between NO and chassis
-Turn starting disconnection in wiring
_ L60 (2), (4). (5) and _ switch ON. ground normal?
NO chassis ground harness between LO6 Repair or
normal? * 20 - 30 v NC (female) (I) and L60 replace
- Turn starting (female) (6)
*20-30V
. Turn starting
switch ON. disconnection in wiring Repair or
NO harness between L60 replace
(female) (2), (41, (5) and
FS5 (female) (I)
I
b) Working lamp lights up but monitor display does not light up
Cause Remedy
YES
Replace
il Defective main monitor
between LO5 (17)

Repair or
harness between LO5
*20-30V NO replace
* Turn starting (female) (I)
switch ON.
cl Monitor display lights up but front working lamp Cause Remedy

does not light up
harness between L60
(female) (1) - CO3 Repair or
(female) fl), CO4 (female) replace
(l), or L60 (female) (3) -
WORK (female) (I), or
blown working lamp bulb
20-522 WA8003
Front right WORK Front right

Front workino lame relay working IamP
FOl (M4) (M2)
r-mt--b/l-f&
I___
fin
nnn 1
F02 043)
,I
C
Front left
FL1 El2
WORK Front left
-Da
LO6 (04016)
working lamp
Fronl
rorkino law outut LRl (SWP14) GR1 (SWPlP)
I I I I I 1 I I GO7 (M2) workina
Rear right
working lamp
GO6 (“2) workinoIamp
L61
Rear warktna lamp rely
TWW01769
WA800-3 20-523
TROUBLESHOOTING M-II
M-II Abnormality in rear working lamp
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Before starting troubleshooting, check that the monitor 1ightin.g is lighted up.
a) Neither monitor display nor rear working lamp light up
Cause Remedy
YES harness between L61 Repair or
(female) (I) - LO5 replace
(female) (IS), LRI
(female) (12)
YES Defective rear working
Is voltage , I lamp relay
Replace
between L61 (1)
and chassis
ground normal?
, Defective main monitor Replace
*20-30V
. Turn starting
Is voltage between Defective contact or
switch ON.
L61 (Z), (4), (5) and disconnection in wiring
harness between LO6 Repair or
* Max. 1V NO (female) (2) and L61 replace
I
*20-30V
* Turn starting
switch ON. disconnection in wiring Repair or
NO harness between L61 replace
(female) (2), (4). (5) and
FS5 (female) (2)
b) Rear working lamp lights up but monitor display does not light up
Cause Remedy
1 YFS
between LO5 (18)

Repair or
harness between LO5
-2O-30V NO reolace
switch ON.
cl Monitor display lights up but rear working lamp

Cause 1 Remedy 1
does not light up
harness between L61
(female) (I) - GO3 (female) Repair or
(l), GO7 (female) (l),or L61 replace
(female) (3) - GO2 (female)
(1). GO8 (female) (I), or
blown working lamp bulb
20-524 WA800-3
TROUBLESHOOTING M-II
M-l 1 Related electrical circuit diagram
Front right WORK Front right

Front working IamP relay worklno Iam1
FOl (M4) (M2)
L60
Front left CL1

El21 F,O4!U4,
WORK Front left
-ix
Main monitor
Fuse (II)
FS5 (M6)
LO6(04016) Rear right

D
1
G07 tM2) working lamp
Rear rieht
6 6
L61
Rear workins Iamp relay
WA800-3 20-525
M-12 Abnormality in transmission cut-off

sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a) When monitor switch (transmission cut-off switch) is pressed,

Cause Remedy
cut-off function is not switched and display does not change I
b) When monitor switch (transmission cut-off switch) is OFF,

monitor display goes out but cut-off function is actuated when
pedal is depressed
1 YES Repair or
harness between LO6
Is voltage replace
(female) (3) and C5
between LO6 (3) (female) (6)
and chassis
ground normal?
* Max 1 V NO
* Turn starting
switch ON.
- Disconnect L12.
-
cl When monitor display is turned off (transmission cut-off switch
Cause Remedy
turned OFF), cut-off function is always actuated
2 YES harness between L12 Repair or
Is resistance (female) (1) and C5 replace
YES between L12 (female) (6)
- (female) (2)and -
~
1
chassis ground Defective contact or
Is resistance nOrmal? disconnection in wiring Repair or
between LIZ _ * Max. 1 0 harness between L12 replace
NO
(male) (1) and (2) * Turn startinq (female) (2) and chassis
normal? switch OFF.- ground
* Disconnect L12. Defective transmission
. Max. 1 R Replace
* Turn starting NO cut-off switch
switch OFF.
* Disconnect L12.
I
d) Cut-off function is always actuated regardless of monitor Cause Remedy
display (transmission cut-off switch ON or OFF)
YES Defective transmission FIeplace

controller
Fiepair or
harness between C5
r,eplace
(female) (3), L12 (female)
(1)
20-526 WA800-3
e) Monitor display lights up (transmission cut-off switch turned

ON), but cut-off function is not actuated
Cause Remedy
YES Defective transmission

Replace
cut-off switch
4
function work
YES
2
disconnected?
Does cut-off
* Disconnect L12.
function work
. Turn starting Defective transmission &
NO when LO6 is 3 YES
switch ON. joystick steering Replace
disconnected? _ Is voltage controller
* Disconnect L06. _ between C5 (6)
NO and chassis Short circuit with chassis
. Turn starting
ground normal? ground in harness
switch ON. Repair or
. Disconnect L12. NO replace
- C5 (female) (61, L12
. Turn starting (female) (I)
switch ON.
*20-30V
Transmission &
joystick steering
controller
C5 (MIC;7)
Transmission
E
cut-off switch
Transmission
Main monitor cut-off switch
1 (OFF at left
LO6 (04016) L12 (X2) brake depressed)
Transmission
a -3
cut-off switch
-3
I LR5 (X4)
3
TWW01771
WA800-3 20-527
M-13 Abnormality in low idling selection
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a) When monitor switch (Low idle selector switch) is turned Remedy

Cause
ON, the low idling speed does not rise and display does not
change
b) When the monitor switch (Low idle selector switch) is turned

ON, the monitor lights up but the low idling speed does not
rise
Cause Remedy
YES Defective low idle

Replace
selector switch
4 YEI
- GotoA
Is voltage between
YES LO6 (female) (7)
disconnection or short
3 and chassis
replaced with other circuit with chassis ground
- ground normal? Repair or
Is voltage in wiring harness between
YES between L50 (1). .20-3ov NC L50 (female) (2) and LO6 replace
- Replace low idle
(3) and chassis *Turnstarting switch ON. (female) (7)
selector relay 2 -Turnlow idle selector
_ ground normal?
I?!zL-I
(L50) with other switch ON. Defective contact or
Is resistance
relay of same *20-3ov disconnection or short Repair or
between BOl circuit with chassis ground
- *Turn starting NO replace
type. 1 (male) (I) and (2) switch ON. in wiring harness between
*Start engine. N normal?
*Turn low idle fuse I (11) and L50 (female)
(1). (3)
selector switch
ON. Defective low idle Replace
switch OFF. NO selector solenoid
. Disconnect BOl.
6 YES
1 Is resistance II
(female) (5) and l-l
1;h&sground 11 Short circuit with chassis
From
- Min. 1 MR NO between L50 (female) (5) replace
. Turn starting and BOl (female) (I)
switch OFF. Defective contact or
* 19-23R . Disconnect L50 and BOI. disconnection in wiring Repair or
*Turn starting hIO harness between L50 reolace
. Disconnect L50. ground
20-528 WA800-3
c) When the monitor switch (Low idle selector switch) is turned

OFF, the monitor goes off but the low idling speed does not
lower
Cause Remedy
Defective low idle

selector switch
I -
Does condition Short circuit with power
become normal 3 YES source in wiring harness Repair or
when L50 is Is voltage between between L50 (female) (5) replace
replaced with other YES LO6 (female) (7) and BOI (female) (I)
relay Of *ame type?
2 and chassis
* Replace low idle ground normal?
selector relay Is resistance
Defective main monitor Reolace
(l-50) with other _ between BOI . Max. 1 V NO
relay of same NO (male) (1) and (2) . Turn starting switch ON.
type.
* Start engine.
. Turn low idle
normal?
.19-23R
*Turn starting
I* Turn low idle selector
switch OFF. Defective low idle
selector solenoid
Replace
NO
selector switch switch OFF.
OFF. - Disconnect BOl.
M-13 a), b), c) Related electrical circuit diagram
Maln monitor
LO6(04Oi6)
Low idling Low idl ina

selection select ion
relay L50 LRl BP1 BOl solenoid
m ccr) ICI r) c.I,.,\ Fuse(I)
TWW01772
WA800-3 20-529
M-14 Abnormality in emergency steering normal display
Emergency steering normal display does not light up
Cause Remedy
- YES
I
Iand chassis
ground normal?
I
harness between LO5
Repair or
replace
*20-30V NO
(female) (IO) -chassis
*Turn starting
switch ON.
M-l 4 Related electrical circuit diagram
LR4 (M4)
Main monitor
I
LO5 (04020)
Emergency
LR2 (SWP12) ROl (X2) steering switch
Emergency steering a .D
TWWOl773
20-530 WA800-3
M-15 Abnormality in emergency steering actuation display
a) Emergency steering actuation display does not light up
r Cause Remedy
2 YES
Is resistance II
YES between LOS
(female) (11) and -
1 chassis ground Short circuit with chassis
Is resistance normal? ground in harness Repair or
between ROI . Min. 1 MR NO between LO5 (female) replace
(male) (I) and (2) *Turn starting switch OFF. (II) and ROI (female) (1)
1 normal? * Disconnect LO5 and ROl.
. Min. 1 MD i[ Defective emergency
Replace
* Turn starting NO steering indicator switch
switch ON.
* Disconnect ROl.
b) Emergency steering actuation display stays lighted up
F-
Remedy
2 YES
Defective main monitor
Is voltage
YES between LO5 (I I)
1 I
Is resistance Repair or
harness between LO5
between ROI -2O-30V NO replace
(female) (1 I) and chassis
(male) (I) and (2) *Turn starting ground
switch ON.
* Max. 1 R Defective emergency
Replace
steering indicator switch
-Start engine. NO
* Disconnect ROl.
.I5 Related electrical circuit diagram
LR4 (M4)
Main monitor
I
LO5 (04020)
Emersencv
Emergency steering GN . LR2 (SWP12) ROl (X2) steering switch
Emergency steering 3
WA800-3 20-53 1
M-16 Abnormality in parking brake dragging warning

a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at N
Cause Remedy
1 Defective main monitor Replace

Is voltage
between LO5 (8)
and chassis
1ground normal? harness between LO5
Repair or
NO replace
.20-30V (female) (8) - LO4
switch ON.
* Directional lever: N
b) When parking brake is applied, buzzer does not sound and CAUTION lamp does not light up even
when directional lever is at position other than N
+ Check that the synchronous flash is normal.
Cause Remedy
‘ES

between LO5 (8) supply in wiring harness
2 YES between LO5 (female) (8) Repair or
- LO4 (female) (3). or replace
Is resistance
defective directional
*o-5v between LO5 u lever
* Turn starting NO (male) (8) and (3)
switch ON. normal?
* Directional lever:
.3kR-4kR NO
Other than N
* Turn starting
switch OFF.
* Disconnect L05.
20-532 WAND3
Main monitor
Directional 6 shift switch
I rn.3”r,r,;,\ LO4 (SWP 14)

I -
TWW01775
WA800-3 20-533
M-17 Abnormality in parking brake dragging warning (When joystick

steering mode (OP))
J, Always connect any disconnected connectors before going on to the next step.
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at N
Cause Remedy
See troubleshooting of
1 YES -
transmission controller
system (T mode)
Is S-net has any
trouble?
Repair or
Defective main monitor
*20-30V NO replace
. Turn starting
switch ON.
. Directional lever: N
b) When parking brake is applied, buzzer does not sound and CAUTION lamp does not light up even
when directional lever is at position other than N
I
Ir Check that the synchronous flash is normal.
Cause Remedy
1 YES See troubleshooting (T- Repair or

I II mode) for transmission replace
Is S-net has any
trouble?

* Max. 1 V NO
-Turn starting
switch ON.
F or R
20-534 WA800-3
Transmission &
joystick steering
Directional & shift switch
controller
I
C3BtO4016)
Neutral sIgnal
Main monitor
LO8 (0408)
To management
monitor (OP)
TWW01776
WA800-3 20-535
M-18 When parking brake dragging warning is given, buzzer and

CAUTION lamp are actuated continuously, or they are not actuated
a) Actuated continuously
Cause Remedy
YES
1
Does buzzer stop

and lamp go out? Defective maintenance
Reolace
monitor (sub monitor)
* Turn starting Does buzzer stop
switch ON. NO and lamp go out? Defective contact or
- Connect LO7 disconnection in wiring
Repair or
(male) (6) to harness between LO7
* Turn starting NO (female) (6) and L19
replace
chassis ground.
* Connect L19
(female) (5) to
chassis ground.
F
b) Not actuated
Cause Remedy
YES
1
Do buzzer and
lamp work? 2 YES Defective maintenance
Replace
monitor (sub monitor)
- Turn starting Do buzzer and
switch ON. NO lamp work? Short circuit with power
- Disconnect L07. source in harness Repair or
- Turn starting NO between LO7 (female) (6) replace
* Disconnect L19.
Main monitor Maintenance monitor

I I
LO7 (04012) L19 (0408)
Flicker signal 3 Flicker signal
TDW01427
20-536 WA800-3
M-19 Abnormality in buzzer
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
YES Repair or
1 I I harness between LO6
replace
II I (female) (8) and L43
b-nale) (1)
Does buzzer
sound? 2 YES
Defective buzzer Replace
_ Is voltage between
* Turn starting L42 (female) (1)
NO and chassis Defective contact or
switch ON.
* Contact L43
L I harness between L42
Repair or
(female) to *20-30V replace
NO (female) (I) and FS2
chassis ground. . Turn starting (female) (9)
switch ON.
b) Buzzer always sounds

Cause Remedy
YES
Does buzzer stoo III

See troubleshooting (K
mode) for maintenance -
monitor

switch ON. -
ground in harness iepair or
- Disconnect L06. No disconnected?
between LO6 (female) (8) eplace
and L43 (male) (1)
~zz-j~[~
Defective buzzer qeplace

*Turn starting NO
switch ON.
* Disconnect L43.
Maintenance monitor Fuse (I)

FS2 (S12)
t IL
F?y&
Buzzer
Main monitor
I ld1
L43
TWW01777
WA800-3 20-537
M-20 Condition of monitor switches is not stored in memory
I Cause Remedy
1 YES
between LO7 (I 0)
Repair or
harness between LO7
NO (female) (IO) and LO9 replace
switch ON.
StartIns switch
20-538 WA800-3
M-21 Abnormality in failure display mode
a) Does not enter failure display mode r

Cause Remedy
YES
I Is voltage
between LO5 (5)
and chassis
ground normal?
between LO5 (female) (5) Repair 01
so-5v NO -alternator terminal R, 01 replace
. Turn starting defective alternator
switch ON.
b) Count for time elapsed since failure in failure display mode Cause
does nor advance
YES
between LO5 (5) Defective contact or

ground normal? harness between LO5 Repair or
*20-30V NO (female) (5) -alternator
* Start engine. i terminal R, or defective
alternator
Main monitor Alternator
LR3 (SWP16) ERl (SWP12)

a @
Maintenance monitor
L18 (04Oi6)
Battery charge
~22 (KES~ 2)
Service meter
TWW01779
WA800-3 20-539
M-22 Buzzer is not made to sound by transmission & joystick steering

controller
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
2 YES
transmission controller Replace
system (T mode)
harness between LO8 replace
when C2 (female) (female) (6) and C2
(10) is grounded to
(female) (IO)
chassis?
*Turn starting Defective main monitor Reolace

switch ON. NO
- Disconnect Cl.
- Connect Cl
(female) (2) to
chassis ground.
Transmission &
joystick steering
Main monitor controller
I I
LO8 (0408) C2 (MIC21)
Buzzer ON
TWW01780
20-540 WA8QG3
M-23 Abnormality in auto-greasing system (OP)
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a) Forced greasing cannot be carried out

Cause I Remedy
See “Handling auto-

2 YES oreasinq svstem” in -
Operation and
Is voltage
Maintenance Manual
YES between GRE (1)
1 and chassis Defective contact or
- ground normal? disconnection in wiring Repair or
Is voltage replace
harness between LO6
between LO6 (5) _ - Max. 3 V NO
(female) (5) and GRE (1)
and chassis . Turn starting switch ON.
ground normal? . Turn auto-greasing
P switch ON.
. Max. 3 V Defective main monitor Replace
. Turn starting NO
switch ON.
. Turn auto-greasing
switch ON.
b) Monitor display flashes rapidly (2 timeskec) Cause Remedy
YES Defective main monitor Replace

1
Is voltage
and chassis 2 YES disconnection in wiring Repair or
ground normal? harness between LO8 replace
Is voltage
.20-3ov between GRE (3)
. Turn starting NO and chassis See “Handling auto-
switch ON. ground normal? greasing system” in -
Operation and
.20-30V NO
Maintenance Manual
. Turn starting
switch ON.
c) When no more grease remains, monitor display flashes Cause Remedy

rapidly (2 times/se4
YES Defective main monitor Replace

1
Is voltage
and chassis 2 YES disconnection in wiring Repair or
ground normal? harness between LO7 replace
Is voltage
*20-30V between GRE (2)
. Turn starting NO and chassis See “Handling auto-
switch ON. ground normal? greasing system” in -
Operation and
* 20 - 30 v NO
Maintenance Manual
. Turn starting
switch ON.
WA800-3
20-541
d) Monitor display flashes slowly (1 time/set)

Remedy 1
Confirm that grease is not empty.

greasing system” in -
Operation and
Maintenance Manual
e) Monitor display goes out

Cause Remedy
YES
1 I
(female) (11) and GRE replace
(female) (2)
greasing system” in
*2-3V NO Operation and
* Turn starting Maintenance Manual
switch ON.
* Disconnect GRE.
Table I (Relationship between input signal and display)
When auto-greasing is installed, remove

Main monitor
and connect auto-greasing connector
GRE(SWP6)
3
3
LO7 (040 12) 3 0
I \ I
I I Auto greasing A INPUT)p
Fuse(1) FS2 (S12)
3
I ’
I ,
I I
LO8 (0408)
\ -1
I1 Auto greasing B INPUT
Fuse aI) FSfi (M4) 1 1 194 CM41
TWW0178i
20-542 WA800-3
M-24 Failure code is not sent to main monitor (abnormality in

network) (OP)
* Set dipswitch 3 at the rear of the main monitor to “F”.
Cause Remedy
transmission & joystick
controller system (T mode)
3 YES or defective control -
I Isresistance II monitor (OP)
(female) (1). (3) - C3B replace
(female) (4). (12)
- Defective contact or
Is voltage disconnection in wiring Repair or
* Repeats 0 V and harness between LO8
between LO8 replace
- 12v. NO (female) (11, (3). LO8
(male) (I) and (2)
* Turn starting (female) (2), (4) - LMl
normal?
~ switch ON. (male) (5). (6)
- Repeats 0 V and . Disconnect LMl.
12 v. Defective main monitor Replace
NO
* Turn starting
switch ON.
* Disconnect L08.
Transmission &
joystick steering
controller
LMl (SlO)
lain monitor
I
LO8 (0408)
System network
TWW01782
WA800-3 20-543
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
Electrical circuit diagram for maintenance monitor.. ......................................................................... 20-602

K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not light up
for 3 seconds, maintenance monitor does not work .............................................................. 20-604
a) No lamps on maintenance monitor light up ..................................................................... 20-604
b) Some lamps do not light up ................................................................................................ 20-604
K- 2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out (even after 3 seconds). ................................................................................ 20-605
K- 3 When engine is started immediately after starting switch is turned ON (within 3 seconds),
no lamps on maintenance monitor go out .............................................................................. 20-606
K- 4 When starting switch is turned ON (engine stopped), CHECK items flash ......................... 20-607
a) Engine oil level display flashes.. ......................................................................................... 20-607
b) Engine water level display flashes.. .................................................................................... 20-608
K- 5 When starting switch is turned ON (engine started), CAUTION items flash ....................... 20-609
a) Engine oil pressure display flashes .................................................................................... 20-609
b) Battery charge display flashes ............................................................................................. 20-610
c) Brake oil pressure display flashes ...................................................................................... 20-611
d) Air cleaner (R.H.) clogging display flashes ....................................................................... .20-613
e) Air cleaner (L.H.) clogging display flashes.. ....................................................................... 20-614
f) Transmission oil filter display flashes. ............................................................................... 20-615
K- 6 CAUTION items are flashing but buzzer does not sound ...................................................... .20-616
K- 7 There is no abnormality in monitor display but caution buzzer sounds ............................. 20-617
K- 8 CAUTION items are flashing but neither CHECK lamp nor CAUTION lamp flashes.. ........ 20-618
a) CHECK lamp.. ........................................................................................................................ 20-618
b) CAUTION lamp.. .................................................................................................................... 20-618

K- 9 There is no abnormality in maintenance monitor display but CHECK lamp or
CAUTION lamp lights up.. .......................................................................................................... 20-619
a) CHECK lamp. ......................................................................................................................... 20-619

b) CAUTION lamp.. .................................................................................................................... 20-619
K-10 Only night lighting of maintenance monitor does not light up when lighting switch
is turned ON ................................................................................................................................ 20-620
K-II Night lighting lights up even when lighting switch is turned OFF ........................................ 20-621
K-12 Service meter does not work.. ................................................................................................... 20-622

K-13 Service meter is running even when engine is stopped ........................................................ 20-622
K-l 4 Abnormality in gauge display.. .................................................................................................. 20-623
a) Abnormality fuel gauge.. ...................................................................................................... 20-623
b) Abnormality in engine water temperature gauge ............................................................. 20-624
c) Abnormality in torque converter oil temperature gauge ................................................. 20-625
WA800-3 20-601
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM MAINTENANCE MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM MAINTENANCE MONITOR

SYSTEM
Maintenance monltar
I Transmlsslon
lovstlck
b
steering
LR2 ISWP 12)
Joust ick
steering
switch
LR3 (SWPI 6)
Startin@ switch
CBLl (SWPB)
Main monitor
II
I I I
I
1 LO6 (04016)
P(l 7
CIUTIDH I1DP 0 6,L” I , _
CHECK II”P 1
Engine Neutral Joust ick
20-602 WA800-3
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM MAINTENANCE MONITOR SYSTEMS
fl This circuit diagram is made by extracting the part of the maintenance monitor system from the
general circuit diagram.
WA800-3 20-603
5
TROUBLESHOOTING K-l
K-l When starting switch is turned ON, all lamps on maintenance monitor
do not light up for 3 seconds, maintenance monitor dose not work
a) No lamps on maintenance monitor light up
Cause Remedy
Defective monitor
module of maintenance
monitor
1 disconnection in wiring
Repair or
YES harness between L18
replace, or
(female) (I 1, (2) -fuse
between L18 (11, replace fuse
317 I-10 - FSI (male) (2), or
1Is voltage between 11 blown fuse I-IO
YES FSl (female) (2)
*20-30V r and chassis
ground normal? Defective contact or
*Turn starting 2 disconnection in wiring Repair or
switch ON. Is resistance .20-30V harness between FSI replace, or
between L18 * Disconnect FSI. NO (female) (2) -battery
- (female) (3).(9).L19 - replace fuse
*Turn starting relay, or blown slow
1 (8) and chassis
switch ON. blow fuse (120A)
ground normal?
* Max. 1 R
*Turn starting Defective contact or Repair or
switch OFF. disconnection in wiring replace
. Disconnect L18, harness between L18 (3),
L19. (9), L19 (female) (8) -
chassis ground
Cause Remedy
b) Some lamps do not light up
Defective monitor
module of maintenance Replace
monitor
20-604 WA800-3
TROUBLESHOOTING K-2
K-2 When starting switch is turned ON, all lamps on maintenance monitor
light up but do not go out (even after 3 seconds)
Cause Remedy
K-l, 2 Related electrical circuit diagram
Buzzer
L42
Maintenance monitor
I I Battery relay
Battery relay
Main monitor
LO5 (04020) FSl (L2)
LO6 (04016) I LR5 (L2)
LO7 (04012)
I \ I I
Slow blow fuse
I ?7&-- TWWO1785
WA800-3 20-605
TROUBLESHOOTING K-3
K-3 When engine is started immediately after starting switch is turned

ON (within 3 seconds), no lamps on maintenance monitor go out
Remedy
Replace
engine, is voltage
between L19 lfemalel
(1) and chassis
Repair or
*20-30V replace
* Disconnect L19. (female) (1) - L57
. Start engine. (female) (3)
- Measure when starting motor is turning.
(starting switch at START).
K-3 Related electrical circuit diagram

El4
Transmission b Neutral relay Joystick neutral relay
joystick steering (KEsI 2)
controller
L57 L66
2
1
Maintenance monitor
I I
L19 (0408) I L
P
I LR3tSWP16)
F
El6
Main monitor
I (KES~ 2)
2
LR4 (M4)
t El7
bEI
Directional b shalt switch
E06 (X2) (KEsI 2)
2
@I
I
Starting motor
Starttng switch
Startlno motor
TWW01786
20-606 WAND3
TROUBLESHOOTING K-4
K-4 When starting switch is turned ON (engine stopped), CHECK items

flash
a) Engine oil level display flashes

* Before starting troubleshooting, check the engine oil level again.
(Check that the engine oil level is correct.)
Cause Remedy
Defective monitor
2 YES module of maintenance
Replace
Is resistance monitor
YES between L18
1 chassis ground
between R02 harness between L18 replace
NO
(male) (1) and (female) (13) and R02
1;ha&ground 1 - Turn starting
(female) (1)
switch OFF.
* Disconnect L18.
* Max. 1R Defective engine oil level
Replace
*Turn starting NO sensor
switch OFF.
* Disconnect R02.
K-4 a) Related electrical circuit diagram triune 01 I

level switch
Maintenance monitor
I
L18 (0408) LR3 (SWP16) R02 (Xl)
Engine oil level 777T
TWWOl787
WA800-3 20-607
TROUBLESHOOTING K-4
b) Engine water level display flashes

* Before starting troubleshooting, check the engine water level again.
(Check that the engine water level is correct.)
Remedy
Defective monitor
3 YES module of maintenance Replace
monitor
YES between L18
- iL_::rra"d
1s resistance normal? harness between L18 Repair or
YES between GO6 . Max. 1 R NO (female) (8) and GO1 replace
chassis ground
1 switch OFF.
- normal? Defective contact or
Is resistance P - Disconnect L18. disconnection in wiring Repair or
* Max. 1 R
between G06 - *Turn starting NO harness between GO6 replace
(male) (I) and (2) (female) (2) and chassis
switch OFF.
normal? ground
* Disconnect G06.
- Max. 1 R
* Turn starting Defective radiator water Replace
NO
switch OFF. level sensor
* Disconnect G06.
K-4 b) Related electrical circuit diagram

Water level switch
Maintenance monitor
I
L18 (0408) LR2 (SWP12) GRl (SWP12) GO6 (X2)
@ -3
(TJ- .a
Battery
II II-II II
TWW01788
20-608 WA800-3
TROUBLESHOOTING K-5
K-5 When starting switch is turned ON (engine started), CAUTION

items flash
a) Engine oil pressure display flashes

(Check that the engine oil puressure is correct.)
Cause Remedy
YES Defective engine oil Replace

pressure switch
1
Does display go YES Defective engine oil Replace

out when E09 is - pressure relay
disconnected?
2
* Start engine. Does condition
4 YES Defective monitor
become normal
* Disconnect E09. module of maintenance Replace
_ when engine oil _ Is resistance
NO pressure relay L64 monitor
YES between L18
is interchanged? - (female) (10)and - Defective contact or
- Interchange 3 chassis ground disconnection in wiring
engine oil Repair or
- harness between L18
pressure relay NO (female) (10) - L64 (3). (6) replace
,;ha?;mnt~ chassis
*20-30V ground in harness Repair or

between E09 - L64 replace
* Start engine. (female) (2)
K-5 a) Related electrical circuit diagram
Maintenance monitor
LR3 (SWP16) ER1 (SWP12) ;;;;;;r;i;wiich
L18 (04Oi6) a-
' E09
pxx-p/7
~64 (KES~ 5)
Engine oil
Pressure relay TWWOl789
WA8003 20-609
TROUBLESHOOTING K-5
b) Battery charge level display flashes
I Cause Remedy
Defective monitor
2 YES
Is voltage between monitor
YES L18 (female) (12)
1 and chassis Defective contact or
- ground normal? disconnection in wiring
Is voltage between ~ Repair or
harness between L18
alternator terminal _ * 20 - 30 V NO replace
(female) (12) -alternator
Rand chassis * Start engine. terminal R
ground normal?
*20-30V
Defective alternator Replace
* Start engine. NO
Maintenance monitor
I I
I L18 (04016) LR3 (SWP16) ~04 (KES~ :2)
l 3
p
J
Main monitor
I
LO5 (04020)
w
Starting motor
Battery relay
Starting motor ERl
(SWP12)
%I-
w
Alternator
CI+ TWWOI790
20-610 WA%OO-3
TROUBLESHOOTING K-5
cl Brake oil pressure display flashes

(Check that the brake oil pressure is correct.)
Cause Remedy
4 YE!
-GotoA
Is resistance
YES between BC07
3 (male) (1) and (2) Defective brake
I= I TCSIDLCII
ILG normal? accumulator oil pressure
/ES _ between BC06 * Max. 1 Q NC (low pressure) switch
(male) (1) and (2) * Start engine. wv4)
1!
normal? * Disconnect BC07. Defective brake
Is resistance
* Max. 1 R accumulator oil pressure
YES between BC05 Replace
. Start engine. NO (low pressure) switch
(male) (1) and (2)
1 * Disconnect BC06. wv3)
normal?
Is resistance * Max. 1 R Defective brake
between BC04 accumulator oil pressure
- * Start engine. Reolace
(male) (1) and (2) * Disconnect BC05. hIO (low pressure) switch
normal? (SW21
* Max. 1 R Defective brake
* Start engine. accumulator oil pressure
* Disconnect BC04. Replace
(low pressure) switch
wvl)
Defective monitor
6 YES
I Isresistance II Replace
between LX3
monitor
YE
(female) (11) and - Defective contact or
5
I-
BC04 (female) (1)
normal? Repair or
between BC04 harness between L18
* Max. 1 R NO (female) (I I) and BC04 replace
From A- (female) (2) and
chassis ground
normal? switch OFF.
Max. 1 <L
* Disconnect L18 and BC04. Defective contact or
* Turn starting NU harness between BC04 reolace
* Disconnect BC04. ground
WA800-3 20-611
TROUBLESHOOTING K-5
K-5 cl Related electrical circuit diagram
Maintenance monitor
1 Brake accumulator
L18 (04016) CBLl (SWP8) BC04 (X2) 10~ Pressureswitch
a 3
Switch 1
a- -3
BC05 (X2)
Switch 2
Switch 3
Switch 4
TWWOl791
20-612 WA800-3
TROUBLESHOOTING K-5
d) Air cleaner (R.H.) clogging display flashes

Cause Remedy
(Check that the air cleaner (R.H.) is not clogged.)
YES Defective dust indicator

Replace
(R.H.) sensor
1
Does display go
out when BO9 is - Reolace
(R.H.) relay
disconnected?
2
. Start engine.
* Disconnect BO9. Does display go
4 YE:
out when dust -GotoA
Is resistance
NO indicator relay
YES between L80
L80 is replaced? - (female) (6) and -
~ chassis ground disconnection in wiring
Is voltage between normal? Repair or
harness between L80
609 (female) (1) reolace
NO and chassis - Turn starting ground
switch OFF.
. Disconnect L80. Short circuit with chassis
switch ON. replace
between B09 (female1 (1)
* Disconnect BO9.
* ZO-30V
Defective monitor
6 YES
monitor
harness between B08 Repair or
(female) (1) and BR1 replace
(female) (9)
normal?
* Max. 1Q disconnection in wiring Repair or
* Turn starting NO harness between L18 replace
switch OFF. (female) (14) and L80
* Disconnect L18. (female) (3)
K-5 d) Related electrical circuit diagram
Maintenance monitor
L18 (04Oi6)
p-ppx/q;'"
LR4 (M4)
BRl
(SWP12) B08
@ a I
L80
Dust indicator (R. H) relay TWWOl792
WA800-3 20-613
TROUBLESHOOTING K-5
e) Air cleaner (L.H.) clogging display flashes Cause Remedy

(Check that the air cleaner (L.H.) is not clogged.)
ES Defective dust indicator qeolace

(L.H.) sensor

out when 807 is
1L.H.) relay
H
disconnected? I
2
* Start engine.
Does display go
. Disconnect 807.
out when dust GotoA
indicator relay
I Isresistance
F between L79 Defective contact or
L79 is replaced? (female) (6) and - disconnection in wiring
I
chassis ground harness between L79
Is voltage between normal7 Repair or
B07 (female) (I) * Max. 1R NO replace
ground
NC and chassis * Turn starting
ground normal? switch OFF.
ground in harness
- Disconnect L79. Repair or
* Turn starting L between 807 (female) (1)
switch ON NO and L79 (female) (2) replace
* Disconnect 807. (contact with chassis
. 20-30V ground)
6 YES Defective monitor Replace
Is resistance module of maintenance
YES between B06 monitor
- (female1 (1) and -
_ chassis ground
between L18 harness between B06 replace
NO
From A - (female) (15) and - (female) (1) and BRl
chassis ground (female) (9)
normal?
* Max. 1 R
* Turn starting NO harness between L18
switch OFF.
* Disconnect L18.
(female) (3)
K-5 e) Related electrical circuit diagram
laintenance monitor FS2k12 blue) _?
1 1 Air cleaner (L. H)\d I I \ I
LR2
(SWP12) B07
LR4 (M4)
3
I,.\
/r BRl
I
L79
Dust indicator (L. H) relay TWWOl793
20-614 WA800-3
TROUBLESHOOTING K-5
f) Transmission oil filter display flashes

(The transmission oil filter must not be clogged.)
Cause Remedy
Defective monitor
4YE!
Is resistance
monitor
YES between L18
#
- (female) (161 and - Defective contact or
- BCO3 (female) (2) disconnection in wiring
llCJrlllal7
. Max. 1R replace
(female) (16) and BC03
(female) (2)
yEd&fl ~~~~~~-~~~~~~~:1” NC Defective contact or
harness between BC03 replace
normal? I - Disconnect BC03. ground
* Max. 1R
between BC03
* Start engine. Replace
(male) (I) and (2) oil filter sensor (BCO2
- Disconnect BC02. NO
side)
- Start engine. I oil filter sensor (BCO3 Replace
* Disconnect BC03. NO side)
K-5 f) Related electrical circuit diagram
Maintenance monitor
L18 (SWP16) CBLl (SWP8) BC02 (X2)

I$+
oi I
ns switch
TWW01794
WA%OO-3 20-615
TROUBLESHOOTING K-6
K-6 CAUTION items are flashing but buzzer does not sound
t Buzzer does not sound when battery charge or engine oil level is abnormal.
* Before carrying out troubleshooting, check that all the related connectors are properly connected.
Ir Check that fuse I-IO is normal. If it is blown, check for a short circuit with the chassis ground in
wiring harness between fuses I-IO to FS2 (9) and L42 (1).
Remedy
t-=
harness between L19 Replace
(male) (1)
Defective buzzer
Is voltagebetween Defective monitor

L42 (female) (1) module of maintenance Replace
monitor
Repair or
* Disconnect L42. harness between FS2
replace
* Turn starting (female) (9) and L42
switch ON. (female) (I)
Buzzer
Maintenance monitor
+$-+fj
Main monitor
LO6 (04016)
Fuse (I)
Inu-;i.,1,.1- FS2 (S12)
TWW01795
20-616 WA8003
TROUBLESHOOTING K-7
K-7 There is no abnormality in monitor display but caution buzzer sounds
f Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Sr Before carrying out troubleshooting, check that buzzer stays sounded when LO6 is disconnected.
Defective monitor
2 YES
Is resistance
monitor
YES between L19
- (female) (4) and - Short circuit with chassis
_ 1 chassis ground ground in wiring harness
Is resistance nCXIllal? Repair or
between L43 between L19 (female) (4)
NO replace
(female) (1) and - * Min. ’ MR - L43 (male) (1) - LO6
* Turn starting switch OFF. (female) (8)
chassis ground
normal? - Disconnect LO6 L19 and
- L43.
* Min. 1 MQ Defective buzzer
* Turn starting NO
switch OFF.
+ Disconnect L42
and L43.
Buzzer
Maintenance monitor
Fz#?y&
(
I I
Main monitor
L43
I I
LO6 (04Oi6)
piZ~5/--
TWW01795
WA800-3 20-617
TROUBLESHOOTING K-8
K-8 CAUTION items are flashing but neither CHECK lamp nor
Ir Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a) CHECK lamp Cause Remedy
Defective monitor
1
monitor
light up when L19 Defective contact or

Repair or
harness between L19
replace
* Disconnect L19. (female) 110)
* Turn startrng NO I connected to II
switch ON. chassis ground ?
- Disconnect LO6 NO
*Turn starting
switch ON.
b) CAUTION lamp Cause Remedy
Defective monitor
1 monitor
lamp light up when Defective contact or
L19 (female) (3) is disconnection in wiring
2 YES Repair or
harness between L19
replace
J (female) (3) and LO6
- Disconnect L19. (female) (10)
_
* Turn startmg
switch ON. NoI :;!%;:o?“d ?
Defective main monitor Reoface
* Disconnect L06. NO
- Turn starting
switch ON.
K-8 a), b) Related electrical circuit diagram
Maintenance monitor Main monitor

I I
L19 (0408) LO6 (04016)
CHECK lamp a
CAUTION lamp a CAUTION lamp
TWW01797
20-618 WA800-3
TROUBLESHOOTING K-9
K-9 There is no abnormality in maintenance monitor display but CHECK

lamp or CAUTION lamp lights up
j, Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a) CHECK lamp
Cause Remedy
Defective monitor
1 YES
Is resistance
monitor
between L19
(female1 (2) and -
chassis ground
llOUl-d? II
between L19 (female) (2) replace
- Min. 1 MR NO
and LO6 (female) (10)
- Turn starting
switch OFF.
* Disconnect LO6
and L19.
b) CAUTION lamp
I Cause I Remedy
Defective monitor
1 YES module of maintenance Replace
Is resistance monitor
between L19
(female) (3) and -
chassis ground
normal?
between L19 (female) (3) replace
- Min. 1 MR NO
and LO6 (female) (9)
*Turn starting
switch OFF.
- Disconnect LO6
and L19.
Maintenance monitor Main monitor

I I
L19 (0408) LO6 (04016)
CHECK lamp
CAUTION IamP CAUTION lamp
TWW01797
WA800-3 20-6 19
TROUBLESHOOTING K-10
K-10 Only night lighting of maintenance monitor does not light up when
lighting switch is turned ON
Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause Remedy
1 YES Disconnection in wiring

Replace
harness of lamp holder
kz?-lII
L2l(femalei (II Defective contact or
and (2) normal? disconnection in wiring Repair or
harness between L21 reolace
*20-30V NO
(female) (1) and FS2 (5)
* Disconnect L21.
*Turn starting
switch ON.
*Turn lamp switch
ON.
Maintenance monitor
1 Light ins switch
~21 (KEN 2)_ n-m-l
1 I
Main monitor I I
1
LO5 (04020)
Night lighting
I \ I
TDWO
20-620 WA8003
TROUBLESHOOTING K-l 1
K-II Night lighting lights up even when lighting switch is turned OFF
Cause Remedy

supplyin wiring harness
2 YES between FS2 (male) (4) - Repair or
Is voltage between fuse box - L21 (female) replace
YES FS2 (female) (4) (1)
1 and chassis
- ground normal?
supply in wiring harness Repair or
Is lighting switch _ * Max. 1 V NO between LO2 (female) (5) replace
normal? * Disconnect FS2. and FS2 (female) (4)
*Turn lighting switch OFF.
* Turn starting switch ON.
* Turn starting Defective lighting switch Replace
switch OFF. NO
* Disconnect L02.
-Check that continuity between
LO2 (male) (1) and (5) is as
shown in table below when
lamp switch is turned ON-OFF.
K-II Related electrical circuit diagram
Maintenance monitor
Lighting switch
L21 (KES1.2)
pG--p- L/5;&
-
I
Main monitor
LO5 (04020)
WA800-3 20-62 1
TROUBLESHOOTING K-12. 13
K-12 Service meter does not work

* Before carrying out troubleshooting, check that all the
[ Remedy
related connectors are properly inserted.
Ir Always connect any disconnected connectors before going
on to the next step.
YFS I
Defective service meter Replace
(female) (2) and replace
(female) (2) and
alternator terminal R
/z&z&q/r-
*20-3ov Defective contact or
. Start engine.
alternator terminal * Turn starting NO harness between L22 replace
* Disconnect L22.
N switch OFF. (female) (1) and chassis
ground normal? * Disconnect L22. ground
*20-30V Defective alternator Replace

. Start engine.
K-13 Service meter is running even when engine is stopped
* Before carrying out troubleshooting, check that all the

Cause Remedy
related connectors are properly inserted.
* Always connect any disconnected connectors before going
YES
Defective service meter Replace
1 -
Is voltage
between L22 Short circuit with power
(female) (2) and - 2 YES supply in wiring harness Repair or
(1) normal? between L22 (female) (2) replace
Is voltage between
* Max. 3 V alternator terminal and alternator terminal R
* Turn starting NO Rand chassis
switch ON. ground normal?
+ Disconnect L22. Defective alternator Replace
* Max. 3 V NO
* Turn starting
switch ON.
K-12, 13 Related electrical circuit diagram

Maintenance monitor
I I
L22 (KESI 2) LR3 (SWP16)
Service meter I+1 2
Sernce meter l-1 c

LR4 CM41
ERl
E07 (X2) (SWP12)
Start inn
motor
Alternator
I
TWWO
20-622 WA800-3
K-14 Abnormality in gauge display
a) Abnormality in fuel gauge

+ Before carrying out troubleshooting, check the fuel level again.
(Check that the fuel level is correct.)
(I) Little or nothing is displayed in display area Cause Remedy
Defective monitor
YES
short connector -
r module of maintenance
monitor
Replace
YES chassis ground

is connected to normal when short
R05 (female)? connector is Defective contact or
2 i--i
. Disconnect RO5, ~ disconnection in wiring
Is resistance Repair or
* Connect short * Max. 1 R harness between R05
between R05 replace
connector to R05 _ (female) (2) and _ . Turn starting No (female) (1) and L18
(female). NO chassis ground switch OFF. (female) (6)
*Turn starting normal? * Connect short connector
switch ON. * Max. 1 R to R05 (female).
-Turn starting * Disconnect L18. Repair or
harness between R05
switch OFF. NO replace
* Disconnect R05. ground
Remedy
(2) Display always shows FULL and does not move
YES Defective fuel level

1 I I sensor
Do all display areas
on fuel gauge go
Defective monitor
out when R05 is YES
disconnected? module of maintenance Replace
Is resistance
monitor
between R05
* Disconnect R05.
- Turn starting Short circuit with chassis
NO chassis ground
switch ON. normal? ground in wiring harness Repair or
f Min. 1 MR NO between R05 (female) (1) replace
*Turn starting switch OFF. - L18 (female) (6)
* Disconnect L18 and R05.
K-14 a) Related electrical circuit diagram
Maintenance monitor Fuel level sensor

I
L18 (04016) LR2 (SWP12)
Fuel level @
Bat terv
Il 11-11 II
TWWOIEOO
WA800-3 20-623
b) Abnormality in engine water temperature gauge

(1) Nothing is displayed in display area
YES Defective engine water

Replace
1 temperature sensor
Does engine water
temperature gauge
show minimum - Defective monitor
level when E04 is
2 YES
disconnected? Is resistance
monitor
* Disconnect E04. between E04
* Turn starting Short circuit with chassis
NO chassis ground
switch ON. “OVllC3l? ground in wiring harness Repair or
NO between E04 (female) (1) replace
- Min. 1 MR
- L18 (female) (4)
* Turn starting
switch OFF.
* Disconnect L18
and E04.
Cause Remedy
(2) Display shows lowest level and does not move
YES Defective engine water

temperature sensor
Whenshort I, ~ Defective monitor

3 YES
connector is module of maintenance Replace
connected to E04
(female), does engine -7 monitor
water temperature (female) (4) and
gauge display area
rise one stage at a
time, and finally do normal when short
all IamDS cl0 out? t Defective contact or
. Disconnect E04. disconnection in wiring
Repair or
* Connect short
connector to E04
between E04
(female) (2) and
- Max. 1 R NO
harness between E04
(female) (I) - L18
replace
NO chassis ground *Turn starting switch OFF. (female) (4)

(female).
* Turn starting
* Connect short connector to
E04 (female). Defective contact or
switch ON. * Turn starting
switch OFF.
* Disconnect L18. disconnection in wiring
Repair or
* Disconnect E04. ’ harness between E04
replace
NO
* Max. 1 R (female) (2) -chassis
ground
Maintenance monitor Engine water
L18 (04016) LR3 (SWP16) ERl (SWP12) E04 (X2) temPerature

SenSor
Engine water
@ c @ $)
temperature
E 3
Bat terv
II II-II ID\
I
TWWOllOl
20-624 WA8033
c) Abnormality in torque converter oil temperature gauge

(1) Nothing is displayed in display area Remedy
Defective torque
YES Replace
converter oil temperature
1 I sensor
Defective monitor
monitor

Repair or
between TO2 (female) (1)
replace
*Turn starting - L18 (female) (5) (contact
switch OFF. with chassis ground)
* Disconnect L18
and T02.
. Min. 1 MQ
Cause Remedy
(2) Display shows lowest level and does not move
Defective torque
YES converter oil temperature Replace
sensor
7
1
Defective monitor
When short YES
cr~““ect0r is module of maintenance Replace
connected to TOZ. monitor
does torque converter between L18
oil temperature (female) (5) and
gauge display area
rise one stage at a
time, and finally do all normal when short
lamps go out? Defective contact or
connected to TO2 disconnection in wiring
* Disconnect T02. , Repair or
! harness between TO2
. Connect short replace
between TO2 - Max. 1 R NO (female) (1) - L18
connector to TO2
*Turn starting switch OFF. (female) (5)
(female).
* Connect short connector to
- Turn starting
TO2 (female). Defective contact or
switch ON.
* Disconnect L18. disconnection in wiring
*Turn starting 1 Repair or
L harness between TO2
switch OFF. replace
NO (female) (2) -chassis
* Disconnect T02.
ground
K-14 c) Related electrical circuit diagram

Torque converter
Maintenance monitor oil temperature
I
L18 (04016) LR2 (SWP12) TRl (SWP8) TO2 (X2) SenSor
oil temperature
TWW01802
WA800-3 20-625
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Electrical circuit diagram for power supply, engine starting, engine stopping
and preheating.. ........................................................................................................................... 20-702
Electrical circuit diagram for parking brake ........................................................................................ 20-704
Electrical circuit diagram for boom kick-out and bucket positioner.. ............................................... 20-705
E- 1 Engine does not start .................................................................................................................. 20-706
a) Starting motor does not turn .............................................................................................. 20-706

b) Starting motor turns (STD spec.) ........................................................................................ 20-710
E- 2 Engine does not stop (STD spec.) ............................................................................................. 20-7 12
E- 3 Engine stops when machine is traveling (STD spec.) ............................................................. 20-713
E- 4 Abnormality in preheating system ............................................................................................ 20-715

a) Does not carry out preheating ............................................................................................ 20-715
b) Always carries out preheating for 45 seconds .................................................................. 20-716
c) Preheating stays on .............................................................................................................. 20-716
d) Preheating time becomes shorter, or there is fluctuation.. .............................................. 20-717
E- 5 Parking brake does not have effect.. ......................................................................................... 20-719

a) Parking brake has no effect when parking brake switch is turned ON ......................... 20-719
b) Parking brake has no effect when brake pressure (accumulator pressure) drops
(Does not work as emergency brake). ................................................................................ 20-719
E- 6 Parking brake is applied when machine is traveling.. ............................................................. 20-720
E- 7 Parking brake is released when starting switch is turned ON ............................................... 20-722
E- 8 Transmission does not change to neutral when parking brake is applied

(but parking brake works normally) .......................................................................................... 20-722
E- 9 Kick-down switch does not work ............................................................................................... 20-724
a) Kick-down switch does not work even though gear shift works normally.. ................. 20-724
b) Kick-down cannot be canceled.. .......................................................................................... 20-725
E-10 Boom kick-out does not work.. .................................................................................................. 20-726
E-l 1 Abnormality in bucket positioner function.. ............................................................................. 20-730
E-12 Abnormality in lighting up of front working lamp ................................................................. .20-733

E-13 Abnormality in lighting up of rear working lamp.. .................................................................. 20-733
E-14 Abnormality in transmission cut-off.. ........................................................................................ 20-733
E-15 Abnormality in low idling selection .......................................................................................... 20-733
E-16 Abnormality in parking brake dragging warning ..................................................................... 20-733
E-17 Abnormality in buzzer.. ............................................................................................................... 20-733
WA800-3 20-701
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,
TROUBLESHOOTING ENGINE STARTING, ENGINE STOPPING AND PREHEATING

ENGINE STARTING, ENGINE STOPPING AND PREHEATING
FS3 (M6)
Fuse (II
Transmission b joy
steerine controlle
JoYslick switch N
Jorstick su~tch N
Preheating 0
PreheatInn outs”, +
System
cut-off
switch
Neutral
switch
I
Starting switch
I
shift switch
III,
;:;;;atins Engine Neutral by;;ick

stopping relay
relay
TWWOl803
20-702 WA800-3
TROUBLESHOOTING ENGINE STARTING, ENGINE STOPPING AND PREHEATING
fl This circuit diagram is made by extracting the parts of the power supply, engine starting, engine
stopping, and preheating systems from the general circuit diagram.
WA800-3 20-703
5
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE

fl This circuit diagram is made by extracting the part of the parking brake system from the general
circuit diagram.
20-704 WA800-3
5
ELECTRICAL CIRCUIT DIAGRAM FOR
TROUBLESHOOTING BOOM KICK-OUT AND BUCKET POSITIONER
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND

BUCKET POSITIONER
fl This circuit diagram is made by extracting the parts of the boom kick-out and bucket positioner
systems from the general circuit diagram.
WA800-3 20-705
5
TROUBLESHOOTING E-l
E-l Engine does not start

* When connecting or disconnecting the T-adapter (or socket adapter) or shot-t connector to carry out
checks, always turn the starting switch OFF before starting.
* When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOn( ).
* After checking, connect the disconnected connectors and disconnect the T-adapter immediately to
return to the original condition before going on to the next check.
a) Starting motor does not turn
YES
i YES
I
1chassis normal?
. Turn starting I
switch OFF. * Turn startina NO
.20-30V switch ON. -
relay make sound - Check voltage
between chassis
and both
* Starting switch
ON c) OFF.
YE between starting
motor terminal E
-1 _... _._._ _
. Turn
L
startina
LIT\
switch OFF. * Turn starting
Max. 1 R switch OFF.
*20-30V
1 IV”
Is voltage
between E06, E07
(female) (1) and
chassis normal?
1
* Disconnect E06,
E07.
Neutral
NO
* Turn starting
switch to START.
.20-3ov
20-706 WA800-3
TROUBLESHOOTING E-l
Cause Remedy
Defective starting motor

qeplace
assembly
disconnection in cable Repair or
between battery relay and
replace
starting motor terminal B
)If answer is NO for both
terminals: Defective contact
or disconnectionin wiring
harness between battery Repair or
and battery relay replace
If answer is NO for one
terminal: Defective battery
relay
Defective battery relay qeplace
a YES harness between starting
Replace
switch terminal BR - AROI,
Is resistance
AL01
YES
r
between AR02 _
I l,
Is voltage between _I
AL02 and chassis
normal?
starting switch . Max. 1 12 harness between AR02, replace
NO
terminal BR and *Turn starting AL02 and chassis ground
chassis normal? switch OFF.
-Turn- starting
* Disconnect R13.
Defective starting switch Replace
switch ON. NO
.20-30V
Repair or
disconnection in starting
replace
motor ground cable
Go to A on next page
WA800-3 20-707
TROUBLESHOOTING E-l
YES
H
11
Is voltage between 13 YES
I
L57 (female) (5) and
chassis ground
1normal?
-1
* Disconnect L57. 12
. Turn starting
* Replace neutral Is voltage between * Turn starting
switch to START
relay (L57) with I -I terminal B of starting switch to START
position.
‘I
switch and chassis position.
other relay of NC
.20-30V
same type. *20-30V
L
* Set directional * Turn starting
lever to N. switch OFF.
* Turn starting * 20 - 30 v N
switch to START
position.
*Turn starting NO
NO switch to START position.
I(2) normal? *20-30V
I
+ Disconnect L57. YES

* Set directional
lever to N.
-Turn starting 16
switch to START
18 YES
position.
replaced with other
relay of same type? YE.S
EH
. Replace
exchange relay
Is resistance between (J/S) (L66) with between L66 (6) - y;;;,oystick steering NO
L57 (female) (2) and other relay of - Setdirectional lever to N.
same type. -Turn startino switch to
. Set directional * Do not use i START posilion.
* Turn starting lever to N. joystick steering N0
switch OFF. * Turn starting switch (OP).
* Disconnect L57. to START position. * Set directional lever to N.
* Min. 1 MR * Turn starting switch to START position.
NO
20-708 WA800-3
TROUBLESHOOTING E-l
Cause Remedy
Defective neutral relay

Replace
(L57)
disconnection I” wiring
Repair or
harness between L57
replace
(female) (3) and E06 (female)
(1). E07 (female) (1)
harness between terminal C
replace
of starting switch and L57
(female) (5)
Defective starting switch Replace
Repair or
harness between terminal B
of starting switch, fuse l-12 replace
and LR4(1)
harness between LR4 (11, replace
slow blow fuse 30A and
battery relay
Defective exchange J/S

Replace
relay (L66)
Trouble of S-net [See

troubleshooting of Repair or
transmission controller replace
system (T mode)1
,
Repair or
replace
Repair or
harness betw&n LO5 - replace
;;male) (8) and L66 (female)
Repair or
replace
WA$OO-3 20-709
TROUBLESHOOTING E-l
b) Starting motor turns (STD spec.)
YES
4 YES
Is resistance
Yl between R06
(female) (8) and
chassis normal?
I I I
* Turn startina NO
3 switch OFF.-
Does engine stop * Disconnect R06.
between R06 (7) * Max. 1 R
* Turn starting
switch ON t) OFF -Turn starting
and check switch ON.
visually. *20-3ov
motor work when YES
L62 is replaced with -
N other relay of same
* Replace engine
stop relay tL62)
with other relay chassis normal?
of same time.
* Turn starting *Turn starting L * Turn startina
switch OFF. switch ON c) N ‘0,(female) (1) and
* Disconnect R06. OFF and check chassis normal?
*20-3ov visually.
* Disconnect L62.
* Turn starting
switch ON.
.20-30V
20-710 WA800-3
TROUBLESHOOTING E-l
Remedy
Defective adjustment of
- wire between engine Adjust
stop motor and lever
Defective engine stop Repair or

motor replace
Repair or
replace
Defective engine stop

Replace
relay (L62)
8 YES Defective engine stop Replace

motor
Is resistance
_ between R06 Defective contact or
(female) (5) and (7) disconnection in wiring
and chassis normal2 harness between R06 Repair or
(female) (5) - L62 (female) replace
* Disconnect R06. NO 15).or between RO6Ifemale)
*Turn starting (7) - L62 (female) (3)
switch ON.
harness between L62
replace
I ground
(female) (1) and LO9 (female)
(21
Blown fuse l-14, or defective
_ contact, or disconnection in qepair or
wiring harness between FS2 replace
(female) (11) - R06 (female)
(4)
WA800-3 20-711
TROUBLESHOOTING E-2
E-2 Engine does not stop (STD spec.)
Ir When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out
* When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOa( ).
* After checking, connect the disconnected connectors and disconnect the T-adapter immediately to
return to the original condition before going on to the next check.
Cause Remedy
Defective adjustment
YES
between engine stop Adjust
motor and stop lever
I 4YE!
H
1
- GotoA
Does engine stop Yf dsu

Defective contact,
motor work? disconnection or short circuit
ground normal? with chassis ground in wiring Repair or
I I1
f 20 - 30 v N( harness between E03 (female) replace
* Turn starting (3) and L62 (female) (6)
switch ON t)
OFF repeatedly Breakage of fuse I(14). or
Does engine stop defective contact,
and check motor work when Repair or
disconnection or short circuit
visually. NO with chassis ground in wiring replace
harness between FS2 (female)
type?
I (11) and E03 (female) (4)
* Replace engine
Defective engine stop
stop relay (L&Z) Reolace
relay (L62)
with other relay
of same type.
* Turn starting
switch ON t) OFF
repeatedly and check
visually.
5 YES Defective engine stop

Replace
motor
Is voltage
From A - between E03 (7) - Defective contact,
and (8) normal? disconnection or short
circuit with chassis ground qepair or
* Turn starting NO in wiring harness between veplace
switch OFF. L62 (female) (3) and E03
*20-30V (female) (7)
20-712 WA800-3
TROUBLESHOOTING E-3
E-3 Engine Stops when machine is traveling (STD spec.)
* Check if the starting motor turns. If it does not turn, check E-l a) Starting motor does not turn.
Cause Remedy
Defective adjustment
YES between engine stop
1 motor and stop lever
Does engine stop

motor work? Defective engine stop
Replace
motor
* Turn starting
switch ON H OFF between E03 (7) and
and check 3 YES Defective engine stop
OVand 20 - 3OV7 Replace
Is voltage between relay
*Turn starting 1 L62 (female) (2) Defective contact or
switch ON t) NO and (female) (1) disconnection or short
OFF. normal? I circuit with chassis Repair or
I
*20-30V ground in wiring harness replace
NO
*Turn starting between starting switch
switch ON. terminal BR - LO9 (2) -
* Disconnect L62 (female) (I)
engine stop relay
(L62).
WA800-3 20-713
TROUBLESHOOTING E-l. E-2. E-3
E-l, 2, 3 Related electrical circuit diagram
RO4 R03
(KES 2) (KES 21
Fuse (11
Heaterrelay
(R. H.)
I 1
Heater
IL H.)
relay
I
E20
EZI
\
\
r
I
E22
motor motor
TWW01807
20-714 WA800-3
TROUBLESHOOTING E-4
E-4 Abnormality in preheating system
a) Does not carry out preheating

Ir Check that the water temperature is below 5°C.
(I) Monitor display also does not light up
Cause Remedy
2 YES
Adjust
Is resistance -II
YE ; between LO5
1
(female) (7) and
i chassisaround H Short circuit with chassis
* Min. 4 kR tib between LO5 (female) (7) replace
(male) and chassis *Turn starting - E05 (female) (1)
switch OFF.
* Disconnect L05.
+ Min. 4 kR Defective engine water
Replace
* Turn starting NO temperature sensor
switch OFF.
* Disconnect E05.
(2) Only monitor display lights up
Cause Remedy
3 YES Repair or
harness between El 1,
Is voltage replace
El3 and terminal B of
YES between Ell, El3 _ starting motor
2 and chassis
pIs voltage between
YES ribbon heater Defective heater relay Replace
.20-30V
- terminal of heater - *Turn starting
relay and chassis
1 switch ON.
- ground normal?
Is voltage
*20-30V Defective ribbon heater Replace
between EIO, El2
T -Turn startina NO
and L56 (3)
switch ON. ”
I normal? I
*20-30V Repair or
*Turn starting replace
NO harness between L56
switch ON.
(female) (3) and ElO, El2
WA800-3 20-715
TROUBLESHOOTING E-4
b) Always carries out preheating for 45 seconds

* Check that the water temperature is above -10°C
Cause Remedy
2 YES
Is resistance
between E05
YE
chassis ground
normal?
harness between LO5 replace
* Max. 9 kR NO (female) (7) - E05
(male) and chassis * Turn starting
(female) (I)
switch OFF.
* Disconnect L05.
* Max. 9 kR Defective engine water
Replace
*Turn starting NO temperature sensor
switch OFF.
- Disconnect E05.
c) Preheating stays on
YES
Does preheating 3 YES Defective preheating

Replace
stop? Is voltage relay
YES between LO6 (4)
2 and chassis Short circuit with chassis
-Turn starting
_ ground normal? ground in wiring harness Repair or
switch OFF.
Does preheating between LO6 (female) (4) replace
- Disconnect L06. _ *20-3ov NO
NO stop? and L56 (female) (2)
*Turn starting
switch ON. Short circuit with power
* Turn starting
NO between L56 (female) (3) replace
switch OFF.
* Remove - EIO, E12, or between
preheating relay. L56 (female) (3) - LO5
(female) (19)
20-716 WA800-3
TROUBLESHOOTING E-4
dl Preheating time becomes shorter, or there is fluctuation
Remedy
3 YES
Is voltage
YES between ~05 (3)
Defective contact of
Repair or
wiring harness between
replace
YES between LO5
; * Max. 0.1 V NO LO5 (3) -chassis ground
- (female) (7) and - *Turn starting
1 I chassis ground as switch ON. Short circuit with ground
shown in table l? I or defective contact of Repair or
between E05 b-de) * See Table 1.
wiring harness between replace
(1)and chassis * Turn starting
LO5 (female) (7) - E05
ground as shown in switch OFF.
(female) (1)
* Defective engine water

I Replace
*Turn starting temperature sensor
NO
switch OFF.
Table 1
(Tolerance + 0.5 kn)
Temperature ("0 -30 -20 0 20 40 60 80 90
Resistance (kR) 19.5 12.1 5.11 2.39 1.21 0.695 0.381 0.295
WA800-3 20-717
TROUBLESHOOTING E-4
E-4 Related electrical circuit diagram
TWWOl808
20-718 WA800-3
TROUBLESHOOTING E-5
E-5 Parking brake does not have effect
Check that the brake hydraulic system is normal.

When carrying out troubleshooting of the brake system, stop the machine on level ground.
When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOn( 1.
Always connect any disconnected connectors and disconnect the T-adapter before going on to the
next step.
a) Parking brake has no effect when parking brake switch is turned ON
Remedy
F
YES Defective parking brake
Replace
switch
Defective parking brake

become normal Replace
Is voltage between solenoid
YES CN-10 (female) (1)
disconnected? Short crrcuit with power
- Start
engine
Is resistance
Repair or
(Charge between LO1(female) (21 and
between LO1 - Max. 1V NO replace
L58 (female) (1). Fll (female)
accumulator).
NG (female) (2) and - - Start engine (Charge (11
(3) normal? accumulator).
I I Short circuit of wiring
* Min. 1 MR
*Turn parking switch ON. harness between LO1 Repair or
* Turn starting NO (female) (2) and L58 (female) replace
switch OFF. (1). Fll (fern&t (1) and
wiring harness between LO1
- Disconnect LOI,
(female) (3) and L59 (female)
L58, L59 and Fll.
(1). (31with each other
b) Parking brake has no effect when brake pressure [accumulator pressure) drops
(Does not work as emergency brake)
I Cause I Remedy
1 YES Defective parking brake

Replace
Is resistance solenoid
between CBLl
(female) (3) and - Defect of all four
(4) normal? emergency brake
Replace
- Start engine NO switches fSW1, SW2,
(Charge SW3. SW4)
accumulator).
WA800-3 20-719
TROUBLESHOOTING E-6
E-6 Parking brake is applied when machine is traveling
* When carrying out troubleshooting of the brake system, stop the machine on level ground.
* When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out
* When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOLI( ).
* Always, connect any disconnected connectors and disconnect the T-adapter before going on to the
next step.
2 YES
Is resistance
between Fll
YIES
(female) (2) and -
chassis ground
normal7
* Disconnect L59. NO
. Turn starting
switch OFF.
* Max. 1 R ‘ES
N
4 YES
El
Fll (female) (1) Does condition
become normal
when L59 is
replaced with other
*20-30V rela of same t e?
* Start engine - Replace parking
(Charge brake safety relay
accumulator). (L59) with other
I
5
relay of same 1Doescondition
become normal when
type. BC08,BCO9,BClOand
* Startengine h Cl1 are connectedtc
(Charge
accumulator). . Connect short ES
connector to -
Is resistance of
BC08 (female),
LO1 (male) (1). (2)
BCO9 (female),
R and (3) as shown
in Table l? BClO (female)
YE
and Cl1 (female] I.
* Disconnect LOl. * Start engine
* Turn starting (Charge with 6
switch OFF. brake oil Is voltage between * Max. 1 Q
* Turn parking pressure). L59 (female) (5) * Turn starting
brake switch ON, NO and chassis switch OFF. iz
OFF. ground normal? . Disconnect L59.
-2O-30V
-Turn starting
switch ON. NO
* Disconnect L59.
Table 1
~“‘,.::‘.:’
20-720 WA800-3
TROUBLESHOOTING E-6
Cause Remedy

Replace
solenoid
harness between Fll replace

Replace
safety relay
Defective emergency
Replace
brake switch
10 YES disconnection in wiring Repair or
Is voltage between
harness between BC08 replace
(female) (1) - Fll (female) (1
YES ~~08 (female) (1)
9 and chassis
normal?
Is resistance disconnection in wiring Repair or
between L59 .20-3ov NO harness between BC08 replace
(female) (2) and * Turn starting switch ON. (female) (11 - LO1 (female) (2
chassis normal? * Turn parking brake switch ON + OFF.

. Max. 1 R * Disconnect BC08. disconnection in wiring Repair or
* Turn starting NO harness between L59 replace
switch OFF. (female) 12) and chassis
. Disconnect L59. Defective cOntact or
disconnection in wiring harness
Repair or
* Turn starting between L59 (female) (1) and LO
NO replace
switch ON. (female) (31, or between FSZ
* Turn parking (female) (7) and LO1 (female) (11
brake switch ON. Defective contact or
* Disconnect L59. disconnection in wiring Repair or
harness between L59 (female) replace
(1) and L59 (female) (3)
(female) (5) -fuse I (9)

qeplace
switch
WA800-3 20-721
TROUBLESHOOTING E-7, E-8
E-7 Parking brake is released when starting switch is turned ON
next step.
Cause Remedy
YES Defective parking safety

Replace
relay
YES Defective parking brake

Replace
2 I switch
Short circuit of wiring
harness between L59
(female) 12) and L59 (female1 Repair or
YES
(1). CBLl (male1 (3) and
wiring harness between L59
replace
relay of same
tvw. (1) with each other
* Start engine. . Start engine. NO (female) (3) and (5)
. Charge * Charge 1 normal? Short circuit of wiring Repair or
accumulator harness between L59
accumulator, * Disconnect L59. NO replace
then turn starting then tu lrn starting
* Turn starting (3) and wiring harness
switch OFF + S Witch OFF +
r switch OFF. between L59 (female) 15) and
ON. 3N. LO1 (female) (1) with each
* Turn parking
other
brake switch OFF.
* Disconnect L59
and LOl.
E-8 Transmission does not change to neutral when parking brake is

applied (but parking brake works normally) _ -
Cause Remedy
1 YES Defective neutralizer

Replace
relay
Is voltage between
neutralizer relay
L58 (female) (5) - Short circuit with power
chassis normal? source in wiring harness Repair or
f Max. 1 V NO between L58 (female) (5) replace
+ Disconnect and C3A (female) (6)
neutralizer relay
L58.
* Turn starting
switch ON.
* Shift directional
lever between F,
N, and R, and
check each
voltage.
20-722 WA800-3
TROUBLESHOOTING E-6, E-7, E-8
E-6, 7, 8 Related electrical circuit diagram
Parking brake Fuse (I)

switch
Transmission&.iovstick
steering controller
Neutralizlno relay
solenoid
:21 SW1
zIIl=@
:21 SW2
Emergency
Eke brake switch
(OFF at low
CBLl (SWP8) accumulator
pressure)
TWW01809
WA&Xl-3 20-723
TROUBLESHOOTING E-9
E-9 Kick-down switch does not work
next step.
a) Kick-down switch does not work even though gear shift works normally
Cause Remedy
UYE! Repair or
Defective main monitor replace
(2). (41and chassis u

Iground normal? 11 Defective transmission &
Repair or
joystick steering
* Max. 1R NC controller
replace
* Disconnect L08.
* Turn starting Defective contact or
switch OFF. disconnectionin wiring
YE
NO (female1 (21and LO8 (female) replace
1 (2). (4)
* Disconnect L15
* Max. 1R and L08.
- Turn starting
(male) (1) and (2) NO harness between L15 replace
switch OFF.
(female) (1) and C5 (female)
* Disconnect L15 (51
* Max. 1R and C5.
* Turn starting Defective kick-down
Replace
switch OFF. switch
- Disconnect L15.
* Press kick-down
switch.
20-724 WA800-3
TROUBLESHOOTING E-9
b) Kick-down cannot be canceled
Cause Remedy
Defective kick-down
Replace
switch
Does condition Defective transmission &

3 YES Repair or
joystick steering
become normal 1Isresistance between 17 controller
replace
when L15 is
Short circuit betweenL15 (female1
(1) and L15 (female) IZI, or short Repair or
circuit with chassis ground in
replace
wiring harness between LO8
(female) (21, (4l- L15 (female) (21
*Turn kick-down switch OFF. Short circuit with power

* Max. 1V -GroundC5 (female) (5) to chassis. source in wiring harness Repair or
between L15 (female) (2) and replace
- Turn starting NO
switch ON. LO8 (female) (2). (4)
- Disconnect CO5
and L08.
Transmission &
joystick steering
controller
Kick-down switch
Main monitor
I I I
LO8 (0468)
Network (-1 a 0
Network (-1 g
TWWOl810
WA800-3 20-725
TROUBLESHOOTING E-10
E-10 Boom kick-out does not work

* Check that fuse I (IO) is normal. If it is blown, check for a short circuit with the ground in the wiring
harness between fuse I (II) - FS2 (IO) - L49 (3), (I), or FS2 (IO) - FL2 (I) - F06 (female) (1).
ES
YES
Is voltage
6r
YES_ between L49 (2) _
and chassis
1
ground normal?
Does condition 1
Is voltage *20-30V
* Turn starting m
YES between F06 (1)
- switch ON.
and chassis * Bring a screwdriver
4
- ground normal? close to boom kickout
. Replace with Is resistance
*20-30V proximity switch.
other relay of YES between LO6
same type. - (female) (3) and - *Turn starting NO
chassis ground switch ON.
3 normal?
* Max. 1 R
YE * Turn starting
NO
(female) (1) and switch OFF.
* Disconnect F06.
L-t 1
Is voltage *19-23R
between each pin * Disconnect L16. NO
h of F06 as shown
in Table?
* See Table 1.
* Turn starting N
switch ON.
Table 1
When screwdriver comes close When screwdriver does not come close
Between (I) and (2) 20 - 30 V Max. 3 V
Between (I) and (3) 20 - 30 V o-3ov
Between (2) and (3) Max. 3 V 20 - 30 v
20-726 WANO-3
c
Defective
CL491
boom relay
Replace
I Isresistance II (female) (5) and L16 replace
H
between L16 (female) (1)
(female1 (2) and Defective contact or
chassis wound disconnection in wiring
normal?~ II harness between L16
Repair or
* Max. 1 R NO (female) (2) -chassis

replace
*Turn starting ground

switch OFF.
- Disconnect L16. Repair or
(female) (2) - F06 (female) (2)
Repair or
harness between fuse I (Ill-
replace
L49 (female1 (1). (3). between
FS2 (10) - F06 (female) (1)
harness between F06 replace
ground
Defective boom kick-out

Replace
solenoid
Reolace
WA800-3 20-727
Boom
kick-out
solenoid
Bucket
positioner
solenoid
i 7 (KEsi 210.,,,,
1
41 I1
43HI 2 o-85e
Bucket
Proximi tu
Fo5 (x3) SW itch
Fuse (I)
FS2 (512) Boom
>58AjlO/ '.'!jRL proximity
0,85RW FOE (x3) SW i t ch
L49 L48
Boom Bucket
kick-out positioner
relay relay TWWOI8lI
20-728 WA800-3
TROUBLESHOOTING E-II
E-II Abnormality in bucket positioner function
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Check that fuse I (IO) is normal. If it is blown, check for a short circuit with the ground in the wiring
harness between fuse I (II) - FS2 (IO) - L48 (I), (3), or FS2 (IO) - FL2 (I) - F05 (female) (I).
YES
-
between L4B (2)
r
Is voltage
rl
*Turn starting
YEis between F05 (1) NO
switch ON.
and chassis * Bring a screwdriver close
ground normal? to bucket positioner
L
* Replace with proiximity switch.
other relay of *20-30V
same type. * Turn starting 40
3 jC,E;prcunc ] switch ON.
Is resistance * Max. 1 R
YES between L17 * Turn starting
NC1
(female) (I) and - switch OFF.
(2) normal? . Disconnect F05.
2
Is voltage *19-23n
between each pin _ * Disconnect L17. NO
r of F05 as shown
in Table?
* See Table 1. ‘I i
* Turn starting ..-
NO
switch ON.
Table 1
When screwdriver comes close When screwdriver does not come close
Between (I) and (2) 20 - 30 U Max. 3 U
Between (I) and (3) 20 - 30 u o-3ou
Between (2) and (3) Max. 3 U 20 - 30 u
20-730 WA8003
Cause Remedy
Defective bucket relay

{eplace
(L48)
1 YES harness between L48 3epair or
I Isresistance II (female) (5) and L17 ,eplace
between L17 (female) (1)
(female) (2) and I-I Defective contact or
1;ha-&sground 11 disconnection in wiring
?epair or
harness between L17
- Max. 1 C2 NO (female) (2) - chassis
replace
* Turn starting ground
* Disconnect L17. disconnection in wiring Repair or
(female) (2) - FO5 (female) (2)
Repair or
harness between fuse I (11) -
replace
L48 (female) (1). (3). between
FS2 (10) - F05 (female) (1)
Defective contati or
harness between F05 replace
ground
Defective bucket
Replace
positioner solenoid
Defective bucket
Replace
proximity switch
WA800-3 m-73 1
TROUBLESHOOTING E-II
E-l 1 Related electrical circuit diagram
Boom
kick-out
solenoid
LR4 (M4)
3fB
2 43A
positioner r#7
Bucket
Proximi tv
Fuse (I)
FS2 (S12) Boom
> 58AI 101 ‘. 85RL Proximi tu
~06 (x3) SW i t c h
L49 L48
Boom Bucket
kick-out positioner
re I ay relay TWW0181 I
20-732 WA800-3
TROUBLESHOOTING E-12, E-13, E-14, E-15, E-16, E-17
E-12 Abnormality in lighting up of front working lamp

* Go to Troubleshooting M-10.
E-13 Abnormality in lighting up of rear working lamp

* Go to Troubleshooting M-l 1.
E-14 Abnormality in transmission cut-off

E-15 Abnormality in low idling selection

E-16 Abnormality in parking brake dragging warning

* Go to Troubleshooting M-16, 17.
E-17 Abnormality in buzzer

Ir Go to Troubleshooting M-18.
WAWQ-3 20-733
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
H- 1 Machine does not move ............................................................................................................. 20-802
H- 2 Machine lacks power or speed (every speed range) ............................................................... 20-803
H- 3 Excessive time lag when starting machine or shifting gear .................................................. 20-804
H- 4 Torque converter oil temperature is high................................................................................. 20-805
H- 5 Steering does not turn ................................................................................................................ 20-806
H- 8 Turning, response of steering is poor ...................................................................................... 20-809
H- 9 Turning, response of steering is poor ...................................................................................... 20-810
H-10 Turning, response of steering is poor ...................................................................................... 20-811
H-11 Steering is heavy ......................................................................................................................... 20-812
H-12 Joystick lever is heavy ................................................................................................................ 20-812
H-13 Joystick lever is heavy ................................................................................................................ 20-813
H-14 Steering wheel shakes or jerks .................................................................................................. 20-814
H-17 Minimum turning radii to right and left are different ............................................................. 20-817
H-18 Minimum turning radii to right and left are different ............................................................. 20-817
H-19 Wheel brakes do not work or braking effect is poor .............................................................. 20-818
H-20 Wheel brakes are not released or brakes drag ........................................................................ 20-819
H-21 Boom does not rise ..................................................................................................................... 20-820
H-22 Boom moves slowly or does not have sufficient lifting power ............................................. 20-821
H-23 When raising boom, becomes slow at certain height ............................................................ 20-822
H-24 Boom cylinder cannot hold down bucket ................................................................................. 20-822
H-25 Boom has large amount of hydraulic drift ............................................................................... 20-822
H-26 Boom fluctuates while working ................................................................................................. 20-823
H-27 Boom drops momentarily when lever is operated from HOLD to RAISE ............................ 20-823
H-28 Bucket does not tilt ..................................................................................................................... 20-824
H-29 Bucket moves slowly or has insufficient tilt back power ........................................................ 20-825
H-30 Bucket movement becomes slow during tilt back ................................................................... 20-826
H-31 Bucket cylinder cannot hold down bucket. ............................................................................... 20-826
H-32 Bucket has large amount of hydraulic drift .............................................................................. 20-826
H-33 Bucket fluctuates while traveling under load (work equipment valve HOLD) ..................... 20-827
H-34 Bucket dumps momentarily when lever is operated from HOLD to TILT ............................ 20-827
H-35 Boom and bucket levers do not move smoothly .................................................................... 20-828
WA800-3 20-801
5
TROUBLESHOOTING H-l
H-l Machine does not move

Ask the operator the following points
. Did the machine suddenly stop moving?
Yes = Component seized or damaged
. Was there any abnormal noise when the
machine stopped moving?
Yes = Component broken.
Checks before troubleshooting

. Is oil level in transmission case correct?
. Is monitor display normal?
. Is drive shaft broken?
Note 1: If the solenoid valve and hydraulic pres-

The following symbols are used to indicate the action
sure are normal, the “m” in the Causes to be taken when a cause of failure is located.
column indicates that the valve spool X: Replace A: Repair
does not work. A: Adjust C: Clean
Note 2: If the transmission clutch pressure is
low, but the cause cannot be found in
the above table, a possible cause is
cracks in the valve or transmission.
20-802 WA800-3
TROUBLESHOOTING H-2
H-2 Machine lacks power or speed (every speed range)

. Is oil level transmission case correct?
. Is there any leakage of oil from joints of
piping or valves?
. Is parking brake or wheel brake dragged?
Checking for abnormalities

. Engine high idling speed
. Torque converter stall speed
. Machine travel speed
. Transmission clutch pressure (both high
pressure and low pressure)
. Pressure at outlet port of torque con-
verter pump
. Pilot reducing pressure
Relief pressure at torque converter too low

8 (Items 5 and 7 normal) 0
Torque converter regulator valve pressure (outlet port

9
pressure) too low 0
,. Iron or alurnirnum particles stuck to strainer of transmission
case. C
11 Modulating pressure drops when oil temperature rises. 0
WAND3 20-803
TROUBLESHOOTING H-3
H-3 Excessive time lag when starting machine or shifting gear

. Is there any leakage of oil from joints of
piping or valves?
Transmission modulating pressure too low in every speed

4 0000
range
5 As in Items 4; indicator fluctuates violently
6 1Torque converter oil temperature is above operating range. (J 0
20-804 WA8QG3
TROUBLESHOOTING H-4
H-4 Torque converter oil temperature is high

. Does torque converter oil temperature
go up during torque converter stall, and
down when the torque converter is not
installed?
Yes = Normal (incorrect selection of gear
speed)

. Is transmission filter clogged?

* If the oil temperature is normal but the
oil temperature gauge is outside the
operating range, the oil temperature
gauge is defective.
WA800-3 20-805
TROUBLESHOOTING H-5
H-5 Steering does not turn


• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when this
happened? Where did the noise come
from?

• Is the oil level in the hydraulic tank cor-
rect?
Is the type of oil correct?
• Is the steering shaft broken?
ool
ool
p
ses
pum
• Is the stop valve stopper properly ad-
d sp
g sp
Cau
justed?
e
itch
man
erin
valv
• Has the safety bar been removed from
e
f de
t
nd s
ion
the frame?
of s
on o
suct
seal
mp
alve
ng a
ion
oll
C pu
ety-
bit-r
ston
op v
tuat
tuat
eeri
f
e PP
e Or
e ac
e ac
e sa
e pi
e st
e st
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Hydraulic Orbit- Stop Cylin-
pump roll valve Steering valve der
a b c d e f g h
Remedy
No. Problems
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns only in one direction (left or right)
3 Steering wheel is heavy in both directions (left and right)
4 Work equipment moves
5 Work equipment does not move
6 Abnormal noise comes from around PTO
7 Abnormal noise comes from around PPC pump or hydraulic tank
Oil pressure is low or there is no pressure in

8 both directions (left and right)
When steering
relief pressure
is measured Oil pressure is low or there is no pressure in
9 one direction (left or right)
10 When Orbit-roll output pressure is measured, oil pressure is

found to be low or there is no oil pressure
11 When PPC valve (Orbit-roll) Oil pressure is low

12 basic pressure is measured There is no oil pressure
fl There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-806 WA800-3
5
TROUBLESHOOTING H-6


from?

rect?
e
valv
oid
ses
ol
ol
ump
• Is the stop valve stopper properly ad-
olen
o
spo
p
Cau
ema ve
justed?
s
of p
ck s
lve
d
ing
l
p va
e
n
valv
r va
ysti
end
teer
ctua n of sto
the frame?
ricto
of jo
tion
of d
of s
ion
• Is the operation of the steering and the
seal
mp
t
suct
-suc
s
tion
ion
ion
roll
e
io
steering mode switch correct?
r
C pu
tuat
ston
tuat
tuat
y
way
rbit-
n at
t
suck TO
e
r
f
filte
e PP
e ac
e ac
e ac
e sa
e pi
e 2-
ed i
a
eP
e
e
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Clog
Defe
Defe
Defe
Air
Hydraulic Orbit- Joystick Stop Steering

pump roll valve Valve Cylin-
der
valve
a b c d e f g h i j k l
Remedy C
No. Problems
1 Steering does not move (steering wheel mode only)
When steering
2 mode switch Steering does not move (joystick mode only)
is switched
3 Steering does not move in either mode
7 Steering wheel is heavy in one direction (left or right)
9 Work equipment also speed is slow
Oil pressure is low, or there is no pressure in

12 When steering both directions (left and right)
relief pressure
is measured Oil pressure is low, or there is no pressure in
When Orbit-roll output pressure is measured, oil pressure is found

14
to be low or there is no oil pressure
When joystick solenoid valve output pressure is measured, oil

15
pressure is found to be low or there is no oil pressure
16 When PPC valve (Orbit-roll) Oil pressure is low

WA800-3 20-807
5
TROUBLESHOOTING H-7


from?

rect?
l
ol
poo
p
ses
spo
pum
nd s
the frame?
Cau
ing
e
itch
valv
ema
• Is steering valve open?
teer
d sw
tion
of d
of s
e
n
seal
valv
mp
-suc
ng a
ion
ion
C pu
ston
tuat
tuat
ary
fety
eeri
t
e PP
e ac
e ac
e sa
e ro
e pi
e st
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Hydraulic Rotary Cylin-
pump valve Steering valve der
a b c d e f g
Remedy
No. Problems
3 Joystick lever is heavy in both directions (left and right)
5 Work equipment does not move

8 both directions (left and right)
When steering
relief pressure
10 When rotary valve output pressure is measured, oil pressure

is found to be low or there is no oil pressure
11 When PPC valve (rotary valve) Oil pressure is low

20-808 WA800-3
5
TROUBLESHOOTING H-8
H-8 Turning, response of steering is poor


from?
• Was there previously any symptom, such
as difficulty in steering?
Yes = Wear of related equipments, de-
fective seal
ses
ol
p
poo
pum
spo
rect?
Cau
e
nd s
valv
ring
d of
e
valv
ema
top
stee
lve
n en
ump
tion
of d
f va
of s
ump
n of
ctio
seal
mp
ng p
relie
-suc
ion
tion
oll
t su
ch p
atio
C pu
bit-r
tuat
ston
fety
eeri
ctua
n
a
actu
O
swit
a i
d in
e Or
e PP
e PT
e ac
e sa
e St
em
e pi
a
e
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
suck
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Hydraulic pump Orbit- Stop Steering valve Cylin-

roll valve der
a b c d e f g h i j k l
Remedy
No. Problems
1 Turning, response of steering is poor in both directions (left and right)
2 Turning, response of steering is poor in one direction (left or right)
3 Steering wheel is heavy in both directions
8 Abnormal noise comes from around steering pump or hydraulic tank
9 Abnormal noise comes from around switch pump or hydraulic tank
relief pressure
When Orbit-roll output pressure is measured, oil pressure is found

12
to be low
When PPC valve (Orbit-roll) basic pressure is measured, oil

13
WA800-3 20-809
5
TROUBLESHOOTING H-9


from?
Yes = Wear of related equipment, defec-
tive seal
e
valv
ses
Defe ive ma tion of op valv lenoid

Cau
ol
l
ctiv -way r ction v ng spoo
rect?
pum
spo
o
e
Defe ive act tion of ystick s
lve
Defe ive act relief v mand
d of
ston estricto lve

r va
i
teer
a
Defe tive saf tion of ve
n en
de
p
jo
al
st
s
Defe tive sw ing pum
p
e PP t suctio
Defe tive act tion of

pum
seal
mp
oll
su
C pu
ety-
bit-r
itch
a
ua
ua
ua
in
eer
a
O
u
r
Defe cked in
Defe ive act

filte
e PT
e Or
e pi
e st
e2
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ct
ct
ct
ct
su
c
Defe
Defe
Defe
Clog
Defe
Defe
Air
Hydraulic Orbit- Joy- Stop Steering Cylin-

pump roll stick valve valve Valve der
a b c d e f g h i j k l m n o
Remedy C
No. Problems
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
13 When steering relief Oil pressure is low in both directions (left and right)
14 pressure is measured Oil pressure is low in one direction (left or right)
15 When Orbit-roll output pressure is measured, oil pressure is found to be low
When joystick solenoid valve output pressure is measured, oil
16 pressure is found to be low
When PPC valve (Orbit-roll) basic pressure is measured, oil
17 pressure is found to be low
20-810 WA800-3
5
TROUBLESHOOTING H-10


from?
fective seal
ses
ool
ump
poo
g sp
rect?
Cau
nd s
of p
alve
erin
ema
end
alve
on v
f ste
p
of d
m
ion
mp
e ac relief v
e
u
ucti
o
valv
seal
mp
p
suct
h pu
ion
ion
ring
ty-s
C pu
tuat
tuat
ston
tary
n at
witc
ain
Stee
O
safe
e PP
e PT
e ac
e ro
em
e pi
ed i
s
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
suck
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Hydraulic pump Rotary Steering valve Cylin-

valve der
a b c d e f g h i j k
Remedy
No. Problems
3 Joystick lever is heavy in both directions
4 Joystick lever is heavy in one direction (left or right)
relief pressure
When rotary valve output pressure is measured, oil pressure is

12
found to be low
When PPC valve (rotary valve) basic pressure is measured, oil

13
WA800-3 20-811
5
TROUBLESHOOTING H-11, H-12
H-11 Steering is heavy


• Is the steering difficult to turn?
Yes = Go to H-8 or H-9
• Measure the operating effort and turn-
ing speed, and check the STANDARD
VALUE TABLE to see if they are abnor-
mal.
aft
g sh
erin
l
r ste
poo
as heavy steering?
ses
e
ng s
el o
valv
Cau
whe
i
tive seal
teer
top
of s
ring
of s
stee
ion
ion
oll
bit-r
tuat
tuat
e of
rect?
e Or
e ac
e ac
enc
ctiv
ctiv
ctiv
rfer
• Is the tire inflation pressure correct?
Defe
Defe
Defe
Inte
Orbit- Stop Steering
roll solenoid valve Others
a b c d
Remedy
No. Problems
1 Steering is heavy when turned in both directions (left and right)
2 Steering is heavy when turned in one direction (left or right)
Steering is heavy even when joint between steering shaft and

3
Orbit-roll is disconnected
4 When steering Oil pressure is low in both directions (left and right)
relief pressure
5 is measured Oil pressure is low in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is

6
found to be low
H-12 Joystick lever is heavy

Causes and Remedy

• Abnormality of joystick lever (x)
(The joystick lever is an electrically operated lever, so if the operating effort is large, the
abnormality is in the joystick lever.)
20-812 WA800-3
5
H-13 Joystick lever is heavy


Yes = Go to H-10
• Measure the operating effort and turn-
ing speed, and check the STANDARD
VALUE TABLE to see if they are abnor-
mal.

haft
ng s
ri
ol
stee
as heavy steering?
ses
spo
r or
Cau
ing
tive seal
leve
teer
of s
tick
e
valv
joys
ion
tuat
tary
e of
rect?
e ac
e ro
enc
ctiv
ctiv
rfer
Defe
Defe
Inte
Rotary Steering
valve valve Others
a b c
Remedy
No. Problems
1 Joystick lever is heavy when turned in both directions (left and right)
2 Joystick lever is heavy when turned in one direction (left or right)
Joystick lever is heavy even when joint between steering

3
shaft and rotary valve is disconnected
4 When steering Oil pressure is low in both directions (left and right)
relief pressure
5 is measured Oil pressure is low in one direction (left or right)
When rotary valve output pressure is measured, oil pressure

6
is found to be low
WA800-3 20-813
5
H-14 Steering wheel shakes or jerks


Yes = Go to H-8
• Is there any abnormal noise from around
the steering equipment?

• Is the steering wheel play correct?
• Is there any abnormality in the connec-
tion between the steering shaft and the
Orbit-roll?
l
poo
poo
ses
e
nd s
ng s
valv
Cau
e
valv
ema
eeri
top
lve
t
tion
of d
f va
s
of s
o f
seal
relie
-suc
ion
ion
ion
oll
bit-r
tuat
tuat
tuat
ston
fety
ain
e Or
e ac
e ac
e ac
e sa
em
e pi
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Orbit- Stop Cylin-
roll valve Steering valve
der
a b c d e f g
Remedy
No. Problems
1 Steering wheel shakes or jerks in both directions (left and right)
2 Steering wheel shakes or jerks in one directions (left or right)
During operations or when traveling (when steering is neutral),

3
steering wheel shakes or jerks in both directions (left and right)

4
steering wheel shakes or jerks in one direction (left or right)
5 Steering wheel jerks or there is excessive shock when

steering is operated to end of its stroke
6 Work equipment also jerks
7 Oil pressure is unstable in both directions

When steering (left and right)
relief pressure
is measured Oil pressure is unstable in one direction
8
(left or right)

When Orbit-roll (left and right)
output pressure
10
(left or right)
11 When PPC valve (Orbit-roll) basic pressure is measured, oil

pressure is found to be unstable
20-814 WA800-3
5


Yes = Go to H-9

• Is any failure code for the electrical sys-
tem displayed on the main monitor?
e
• Is the steering wheel play correct?
valv
oid
ol
ool
olen
spo
ses
Orbit-roll?
d sp
e
ck s
valv
e
Cau
ing
valv
e
n
valv
a
ysti
teer
top
m
e
ctor
valv
e
of jo
tion
of d
of s
of s
r i
seal
lief
t
-suc
s
ion
ion
ion
ion
oll
e
n re
r
bit-r
ston
tuat
tuat
tuat
tuat
fety
way
a i
e Or
e ac
e ac
e ac
e ac
e sa
e pi
em
e 2-
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Charge- Orbit- Joy- Cylin-
valve roll stick Steering valve Valve der
a b c d e f g h i
Remedy
No. Problems
1 Abnormality only in steering wheel mode
When steering
2 mode switch Abnormality only in joystick mode
is switched
3 Abnormality in both modes
5 Steering wheel shakes or jerks in one direction (left or right)
6 During operations or when traveling (when steering is neutral),

7 During operations or when traveling (when steering is neutral),



10 When steering Oil pressure is unstable in both directions (left and right)
relief pressure
11 is measured Oil pressure is unstable in one direction (left or right)
12 When Orbit-roll Oil pressure is unstable in both directions (left and right)
output pressure
13 is measured Oil pressure is unstable in one direction (left or right)
14 When joystick Oil pressure is unstable in both directions (left and right)
solenoid valve
15 output pressure is Oil pressure is unstable in one direction (left or right)
measured
16 When PPC valve (Orbit-roll) basic pressure is measured, oil

WA800-3 20-815
5


Yes = Go to H-10

• Is the joystick lever play correct?
steering pilot valve?
ol
poo
spo
ses
nd s
Cau
ing
e
valv
ema
teer
lve
tion
of d
f va
of s
e
valv
seal
relie
-suc
ion
ion
tuat
tuat
ston
tary
fety
ain
e ac
e ac
e ro
e sa
em
e pi
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Rotary Steering valve Cylin-
valve der
a b c d e f
Remedy
No. Problems
2 Steering wheel shakes or jerks in one directions (left or right)

3

4


When steering (left and right)
relief pressure
8
(left or right)

When rotary
valve output (left and right)
pressure
10 is measured Oil pressure is unstable in one direction
(left or right)
11 When PPC valve (rotary valve) basic pressure is measured, oil

20-816 WA800-3
5
H-17 Minimum turning radii to right and left are different

Cause and remedy

• Defective adjustment of stop valve ()
H-18 Minimum turning radii to right and left are different

Cause and remedy

• Defective adjustment of steering stopper bolt ()
WA800-3 20-817
5
H-19 Wheel brakes do not work or braking effect is poor

• Measure the actual brake performance,
and check if there is actually an abnor-
mality or whether it is just the feeling of
the operator. For details, see TESTING
AND ADJUSTING, Measuring brake per-
formance.
Ask the operator the following points.

ator
mul
accu
from?
rom
• Did the problem gradually appear?
as f
of g
fective seal
ding
ses
blee
Cau
p
ve
pum
ston
l
tive
a
uit
e pi
d of
arge
e rig ake v defec
oil ake circ

rect?
l
brak
djus lve
n en
a
r ch
Defe ive sla brake v e
n se
alv
a
r
o
e
Defe ve brak t suctio
rake
n of
mp
Defe tive pis mulato
t
Brea tive ac e pisto
seal
br
• Is the brake pedal play correct?
sc
e pu
ctiv air from

o
de b
i
e di
ck a
ton
tuat
ft br
• Is there any leakage of oil from the brake
na
ht
cu
xle
k
Air ive PTO
insi
a
brak
e ac
e br
Defe ucked i
e le
e a
tube?
e
e
d th
ctiv
ctiv
ctiv
ctiv
kag
r of
Is there any deformation of the tube?
cti
ct
ct
c
c
s
Defe
Defe
Defe
Wea
Defe
Defe
Defe
Blee
• Is the tire inflation pressure and tread
pattern correct? Brake Charge Accu- Brake Slack-
pump valve mulator valve adjuster Wheel brake Others
a b c d e f g h i j k l m n
Remedy
No. Problems
1 Brake has no effect only when left brake pedal is depressed
2 Left brake pedal is light when it is depressed
3 Right brake pedal is light when it is depressed
4 Left brake pedal is heavy when it is depressed
5 Right brake pedal is heavy when it is depressed
6 Abnormally large operating force is needed to obtain specified braking force
7 Abnormal noise is heard from brake when brake is applied
8 Work equipment, steering also do not work
9 Movement of work equipment, steering is slow
11 Abnormal noise comes from around brake pump or hydraulic tank
12 Many metal particles are found in oil drained from axle case
13 When accumulator charge pressure is measured, oil pressure is found to be low
14 Brake stops having effect immediately when engine is stopped
15 There is a time lag before brake takes effect
16 When brake oil pressure is measured, it is found to be low
17 When drop in brake piston pressure is measured, it is found to be excessive
18 When wear of brake disc is measured, it is found to be excessive
19 When air is bled from brake line, air comes out
20-818 WA800-3
5
H-20 Wheel brakes are not released or brakes drag

Ask the operator the following points.
from?

• Does the brake pedal come back fully?
• Is the parking brake still applied (ON)?
ter
ston
ses
djus
Cau
e pi
ck a
brak
e
valv
a
e
l
valv
te
of s
n of
, pla
rake
ake
ion
atio
disc
ht b
tuat
ft br
u
rake
t
e rig
e ac
e ac
e le
ed b
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Seiz
Brake Slack Wheel
valve adjuster brake
a b c d e
Remedy
No. Problems
1 Machine cannot travel at all
2 Machine can travel a small amount
When remaining pressure is released from brake accumulator

3
circuit with left brake pedal only, brake is released
When remaining pressure is released from brake accumulator

4
circuit with right brake pedal only, brake is released
When air bleed plug in wheel portion is loosened, oil flows

5
out and brake is released
6 When air bleed plug is loosened, a large amount of oil flows out
When brake disc wear is measured and brake pedal is released,

7
piston returns
When brake disc wear is measured and brake pedal is released,

8
piston does not return
WA800-3 20-819
5
H-21 Boom does not rise

• Did the problem suddenly fail to rise?
→ Seizure or damage to various units.
oil
• Was unusual noise produced? (Where did
in
it emanate from?)
ined
• Were there previous signs of the boom
onta
slowing down?
air c
→ Wear of parts of flattening of spring.
of
unt
amo
• Is oil level in hydraulic tank correct?
sive
• Is travel of lift arm control lever and spool
xces
correct?
ool)
lve
or e
ses
eal
ol
t sp
f va
p
spo
Cau
on s
mp
pum
f
relie
valv
y (li
en
u
and
pist
p
driv
itch
d
rt of
l
ain
f
poo
e bo
dem
der
i
d sw
l
ing
of m
e
n po
of s
of r
ylin
valv
n of
t be
lty P aulic an
ctio
ion
ion
ion
mc
ump
atio
age
o
tuat
tuat
tuat
n
Pum e in su
boo
actu
dam
O is
PC p
e ac
e ac
e ac
ydr
ged
p PT
e
lty h
rnal
kag
ctiv
ctiv
ctiv
ctiv
ama
Defe
Defe
Defe
Defe
Bloc
Inte
Fau
Fau
D
Steering PPC Work
Tank-pump equipment Cylin-
valve valve control valve der
a b c d e f g h i j
Remedy C
No. Problems
1 Bucket cannot be operated and boom is unable to rise.
The machine body can be lifted up by the boom however, the

2 boom is unable to rise. Or, the bucket operates but the boom is
unable to rise.
3 The boom can rise under no load but cannot rise under load.
4 The hydraulic pump produces an abnormal noise.
5 Boom cylinder has large amount of hydraulic drift.
6 When the engine is at full, steering action is light and excessively

fast.
7 When the engine is at full, steering action is heavy and slow.
20-820 WA800-3
5
H-22 Boom moves slowly or does not have sufficient lifting power
• Is the travel of the boom control lever
il
in o
and also the spool of the work equip-
sted
ned
ment control valve correct?
ntai
adju
• Seizure of work equipment linkage bush-
ir co
ing.
erly
of a
(Does emits abnormal noise)
prop
unt
t y im
Fault check
amo
faul
There is a strong relationship between faults
sive
involving lifting force and lifting speed. Such
and
xces
faults appear initially in the from of insuffi-
lve
or e
cient lifting speed. Measure the lifting speed
f va
y
o
eal
d
o
ses
e bo
ump
of the lift arm when loaded and refer to the
d sp
e
ump
relie
on s
l v
Cau
a
standard value table to determine whether
valv
man
v
ch p
pist
of p
ain
ool
lief
or not there is a fault.
of m
swit
orn
e
der
of re
port
of d
f s
or w
cylin
on o
and
ion
ion
ion
ion
i
age
suct
tuat
tuat
tuat
tuat
om
ulic
dam
d bo
ydra
e ac
e ac
e ac
e ac
e of
age
ctiv
ctiv
ctiv
ctiv
lty h
rnal
kag
Defe
Defe
Defe
Defe
Dam
Bloc
Inte
Fau
Tank- Steering PPC Work equipment Cylin-

pump valve valve control valve der
a b c d e f g h
Remedy C
No. Problems
Bucket tilt back force and speed are abnormal and boom
1
lifting speed is low.
Bucket tilt back force and speed are normal but boom lifting
2
speed is slow.
Some as Item 1 except that boom lifting speed becomes

3
particularly low when oil temperature rises.
4 Hydraulic pump emits abnormal noise.
When the engine is at full, steering action is light and

5
excessively fast.
6 When the engine is at full, steering action is heavy and slow.

7 Cylinder has a large amount of hydraulic drift.
The relief pressure of relief valve of work equipment control

8
valve.
WA800-3 20-821
5
TROUBLESHOOTING H-23, H-24, H-25
H-23 When raising boom, becomes slow at certain height

•. External deformation of boom cylinder.
Cause
• Swollen or internally damaged boom cylinder tube.
fl Regarding other faults occurring during boom rise, refer to item “H-22 Boom moves slowly or
does not have sufficient lifting power”.
H-24 Boom cylinder cannot hold down bucket

Refer to item “H-22 Boom moves slowly or does not have sufficient lifting power”.

• Is travel of boom spool of work equipment control valve correct?
Cause
• Defective boom cylinder rod side suction valve seat of work equipment control valve
• Oil leakage from boom cylinder piston seal
H-25 Boom has large amount of hydraulic drift

• Did the hydraulic drift suddenly become large?
→ Dirt lodged in valve or damaged parts.
• Did the hydraulic drift gradually become large?
→ Worn parts.

• Is the boom spool in the hold position?
→ Seized ring bushing, defective spool detent.
Troubleshooting and cause

• When measuring hydraulic drift, internal leakage of boom cylinder makes oil leakage noise.
→ Damaged cylinder packing.
• When measuring hydraulic drift, boom cylinder does not make oil leakage noise.
→ Defective oil sealing of boom spool.
→ Defective check valve between pipings.
20-822 WA800-3
5
H-26 Boom fluctuates while working

During excavation or ground leveling when the boom control lever is in the “HOLD” position, the
bucket and boom move up and down in accordance with the terrain.
Troubleshooting and cause

Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the
boom cylinder.
1. If the amount of hydraulic drift is greater than the standard value, refer to item “H-25 Boom
has large amount of hydraulic drift”.
2. If the machine body can not be lifted up by the boom cylinder, refer to item “H-24 Boom
cylinder cannot hold down bucket”.
3. If the amount of hydraulic drift is normal and the machine body can be lifted up by the boom
cylinder after the boom is moved several times to cause the boom cylinder to move through its
entire stroke → the trouble is due to the generation of a vacuum in the cylinder.
fl If a vacuum is generated frequently Æ defective suction valve on boom cylinder rod side.
H-27 Boom drops momentarily when lever is operated from HOLD to

RAISE
The boom drops momentarily under its own weight when the boom control lever is gradually
shifted from the “HOLD” position to the “RAISE” position while the engine is at low idling. When
the control lever is put completely into the “RAISE” position, the boom moves normally.
Cause
• Defective seating of work equipment control valve or boom spool check valve.
WA800-3 20-823
5
H-28 Bucket does not tilt back

• Did the bucket suddenly cease to move?
→ Seized or damaged equipment.
• Was any abnormal noise emitted (where
did it emanate from?)
• Was there previous signs of the bucket
il
in o
slowing down?
→ Worn parts or flattening of spring.
ned
n ta i
ir co
of a
• Is the travel of the bucket control lever
unt
and spool correct?
amo
ive
ses
ol)
cess
spo
lve
r ex
Cau
p
pum
ool
eal
ump
f va
o
on s
p
lve
mp
relie
nd s
ing
y (d
a
iven
u
pist
v
teer
of p
bod
ema
ain
lief
g dr
der
nd s
of m
of re
port
of d
lve
cylin
bein
lic a
d va
mp
ion
ion
ion
ion
C pu
drau
cket
not
age
tuat
tuat
suct
tuat
ool
dam
O is
d bu
e PP
e sp
e hy
e ac
e ac
e ac
e in
p PT
age
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
rnal
kag
Defe
Defe
Defe
Defe
Dam
Defe
Defe
Pum
Bloc
Inte
Tank-pump Steering PPC Work equipment
valve valve control valve Cylinder
a b c d e f g h i j
Remedy C A
No. Problems
1 Boom cannot be operated and bucket is unable to tilt back.
2 The machine can be lifted up by the bucket but the bucket cannot
tilt back. Or, the boom operates but the bucket cannot tilt back.
3 The bucket can tilt back under no load but cannot excavate or scoop.
4 The hydraulic pump produces an abnormal noise.
5 Bucket cylinder has large hydraulic drift.
6 Steering action is light and excessively fast when the engine is at

full.
7 Steering action is heavy and slow when the engine is at full.
20-824 WA800-3
5
H-29 Bucket moves slowly or has insufficient tilt back power

• Is the travel of the bucket control lever
il
r
in o
inde
and the work equipment control valve
t cyl
ned
spool correct?
ucke
ntai
• Seizure of bushing in bucket linkage?
ted
the b
ir c o
(Does emits abnormal noise?)
djus
of a
e of
tly a
Fault checks
d sid
unt
ol)
• Check deficient tilt back force by per-
rrec
on ro
amo
spo
forming actual work.
inco
lve)
ket
s ive
• Measure the operating speed of the
an d
n va
buc
x c es
bucket and check it against the standard
uctio
dy (
lve
value table to determine whether or not
or e
ol
eal
f va
e bo
m
ith s
o
ses
it is normal.
on s
u
e
ump
relie
p
valv
e (w
valv
d
Cau
pist
n
witc
of p
valv
ema
ool
ain
lief
g e
der
nd s
p
of m
of re
ama
fety
port
of s
cylin
o f
of sa
lic a
or d
ion
ion
ion
ion
ion
drau
cket
ation
tuat
tuat
tuat
suct
tuat
orn
d bu
e hy
e ac
e ac
e ac
e ac
actu
ly w
e in
age
ctiv
ctiv
ctiv
ctiv
ctive
ctiv
rnal
kag
Defe
Defe
Defe
Defe
Dam
Defe
Bloc
Defe
Inte
Tank- Steering PPC Main control Cylin-
pump valve valve valve der
a b c d e f g h i
Remedy C A
No. Problems
Boom lifting force and lifting speed are abnormal and also
1
bucket tilt force and tilt speed are abnormal.
Boom lifting force and lifting speed are normal but bucket tilt
2
force and tilt speed are abnormal.
Phenomena of item 1 become particularly bad when the oil

3
temperature increases.
4 The hydraulic pump emits an abnormal noise.
Steering action is light and excessively fast when the engine

5
is at full.
6 Steering action is heavy and slow when the engine is at full.

7 The bucket cylinder has a large amount of hydraulic drift.
8 The relief pressure of relief valve of work equipment control

valve is also low.
9 The discharge volume of the hydraulic pump is low.
WA800-3 20-825
5
TROUBLESHOOTING H-30, H-31, H-32
H-30 Bucket movement becomes slow during tilt back

• External deformation of bucket cylinder.
Cause
• Swollen or internally damaged bucket cylinder tube.
• As to other faults which occur when operating bucket, refer to item “H-29 Bucket moves
slowly or has insufficient tilt back power”.
H-31 Bucket cylinder cannot hold down bucket

Refer to item “H-29 Bucket moves slowly or has insufficient tilt back power”.

• Is the travel of bucket spool of work equipment control valve correct?
Cause
• Defective seat of safety valve (with suction valve) of the rod side of bucket cylinder of work
equipment valve.
• Oil leakage from seal of bucket cylinder piston.
H-32 Bucket has large amount of hydraulic drift

• Did the hydraulic drift suddenly become large?
→ Dirt lodged in valve or damaged parts.
• Did the hydraulic drift gradually become large?
→ Worn parts.

• Is the bucket spool in the hold position?
→ Seized ring bushing, faulty spool detent.
Fault check
• Use the standard value table to check whether or not the hydraulic drift of the bucket is
actually large.
Cause
• Oil leakage in bucket cylinder
• Defective seating of safety valve (with suction valve) at bottom side.
Defective oil sealing of bucket spool.
• Defective check valve between pipings.
20-826 WA800-3
5
H-33 Bucket fluctuates while traveling under load

(work equipment valve “HOLD”)
• Excessive play in pin and bushing of work equipment linkage. (Was an abnormal noise
produced?)
Cause
• Defective piston seal of bucket cylinder.
• Defective safety valve (with suction valve) for the head side of bucket cylinder.
If the above symptoms occur together, refer to the troubleshooting items corresponding to
each fault.
H-34 Bucket dumps momentarily when lever is operated from HOLD

to TILT
The bucket dumps momentarily under its own weight when the bucket control lever is gradually
shifted from the “HOLD” position to the “TILT” position while the engine is at low idling.
When the control lever is put completely into the “TILT” position, the bucket moves normally.
Cause
• Defective seating of bucket spool check valve of work equipment valve.
WA800-3 20-827
5
H-35 Boom and bucket levers do not move smoothly

Fault check
Using the standard value table, check
whether or not the operating effort of the
lever is large.
l
bolt
poo
ting
nd s
oun
dy a
l
poo
lve m
e bo lve bo
ool
nd s
e sp
f va
ol
dy a
a
o
ool
rol v
valv
ng o
s p
d sp
lve
t
teni
trol
on
valv
l va
y an
c
link
tigh
con
ool
nt
ntro
trol
bod
e
s of
form
d sp
ent
uipm
ool
t co
con
lve
part
ipm
e sp
y an
-uni
ses
k eq
men
C va
ent
lve
equ
ting
valv
non
bod
Cau
wor
a
uipm
quip
P
ork
rota
C
e to
trol
alve
een
een
e
nw
k eq
in P
u
con
k
o f
PC v
wor
etw
betw
ed i
wor
ver
y
ged
bod
ent
ol
ce b
P
t of
odg
ol le
nce
r lod
s of
s of
ipm
p
eten
aran
s
valv
ter l
ontr
a
e
nes
nes
equ
Poo ct clear
atte
valv
of d
t cle
mat
n of
of c
und
und
m
r k
C
t wo
ortio
rrec
king
ign
ign
t PP
r ro
r ro
ure
rre
Fore
Fore
Inco
Inco
Ben
Seiz
Poo
Stic
Ben
Dist
PPC valve Work equipment
Lever control valve
a b c d e f g h i j k
Remedy C C
No. Problems
Movement of boom and bucket levers becomes sluggish when
1
load is applied and oil pressure increase.
2 Movement of boom and bucket levers becomes sluggish along

with change in oil temperature.
3 Movement of boom and bucket levers becomes partially sluggish

irrespective of oil pressure and temperature.
4 Movement of boom and bucket levers becomes generally sluggish

irrespective of oil pressure and temperature.
Movement of boom and bucket levers does not become light even
5 when the link of the control lever is disconnected at the valve
connection part and the lever operated.
20-828 WA800-3
5
TROUBLESHOOTING OF JOYSTICK STEERING
CONTROL SYSTEM
(J MODE)
Judgement table for joystick steering control system related parts ................................................ 20-852
Action taken by controller when abnormality occurs and problems on machine ......................... 20-854
Electrical circuit diagram for joystick steering control system ......................................................... 20-858
J- 1 Failure code [56] (Short circuit, disconnection in caution relay output) is displayed ........ 20-860
J- 2 Failure code [57] (Short circuit in steering right solenoid (detected when signal
is output)) is displayed ............................................................................................................... 20-861
J- 3 Failure code [58] (Short circuit in steering left solenoid (detected when signal
is output)) is displayed ............................................................................................................... 20-862
J- 4 Failure code [59] (Short circuit in steering right solenoid (power supply side))
is displayed .................................................................................................................................. 20-863
J- 5 Failure code [60] (Short circuit in steering left solenoid (power supply side))
is displayed .................................................................................................................................. 20-864
J- 6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay
output) is displayed..................................................................................................................... 20-865
J- 7 Failure code [62] (Short circuit, disconnection in joystick steering neutral
circuit) is displayed ..................................................................................................................... 20-866
J- 8 Failure code [63] (Short circuit, disconnection in joystick steering lever
potentiometer) is displayed ........................................................................................................ 20-867
J- 9 Abnormality in power supply, power supply voltage ............................................................. 20-868
J-10 Abnormality in joystick steering ON-OFF circuit ...................................................................... 20-869
J-11 Disconnection in steering right solenoid .................................................................................. 20-870
J-12 Disconnection in steering left solenoid ..................................................................................... 20-871
WA800-3 20-851
5
JUDGEMENT TABLE FOR JOYSTICK STEERING
TROUBLESHOOTING CONTROL SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR JOYSTICK STEERING CONTROL

SYSTEM RELATED PARTS
Location of failure
Short circuit in steering right solenoid (detected when signal is output)

Short circuit in steering left solenoid (detected when signal is output)
Short circuit, disconnection in steering solenoid cut relay output

Short circuit, disconnection in joystick steering neutral switch
Short circuit, disconnection in joystick caution relay output
Short circuit in steering right solenoid (power supply side)

Short circuit in steering left solenoid (power supply side)
Short circuit, disconnection in joystick potentiometer

Abnormality in power supply, power supply voltage
Troubleshooting code
when no abnormality
display is given
Abnormality in joystick ON-OFF circuit
Failure
code
Transmission & joystick
Failure mode steering controller
56 57 58 59 60 61 62 63 — —
1 Buzzer does not stop fi T-16
2 Steering does not turn to left fi fi fi fi H-6, H-9, H-12,H-15,J-9, J-12
3 Steering does not turn to right fi fi fi fi H-6, H-9, H-12,H-15,J-9, J-11
4 Steering is always turned to left fi fi fi
5 Steering is always turned to right fi fi fi
6 Both steering and transmission do not work at all fi fi J-9, J-10
Troubleshooting code when error code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7 J-8 — —
20-852 WA800-3
5

OCCURS AND PROBLEMS ON MACHINE
JOYSTICK CONTROL SYSTEM
Iailure code Abnormal system Nature of abnormality
1) Defective caution relay

2) Short circuit with ground, defective contact, or
disconnection in wiring harness between C2 (female) (9) -
L65 (1)
56 Joystick caution relay
disconnection in wiring harness between C2 (female) (19)
- L65 (2) - chassis ground
4) Defective transmission & joystick steering controller
1) Defective steering right solenoid

2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between C2 (female) (2) -
(13)
Short circuit with ground, defective contact, or disconnection
in the following wiring harness
57 Steering right solenoid 4) Wiring harness between C2 (female) (2) - L27 (2)
5) Wiring harness between C2 (female) (13) - L67 (3)
6) Wiring harness between L67 (female) (5) - L27 (I)
1) Defective steering left solenoid

2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between C2 (female) (3) -
(14)
Short circuit with ground, defective contact, or disconnection
in the following wiring harness
58 Steering left solenoid 4) Wiring harness between C2 (female) (3) - L26 (14)
5) Wiring harness between C2 (female) (14) - L67 (3)
6) Wiring harness between L67 (female) (5) - L26 (1)
I) Defective steering right solenoid

Short circuit with power source 2) Short circuit with power source in wiring harness between
in steering right solenoid C2 (female) (2; - L27 (2)
59
circuit 3) Defective transmission & joystick steering controller
I) Defective steering left solenoid

2) Short circuit with power source in wiring harness between
Short circuit with power source C2 (female) (3) - L26 (2)
60
in steering left solenoid circuit 3) Defective transmission & joystick steering controller
20-854 WA800-3

1) Joystick caution relay: ON (voltage between C2 Caution output: OFF Joystick caution
(9) - (19): 20 - 30 V) actuated
2) Resistance of relay coil between C2 (female) (9)
- (19): 200 - 400 R
J-l
3) Resistance of wiring harness between C2
(female) (9) - L65 (female) (1): Less than 1 R
4) Resistance of wiring harness between L65
(female) (2) - C2 (19): Less than 1 R
1) Steering solenoid cut relay: ON (voltage Steering right, left Impossible to use
between C2 (2) and chassis ground: 20 - 30 V) solenoid output: OFF joystick
2) Resistance of steering right solenoid: 10 - 20 R and steering solenoid and joystick caution
3) Resistance between C2 (female) (2), (13) - cut relay output: OFF actuated
chassis ground: Min. 1 MQ and caution relay
Resistance of the following wiring harness: Less output: OFF
than 1 R J-2
4) Wiring harness between C2 (female) (2) - L27
(female) (2)
(female) (3)
6) Wiring harness between L67 (female) (5) - L27
(female) (I 1
between C2 (3) - chassis ground: 20 - 30 VI solenoid output: OFF joystick
2) Resistance of steering left solenoid: 10 - 20 R and steering solenoid and joystick caution
3) Resistance between C2 (female) (31, (14) - cut relay output: OFF actuated
chassis ground: Min. 1 MQ and caution relay
Resistance of the following wiring harness: Less output: OFF
than 1 R J-3
(female) (2)
(female) (3)
6) Wiring harness between L67 (female) (5) - L27
(female) (1)
When joystick lever is at neutral Steering right, left Impossible to use

Voltage between C2 (female) (2) - chassis ground: solenoid output: OFF joystick
Less than 1 V and steering solenoid and joystick caution
J-4
cut relay output: OFF actuated
and caution relay
output: OFF
Steering right, left Impossible to use

When joystick lever is at neutral
joystick
Voltage between C2 (female) (3) - chassis ground: “lenoid output’ OFF
and steering solenoid and joystick caution
Less than 1 V J-5
and caution relay
output: OFF
WA8003 20-855
‘ailure code Abnormal system Nature of abnormality
1) Defective steering solenoid relay

disconnection in wiring harness between Cl (female) (I) -
L67 (female) (1)
61 Steering solenoid cut relay disconnection in wiring harness between JS5 (3) -chassis
ground
I) Defective joystick neutral switch

disconnection in wiring harness between C5 (female) (11)
- JS5 (female) (1)
62 Joystick neutral switch between JS5 (3) - chassis ground
1) Defective boom angle potentiometer

2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness
between C3A (female) (3) - JS2 (1)
3) Short circuit with power source, defective contact, or
63 Joystick potentiometer disconnection in wiring harness between C3A (female) (7)
- JS2 (2)
4) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness
between C3A (female) (17) - JS2 (female) (3)
20-856 WA800-3

Resistance between C5 (female) (11) - chassis Steering right, left Impossible to use
ground: Min. 1 MR (joystick at neutral), Less than solenoid output: OFF joystick
1 R (joystick angled k 5 - 15” from neutral) and steering solenoid and joystick caution
and caution relay
output: OFF J-6
Voltage between C3A (female) (3) - (17): 0.5 - 4.5 V Steering right, left Impossible to use
(voltage when joystick is at neutral: Approx. 2.5 V) solenoid output: OFF joystick
and steering solenoid and joystick caution
and caution relay
output: OFF J-7
between Cl (1) - chassis ground: 20 - 30 V) solenoid output: OFF joystick
2) Resistance of relay coil between Cl (female) (1) and steering solenoid and joystick caution
- chassis ground: 200 - 400 R cut relay output: OFF actuated
3) Resistance of wiring harness between Cl and caution relay
(female) (1) - L67 (female) (1): Less than 1 R output: OFF
4) Resistance of wiring harness between steering J-8
solenoid cut relay L67 (female) (2) - chassis
ground: Less than 1 R
WA800-3 20-857
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK
TROUBLESHOOTING STEERING CONTROL SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING

CONTROL SYSTEM
20-858 WA800-3
5
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK
TROUBLESHOOTING STEERING CONTROL SYSTEM
from the general circuit diagram.
WA800-3 20-859
5
TROUBLESHOOTING J-l
J-l Failure code 1561 (Short circuit, disconnection in caution relay

output) is displayed
Ir When the joystick steering lever is not being used, leave it at the neutral position and turn the
joystick steering selector switch ON.
* Always turn the starting switch OFF before disconnecting any connector.
Remedy

4YES
I Is resistance A
controller
YES between Cl
~ 3 chassis ground Short circuit with chassis
Is resistance normal? ground in harness between Repair or
YES between C2
* Min. 1 MD NO C2 (female) (19) and L65 replace
chassis ground
2_
* Min. 1 MR * Disconnect C2. ground in harness between Repair or
Is resistance
between C2 * Turn starting C2 (female) (1) and L65 replace
YE NO
Ifemale)(9) and C2 - switch OFF. (female) (1)
ffemale) (19) * Disconnect C2. Defective contact or
WXllVal?
5 YES Repair or
1 * 200 - 400 R harness between C2
/I:
* Turn starting replace
Isailure code (female) (19) and L65
displayed when L65 switch OFF. (female) (2)
is replaced with . Disconnect C2.
other relay of same Repair or
t e? replace
* Max. 1 R NO harness between C2
* Turn starting * Turn starting (female) (9) and L65
switch OFF. switch OFF. (female) 11)
* Replace L65 with
o * Disconnect c2 and L65. 1 D$ctive caution (J/S)
another relay of Replace
same type.
. Turn starting
switch ON.
J-l Related electrical circuit diagram

Buzzer
Fuse (I)
FS2 612) L42
a- .D
c.
Transmission & L43

joystick steering
controller
L65
C2 (MI& Joystick caution relay
Joust ick taut ion (-)
LR4 (M4)
TWW01814
20-860 WA800-3
TROUBLESHOOTING J-2
J-2 Failure code [57] (Short circuit in steering right solenoid (detected
when signal is output)) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
to its original position, if the failure code is no longer displayed on the monitor display, the
When the joystick steering lever is not being used, leave it at the neutral position and turn the
Cause Remedy

joystick controller Replace
Short circuit of wiring

harness between C2 (female)
(21 and L27 (female) (2) and
Repair or
wiring harness between C2
, (female) (13) and L67
replace
(female) (13) and
chassis ground * Turn starting (female) (3) with each other
2
switch OFF. Short circuit with chassis
Is resistance
YES between C2 *Min. 1 MR - Disconnect C2. ground in harness between Repair or
- (female) (2) and - *Turn starting NO C2 (female) (13) and L67 replace
chassis ground switch OFF. (female) (3)
1 normal? * Disconnect C2
Is failure code -Min. 1 MR Short circuit with chassis
and L67.
displayed when L67 ground in harness between Repair or
+ Turn starting
is replaced with - NO C2 (female) (2) and L27 replace
switch OFF.
other relay of same (female) (2)
type? * Disconnect C2
and L27.
*Turn starting
Defective steering
switch OFF. I Replace
solenoid cut relay
- Replace L67 with NO
other relay of
same type.
* Turn starting
switch ON.
J-2 Related electrical circuit diagram
Transmission &
Joystick steerlns
ontrol ler
I
c2 MIC21)
Steerins right
@
solenoid (+)
Steering rioht
@
solenoid (-1
Steering left 0
@
solenoid (-1
I
LR4 (M4)
Cl (MIC13)
-q”;,
A-= L67
Joystick solenoid
cut relay
n
Steering right solenoid
TWWOl815
WA800-3 204361
TROUBLESHOOTING J-3
J-3 Failure code 1581 (Short circuit in steering left solenoid (detected
when signal is output)) is displayed
joystick steering selector switch ON. T
Cause Remedy

Is reststance
II joystick controller Replace
YES between Ci! Short circuit of wiring

3 (female) (3) and harness between C2 (female)
Is resistance (14) normal? (3) and L26 (female) (2) and Repair or
YES between C2 wiring harness between C2 replace
NO
- (female) (14) and - ’ Min. ’ MQ (fern&l (141and L67
chassis ground *Turn starting (female) (3) with each other
2
normal? switch OFF.
YES between C2 * Min. 1 MR * Disconnect L26. Repair or
ground in harness betweer I
- (female) (3) and - . Turn starting NO C2 (female) (14) and L67 replace
chassis ground switch OFF. (female) (3)
1 IlClrlllal? * Disconnect C2
Is failure code *Min. 1 MQ Short circuit with chassis
and L67.
displayed when L67 ground in harness betweer Repair or
* Turn starting I
is replaced with - NO C2 (female) (3) and L26 replace
switch OFF.
other relay of same (female) (2)
type? . Disconnect C2
and L26.
* Turn starting
switch OFF. Defective steering
Replace
* Replace L67 with NO solenoid cut relay
other relay of
same type.
. Turn starting
switch ON.

Transmission &
joystick steering
controller
c2 (MIC;l)
Steering left
@
solenoid (t)
Steerins right
a’-
solenord f-1
LR4 (M4)
Steerins left , I I
solenord (-1
I
Cl (MIC13) _L67
>teertns solenald
cut relay
L26 (X2)
Steering left solenoid TWWOIBIG
20-862 WA800-3
TROUBLESHOOTING J-4
J-4 Failure code [59] (Short circuit in steering- riqht

- solenoid (power
supply side)) is displayed
* When the joystick steering lever is not being used, leave it at the neutral position and turn the
Cause I Remedy

H
C2 (female) (2) and
* Max. 1V NO between C2 (female) (2) replace
* Turn starting and L27 (female) (21
switch ON.
Transmission &
joystick steering
control Ier
I I
c2 (MIC21)
solenoid (+I
Steering right
solenoid 1-j
SteerIn left 0
solenoid (-)
I
LR4 (M4)
Cl (MIC13)
L67
Steering solenoid
cut relay
TWW01817
WA800-3 20-863
TROUBLESHOOTING J-5
J-5 Failure code 1601 (Short circuit in steering left solenoid (power
supply side)) is displayed
* Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter
(or socket adapter).

1 YES Replace
joystick steering
C2 (female) (3) and
- Max. 1 V NO between C2 (female) (3) replace
-Turn starting and L26 (female) (2)
switch ON.
Transmission &
joystick steering
controller
I
c2 (MIC21)
SteerIns left
solenoid (+)
Steerlna right
solenoid (-1
Steerins left LR4 (M4)
solenoid (-)
I
Cl (MIC13)
L26 (X2)
Steering left solenoid TWW01818
20-864 WA800-3
TROUBLESHOOTING J-6
J-6 Failure code [611 (Short circuit, disconnection in steering- solenoid

cut relay output) is displayed
Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
Always connect any disconnected connectors before going Cause Remedy
When the joystick steering lever is not being used, leave it at
the neutral position and turn the joystick steering selector
switch ON. 4YES
- GotoA I Is resistance tr-
YES between L67
- (female) (2) and - Defective contact or
3 disconnection in wiring
_ chassis ground
Is resistance normal? harness between L67 Repair or
YES between Cl (female) (2) and chassis replace
* Max. 1 R NO
- (female) 11) and -
* Turn starting ground
2 chassis ground
~ normal? switch OFF. Short circuit with chassis
Is resistance *Min. 1 MD * Disconnect L67. ground in harness Repair or
YES between Ct
between Cl (female) (1) replace
- * Turn starting NO
switch OFF. and L67 (female) (1)
1 (female1 (1) normal?
Is failure code * Disconnect Cl Defective contact or
. Max. 1 R and L67.
displayed when L67 disconnection in wiring qepair or
is replaced with - ’ Turn starting harness between Cl ,eplace
switch OFF. NO
other relay of same (female) (1) and L67
type7 * Disconnect Cl
(female) (1)
* Turn starting and L67.
switch OFF. Defective steering
?eplace
* Replace L67 with NO solenoid cut relay
other relay of
same type.
- Turn starting Defective transmission &
5 YES
joystick steering qeplace
switch ON. Is resistance
between C5
controller
From A- (female) (11) and -
JS5 (female) (1)
normal? qepair or
harness between C5
* Max. 1 R NO .eplace
(female) (11) and JS5
* Turn starting switch OFF. (female) (1)
- Disconnect C5 and JS5.
WA800-3 20-865
TROUBLESHOOTING J-7
J-7 Failure code [62] (Short circuit, disconnection in joystick

_ _ steering
neutral circuit) is displayed
Cause Remedv

YES joystick controller or
Replace
defective installation of
joystick potentiometer
2
Is resistance Defective contact or
YES between C5 4 YE: disconnection in wiring Repair or
- (female) (11) and - Is resistance harness between JS5 replace
chassis ground between JS5 (female) (I) and C5
YE
lVXm?ll? (female) (3) and (female) (II)
* Disconnect C5. 3 chassis ground
* Pull JST lever to Is resistance Hn0rlllal? disconnection in wiring
Repair or
1 right or left end. between JS5 * Disconnect JS5. NC replace
harness between JS5
Is resistance * Max. 1 n NO (male) (1) and (3) * Max. 1 Q (female) (3) and chassis
between C5
normal? ground
(female) (11)and -
chassis ground * Disconnect JS5. Defective neutral switch Replace
IlOrlTal? * Pull JST lever to
* Disconnect C5. right or left end.
*Min. 1 MR * Max. 1 R Short circuit with chassis
between JS5 (female) (I) replace
and C5 (female) (11)
Defective neutral switch Replace

* Disconnect JS5. NO
* Min. 1 MQ
Joystick neutral
JLl 68) JS5 (X3) switch
Transmission &
joystick steering
controller
I
C5tMIC17)
TWWOl820
20-866 WA800-3
TROUBLESHOOTING J-8
J -8 Failure code [63] (Short circuit, disconnection in joystick steering_

lever potentiometer) is displayed
sr After connecting the T-adapter, turn the starting switch ON.
Cause Remedy
Defective joystick Repair, adjust

YES neutral
potentiometer, neutral
2 position misaligned position again
Does voltage
YE between C3A _ source, short circuit with
(female) (3) - (17) 3 YES ground. defective contact, or Repair or
change? Does resistance disconnection in wiring replace
_ between JS2 harness between C3A
. Turn joystick
(female) (3) - JS2 (female) (11
lever to left or toN0 (male) (1) and (3)
between C3A (7) right. change? Defective joystick
Replace
- (17) change? - 0.5 - 4.5 v * Turn joystick NO potentiometer
lever to left or to
right.
. 0.2 - 5 kR Defective transmission &
JO controller
Transmission &
joystick steering
controller
I I
C3A(040iO) JLl (S8) JS7 (X3) Potentiometer
Potentiometer 3 3
3 3
8 3
TWW01821
WA800-3 20-867
TROUBLESHOOTING J-9
J-9 Abnormality in power supply, power supply voltage
* Check that fuse I (IO) is normal.
I Cause Remedy

- YES
1 joystick steering Replace
Cl (female) (7),
Repair or
*20-3ov replace
* Turn starting
switch ON.
Transmission &
joystick steering
controller
Fuse au
Power SUPPIY +24V
TWW01822
20-868 WAKD3
TROUBLESHOOTING J-IO
J-IO Abnormality in joystick steering ON-OFF circuit
* Check that fuse I (I 1) is normal.
Cause Remedy

YES
controller
Is voltage 3 YES Defective system cut-off

Replace
between C3A (19) Is voltage switch
-chassis normal? tl YES between JS3 Defective contact or
I (female) -and disconnection in wiring
*20-30V chassis normal? harness between fuse I (11) - Repair or
* Turn starting L27 (female) (14) and FS2(10)-L32 (l)-JS3 replace
switch ON. .20-30V NO
chassis normal when (female)
* Turn starting
- Turn joystick
ON- OFF switch:
Replace switch,
* Turn starting disconnection in wiring
ON. or repair or
harness between L27
switch OFF. NO replace
(female1 (14) - JS5 (1). (2) -
* Disconnect S4 S4 (male), or defective
and L27. joystick ON-OFF switch
* Max. 1 R
J-IO Related electrical circuit diagram
Joystick UN-Ott switch
FS2
L39
(KES~ 2)
ti
Transmission & System cut-off
joystick steering
switch
controller
I I
C3A1040iO)
+I
:":::'""'""
JS4
TWWOl823
WA800-3 20-869
TROUBLESHOOTING J-II
J-II Disconnection in steering right solenoid
Cause Remedy

joystick controller Replace
YEi-S Defective contact or

3 E/- disconnection in wiring
Is resistance harness between L27 Repair or
YE (female) (1) and L67 replace
* Max. 1 R NO
(female) (13) and (female) (5)
L67 (female) (3) * Turn starting
* Disconnect L27 and L67. disconnection in wiring
Repair or
harness between C2
(female) (2) and L27 * Turn starting RIO (female) (13) and L67 replace
switch OFF. (female) (3)
* Disconnect C2
and L67.
between L27
UO harness between C2 replace
(male) (1) and (2) switch OFF.
* Disconnect C2
(female) (2)
I
.lO-20R
’ and L27.
Defective joystick
* Turn starting I steering right solenoid Replace
switch OFF. NO
valve
* Disconnect L27.
Transmission b
joystick steerlna
controller
L67
Steerina solenoid
cut relay
&27’x2)’
TWWOl817
20-870 WA800-3
J-12
TROUBLESHOOTING
J-12 Disconnection in steering left solenoid
leave it at the neutral position and turn the
* When the joystick steering lever is not being used,
I
Cause Remedy

Ilr Ieplace
ioystick controller
Is resistance
YES between L26 Defective contact or
3 (female) (1) and L67 disconnection in Wiring
Is resistance
- (female) (5) normal? harness between L26 qepair or
yfzz between C2 (female) (1) and L67 replace
- Max. 1 Q NO
- (female) (14) and - (female) (5)
-Turn starting
2 L67 (female) (3) Defective contact Or
P normal? switch OFF.
disconnection in Wiring
Is resistance * Disconnect L26 and L67. Repair or
* Max. 1 R harness between C2
between C2 replace
- (female) (3) and L26 - ’ Turn starting NO (female) (14) and L67
(female) (2) normal? switch OFF. (female) (3)
* Disconnect C2 Defective contact Or
- Max. 1 R and L67. disconnection in Wiring Repair or
-Turn starting harness between C2 replace
switch OFF. NO
normal? - Disconnect c2 (female) (2)
I and L26.
.lO-20R Defective joystick
steering left solenoid Replace
-Turn starting
switch OFF. NO valve
* Disconnect L26.
Transmission h
joystick steering
controller
I I
L” I
Cl (MIC13) Steering solenoid

cut relay
Steering solenoid
cut relay
Steering left solenoid
20-871
WA800-3
TROUBLESHOOTING OF
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)
CONTROL SYSTEM
(A MODE)

Judgement table for AJSS (Advanced Joystick Steering System) control system ........................20-902
Operations of controller against abnormality and conditions of machine caused
by abnormality ..................................................................................................................................20-904
Electric circuit diagram for AJSS (Advanced Joystick Steering System) control ........................... 20-908
A- 1 Failure code [56] (Disconnection or short circuit with chassis ground in
caution buzzer relay system) is displayed ........................................................................20-910
steering lever angle sensor system) is displayed ...........................................................20-911
A- 3 Failure code [58] (Deviation of steering lever angle sensor and frame
angle sensor signals) is displayed ....................................................................................20-912
frame angle sensor system) is displayed .........................................................................20-913
steering lever lock pressure switch system) is displayed ..............................................20-914
steering neutral interlock relay system) is displayed ......................................................20-915
A- 7 Failure code [63] (Disconnection, short circuit with chassis ground, or
short circuit with power source in steering main pressure control EPC
solenoid system) is displayed ............................................................................................20-916
A- 8 Steering speeds in both directions are different ......................................................................20-917
A- 9 Abnormality in console switch (adjustment of steering lever angle sensor
and frame angle sensor is impossible) ............................................................................20-918
A-10 Abnormality in power source and voltage ...............................................................................20-919
WA800-3 20-901
5
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK
TROUBLESHOOTING STEERING SYSTEM) CONTROL SYSTEM
JUDGEMENT TABLE FOR AJSS (ADVANCED JOYSTICK

STEERING SYSTEM) CONTROL SYSTEM
Self-diagnosis display (Display of abnormality)
Disconnection, short circuit with chassis ground, or short circuit with power source in
Disconnection or short circuit with chassis ground in steering lever lock pressure switch system
Disconnection or short circuit with chassis ground in steering neutral interlock relay system
Disconnection or short circuit with chassis ground in steering lever angle sensor system
Deviation of steering lever angle sensor and frame angle sensor potentiometer signals
Disconnection or short circuit with chassis ground in caution buzzer relay system
Disconnection or short circuit with chassis ground in frame angle sensor system
Location of failure
Diagnosis code when failure code is not displayed

steering main pressure control EPC solenoid system
Failure
code
Failure mode
56 57 58 59 60 62 63
1 Engine cannot be started fi E-1
2 Steering speed is heightened fi —
3 Steering speed is lowered fi H-7, H-10, H-13, H16
4 Response of steering system is heightened fi —
5 Response of steering system is lowered fi H-7, H-10, H-13, H16
6 Steering speeds in both directions are different fi fi fi —
7 Machine is steered suddenly after engine is started fi —
8 Engine can be started while machine is steered fi —
9 Caution buzzer does not sound or keeps sounding fi M-22
Diagnosis code when failure code is displayed A-1 A-2 A-3 A-4 A-5 A-6 A-7
20-902 WA800-3
5
(9)
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY

AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Failure code Abnormal system Contents of abnormality
1) Defective caution buzzer relay

2) Disconnection, defective contact, or short circuit with
chassis ground in wiring harness between T/M and J/S
controller C2 (female) (9) – L65 (female) (1)
Disconnection or short
56 circuit with chassis ground between T/M and J/S controller C2 (female) (19) – L65
in caution buzzer relay
(female) (2)
system
4) Defective T/M and J/S controller
1) Improper installation (Misalignment) of steering lever angle

sensor
2) Defective steering lever angle sensor
Disconnection or short 3) Disconnection, defective contact, or short circuit with
circuit with chassis ground chassis ground in wiring harness between T/M and J/S
57
in steering lever angle controller C3A (female) (3) – JS2 (female) (1)
sensor (potentiometer) 4) Defective T/M and J/S controller
system
1) Improper installation (Misalignment) of steering lever angle

sensor
2) Defective steering lever angle sensor
3) Improper installation (Misalignment) of frame angle sensor
4) Defective frame angle sensor
Deviation of steering lever 5) Disconnection, defective contact, or short circuit with
58 angle sensor and frame chassis ground in wiring harness between T/M and J/S
angle sensor signals controller C3A (female) (3) – JS2 (female) (1)
controller C3A (female) (13) – L27 (female) (1)
1) Improper installation (Misalignment) of frame angle sensor

2) Defective frame angle sensor
Disconnection or short chassis ground in wiring harness between T/M and J/S
circuit with chassis ground controller C3A (female) (13) – L27 (female) (1)
59
in frame angle sensor 4) Defective T/M and J/S controller
(potentiometer) system
20-904 WA800-3
5
Normal condition Operation of controller Condition of machine Diagnosis

(Voltage, current, resistance) against abnormality caused by abnormality code
1) Voltage between relay L65 (1) – chassis ground Does not operate at Caution buzzer does
when caution buzzer is turned on: 20 – 30 V all. not sound or keeps
2) Resistance between T/M and J/S controller C2 sounding.
(female) (9) – (19), caution buzzer relay: 200 –
400Ω
3) Resistance between T/M and J/S controller C2 A-1
(female) (9) – L65 (female) (1): Max. 1 Ω
4) Resistance between T/M and J/S controller C2
(female) (19) – L65 (female) (2): Max. 1 Ω
1) Voltage between T/M and J/S controller C3A (7) 1) Turns off steering Steering speeds in
– (16): 0.5 – 4.5 V main pressure both directions are
2) Resistance between steering lever angle sensor control EPC different.
JS2 (male) (1) – (2): 0 – 5 kΩ solenoid output.
2) Controls steering
lever angle sensor A-2
signal voltage as
input voltage.
1) Voltage between T/M and J/S controller C3A (7) Turns off steering Steering speeds in
– (16): 0.5 – 4.5 V main pressure control both directions are
2) Voltage between T/M and J/S controller C3A (3) EPC solenoid output. different.
– (16): 0.5 – 4.5 V
3) Resistance between steering lever angle sensor
JS2 (male) (1) – (2): 0 – 5 kΩ
4) Resistance between frame angle sensor L27 A-3
(male) (1) – (2): 0 – 5 kΩ
1) Voltage between T/M and J/S controller C3A (7) 1) Turns off steering Steering speeds in
– (16): 0.5 – 4.5 V main pressure both directions are
2) Resistance between frame angle sensor L27 control EPC different.
(male) (1) – (2): 0 – 5 kΩ solenoid output.
2) Controls frame
angle sensor signal A-4
voltage as input
voltage.
WA800-3 20-905
5
Failure code Abnormal system Contents of abnormality
1) Defective steering lock pressure switch

controller C3B (female) (9) – L39 (female) (1)
between T/M and J/S controller L39 (female) (2) – chassis
Disconnection or short ground
circuit with chassis ground 4) Defective T/M and J/S controller
60
in steering lever lock
pressure switch system
1) Defective steering neutral interlock relay

Disconnection or short
controller C2 (female) (8) – L95 (female) (1)
circuit with chassis ground 3) Disconnection or defective contact in wiring harness
62
in steering neutral interlock
between L95 (female) (2) – chassis ground
relay system
1) Defective steering main pressure control EPC solenoid

system
Disconnection, short circuit 2) Disconnection, defective contact, short circuit with chassis
with chassis ground, or ground, short circuit, or short circuit with power source in
short circuit with power wiring harness between T/M and J/S controller C2 (female)
63 (7) – L26 (female) (2)
source in steering main
pressure control EPC 3) Short circuit with chassis ground in wiring harness
solenoid system between T/M and J/S controller C2 (female) (17) – L26
(female) (1)
20-906 WA800-3
5
Normal condition Operation of controller Condition of machine Diagnosis

(Voltage, current, resistance) against abnormality caused by abnormality code
Voltage between T/M and J/S controller L39 (female) Turns on caution (In case of
(1) – chassis ground: buzzer. disconnection)
• When steering lock lever is in LOCK: 20 – 30 V 1) Transmission is
• When steering lock lever is in FREE: Max. 1 V kept in N.
2) Steering system is
operable normally.
(In case of short circuit

with chassis ground) A-5
1) Machine can travel
although steering
system is locked.
2) Gear is shifted in F
or R.
3) Gear is shifted in F
or R.
Voltage between T/M and J/S controller C2 (8) – Does not operate at 1) Engine can be
chassis ground: all. started while
• When steering lock lever is in NEUTRAL: Max. 1 V machine is steered.
2) Machine is steered
suddenly after A-6
engine is started
3) Engine cannot be
started.
Current flowing between T/M and J/S controller C2 Turns off steering 1) Response of
(7) – (17): 600 ± 80 mA main pressure control steering system is
EPC solenoid output. lowered.
2) Steering speed is
lowered.
3) Response of A-7
steering system is
heightened
4) Steering speed is
heightened
WA800-3 20-907
5
ELECTRIC CIRCUIT DIAGRAM FOR AJSS (ADVANCED
TROUBLESHOOTING JOYSTICK STEERING SYSTEM) CONTROL

JOYSTICK STEERING SYSTEM) CONTROL
20-908 WA800-3
5
TROUBLESHOOTING JOYSTICK STEERING SYSTEM) CONTROL
from the general circuit diagram.
WA800-3 20-909
5
TROUBLESHOOTING A-1
A-1 Failure code [56] (Disconnection or short circuit with chassis

ground in caution buzzer relay system) is displayed
fl When the joystick steering lever is not being used, leave it at the neutral position.
Cause Remedy
4 YES Defective T/M and J/S

Replace
YES between C2
(female) (9) and Short circuit or short circuit
3 chassis ground with chassis ground in
Is resistance normal? wiring harness between C2 Repair or
YES between C2 NO (female) (9) – L65 (female) replace
• Min. 1 MΩ
(female) (9) and L65 • Turn starting (1)
Is resistance Disconnection or defective
• Disconnect C2 and L65.
between L65 • Max. 1 Ω contact in wiring harness Repair or
YES between C2 (female) (9) –
(female) (2) and • Turn starting NO replace
chassis ground switch OFF. L65 (female) (1)
1 normal?
• Disconnect C2 Disconnection or defective
Is resistance • Max. 1 Ω and L65. contact in wiring harness Repair or
(male) (1) and (2) NO between C2 (female) (19) – replace
switch OFF. L65 (female) (2)
normal? • Disconnect L65.
• 200 – 400 Ω
• Turn starting Defective caution buzzer
relay Replace
switch OFF. NO
• Disconnect L65.
A-1 Related electrical circuit diagram
20-910 WA800-3
5
TROUBLESHOOTING A-2

ground in steering lever angle sensor system) is displayed
Cause Remedy
Improper installation of Replace or

YES steering lever angle adjust neutral
2 sensor (Deviation of position
neutral position)
Does voltage Disconnection, defective
YES
between C3A (3) contact, short circuit with
and (16) change?
3 YES chassis ground, or short circuit Repair or
Does resistance with power source in wiring replace
1
• Lean steering between JS2 harness between C3A (female)
lever to right or NO (male) (1) and (3) (3) – JS2 (female) (1)
Is voltage
between C3A (7) left change? Defective steerintg lever
• 0.5 – 4.5 V Replace
and (16) normal? • Lean steering NO angle sensor
• Starting switch lever to right or
• 4.9 – 5.1 V ON. left
• Starting switch
• 0.2 – 5 kΩ Defective T/M and J/S
ON. Replace
NO • Starting switch OFF. controller
• Disconnect JS2.
WA800-3 20-911
5
TROUBLESHOOTING A-3
A-3 Failure code [58] (Deviation of steering lever angle sensor and
frame angle sensor signals) is displayed
fl When the joystick steering lever is not being used, leave it at
the neutral position. Cause Remedy
fl Always connect any disconnected connectors before going
Improper installation of
Replace or
YES steering lever angle
adjust neutral
sensor (Deviation of
position
neutral position)
2
Improper installation of
4 YES frame angle sensor Replace or
YES Does voltage adjust neutral
between C3A (3) (Deviation of neutral
and (16) change? Does voltage position
YES position)
between C3A (13)
3 and (16) change?
• Lean steering
1 Does resistance
lever to right or Go to A.
between JS2 • Change frame NO
Is voltage left
• 0.5 – 4.5 V NO (male) (1) and (3) angle
between C3A (7) change?
• Starting switch • 0.5 – 4.5 V
and (16) normal?
ON. • Lean steering • Start engine. Defective steerintg lever
Replace
• 4.9 – 5.1 V lever to right or NO angle sensor
• Starting switch left
ON. • 0.2 – 5 kΩ
• Starting switch OFF. Defective T/M and J/S Replace
NO • Disconnect JS2. controller
Disconnection, defective
contact, short circuit with
chassis ground, or short circuit Repair or
6 YES replace
with power source in wiring
Is harness between C3A
harness between C3A (female)
(female) (3) and JS2
YES (female) (1) normal (no (13) – L27 (female) (1)
5 disconnection and short
circuit with chassis
Disconnection, defective
Does resistance ground or power source)? contact, short circuit with
chassis ground, or short circuit Repair or
between L27 • Disconnect C3A, NO with power source in wiring replace
From A
(male) (1) and (3) JS2. harness between C3A (female)
change? (3) – JS2 (female) (1)
• Change frame Defective frame angle

Replace
angle NO sensor
• 0.2 – 5 kΩ
• Start engine.
• Disconnect L27.
20-912 WA800-3
5
TROUBLESHOOTING A-4

ground in frame angle sensor system) is displayed
Cause Remedy
Improper installation of Replace or

YES frame angle sensor adjust neutral
2 (Deviation of neutral position
position)
YES Does voltage Disconnection, defective
between C3A (13) contact, short circuit with
3 YES Repair or
and (16) change? chassis ground, or short circuit
Does resistance with power source in wiring replace
1
• Change frame between L27 harness between C3A (female)
(13) – L27 (female) (1)
Is voltage angle NO (male) (1) and (3)
between C3A (7) • 0.5 – 4.5 V change? Defective frame angle
and (16) normal? • Start engine. Replace
• Change frame NO sensor
angle
• 4.9 – 5.1 V
• 0.2 – 5 kΩ
• Turn starting switch
• Start engine. Defective T/M and J/S
ON. Replace
NO • Disconnect L27. controller
WA800-3 20-913
5
TROUBLESHOOTING A-5

ground in steering lever lock pressure switch system) is displayed
fl When the steering lock lever is in the LOCK position, the steering lock pressure switch is opened
(since the oil pressure is not heightened).
Cause Remedy

Replace
YES between L39
(female) (2) and
3 chassis ground Disconnection or defective
Is resistance normal? contact in wiring harness Repair or
between C3B replace
YES
(female) (9) and • Max. 1 Ω NO between L39 (female) (2) –
chassis ground
2 chassis ground • Turn starting
normal? switch OFF. Disconnection or defective
Is voltage • Disconnect L39. contact in wiring harness Repair or
YES between C3B (9) • Min. 1 MΩ
• Turn starting between C3B (female) (9) – replace
and chassis NO
1 ground normal?
• Disconnect C3B Short circuit with chassis
Is resistance •0–2V and L39. ground in wiring harness Repair or
between L39 • Start engine.
between C3B (female) (9) replace
(male) (1) and (2) • When steering NO
normal? – L39 (female) (1)
lock lever is in
• Max. 1 Ω FREE.
• Disconnect L39. Defective steering lock
Replace
• Start engine. NO pressure switch
When steering
lock lever is in FREE:
Max. 1 Ω
When steering
lock lever is in LOCK:
Min. 1 MΩ
20-914 WA800-3
5
TROUBLESHOOTING A-6

ground in steering neutral interlock relay system) is displayed
Cause Remedy
YES Defective steering neutral

relay Replace
1 4 YES Defective T/M and J/S

Is resistance controller Replace
If L95 relay is YES between L95
replaced, is (female) (2) and
3 chassis ground
Disconnection or defective
system normal? Is resistance contact in wiring harness Repair or
normal?
YES between C2 between L95 (female) (2) – replace
• Replace L95 with (female) (8) and • Min. 1 Ω NO chassis ground
normal relay. 2 chassis ground • Turn starting
Is resistance • Disconnect L95. ground in wiring harness Repair or
Min. 1 MΩ
between C2 between C2 (female) (8) –
NO (female) (8) and L95
(female) (1) normal?
• Disconnect C2 Disconnection or
• Max. 1 Ω and L95. defective contact in
• Turn starting Repair or
NO wiring harness between replace
switch OFF. C2 (female) (8) – L95
• Disconnect C2 (female) (1)
and L95.
WA800-3 20-915
5
TROUBLESHOOTING A-7
A-7 Failure code [63] (Disconnection, short circuit with chassis ground,
or short circuit with power source in steering main pressure
control EPC solenoid system) is displayed
Cause Remedy
4 YES
Go to A.
Is resistance
YES between C2 Short circuit of wiring
3 (female) (7) and harness between C2
Is resistance (17) normal? (female) (7) – L26 (female) Repair or
(2) with wiring harness replace
YES between C2 • Min. 1 MΩ NO between C2 (female) (17)
(female) (17) and
chassis ground • Turn starting and L26 (female) (1)
2 switch OFF.
• Disconnect C2 andL26. Short circuit with chassis
YES between C2 ground in wiring harness
(female) (7) and • Turn starting NO between C2 (female) (17) – replace
chassis ground switch OFF. L26 (female) (1)
1 normal?
If L26 is replaced • Disconnect C2 Short circuit with chassis
with other same • Min. 1 MΩ and L26. Repair or
EPC solenoid, • Turn starting between C2 (female) (7) – replace
does failure code switch OFF. NO
L26 (female) (2)
appear? • Disconnect C2
• Turn starting and L26. Defective steering main
switch OFF. pressure control EPC Replace
• Replace with NO solenoid
other same EPC
solenoid.
• Turn starting 5 YES Defective T/M and J/S
switch ON. Is resistance controller Replace
between C2
From A (female) (7) and
• Max. 1 V NO between C2 (female) (7) – replace
• Disconnect C2 L26 (female) (2)
and L26.
• Turn starting
switch ON.
20-916 WA800-3
5
TROUBLESHOOTING A-8
A-8 Steering speeds in both directions are different

fl If an error code is displayed, check the parts corresponding to it.
Cause Remedy
Deviation of steering
lever angle sensor or Repair or
frame angle sensor replace
potentiometer
WA800-3 20-917
5
TROUBLESHOOTING A-9
A-9 Abnormality in console switch (adjustment of steering lever angle

sensor and frame angle sensor is impossible)
Cause Remedy

controller Replace
Is voltage between
YES C3A (female) (19)
3 and chassis ground
normal? Repair or
Is resistance source in wiring harness
YES between C3A • Max. 1 V NO between C3A (female) (19) replace
(female) (6) and JS3 • Turn starting switch – JS4 (male) (1)
2 (female) (1) normal? ON.
Is resistance • Disconnect C3A and JS4. Disconnection or defective
• Max. 1 Ω • Turn starting switch ON contact in wiring harness Repair or
YES between C3A
(female) (19) and • Turn starting NO between C3A (female) (6) – replace
JS4 (male) (1) switch OFF. JS3 (female) (1)
1
normal? • Disconnect C3A
Is resistance Disconnection or defective
between console • Max. 1 Ω and JS3. contact in wiring harness
switch JS3 (male) • Turn starting Replace
between C3A (female) (19)
(1) and JS4 (female) switch OFF. NO
– JS4 (male) (1)
(1) normal? • Disconnect C3A
• When left armrest is and JS4.
at rearmost position Defective console switch Replace
(switch is ON): NO
Max. 1 Ω
• When left armrest is not at rearmost
position (switch is OFF): Min. 1 MΩ
• Disconnect JS3 and JS4.
20-918 WA800-3
5
TROUBLESHOOTING A-10
A-10 Abnormality in power source and voltage

Cause Remedy
YES Defective T/M and J/S Replace

1 controller
Is voltage between Short circuit with chassis
C1 (7), (13), C2 (1), ground, disconnection, or
(12) and C1 (6),
(12), C2 (11), (21)
2 YES defective contact in wiring
Repair or
Is resistance harness between C1
normal?
between C1
replace
(female) (7), (13), C2
• 20 – 30 V (female) (6), (12), C2 (female) (1), (12) - fuse II (6)
• Turn starting (female) (11), (21)
NO and chassis ground Disconnection or defective
switch ON. normal?
contact in wiring harness Repair or
• Max. 1 Ω NO between C1 (female) (6), replace
• Turn starting (12), C2 (female) (1), (12) –
switch OFF. chassis ground
• Disconnect C1
and C2.
WA800-3 20-919
5
TROUBLESHOOTING OF WORK EQUIPMENT
CONTROL SYSTEM
(WRK MODE)
Contents of abnormality in work equipment control system and

actions of controller against them ................................................................................... 20-1004
Electrical circuit diagram for work equipment control system ...................................................... 20-1010
[WRK-1] Lowering of work equipment controller source voltage ............................................... 20-1013
[WRK-2] Abnormality in sensor power source system ................................................................. 20-1014
[WRK-3] Abnormality in solenoid power source system .............................................................. 20-1016
[WRK-4] Grounding fault in remote positioner RAISE position set switch system ................... 20-1017
[WRK-5] Disconnection or short circuit (with power source) in remote positioner
RAISE position set switch .................................................................................................. 20-1018
[WRK-6] Grounding fault in remote positioner LOWER position set switch system ................. 20-1019
LOWER position set switch system .................................................................................. 20-1020
[WRK-8] Grounding fault in remote positioner RAISE/LOWER selector switch system ............ 20-1021
RAISE/LOWER selector switch system ............................................................................. 20-1022
[WRK-10] Disconnection, grounding fault, or short circuit (with power source)
in boom angle potentiometer signal system ...................................................................20-1023
[WRK-11] Abnormality in boom EPC lever potentiometer system
(Disconnection or grounding fault in main circuit) ........................................................ 20-1024
[Short circuit in main circuit (with source power)] ........................................................ 20-1025
(Disconnection or grounding fault in sub circuit) ............................................................20-1026
[Short circuit in sub circuit (with source power)] ............................................................20-1027
(Shifting of main circuit and sub circuit form each other) ............................................ 20-1028
[WRK-16] Abnormality in bucket EPC lever potentiometer system
(Disconnection or grounding fault in main circuit) ........................................................ 20-1029
[Short circuit in main circuit (with source power)] ........................................................ 20-1030
(Disconnection or grounding fault in sub circuit) ............................................................20-1031
(Short circuit in sub circuit) ............................................................................................... 20-1032
(Shifting of main circuit and sub circuit form each other) ............................................ 20-1033
WA800-3 20-1001
(7)
[WRK-21] Disconnection in engine speed sensor system ............................................................... 20-1034
[WRK-22] Grounding fault in engine speed sensor system ............................................................20-1035
[WRK-23] Grounding fault in remote positioner RAISE position set display system ...................20-1036
[WRK-24] Disconnection in remote positioner RAISE position set display system ..................... 20-1037
[WRK-25] Short circuit (with power source) in remote positioner
RAISE position set display system ................................................................................... 20-1038
[WRK-26] Grounding fault in remote positioner LOWER position set display system ............... 20-1039
[WRK-27] Disconnection in remote positioner LOWER position set display system ...................20-1040
LOWER position set display system .................................................................................20-1041
RAISE stop display system .................................................................................................20-1042
[WRK-30] Disconnection in remote positioner RAISE stop display system ...................................20-1044
[WRK-31] Grounding fault in remote positioner RAISE stop display system............................... 20-1046
LOWER stop display system ............................................................................................. 20-1048
[WRK-33] Disconnection in remote positioner LOWER stop display system ............................... 20-1050
[WRK-34] Grounding fault in remote positioner LOWER stop display system ............................ 20-1052
[WRK-35] Disconnection in boom RAISE magnet detent system ...................................................20-1054
[WRK-36] Short circuit (with power source) in boom RAISE magnet detent system ................. 20-1055
[WRK-37] Grounding fault in boom RAISE magnet detent system ............................................... 20-1056
[WRK-38] Disconnection in boom FLOAT magnet detent system ................................................. 20-1057
[WRK-39] Short circuit (with power source) in boom FLOAT magnet detent system ................ 20-1058
[WRK-40] Grounding fault in boom FLOAT magnet detent system .............................................. 20-1059
[WRK-41] Disconnection in bucket TILT magnet detent system .................................................... 20-1060
[WRK-42] Short circuit (with power source) in bucket TILT magnet detent system ................... 20-1061
[WRK-43] Grounding fault in bucket TILT magnet detent system ................................................. 20-1062
[WRK-44] Disconnection or grounding fault in work equipment neutral lock solenoid
A system ...............................................................................................................................20-1063
[WRK-45] Short circuit (with power source) in work equipment neutral lock solenoid
A system ...............................................................................................................................20-1064
[WRK-46] Disconnection or grounding fault in work equipment neutral lock solenoid
B system ...............................................................................................................................20-1065
[WRK-47] Short circuit (with power source) in work equipment neutral lock solenoid
B system ...............................................................................................................................20-1066
[WRK-48] Disconnection in alarm buzzer system ............................................................................ 20-1067
[WRK-49] Grounding fault in alarm buzzer system ..........................................................................20-1068
[WRK-50] Short circuit (with power source) in alarm buzzer system ............................................ 20-1069
[WRK-51] Disconnection or short circuit (with power source) in boom RAISE EPC solenoid
A system ...............................................................................................................................20-1070
20-1002 WA800-3
(7)
[WRK-52] Grounding fault in boom RAISE EPC solenoid A system ............................................. 20-1071
[WRK-53] Disconnection or short circuit (with power source) in boom RAISE EPC solenoid
B system ...............................................................................................................................20-1072
[WRK-54] Grounding fault in boom RAISE EPC solenoid B system .............................................. 20-1073
[WRK-55] Disconnection or short circuit (with power source) in boom LOWER EPC solenoid
A system ...............................................................................................................................20-1074
[WRK-56] Grounding fault in boom LOWER EPC solenoid A system ............................................20-1075
[WRK-57] Disconnection or short circuit (with power source) in boom LOWER EPC solenoid
B system ...............................................................................................................................20-1076
[WRK-58] Grounding fault in boom LOWER EPC solenoid B system ............................................20-1077
[WRK-59] Disconnection or short circuit (with power source) in bucket TILT EPC solenoid
A system ...............................................................................................................................20-1078
[WRK-60] Grounding fault in bucket TILT EPC solenoid A system ............................................... 20-1079
[WRK-61] Disconnection or short circuit (with power source) in bucket TILT EPC solenoid
B system ...............................................................................................................................20-1080
[WRK-62] Grounding fault in bucket TILT EPC solenoid B system .................................................20-1081
[WRK-63] Disconnection or short circuit (with power source) in bucket DUMP EPC solenoid
A system ...............................................................................................................................20-1082
[WRK-64] Grounding fault in bucket DUMP EPC solenoid A system ............................................ 20-1083
[WRK-65] Disconnection or short circuit (with power source) in bucket DUMP EPC solenoid
B system ...............................................................................................................................20-1084
[WRK-66] Grounding fault in bucket DUMP EPC solenoid B system ............................................ 20-1085
[WRK-67] Abnormality in work equipment lever neutral caution system .....................................20-1086
[WRK-68] Disconnection or grounding fault in boom lock switch system ................................... 20-1087
[WRK-69] Short circuit (with power source) in boom lock switch system ................................... 20-1088
[WRK-70] Abnormality in bucket cylinder proximity switch system ............................................. 20-1089
in EPC lever adjustment mode input system ...................................................................20-1090
in boom angle adjustment mode input system ............................................................. 20-1091
WA800-3 20-1003
(7)
CONTENTS OF ABNORMALITY IN WORK EQUIPMENT CONTROL
TROUBLESHOOTING SYSTEM AND ACTIONS OF CONTROLLER AGAINST THEM

SYSTEM AND ACTIONS OF CONTROLLER AGAINST THEM
Actions of controller
Boom LOWER output A
Boom LOWER output B

Boom RAISE output A
Boom RAISE output B
Boom LOWER detent

Boom RAISE detent
No. Content of Behavior
Bucket TILT A
Bucket TILT B
abnormality of machine
Grounding fault in remote positioner State of remote positioner RAISE

1 RAISE position set switch stop position set mode is maintained. – – – – – – – –
Grounding fault in remote positioner State of remote positioner LOWER
2 LOWER position set switch stop position set mode is maintained. – – – – – – – –
Grounding fault in remote positioner Remote positioner does not
3 RAISE/LOWER selector switch function. – – – – – – – –
Disconnection or grounding fault in Remote positioner does not
4 boom angle potentiometer signal system function. – – – – – – – –
Short circuit with 24-V system in boom Remote positioner does not
5 angle potentiometer signal system function. – – – – – – – –
Disconnection or grounding fault in boom If sub potentiometer is normal,
6 lever main potentiometer signal system operation is continued normally. () () () () () () – –
Short circuit with 24-V system in boom If sub potentiometer is normal,
7 lever main potentiometer signal system operation is continued normally. () () () () () () – –
Disconnection or grounding fault in boom
8 lever sub potentiometer signal system Operation is continued normally. () () () () () () – –
Short circuit with 24-V system in boom
9 lever sub potentiometer signal system Operation is continued normally. () () () () () () – –
Deviation of boom lever potentiometer
10 signal Boom does not operated. – –
Disconnection or grounding fault in bucket If sub potentiometer is normal,
11 lever main potentiometer signal system operation is continued normally. – – – – – – () ()
Short circuit with 24-V system in bucket If sub potentiometer is normal,
12 lever main potentiometer signal system operation is continued normally. – – – – – – () ()
Disconnection or grounding fault in bucket
13 lever sub potentiometer signal system Operation is continued normally. – – – – – – () ()
Short circuit with 24-V system in bucket
14 lever sub potentiometer signal system Operation is continued normally. – – – – – – () ()
Deviation of bucket lever potentiom-
15 eter signal Bucket does not operate. – – – – – –
Disconnection in engine speed sensor Engine speed is assumed to be 2,100
16 signal system rpm and remote positioner functions. – – – – – – – –
Grounding fault in remote positioner RAISE set indicator does not
17 RAISE set display system light up. – – – – – – – –
Grounding fault in remote positioner LOWER set indicator does not
18 LOWER set display system light up. – – – – – – – –
Short circuit with 24-V system in remote RAISE stop indicator does not
19 positioner RAISE stop display system light up. – – – – – – – –
Short circuit with 24-V system in remote LOWER stop indicator does not
20 positioner LOWER stop display system light up. – – – – – – – –
Disconnection or short circuit with 24-V RAISE detent is not turned ON or
21 system in boom RAISE detent solenoid OFF automatically. – – – – – – – –
Grounding fault on power supply side
22 of boom RAISE detent solenoid RAISE detent is not turned ON. – – – – – – –
Disconnection or short circuit with 24-V FLOAT detent is not turned ON
23 system in boom FLOAT detent solenoid or OFF automatically. – – – – – – – –
24 of boom FLOAT detent solenoid FLOAT detent is not turned ON. – – – – – – –
Disconnection or short circuit with 24- TILT detent is not turned ON or
25 V system in bucket TILT detent system OFF automatically. – – – – – – – –
20-1004 WA800-3
(7)
(: Stops function, : Flashes error indicator LED)

Display of LOWER stop
Display of RAISE stop
Display of LOWER set

Display of RAISE set
Bucket TILT detent
Remote positioner
Remote positioner
Remote positioner
Remote positioner
Bucket DUMP A
Bucket DUMP B
LOWER control
RAISE control
Error Remarks Diagnosis
Buzzer
LOWER set
LED code
RAISE set
Flashing
– – – – – – – – (1Hz) – WRK-4
Flashing
– – – – – – – – (1Hz) – WRK-6
Flashing
– – – – – (1Hz) – WRK-8
Flashing
– – – (1Hz) – WRK-10
Flashing
– – – (1Hz) – WRK-10
Flashing (1.6 sec Only when main and sub potentiom-
– – – – – – – (1Hz) 50% duty) eters have abnormality simulta- WRK-11
(1.6 sec neously, output is kept OFF until key
Flashing
– – – – – – – (1Hz) 50% duty) is turned to OFF position. WRK-12
If sub potentiometer is normal,
Flashing (1.6 sec control is continued with its voltage.
– – – – – – – (1Hz) 50% duty) Once any abnormality is detected,
WRK-13
Flashing (1.6 sec error LED and buzzer are kept ON
– – – – – – – (1Hz) 50% duty) until key is turned to OFF position. WRK-14
Flashing 1.6 sec
– – – – – – – (1Hz) 50% duty WRK-15
Flashing (1.6 sec Only when main and sub potentiom-
() () () – – – – 50% duty) eters have abnormality simulta- WRK-16
(1Hz)
neously, output is kept OFF until key
Flashing (1.6 sec
() () () – – – – 50% duty)
is turned to OFF position. WRK-17
(1Hz)
If sub potentiometer is normal,
Flashing (1.6 sec
() () () – – – – 50% duty)
control is continued with its voltage. WRK-18
(1Hz) Once any abnormality is detected,
Flashing (1.6 sec error LED and buzzer are kept ON
() () () – – – – 50% duty) until key is turned to OFF position. WRK-19
(1Hz)
Flashing (1.6 sec
() () () – – – – 50% duty) WRK-20
(1Hz)
Flashing 1.6 sec Engine speed is assumed to be
– – – – – – – – –
(1Hz) 50% duty 2,100 rpm. WRK-21
– – – – – – – – – – – – WRK-23
– – – – – – – – – – – – WRK-26
– – – – – – – – – – – – WRK-29
– – – – – – – – – – – – WRK-32
Flashing WRK-35
– – – – – (2Hz) –
WRK-36
Flashing
– – – – – (2Hz) – WRK-37
Flashing WRK-38
– – – – – (2Hz) –
WRK-39
Flashing
– – – – – (2Hz) – WRK-40
Flashing WRK-41
– – – – – – – (2Hz) – WRK-42
WA800-3 20-1005
(7)
Boom LOWER output A
Boom LOWER output B

Boom RAISE output A
Boom RAISE output B
Boom LOWER detent

Boom RAISE detent
Bucket TILT A
Bucket TILT B

26 of bucket TILT detent system TILT detent is not turned ON. – – – – – – – –
Disconnection or grounding fault in Even if safety lock lever is in LOCK position,
27 work equipment neutral lock neutral lock solenoid does not operate. – – – – – – – –
solenoid A Work equipment can operate normally.
28 Short circuit with 24-V system in work Work equipment speed is – – – – – – – –
equipment neutral lock solenoid A reduced to half.
Disconnection or grounding fault in Even if safety lock lever is in LOCK position,
29 work equipment neutral lock neutral lock solenoid does not operate. – – – – – – – –
solenoid B Work equipment can operate normally.
30 Short circuit with 24-V system in work Work equipment speed is – – – – – – – –
equipment neutral lock solenoid B reduced to half.
Disconnection, short circuit with 24-V
31 system, or grounding fault in alarm buzzer Buzzer does not sound or stop. – – – – – – – –
Disconnection or short circuit with 24-V Work equipment speed is
32 system in boom RAISE EPC solenoid A reduced to half. – – – – – – –
Grounding fault in boom RAISE EPC Boom RAISE speed is reduced to
33 solenoid A half. – – – – – – –
34 system in boom RAISE EPC solenoid B reduced to half.
– – – – – – –
Grounding fault in boom RAISE EPC Boom RAISE speed is reduced to
35 solenoid B half.
– – – – – – –
36 system in boom LOWER EPC solenoid A reduced to half.
– – – – – – –
Grounding fault in boom LOWER EPC Boom LOWER speed is reduced
37 solenoid A to half.
– – – – – – –
38 system in boom LOWER EPC solenoid B reduced to half.
– – – – – – –
Grounding fault in boom LOWER EPC Boom LOWER speed is reduced
39 solenoid B to half.
– – – – – – –
40 system in bucket TILT EPC solenoid A reduced to half.
– – – – – – –
Grounding fault in bucket TILT EPC Bucket TILT speed is reduced to
41 solenoid A half.
– – – – – – –
42 system in bucket TILT EPC solenoid B reduced to half.
– – – – – – –
Grounding fault in bucket TILT EPC Bucket TILT speed is reduced to
43 solenoid B half.
– – – – – – –
44 system in bucket DUMP EPC solenoid A – – – – – – – –
reduced to half.
Grounding fault in bucket DUMP EPC Bucket DUMP speed is reduced
45 solenoid A – – – – – – – –
to half.
46 system in bucket DUMP EPC solenoid B – – – – – – – –
reduced to half.
Grounding fault in bucket DUMP EPC Bucket DUMP speed is reduced
47 solenoid B – – – – – – – –
to half.
Lowering of work equipment control-
48 ler source voltage Work equipment stops in neutral.
Abnormality in sensor power source
49 (5 V) Work equipment cannot operate.
Abnormality in solenoid power source
50 system Work equipment stops in neutral.
Abnormality in work equipment lever
51 neutral caution system Work equipment cannot operate.
20-1006 WA800-3
(7)


Bucket TILT detent
Remote positioner
Remote positioner
Remote positioner
Remote positioner
Bucket DUMP A
Bucket DUMP B
LOWER control
RAISE control
Buzzer
LOWER set
LED code
RAISE set
Flashing
– – – – – – (2Hz) – WRK-43
Flashing
– – – – – – – (2Hz)
– WRK-44
Flashing
– – – – – – – (2Hz) – WRK-45
Flashing
– – – – – – – (2Hz) – WRK-46
Flashing
– – – – – – – (2Hz)
– WRK-47
WRK-48
– – – – – – – – – – – – – WRK-49
WRK-50
Flashing (1.6 sec In addition to left, 24-V output of work
– – – – – – – (2Hz) 50% duty) equipment neutral lock solenoid A WRK-51
Flashing (1.6 sec
– – – – – – –
(2Hz) 50% duty) WRK-52
– – – – – – –
(2Hz) 50% duty) equipment neutral lock solenoid B WRK-53
Flashing (1.6 sec
– – – – – – –
– – – – – – –
(2Hz) 50% duty) equipment neutral lock solenoid A WRK-55
Flashing (1.6 sec
– – – – – – –
– – – – – – –
(2Hz) 50% duty) equipment neutral lock solenoid B WRK-57
Flashing (1.6 sec
– – – – – – –
– – – – – – –
(2Hz) 50% duty) equipment neutral lock solenoid A WRK-59
Flashing (1.6 sec
– – – – – – –
– – – – – – – (2Hz) 50% duty) equipment neutral lock solenoid B WRK-61
Flashing (1.6 sec
–– – – – – – – (2Hz) 50% duty) WRK-62
– – – – – – (2Hz) 50% duty) equipment neutral lock solenoid A WRK-63
Flashing (1.6 sec
– – – – – – (2Hz) 50% duty) WRK-64
– – – – – – (2Hz) 50% duty) equipment neutral lock solenoid B WRK-65
Flashing (1.6 sec
– – – – – – (2Hz) 50% duty) WRK-66
Flashing (1.6 sec
– – – – (5Hz) 50% duty) WRK-1
Flashing (1.6 sec
– – – – (5Hz) 50% duty) WRK-2
Flashing (1.6 sec
– – – – (5Hz) 50% duty) WRK-3
240msec
– – – – – – – – – ON:80msec, WRK-67
OFF:160msec
WA800-3 20-1007
(7)
Boom LOWER output A
Boom LOWER output B

Boom RAISE output A
Boom RAISE output B
Boom LOWER detent

Boom RAISE detent
Bucket TILT A
Bucket TILT B
Disconnection or grounding fault in work Work equipment does not move

52 equipment safety lock lever switch when safety lock lever is in FREE – – – – – – – –
position.
Short circuit with 24-V system in work Work equipment moves when
53 equipment safety lock lever switch safety lock lever is in LOCK – – – – – – – –
position.
Disconnection or short circuit with 24- Remote positioner RAISE stop
54 V system in remote positioner RAISE position cannot be set. – – – – – – – –
position set switch
Disconnection or short circuit with 24- Remote positioner LOWER stop
55 V system in remote positioner LOWER position cannot be set. – – – – – – – –
position set switch
Disconnection or short circuit with 24- Remote positioner RAISE and
56 V system in remote positioner RAISE/ LOWER cannot be selected. – – – – – – – –
LOWER selector switch
Disconnection or short circuit with 24- Bucket positioner does not function
57 V system in bucket cylinder proximity (Tilt detent is not turned OFF when – – – – – – – –
switch bucket is higher than level position).
Bucket positioner does not
58 Grounding fault in bucket cylinder function (Tilt detent is not turned
ON when bucket is lower than – – – – – – – –
proximity switch
level position).
Disconnection or short circuit with 24-
59 V system in EPC lever adjustment Initial values cannot be adjusted. – – – – – – – –
mode input system
Grounding fault in EPC lever adjust- Operating feel of lever is differ-
60 ment mode input system ent. – – – – – – – –
Disconnection or short circuit with 24-
61 V system in boom angle adjustment Initial values cannot be adjusted. – – – – – – – –
mode input system
Grounding fault in boom angle Remote positioner stop position
62 is irregular. – – – – – – – –
adjustment mode input system
Grounding fault in engine speed Remote positioner stop position
63 is deviated. – – – – – – – –
sensor system
Disconnection in remote positioner RAISE set lamp does not light
64 up. – – – – – – – –
RAISE set display system
Short circuit with 24-V system in remote RAISE set lamp does not go off. – – – – – – – –
65 positioner RAISE set display system
Disconnection in remote positioner LOWER set lamp does not light
66 up. – – – – – – – –
LOWER set display system
Short circuit with 24-V system in remote – – – – – – – –
67 positioner LOWER set display system LOWER set lamp does not go off.
Disconnection in remote positioner RAISE stop lamp does not light
68 up. – – – – – – – –
RAISE stop display system
Grounding fault in remote positioner – – – – – – – –
69 RAISE stop display system RAISE stop lamp does not go off.
Disconnection in remote positioner LOWER stop lamp does not light – – – – – – – –
70 LOWER stop display system up.
Grounding fault in remote positioner LOWER stop lamp does not go – – – – – – – –
71 LOWER stop display system off.
Work equipment stops in neutral.
If machine stops with work
72 Abnormal operation of CPU equipment lever in neutral and key – – – – – – – –
is turned to OFF position, normal
operation is started again.
20-1008 WA800-3
(7)


Bucket TILT detent
Remote positioner
Remote positioner
Remote positioner
Remote positioner
Bucket DUMP A
Bucket DUMP B
LOWER control
RAISE control
Buzzer
LOWER set
LED code
RAISE set
– – – – – – – – – – – – – WRK-68
– – – – – – – – – – – – – WRK-69
– – – – – – – – – – – – – WRK-5
– – – – – – – – – – – – – WRK-7
– – – – – – – – – – – – – WRK-9
– – – – – – – – – – – – – WRK-70
– – – – – – – – – – – – – WRK-70
– – – – – – – – – – – – – WRK-71
– – – – – – – – – – – – – WRK-71
– – – – – – – – – – – – – WRK-72
– – – – – – – – – – – – – WRK-72
– – – – – – – – – – – – – WRK-22
– – – – – – – – – – – – – WRK-24
– – – – – – – – – – – – – WRK-25
– – – – – – – – – – – – – WRK-27
– – – – – – – – – – – – – WRK-28
– – – – – – – – – – – – – WRK-30
– – – – – – – – – – – – – WRK-31
– – – – – – – – – – – – – WRK-33
– – – – – – – – – – – – – WRK-34
– – – – – – – – – – – – – –
WA800-3 20-1009
(7)
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT

CONTROL SYSTEM
20-1010 WA800-3
(7)
WA800-3 20-1011
(7)
TROUBLESHOOTING WRK-1
[WRK-1] Lowering of work equipment controller source voltage
Troubleshooting
Code
Trouble Lowering of work equipment controller source voltage
WRK-1
Description of
Trouble • The source voltage of the work equipment controller is low.
Controller
Reaction • Cannot detect interlock signals normally.
Effect on
Machine • The work equipment stops in neutral.
Related • All of the LED segments flash (to indicate the error).
Information • The buzzer sounds.
Causes Standard Value in Normal State and Remarks on Troubleshooting

1) Turn starting switch OFF. 2) Disconnect connectors P03 and
Disconnection in FS3. 3) Connect T-adapter.
wiring harness
1 (Disconnection in Wiring harness between P03 (female) Resistance Max. 1 Ω
wiring or defective (1), (11) and FS3 (female) (5)
contact in connector) Between P03 (female) (21), (31), (32), Resistance Max. 1 Ω
Possible Causes (33), and chassis
and Standard Grounding fault in 1) Turn starting switch OFF. 2) Disconnect connectors P03 and
Values wiring harness FS2A. 3) Connect T-adapter.
2
flIf this trouble occurs, Between P03 (female) (1), (11), FS3 (5)
fuse (A-13) is broken. and chassis Resistance Min. 1 MΩ
1) Turn starting switch OFF. 2) Disconnect connector P03.
3 Defective work equip- 3) Connect T-adapter. 4) Connect connector. 5) Turn starting
ment controller switch ON.
Between P03 (1), (11) and chassis Voltage 20 – 30V
WRK-1 Related electrical circuit diagram
WA800-3 20-1013
(7)
[WRK-2] Abnormality in sensor power source system
Troubleshooting
Code Abnormality in sensor power source system
Trouble
WRK-2
Description of • The source voltage becomes abnormal because of disconnection, grounding fault, or short
Trouble circuit (short circuit with power source) in the sensor source voltage (5 V) system.
Controller
Reaction • Turns OFF the output to the all EPC.
Effect on
Machine • The work equipment cannot operate.

1) Turn starting switch OFF. 2) Disconnect connectors P01, P15,
P14, and P39. 3) Connect T-adapter.
Wiring harness between P01 (female) Resistance Max. 1 Ω
1 Disconnection in (22) and P15 (female) (4)
wiring harness Wiring harness between P01 (female) Resistance Max. 1 Ω
(22) and P14 (female) (4)
Grounding fault in P14, and P39. 3) Connect T-adapter.
2 wiring harness
Between P01 (female) 22 and chassis Resistance Min. 1 MΩ
Short circuit in 1) Turn starting switch OFF. 2) Disconnect connector P01.
wiring harness 3) Connect T-adapter. 4) Turn starting switch ON.
3
Possible Causes (Short circuit with
power source) Between P01 (female) (22) and chassis Voltage Max. 1 V
and Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector P15.
Defective boom EPC 3) Connect T-adapter.
4
lever potentiometer Between P15 (male) (4) and (1) Resistance 2.5 – 3.9 kΩ
Between P15 (male) (4) and chassis Resistance Min. 1 MΩ
Defective bucket EPC 3) Connect T-adapter.
5 lever potentiometer Between P14 (male) (4) and (1) Resistance 2.5 – 3.9 kΩ
Defective boom EPC 3) Connect T-adapter.
6 lever potentiometer Between P39 (male) (3) and (1) Resistance 4 – 6 kΩ
7 Defective work 3) Connect T-adapter. 4) Connect connector. 5) Turn starting
equipment controller switch ON.
Between P01 (22) and (21) Voltage 4.7 – 5.3 V
20-1014 WA800-3
(7)
WA800-3 20-1015
(7)
[WRK-3] Abnormality in solenoid power source system
Troubleshooting
Code Abnormality in solenoid power source system
Trouble
WRK-3
Description of
Trouble • The power source voltage of the solenoid is low.
Controller • Cannot output power to the solenoid (If the source voltage is below 18 V, all
Reaction outputs are turned OFF).
Effect on • The work equipment cannot operate.
Machine

Disconnection in FS2A. 3) Connect T-adapter.
1 (Disconnection in (2), (12), (22) and FS2A (female) (8)
wiring or defective
contact in connector) Between P03 (female) (21), (31), (32), Resistance Max. 1 Ω
(33), and chassis
Possible Causes Grounding fault in 1) Turn starting switch OFF. 2) Disconnect connectors FS1 and
and Standard wiring harness battery relay R10. 3) Connect T-adapter to FS1.
Values 2 flIf this trouble
occurs, fuse (A-9) Between P03 (female) (2), (12), (22) –
FS2A (8) and chassis Resistance Min. 1 MΩ
is broken.
3) Insert T-adapter. 4) Connect connector. 5) Turn starting
3 Defective work switch ON.
Between P03 (female) (2), (12), (22) Voltage 20 – 30 V
and chassis
20-1016 WA800-3
(7)
[WRK-4] Grounding fault in remote positioner RAISE position set

switch system
Troubleshooting
Code Grounding fault in remote positioner RAISE position set switch system
Trouble
WRK-4
Description of • Since there is a grounding fault in the remote positioner RAISE position set switch system,
Trouble the RAISE position cannot be set.
Controller • Cancels setting of the RAISE position.
Reaction • Cancels stopping of the remote positioner RAISE operation.
Effect on
Machine • RAISE position cannot be set.
Related
Information • The RAISE set indicator LED flashes (to indicate the error).

Grounding fault in P04. 3) Connect T-adapter.
1
wiring harness Between P02 (female) (13) – P04 Resistance Min. 1 MΩ
Defective remote 3) Connect T-adapter.
2 positioner set switch Remote positioner
Possible Causes (maintenance Between RAISE set switch: ON Resistance Max. 1 Ω
and Standard monitor) P04 (male)
(3) and (5) Remote positioner
Values RAISE set switch: OFF Resistance Min. 1 MΩ
Work equipment switch ON.
3 Remote positioner
controller Voltage Max. 1 V
Between RAISE set switch: ON
P02 (13)
and chassis Remote positioner Voltage 17 – 30 V
RAISE set switch: OFF
WA800-3 20-1017
(7)
[WRK-5] Disconnection or short circuit (with power source) in remote

positioner RAISE position set switch
Troubleshooting
Code Trouble Disconnection or short circuit (with power source) in remote positioner RAISE
position set switch
WRK-5
Description of • Since there is a disconnection or a short circuit with 24-V system in the remote positioner
Trouble RAISE position set switch system, the RAISE position cannot be set.
Controller
Reaction
Effect on
Machine • The RAISE position cannot be set.
Related
Information

Disconnection or 1) Turn starting switch OFF. 2) Disconnect connectors P02 and
defective contact in P04. 3) Connect T-adapter.
1
Short circuit in 1) Turn starting switch OFF. 2) Disconnect connectors P02 and
2 wiring harness (with P04. 3) Insert T-adapter. 4) Connect connector P02. 5) Turn
power source) starting switch ON.
Between P02 (13) and chassis Voltage Max. 1 V
Possible Causes Turn starting switch OFF. 2) Disconnect connector P04.
and Standard Defective remote 3) Connect T-adapter.
Values positioner set switch Remote positioner
3
(maintenance Between RAISE set switch: ON Resistance Max. 1 Ω
monitor) P04 (male)
RAISE set switch: OFF Resistance Min. 1 MΩ
switch ON.
Defective work
4 equipment controller Remote positioner Voltage Max. 1 V
Between RAISE set switch: ON
P02 (13)
and chassis Remote positioner Voltage 17 – 30 V
RAISE set switch: OFF
20-1018 WA800-3
(7)
[WRK-6] Grounding fault in remote positioner LOWER position set

switch system
Troubleshooting
Code Trouble Grounding fault in remote positioner LOWER position set switch system
WRK-6
Description of • Since there is a grounding fault in the remote positioner LOWER position set switch
Trouble system, the LOWER position cannot be set.
Controller • Cancels setting of the LOWER position.
Reaction • Cancels stopping of the remote positioner LOWER operation.
Effect on
Machine • The LOWER position cannot be set.
Related
Information • The LOWER set indicator LED flashes (to indicate the error).

1
wiring harness Between P02 (female) (3) – P04 (female) Resistance Min. 1 MΩ
(4) and chassis
Turn starting switch OFF. 2) Disconnect connector P04.
positioner set switch Remote positioner
Possible Causes 2 (maintenance Between LOWER set switch: ON Resistance Max. 1 Ω
and Standard monitor) P04 (male)
Values (3) and (4) Remote positioner Resistance Min. 1 MΩ
LOWER set switch: OFF
switch ON.
Defective work
Between LOWER set switch: ON
P02 (3) and
chassis Remote positioner
LOWER set switch: OFF Voltage 17 – 30 V
WA800-3 20-1019
(7)

positioner LOWER position set switch system
Troubleshooting
Code Trouble Disconnection or short circuit (with power source) in remote positioner LOWER
position set switch system
WRK-7
Trouble LOWER position set switch system, the LOWER position cannot be set.
Controller
Reaction
Effect on
Machine • The LOWER position cannot be set.
Related
Information

Disconnection or 1) Turn starting switch OFF. 2) Disconnect connectors P02 and
defective contact in P04. 3) Connect T-adapter.
1
Possible Causes Turn starting switch OFF. 2) Disconnect connector P04.
and Standard Defective remote 3) Connect T-adapter.
Values positioner set switch Remote positioner
3
(maintenance Between LOWER set switch: ON Resistance Max. 1 Ω
monitor) P04 (male)
LOWER set switch: OFF Resistance Min. 1 MΩ
switch ON.
Defective work
Between LOWER set switch: ON
P02 (3) and
LOWER set switch: OFF Voltage 17 – 30 V
20-1020 WA800-3
(7)
[WRK-8] Grounding fault in remote positioner RAISE/LOWER selector

switch system
Troubleshooting
Code Trouble Grounding fault in remote positioner RAISE/LOWER selector switch system
WRK-8
Description of • Since there is a grounding fault in the remote positioner RAISE/LOWER selector switch
Trouble system, the remote positioner does not function.
Controller • Cancels the RAISE/LOWER stop control function.
Reaction • Cancels the RAISE/LOWER stop position setting function.
Effect on • The remote positioner does not function.
Machine
Related • The RAISE/LOWER stop indicator LED flashes (to indicate the error).
Information

1 Grounding fault in P04. 3) Connect T-adapter.
wiring harness
Between P02 (female) and chassis Resistance Min. 1 MΩ
positioner RAISE/ Remote positioner RAISE/
2 LOWER selector Between LOWER set switch: ON Resistance Max. 1 Ω
Possible Causes switch (maintenance P04 (male)
and Standard monitor) (3) and (7) Remote positioner RAISE/ Resistance Min. 1 MΩ
Values LOWER set switch: OFF
switch ON.
Defective work
3 equipment controller Remote positioner RAISE/
Between LOWER set switch: ON Voltage Max. 1 V
P02 (2) and
chassis Remote positioner RAISE/ Voltage 17 – 30 V
LOWER set switch: OFF
WA800-3 20-1021
(7)

positioner RAISE/LOWER selector switch system
Troubleshooting
Code Trouble Disconnection or short circuit (with power source) in remote positioner RAISE/
LOWER selector switch system
WRK-9
Trouble RAISE/LOWER selector switch system, the RAISE and LOWER operations cannot be selected.
Controller
Reaction
Effect on
Machine • The RAISE and LOWER operations cannot be selected.
Related
Information

Disconnection or P04. 3) Connect T-adapter.
1 defective contact in
Between P02 (female) (2) and chassis Voltage Max. 1 V
Turn starting switch OFF. 2) Disconnect connector P04.
Possible Causes positioner RAISE/ Remote positioner
and Standard 3 LOWER selector RAISE/LOWER selector Resistance Max. 1 Ω
Values Between switch: ON
switch (maintenance P04 (male)
monitor) (3) and (7) Remote positioner
RAISE/LOWER selector Resistance Min. 1 MΩ
switch: OFF
switch ON.
Defective work Remote positioner
4 equipment controller RAISE/LOWER selector Voltage Max. 1 V
Between switch: ON
P02 (2) and
RAISE/LOWER selector Voltage 17 – 30 V
switch: OFF
20-1022 WA800-3
(7)
[WRK-10] Disconnection, grounding fault, or short circuit (with power

source) in boom angle potentiometer signal system
Troubleshooting
Code Disconnection, grounding fault, or short circuit (with power source) in boom
Trouble angle potentiometer signal system
WRK-10
Description of • Since there is a disconnection, a grounding fault, or a short circuit with 24-V system in the
Trouble boom angle positioner signal system, the remote positioner does not function.
Controller • Cancels the RAISE/LOWER stop control function.
Reaction • Cancels the RAISE/LOWER stop position setting function.
Effect on • The remote positioner does not function.
Machine
Related • The RAISE stop, LOWER stop, RAISE set, and LOWER set indicator LED’s flash
Information (to indicate the error).

P42 . 3) Connect T-adapter.
Disconnection or (8) and P42 (female) (1)
1 defective contact in Wiring harness between P01 (female) Resistance Max. 1 Ω
wiring harness (21) and P42 (female) (3)
Between P01 (female) (4) and chassis Resistance Max. 1 Ω
1) Turn starting switch OFF. 2) Disconnect connectors P01.
Grounding fault in 3) Connect T-adapter.
2 wiring harness Between P01 (female) (8) and chassis Resistance Min. 1 MΩ
Possible Causes
and Standard Between P01 (female) (22) and chassis Resistance Min. 1 MΩ
Short circuit in 3) Insert T-adapter. 4) Connect connector. 5) Turn starting
3 wiring harness (with switch ON.
power source)
Between P01 (8) and chassis Voltage 4.7 – 5.3 V
Defective boom 3) Connect T-adapter.
4 angle potentiometer Between P42 (male) (1) and (2) Resistance 0.2 – 5 kΩ
Between P42 (male) (2) and (3) Resistance 4 – 5 kΩ
Defective work switch ON.
5 equipment controller
WA800-3 20-1023
(7)

(Disconnection or grounding fault in main circuit)
Troubleshooting
Code Trouble Abnormality in boom EPC lever potentiometer system (Disconnection or ground-
ing fault in main circuit)
WRK-11
Description of • There is a disconnection in the boom EPC lever potentiometer signal system (There is a
Trouble disconnection or a grounding fault in the main circuit).
Controller • If the sub circuit is also abnormal, the controller turns OFF the output to the boom EPC
Reaction solenoid and boom EPC lever magnet detent.
Effect on
Machine • If the sub circuit is also abnormal, the boom does not move.

Disconnection in 1) Turn starting switch OFF. 2) Disconnect connectors P01 and
wiring harness P15. 3) Connect T-adapter.
1 (Disconnection in
wiring or defective Wiring harness between P01 (female) Resistance Max. 1 Ω
contact in connector) (19) and P15 (female) (3)
Possible Causes 2 Short circuit in P15. 3) Connect T-adapter.
and Standard wiring harness
Between P01 (female) (19) and chassis Resistance Min. 1 MΩ
Defective 3) Insert T-adapter. 4) Connect connector. 5) Turn starting
3 potentiometer switch ON. 6) Set work equipment control lever in NEUTRAL.
Defective work 3) Insert T-adapter. 4) Connect connector. 5) Turn starting
4 equipment controller switch ON.
20-1024 WA800-3
(7)

[Short circuit in main circuit (with source power)]
Troubleshooting
Code Trouble Abnormality in boom EPC lever potentiometer system [Short circuit in main
circuit (with source power)]
WRK-12
Description of • The wiring harness of the power source touches the wiring harness of the boom EPC lever
Trouble potentiometer main signal system.
Controller • If the sub circuit is also abnormal, the controller turns OFF the output to the boom EPC
Effect on
Machine • If the sub circuit is also abnormal, the boom does not move.

Short circuit in P15. 3) Connect T-adapter. 4) Turn starting switch ON.
wiring harness (with
1 wiring harness of Between P01 (female) (19) – P15
Possible Causes Voltage Max. 1 V
and Standard power source) (female) (3) and chassis
Values Between P01 (female) (19) and (21) Voltage Max. 1 V
2 switch ON. 6) Set work equipment control lever in NEUTRAL.
WA800-3 20-1025
(7)

(Disconnection or grounding fault in sub circuit)
Troubleshooting
Code Trouble Abnormality in boom EPC lever potentiometer system (Disconnection or ground-
ing fault in sub circuit)
WRK-13
Description of • There is a disconnection in the boom EPC lever potentiometer signal system (There is a
Trouble disconnection or a grounding fault in the sub circuit).
Controller • If the main circuit is also abnormal, the controller turns OFF the output to the boom EPC
Effect on
Machine • If the main circuit is also abnormal, the boom does not move.

1 (Disconnection in
Short circuit in P15. 3) Connect T-adapter.
Possible Causes 2 wiring harness
and Standard Between P01 (female) (13) – P15 Resistance Min. 1 MΩ
Values (female) (2) and chassis
4 equipment controller switch ON. 6) Set work equipment control lever in NEUTRAL.
20-1026 WA800-3
(7)

[Short circuit in sub circuit (with source power)]
Troubleshooting
Code Trouble Abnormality in boom EPC lever potentiometer system [Short circuit in sub circuit
(with source power)]
WRK-14
Description of • The wiring harness of the power source touches the wiring harness of the boom EPC lever
Trouble potentiometer sub signal system.
Controller • If the main circuit is also abnormal, the controller turns OFF the output to the boom EPC
Effect on
Machine • If the main circuit is also abnormal, the boom does not move.

wiring harness (with P15. 3) Connect T-adapter.
1
Possible Causes wiring harness of Between P01 (female) (13) – P15
and Standard power source) (female) (3) and chassis Voltage Max. 1 V
WA800-3 20-1027
(7)

(Shifting of main circuit and sub circuit form each other)
Troubleshooting
Code Trouble Abnormality in boom EPC lever potentiometer system (Shifting of main circuit
and sub circuit form each other)
WRK-15
Description of • The input signals of the boom EPC lever potentiometer system (main circuit and sub
Trouble circuit) are different from each other.
Controller • Turns OFF the output to the boom EPC solenoid.
Reaction • Turns OFF the output to the boom EPC lever magnet detent.
Effect on • The boom does not move.
Machine

switch ON.
Defective Between Lever: Neutral Voltage 2.4 – 2.6 V
potentiometer P15 (3) Lever: Stroke end on RAISE side Voltage 3.9 – 4.4 V
flDefective and (1)
1 installation Lever: Stroke end on LOWER side Voltage 0.6 – 1.1V
(Looseness, play, Between Lever: Neutral Voltage 2.4 – 2.6 V
etc.) P15 (2) Lever: Stroke end on RAISE side Voltage 0.6 – 1.1 V
and (1) Lever: Stroke end on LOWER side Voltage 3.9 – 4.4 V
Possible Causes Disconnection in P15. 3) Connect T-adapter.
Values Wiring harness between P01 (female)
2 (Disconnection in (19) and P15 (female) (3) Resistance Max. 1 Ω
wiring or defective
contact in connector) Wiring harness between P01 (female)
(13) and P15 (female) (2) Resistance Max. 1 Ω
switch ON.
Between Lever: Neutral Voltage 2.4 – 2.6 V
Defective work P01 (19) Lever: Stroke end on RAISE side Voltage 3.9 – 4.4 V
3 equipment controller and (21) Lever: Stroke end on LOWER side Voltage 0.6 – 1.1V
P01 (13) Lever: Stroke end on RAISE side Voltage 0.6 – 1.1 V
and (21) Lever: Stroke end on LOWER side Voltage 3.9 – 4.4 V
20-1028 WA800-3
(7)

(Disconnection or grounding fault in main circuit)
Troubleshooting
Code Trouble Abnormality in bucket EPC lever potentiometer system (Disconnection or ground-
ing fault in main circuit)
WRK-16
Description of • There is a disconnection in the bucket EPC lever potentiometer signal system (There is a
Trouble disconnection or a grounding fault in the main circuit).
Controller • If the sub circuit is also abnormal, the controller turns OFF the output to the bucket EPC
Reaction solenoid and bucket magnet detent.
Effect on
Machine • If the sub circuit is also abnormal, the bucket does not move.

1 wiring harness
2 (Disconnection in
Possible Causes wiring or defective Wiring harness between P01 (female) Resistance Max. 1 Ω
and Standard contact in connector) (7) and P14 (female) (3)
WA800-3 20-1029
(7)

[Short circuit in main circuit (with source power)]
Troubleshooting
Code Trouble Abnormality in bucket EPC lever potentiometer system [Short circuit in main
circuit (with source power)]
WRK-17
Description of • The wiring harness of the power source touches the wiring harness of the bucket EPC
Trouble lever potentiometer main signal system.
Controller • If the sub circuit is also abnormal, the controller turns OFF the output to the bucket EPC
Effect on
Machine • If the sub circuit is also abnormal, the bucket does not move.

Short circuit in P14. 3) Connect T-adapter. 4) Turn starting switch ON.
wiring harness (with
1 wiring harness of Between P01 (female) (7) – P14
Possible Causes (female) (3) and chassis Voltage Max. 1 V
and Standard power source)
Values Between P01 (female) (7) and (21) Voltage Max. 1 V
20-1030 WA800-3
(7)

(Disconnection or grounding fault in sub circuit)
Troubleshooting
Code Trouble Abnormality in bucket EPC lever potentiometer system (Disconnection or ground-
ing fault in sub circuit)
WRK-18
Description of • There is a disconnection in the bucket EPC lever potentiometer signal system (There is a
Trouble disconnection or a grounding fault in the sub circuit).
Controller • If the main circuit is also abnormal, the controller turns OFF the output to the bucket EPC
Effect on
Machine • If the main circuit is also abnormal, the bucket does not move.

1 (Disconnection in
Possible Causes 2 wiring harness
and Standard Between P01 (female) (1) – P14 Resistance Min. 1 MΩ
Values (female) (2) and chassis
WA800-3 20-1031
(7)

(Short circuit in sub circuit)
Troubleshooting
Code Trouble Abnormality in bucket EPC lever potentiometer system (Short circuit in sub
circuit)
WRK-19
Description of • The wiring harness of the power source touches the wiring harness of the bucket EPC
Trouble lever potentiometer sub signal system.
Controller • If the main circuit is also abnormal, the controller turns OFF the output to the bucket EPC
Reaction solenoid and bucket EPC lever magnet detent.
Effect on
Machine • If the main circuit is also abnormal, the bucket does not move.

wiring harness (with P14. 3) Connect T-adapter.
1
Possible Causes wiring harness of Between P01 (female) (1) – P14
power source) Voltage Max. 1 V
and Standard (female) (3) and chassis
20-1032 WA800-3
(7)

(Shifting of main circuit and sub circuit form each other)
Troubleshooting
Code Trouble Abnormality in bucket EPC lever potentiometer system (Shifting of main circuit
and sub circuit form each other)
WRK-20
Description of • The input signals of the boom EPC lever potentiometer system (main circuit and sub
Trouble circuit) are different from each other.
Controller • Turns OFF the output to the boom EPC solenoid.
Reaction • Turns OFF the output to the boom EPC lever magnet detent.
Effect on
Machine • The bucket does not move.

switch ON.
Defective Between Lever: Neutral Voltage 2.4 – 2.6 V
potentiometer P14 (3) Lever: Stroke end on TILT side Voltage 3.9 – 4.4 V
1 flDefective and (1)
installation Lever: Stroke end on DUMP side Voltage 0.6 – 1.1V
(Looseness, play, Between Lever: Neutral Voltage 2.4 – 2.6 V
etc.) P14 (2) Lever: Stroke end on TILT side Voltage 0.6 – 1.1 V
and (1) Lever: Stroke end on DUMP side Voltage 3.9 – 4.4 V
Possible Causes Disconnection in P14. 3) Connect T-adapter.
2 (Disconnection in (7) and P14 (female) (3) Resistance Max. 1 Ω
wiring or defective
contact in connector) Wiring harness between P01 (female) Resistance Max. 1 Ω
switch ON.
Defective work P01 (7) Lever: Stroke end on TILT side Voltage 3.9 – 4.4 V
3 equipment controller and (21)
Lever: Stroke end on DUMP side Voltage 0.6 – 1.1V
P01 (1) Lever: Stroke end on TILT side Voltage 0.6 – 1.1 V
and (21) Lever: Stroke end on DUMP side Voltage 3.9 – 4.4 V
WA800-3 20-1033
(7)
[WRK-21] Disconnection in engine speed sensor system
Troubleshooting
Code Trouble Disconnection in engine speed sensor system
WRK-21
Description of • Since there is a disconnection in the engine speed sensor system, engine speed signals
Trouble are not input.
Controller
Reaction • Cannot sense the engine speed (Assumes the engine speed to be 2,100 rpm).
Effect on • Feeling of work equipment (remote positioner) lowers.
Machine
Related • The RAISE and LOWER set indicator LED’s flash (to indicate the error).
Information

Possible Causes Disconnection in C1. 3) Connect T-adapter.
1 (Disconnection in Wiring harness between P02 (female) Resistance Max. 1 Ω
Values (10) and C1 (female) (4)
wiring or defective
contact in connector) ★ When the transmission controller does not detect ENGINE
SPEED SENSOR TROUBLE (Failure code “23”).
20-1034 WA800-3
(7)
[WRK-22] Grounding fault in engine speed sensor system
Troubleshooting
Code Trouble Grounding fault in engine speed sensor system
WRK-22
Description of • Since there is a grounding fault in the engine speed sensor system, engine speed signals
Trouble are not input.
Controller
Reaction
Effect on
Machine • Feeling of work equipment (remote positioner) lowers.
Related
Information

Possible Causes
and Standard 1) Turn starting switch OFF. 2) Disconnect connectors P02
Grounding fault in 3) Connect T-adapter.
Values 1 wiring harness
WA800-3 20-1035
(7)
[WRK-23] Grounding fault in remote positioner RAISE position set

display system
Troubleshooting
Code Trouble Grounding fault in remote positioner RAISE position set display system
WRK-23
Description of • Since there is a grounding fault in the remote positioner RAISE position set display
Trouble system, the RAISE position set indicator does not light up.
Controller
Reaction • Turns OFF the output to the RAISE position set indicator.
Effect on • The remote positioner RAISE position set indicator does not light up.
Machine
Related
Information

1 wiring harness
3) Insert T-adapter. 4) Connect connector. 5) Connect P04 (1) or
(2) (power source) to (10). 6) Turn starting switch ON.
RAISE position set indicator lights up. Maintenance monitor is
Defective mainte- normal.
Possible Causes 2 nance monitor
and Standard RAISE position set indicator does not Maintenance monitor is
Values light up. defective.
★ Check in advance that there is not grounding fault in wiring
harness.
3) Insert T-adapter. 4) Connect connector. 5) Connect P03 (2)
(power source) to (8). 6) Turn starting switch ON.
Defective work
3 equipment controller RAISE position set indicator lights up. Work equipment control-
ler is defective.
★ Check in advance that there is not grounding fault or discon-
nection in wiring harness.
20-1036 WA800-3
(7)
[WRK-24] Disconnection in remote positioner RAISE position set

display system
Troubleshooting
Code Trouble Disconnection in remote positioner RAISE position set display system
WRK-24
Description of • Since there is a disconnection in the remote positioner RAISE position set display system,
Trouble the RAISE position set indicator does not light up.
Controller
Reaction
Effect on • The remote positioner RAISE position set indicator does not light up.
Machine
Related
Information

RAISE position set indicator lights up. Maintenance monitor is
Defective mainte-
normal.
and Standard RAISE position set indicator does not Maintenance monitor is
harness.
Defective work
3 equipment controller RAISE position set indicator lights up. Work equipment control-
ler is defective.
WA800-3 20-1037
(7)
[WRK-25] Short circuit (with power source) in remote positioner RAISE

position set display system
Troubleshooting
Code Short circuit (with power source) in remote positioner RAISE position set display
Trouble system
WRK-25
Description of • Since there is a short circuit (with the power source) in the remote positioner RAISE
Trouble position set display system, the RAISE position set indicator does not go off.
Controller
Reaction
Effect on • The remote positioner RAISE position set indicator does not go off.
Machine
Related
Information

Short circuit (with 1) Turn starting switch OFF. 2) Disconnect connectors P03 and
1 power source) in P04. 3) Connect T-adapter. 4) Turn starting switch ON.
wiring harness Between P03 (female) (8) and chassis Voltage Max. 1 V
Possible Causes 1) Turn starting switch OFF. 2) Disconnect connector P03.
and Standard 3) Turn starting switch ON.
Values Defective mainte- RAISE position set indicator does not Work equipment control-
2 nance monitor or light up. ler is defective.
work equipment RAISE position set indicator lights up. Maintenance monitor is
controller defective.
harness.
20-1038 WA800-3
(7)
[WRK-26] Grounding fault in remote positioner LOWER position set

display system
Troubleshooting
Code Trouble Grounding fault in remote positioner LOWER position set display system
WRK-26
Description of • Since there is a grounding fault in the remote positioner LOWER position set display
Trouble system, the LOWER position set indicator does not light up.
Controller
Reaction • Turns OFF the output to the LOWER position set indicator.
Effect on • The remote positioner LOWER position set indicator does not light up.
Machine
Related
Information

1 wiring harness
LOWER position set indicator lights up. Maintenance monitor is
Defective mainte- normal.
and Standard LOWER position set indicator does not Maintenance monitor is
harness.
Defective work
3 equipment controller LOWER position set indicator lights up. Work equipment control-
ler is defective.
WA800-3 20-1039
(7)
[WRK-27] Disconnection in remote positioner LOWER position set

display system
Troubleshooting
Code Trouble Disconnection in remote positioner LOWER position set display system
WRK-27
Description of • Since there is a disconnection in the remote positioner LOWER position set display sys-
Trouble tem, the LOWER position set indicator does not light up.
Controller
Reaction
Effect on • The remote positioner LOWER position set indicator does not light up.
Machine
Related
Information

LOWER position set indicator lights up. Maintenance monitor is
Defective mainte-
normal.
and Standard LOWER position set indicator does not Maintenance monitor is
harness.
Defective work
3 equipment controller LOWER position set indicator lights up. Work equipment control-
ler is defective.
20-1040 WA800-3
(7)

LOWER position set display system
Troubleshooting
Code Short circuit (with power source) in remote positioner LOWER position set
Trouble display system
WRK-28
Description of • Since there is a short circuit (with the power source) in the remote positioner LOWER
Trouble position set display system, the LOWER position set indicator does not go off.
Controller
Reaction
Effect on • The remote positioner LOWER position set indicator does not go off.
Machine
Related
Information

and Standard 3) Turn starting switch ON.
Values Defective mainte- LOWER position set indicator does not Work equipment control-
2 nance monitor or light up. ler is defective.
work equipment LOWER position set indicator lights up. Maintenance monitor is
controller defective.
harness.
WA800-3 20-1041
(7)
[WRK-29] Short circuit (with power source) in remote positioner RAISE

stop display system
Troubleshooting
Code Trouble Short circuit (with power source) in remote positioner RAISE stop display system
WRK-29
Description of • Since there is a short circuit (with the power source) in the remote positioner RAISE stop
Trouble display system, the RAISE stop indicator does not light up.
Controller
Reaction • Turns OFF the output to the RAISE stop indicator.
Effect on • The remote positioner RAISE stop indicator does not light up.
Machine
Related
Information

3) Replace relay (P18) with another relay. 4) Turn starting switch
2 Defective relay (P18) ON. 5) Operate remote positioner RAISE/LOWER selector switch.
RAISE stop indicator lights up. Relay (P18) is defective.
RAISE stop indicator does not light up. Relay (P18) is normal.
P18. 3) Insert T-adapter. 4) Connect connector P04. 5) Connect
Possible Causes P04 (12) to (3) (GND). 6) Turn starting switch ON.
and Standard RAISE stop indicator lights up. Maintenance monitor is
Values 3 Defective mainte- normal.
nance monitor
RAISE stop indicator does not light up. Maintenance monitor is
defective.
★ Check in advance that there is not disconnection in wiring
harness.
3) Insert T-adapter. 4) Connect P02 (female) (19) to chassis
(GND). 5) Turn starting switch ON.
4 Defective work RAISE stop indicator lights up. Work equipment control-
equipment controller ler is defective.
★ Check in advance that there is not short circuit or disconnec-
tion in wiring harness.
20-1042 WA800-3
(7)
WA800-3 20-1043
(7)
[WRK-30] Disconnection in remote positioner RAISE stop display

system
Troubleshooting
Code Trouble Disconnection in remote positioner RAISE stop display system
WRK-30
Description of • Since there is a disconnection in the remote positioner RAISE stop display system, the
Trouble RAISE stop indicator does not light up.
Controller
Reaction
Effect on • The remote positioner RAISE stop indicator does not light up.
Machine
Related
Information

and P18. 3) Connect T-adapter.
Wiring harness between P02 (female)
Disconnection or Between P18 (female) (3) and chassis Resistance Max. 1 Ω
1 defective contact in Wiring harness between P18 (female)
wiring harness (5) and P04 (female) (12) Resistance Max. 1 Ω
switch ON.
Between P18 (1) and chassis Voltage 20 – 30 V
Possible Causes RAISE stop indicator lights up. Relay (P18) is defective.
and Standard RAISE stop indicator does not light up. Relay (P18) is normal.
Values
P04 (12) to (3) (GND). 6) Turn starting switch ON.
RAISE stop indicator lights up. Maintenance monitor is
3 Defective mainte- normal.
nance monitor
RAISE stop indicator does not light up. Maintenance monitor is
defective.
harness.
3) Connect T-adapter. 4) Connect P02 (female) (19) to chassis
4 Defective work RAISE stop indicator lights up. Work equipment control-
20-1044 WA800-3
(7)
WA800-3 20-1045
(7)
[WRK-31] Grounding fault in remote positioner RAISE stop display

system
Troubleshooting
Code Trouble Grounding fault in remote positioner RAISE stop display system
WRK-31
Description of • Since there is a grounding fault in the remote positioner RAISE stop display system, the
Trouble RAISE stop indicator does not go off.
Controller
Reaction
Effect on • The remote positioner RAISE stop indicator does not go off.
Machine
Related
Information

1 Grounding fault in Wiring harness between P02 (female)
wiring harness (19) and P18 (female) (2) Resistance Min. 1 MΩ
Wiring harness between P18 (female) Resistance Min. 1 MΩ
3) Connect T-adapter.
Possible Causes 2 Defective relay (P18)
and Standard Between P18 (male) (3) and (5) Resistance Min. 1 MΩ
Values Between P18 (male) (3) and (6) Resistance Max. 1 Ω
3) Insert T-adapter.
3 Defective mainte- Between P04 (female) (12) and (3) Resistance Min. 1 MΩ
nance monitor Between P04 (female) (12) and (16) Resistance Min. 1 MΩ
4 Defective work 3) Insert T-adapter.
20-1046 WA800-3
(7)
WA800-3 20-1047
(7)

LOWER stop display system
Troubleshooting
Code Short circuit (with power source) in remote positioner LOWER stop display
Trouble system
WRK-32
Description of • Since there is a short circuit (with the power source) in the remote positioner LOWER stop
Trouble display system, the LOWER stop indicator does not light up.
Controller
Reaction • Turns OFF the output to the LOWER stop indicator.
Effect on • The remote positioner LOWER stop indicator does not light up.
Machine
Related
Information

LOWER stop indicator lights up. Relay (P19) is defective.
LOWER stop indicator does not light up. Relay (P19) is normal.
Possible Causes P04 (13) to (3) (GND). 6) Turn starting switch ON.
and Standard LOWER stop indicator lights up. Maintenance monitor is
Values 3 Defective mainte- normal.
nance monitor
LOWER stop indicator does not Maintenance monitor is
light up. defective.
harness.
3) Insert T-adapter. 4) Connect P02 (female) (9) to chassis (GND).
5) Turn starting switch ON.
4 Defective work LOWER stop indicator lights up. Work equipment control-
20-1048 WA800-3
(7)
WA800-3 20-1049
(7)
[WRK-33] Disconnection in remote positioner LOWER stop display

system
Troubleshooting
Code Trouble Disconnection in remote positioner LOWER stop display system
WRK-33
Description of • Since there is a disconnection in the remote positioner LOWER stop display system, the
Trouble LOWER stop indicator does not light up.
Controller
Reaction
Effect on • The remote positioner LOWER stop indicator does not light up.
Machine
Related
Information

Wiring harness between P02 (female)
Disconnection or Between P19 (female) (3) and chassis Resistance Max. 1 Ω
1 defective contact in Wiring harness between P19 (female)
wiring harness (5) and P04 (female) (13) Resistance Max. 1 Ω
3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch
ON.
Between P19 (1) and chassis Voltage 20 – 30 V
Possible Causes LOWER stop indicator lights up. Relay (P19) is defective.
and Standard LOWER stop indicator does not light up. Relay (P19) is normal.
Values
P04 (13) to (3) (GND). 6) Turn starting switch ON.
LOWER stop indicator lights up. Maintenance monitor is
3 Defective mainte- normal.
nance monitor
LOWER stop indicator does not Maintenance monitor is
light up. defective.
harness.
3) Connect T-adapter. 4) Connect P02 (female) (9) to chassis
4 Defective work LOWER stop indicator lights up. Work equipment control-
20-1050 WA800-3
(7)
WA800-3 20-1051
(7)
[WRK-34] Grounding fault in remote positioner LOWER stop display

system
Troubleshooting
Code Trouble Grounding fault in remote positioner LOWER stop display system
WRK-34
Description of • Since there is a grounding fault in the remote positioner LOWER stop display system, the
Trouble LOWER stop indicator does not go off.
Controller
Reaction
Effect on • The remote positioner LOWER stop indicator does not go off.
Machine
Related
Information

1 Grounding fault in Wiring harness between P02 (female)
wiring harness (9) and P19 (female) (2) Resistance Min. 1 MΩ
Wiring harness between P19 (female) Resistance Min. 1 MΩ
Possible Causes 2 Defective relay (P19)
and Standard Between P19 (male) (3) and (5) Resistance Min. 1 MΩ
Values Between P19 (male) (3) and (6) Resistance Max. 1 Ω
3) Insert T-adapter.
3 Defective mainte- Between P04 (female) (13) and (3) Resistance Min. 1 MΩ
nance monitor Resistance Min. 1 MΩ
Between P04 (female) (13) and (16)
4 Defective work 3) Insert T-adapter.
20-1052 WA800-3
(7)
WA800-3 20-1053
(7)
[WRK-35] Disconnection in boom RAISE magnet detent system
Troubleshooting
Code Trouble Disconnection in boom RAISE magnet detent system
WRK-35
Description of • Since there is a disconnection in the boom RAISE magnet detent, the detent cannot be
Trouble controlled.
Controller • Turns OFF the remote positioner RAISE function.
Reaction • Turns OFF the output to the remote positioner RAISE stop lamp.
Effect on
Machine • The boom RAISE detent cannot be turned ON.
Related
Information • All of the LED segments flash (to indicate the error).

1 RAISE magnet Between P12 (male) (1) and (2) Resistance 35 – 45 Ω
detent
Possible Causes wiring harness P12. 3) Connect T-adapter.
and Standard 2 (Disconnection in
Values wiring or defective Wiring harness between P03 (female)
(17) and P12 (female) (1) Resistance Max. 1 MΩ
contact in connector)
3 equipment controller Between Lever: Neutral Voltage Max. 1 V
P03 (17)
and chassis Lever: Raising stroke end Voltage 17 – 30 V
20-1054 WA800-3
(7)
[WRK-36] Short circuit (with power source) in boom RAISE magnet

detent system
Troubleshooting
Code Trouble Short circuit (with power source) in boom RAISE magnet detent system
WRK-36
Description of • Since there is a short circuit (with the power source) in the boom RAISE magnet detent,
Trouble the detent cannot be turned OFF.
Controller • Turns OFF the remote positioner RAISE function.
Reaction • Turns OFF the output to the remote positioner RAISE stop lamp.
Effect on
Machine • The boom RAISE detent is not turned OFF automatically.
Related

detent
Possible Causes 1) Turn starting switch OFF. 2) Disconnect connectors P03 and
and Standard Short circuit (with P12. 3) Connect T-adapter. 4) Turn starting switch ON.
Values 2 power source) in
wiring harness Between P03 (female) (17) – P12 (female)
(1) and chassis Voltage Max. 1 V

Defective work 3) Connect T-adapter.
Between P03 (female) (17) and chassis Resistance 35 – 45 Ω
WA800-3 20-1055
(7)
[WRK-37] Grounding fault in boom RAISE magnet detent system
Troubleshooting
Code Trouble Grounding fault in boom RAISE magnet detent system
WRK-37
Description of • Since there is a grounding fault in the boom RAISE magnet detent, the detent cannot be
Trouble controlled.
Controller • Turns OFF the output to the magnet detent solenoid.
Reaction • Turns OFF the remote positioner RAISE function.
• Turns OFF the output to the remote positioner RAISE stop lamp.
Effect on
Machine • The boom RAISE detent cannot be turned ON.
Information

detent
Possible Causes Disconnection in 1) Turn starting switch OFF. 2) Disconnect connectors P03 and
and Standard wiring harness P12. 3) Connect T-adapter.
Values 2 (Disconnection in
wiring or defective Wiring harness between P03 (female)
(17) – P12 (female) (1) and chassis Resistance Min. 1 MΩ
Defective work 3) Insert T-adapter.
Between P03 (17) and chassis Resistance 35 – 45 Ω
20-1056 WA800-3
(7)
[WRK-38] Disconnection in boom FLOAT magnet detent system
Troubleshooting
Code Trouble Disconnection in boom FLOAT magnet detent system
WRK-38
Description of • Since there is a disconnection in the boom FLOAT magnet detent, the detent cannot be
Trouble controlled.
Controller • Turns OFF the remote positioner LOWER function.
Reaction • Turns OFF the output to the remote positioner LOWER stop lamp.
Effect on
Machine • The boom FLOAT detent is not turned OFF automatically.
Related

1 FLOAT magnet Between P13 (male) (1) and (2) Resistance 35 – 45 Ω
detent
Values wiring or defective Wiring harness between P03 (female)
(27) and P13 (female) (1) Resistance Max. 1 MΩ
P03 (27)
and chassis Lever: Float position Voltage 17 – 30 V
WA800-3 20-1057
(7)
[WRK-39] Short circuit (with power source) in boom FLOAT magnet

detent system
Troubleshooting
Code Trouble Short circuit (with power source) in boom FLOAT magnet detent system
WRK-39
Description of • Since there is a short circuit (with the power source) in the boom FLOAT magnet detent,
Trouble the detent cannot be turned OFF.
Controller • Turns OFF the remote positioner LOWER function.
Reaction • Turns OFF the output to the remote positioner LOWER stop lamp.
Effect on
Machine • The boom FLOAT detent is not turned OFF automatically.
Related

detent
wiring harness Between P03 (female) (27) – P13
(female) (1) and chassis Voltage Max. 1 V

20-1058 WA800-3
(7)
[WRK-40] Grounding fault in boom FLOAT magnet detent system
Troubleshooting
Code Trouble Grounding fault in boom FLOAT magnet detent system
WRK-40
Description of • Since there is a grounding fault in the boom FLOAT magnet detent, the detent cannot be
Trouble controlled.
Controller • Turns OFF the output to the magnet detent solenoid.
Reaction • Turns OFF the remote positioner LOWER function.
• Turns OFF the output to the remote positioner LOWER stop lamp.
Effect on
Machine • The boom FLOAT detent cannot be turned ON.
Related

detent
WA800-3 20-1059
(7)
[WRK-41] Disconnection in bucket TILT magnet detent system
Troubleshooting
Code Trouble Disconnection in bucket TILT magnet detent system
WRK-41
Description of • Since there is a disconnection in the bucket TILT magnet detent, the detent cannot be
Trouble controlled.
Controller
Reaction
Effect on • The bucket TILT detent is not turned ON.
Machine
Information

Defective bucket 3) Connect T-adapter.
1 TILT magnet detent Between P11 (male) (1) and (2) Resistance 35 – 45 Ω
Values
P03 (37) and
chassis Lever: Tilt position Voltage 17 – 30 V
20-1060 WA800-3
(7)
[WRK-42] Short circuit (with power source) in bucket TILT magnet

detent system
Troubleshooting
Code Trouble Short circuit (with power source) in bucket TILT magnet detent system
WRK-42
Description of • Since there is a short circuit (with the power source) in the bucket TILT magnet detent, the
Trouble detent cannot be turned OFF.
Controller
Reaction
Effect on
Machine • The bucket TILT detent is not turned OFF automatically.
Related

1 TILT magnet detent Between P11 (male) (1) and (2) Resistance 35 – 45 Ω

WA800-3 20-1061
(7)
[WRK-43] Grounding fault in bucket TILT magnet detent system
Troubleshooting
Code Trouble Grounding fault in bucket TILT magnet detent system
WRK-43
Description of • Since there is a grounding fault in the bucket TILT magnet detent, the detent cannot be
Trouble controlled.
Controller
Reaction • Turns OFF the output to the magnet detent solenoid.
Effect on
Machine • The bucket TILT detent cannot be turned ON.
Related

1
TILT magnet detent Between P11 (male) (1) and (2) Resistance 35 – 45 Ω
20-1062 WA800-3
(7)
[WRK-44] Disconnection or grounding fault in work equipment neutral

lock solenoid A system
Troubleshooting
Code Disconnection or grounding fault in work equipment neutral lock solenoid A
Trouble system
WRK-44
Description of • There is a disconnection or a grounding fault in the power source system of the work
Trouble equipment neutral lock solenoid A system.
Controller
Reaction
Effect on • When the safety lock lever is in the LOCK position, the neutral lock solenoid does not operate.
Machine • The work equipment can be controlled normally.
Information

Defective work 1) Turn starting switch OFF. 2) Disconnect connector P38.
1 equipment neutral 3) Connect T-adapter.
lock solenoid Between P38 (male) (1) and (2) Resistance 35 – 45 Ω
2 (Disconnection in Wiring harness between P03 (female)
Possible Causes wiring or defective (28) and P38 (female) (1) Resistance Max. 1 Ω
and Standard contact in connector) Between P38 (female) (2) and chassis Resistance Max. 1 Ω
Values
3 wiring harness Between P03 (female) (28) – P38 Resistance Min. 1 MΩ
WA800-3 20-1063
(7)
[WRK-45] Short circuit (with power source) in work equipment neutral

lock solenoid A system
Troubleshooting
Code Short circuit (with power source) in work equipment neutral lock solenoid A
Trouble system
WRK-45
Description of • Since there is a short circuit (with the power source) in the work equipment neutral lock
Trouble solenoid A system, the work equipment neutral lock solenoid cannot be turned OFF.
Controller
Reaction
Effect on • The work equipment speed is reduced to a half.
Machine
Information

20-1064 WA800-3
(7)
[WRK-46] Disconnection or grounding fault in work equipment neutral

lock solenoid B system
Troubleshooting
Code Disconnection or grounding fault in work equipment neutral lock solenoid B
Trouble system
WRK-46
Description of • There is a disconnection or a grounding fault in the power source system of the work
Trouble equipment neutral lock solenoid B system.
Controller
Reaction
Effect on • When the safety lock lever is in the LOCK position, the neutral lock solenoid does not operate.
Machine • The work equipment can be controlled normally.
Information

2 (Disconnection in Wiring harness between P03 (female)
Possible Causes wiring or defective (38) and P42 (female) (1) Resistance Max. 1 Ω
and Standard contact in connector) Between P42 (female) (2) and chassis Resistance Max. 1 Ω
Values
1) Turn starting switch OFF. 2) Disconnect connector P03 and
3 wiring harness Between P03 (female) (38) – P42 Resistance Min. 1 MΩ
WA800-3 20-1065
(7)
[WRK-47] Short circuit (with power source) in work equipment neutral

lock solenoid B system
Troubleshooting
Code Short circuit (with power source) in work equipment neutral lock solenoid B
Trouble system
WRK-47
Description of • Since there is a short circuit (with the power source) in the work equipment neutral lock
Trouble solenoid B system, the work equipment neutral lock solenoid cannot be turned OFF.
Controller
Reaction
Effect on
Machine • The work equipment speed is reduced to a half.
Related

20-1066 WA800-3
(7)
[WRK-48] Disconnection in alarm buzzer system
Troubleshooting
Code Trouble Disconnection in alarm buzzer system
WRK-48
Description of • Since there is a disconnection in the alarm buzzer system, the alarm buzzer does not
Trouble sound.
Controller
Reaction
Effect on
Machine • The alarm buzzer does not sound.
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector L43.
3) Connect T-adapter. 4) Turn starting switch ON and check after
5 seconds.
Defective alarm Ground L43 Buzzer sounds. Alarm buzzer is normal.
1 buzzer (1) to chassis. Buzzer does not sound. Alarm buzzer is defective.
★ Check in advance that there is not disconnection in power
source circuit.
3) Replace caution relay (P17) with another relay.
2 Defective caution 4) Turn starting switch ON and check after 5 seconds.
Possible Causes relay
Buzzer sounds. Caution relay (P17) is defective.
and Standard Caution relay (P17) is normal.
Values Buzzer does not sound.
1) Turn starting switch OFF. 2) Disconnect connectors P03, L43,
Disconnection in Wiring harness between P03 (female) Resistance Max. 1 Ω
3 (Disconnection in
wiring or defective Between P17 (female) (2), (3) and Resistance Max. 1 Ω
contact in connector) chassis
(5) and L43 (male) (1)
1) Turn starting switch OFF. 2) Disconnect connector P03
Between P03 (female) (4) and chassis Voltage 20 – 30 V
WA800-3 20-1067
(7)
[WRK-49] Grounding fault in alarm buzzer system
Troubleshooting
Code Trouble Grounding fault in alarm buzzer system
WRK-49
Description of • Since there is a grounding fault in the alarm buzzer system, the alarm buzzer does not
Trouble sound.
Controller
Reaction • Turns OFF the output to the alarm buzzer.
Effect on
Machine • The alarm buzzer does not sound.
Related
Information

1) Turn starting switch OFF. 2) Disconnect connector L43.
3) Connect T-adapter. 4) Turn starting switch ON and check after
5 seconds.
Defective alarm Ground L43 Buzzer sounds. Alarm buzzer is normal.
1 buzzer (1) to chassis. Buzzer does not sound. Alarm buzzer is defective.
★ Check in advance that there is not disconnection in power
source circuit.
and Standard 3) Replace caution relay (P17) with another relay.
Values 2 Defective caution 4) Turn starting switch ON and check after 5 seconds.
relay
Buzzer sounds. Caution relay (P17) is defective.
Buzzer does not sound. Caution relay (P17) is normal.
wiring harness
1) Turn starting switch OFF. 2) Disconnect connectors P03
20-1068 WA800-3
(7)
[WRK-50] Short circuit (with power source) in alarm buzzer system
Troubleshooting
Code Trouble Short circuit (with power source) in alarm buzzer system
WRK-50
Description of • Since there is a short circuit (with the power source) in the alarm buzzer system, the alarm
Trouble buzzer does not stop sounding.
Controller
Reaction
Effect on
Machine • The alarm buzzer does not stop sounding.
Related
Information

Possible Causes 1 power source) in P17. 3) Connect T-adapter. 4) Turn starting switch ON.
and Standard wiring harness Between P03 (female) (4) and chassis Voltage Max. 1 V
Values
2 Defective work 3) Connect T-adapter.
WA800-3 20-1069
(7)
[WRK-51] Disconnection or short circuit (with power source) in boom

RAISE EPC solenoid A system
Troubleshooting
Code Disconnection or short circuit (with power source) in boom RAISE EPC solenoid A
Trouble system
WRK-51
Description of • Since there is a disconnection or short circuit (with power source) in the boom RAISE EPC
Trouble solenoid A system, boom RAISE EPC solenoid A does not operate.
Controller • Turns OFF the output to boom RAISE EPC solenoid A.
Reaction • Turns ON the output to work equipment neutral lock solenoid A.
Machine
Related • The RAISE stop, LOWER stop, RAISE set, and LOWER set indicator LED’s flash (to indicate the error).

1 RAISE EPC solenoid
A Between P30 (male) (1) and (2) Resistance 9 – 10.2 Ω
Between P30 (male) (1) and chassis. Resistance Min. 1 MΩ
P30. 3) Connect T-adapter.
Disconnection or
Possible Causes Wiring harness between P03 (female)
and Standard 2 defective contact in Resistance Max. 1 Ω
Short circuit (with 1) Turn starting switch OFF. 2) Disconnect connector P03.
3 power source) in 3) Connect T-adapter. 4) Turn starting switch ON.
wiring harness Between P03 (female) (6) and chassis. Voltage Max. 1 V
Between P03 (female) (6) and (3) Resistance 9 – 10.2 Ω
20-1070 WA800-3
(7)
[WRK-52] Grounding fault in boom RAISE EPC solenoid A system
Troubleshooting
Code Trouble Grounding fault in boom RAISE EPC solenoid A system
WRK-52
Description of • Since there is a grounding fault in the boom RAISE EPC solenoid A system, boom RAISE
Trouble EPC solenoid A does not operate.
Controller
Reaction • Turns OFF the output to boom RAISE EPC solenoid A.
Effect on
Machine • The boom RAISE speed is reduced to a half.

A
Between P30 (male) (1) and (2) Resistance 9 – 10.2 Ω
Possible Causes Between P30 (male) (1) and chassis Resistance Min. 1 MΩ
and Standard 1) Turn starting switch OFF. 2) Disconnect connectors P03 and
Values Grounding fault in P30. 3) Connect T-adapter.
2 wiring harness
WA800-3 20-1071
(7)

RAISE EPC solenoid B system
Troubleshooting
Code Disconnection or short circuit (with power source) in boom RAISE EPC solenoid B
Trouble system
WRK-53
Description of • Since there is a disconnection or short circuit (with power source) in the boom RAISE EPC
Trouble solenoid B system, boom RAISE EPC solenoid B does not operate.
Controller • Turns OFF the output to boom RAISE EPC solenoid B.
Reaction • Turns ON the output to work equipment neutral lock solenoid B.
Machine

B Between P34 (male) (1) and (2) Resistance 9 – 10.2 Ω
Disconnection or
20-1072 WA800-3
(7)
[WRK-54] Grounding fault in boom RAISE EPC solenoid B system
Troubleshooting
Code Trouble Grounding fault in boom RAISE EPC solenoid B system
WRK-54
Description of • Since there is a grounding fault in the boom RAISE EPC solenoid B system, boom RAISE
Trouble EPC solenoid B does not operate.
Controller
Reaction • Turns OFF the output to boom RAISE EPC solenoid B.
Effect on
Machine • The boom RAISE speed is reduced to a half.

B
2 wiring harness
WA800-3 20-1073
(7)

LOWER EPC solenoid A system
Troubleshooting
Code Disconnection or short circuit (with power source) in boom LOWER EPC solenoid
Trouble A system
WRK-55
Description of • Since there is a disconnection or short circuit (with power source) in the boom LOWER
Trouble EPC solenoid A system, boom LOWER EPC solenoid A does not operate.
Controller • Turns OFF the output to boom LOWER EPC solenoid A.
Machine

1 LOWER EPC sole-
noid A Between P31 (male) (1) and (2) Resistance 9 – 10.2 Ω
Disconnection or
Values Wiring harness between P03 (female) Resistance Max. 1 Ω
Defective work
4 equipment controller 3) Connect T-adapter.
20-1074 WA800-3
(7)
[WRK-56] Grounding fault in boom LOWER EPC solenoid A system
Troubleshooting
Code Trouble Grounding fault in boom LOWER EPC solenoid A system
WRK-56
Description of • Since there is a grounding fault in the boom LOWER EPC solenoid A system, boom
Trouble LOWER EPC solenoid A does not operate.
Controller
Reaction • Turns OFF the output to boom LOWER EPC solenoid A.
Effect on
Machine • The boom LOWER speed is reduced to a half.

1 LOWER EPC sole-
noid A
2 wiring harness
WA800-3 20-1075
(7)

LOWER EPC solenoid B system
Troubleshooting
Code Disconnection or short circuit (with power source) in boom LOWER EPC solenoid
Trouble B system
WRK-57
Description of • Since there is a disconnection or short circuit (with power source) in the boom LOWER
Trouble EPC solenoid B system, boom LOWER EPC solenoid B does not operate.
Controller • Turns OFF the output to boom LOWER EPC solenoid B.
Machine

1 LOWER EPC sole-
noid B Between P35 (male) (1) and (2) Resistance 9 – 10.2 Ω
Disconnection or
Possible Causes 2 defective contact in Wiring harness between P03 (female) Resistance Max. 1 Ω
and Standard wiring harness (36) and P35 (female) (1)
Defective work
4 equipment controller 3) Connect T-adapter.
20-1076 WA800-3
(7)
[WRK-58] Grounding fault in boom LOWER EPC solenoid B system
Troubleshooting
Code Trouble Grounding fault in boom LOWER EPC solenoid B system
WRK-58
Description of • Since there is a grounding fault in the boom LOWER EPC solenoid B system, boom
Trouble LOWER EPC solenoid B does not operate.
Controller
Reaction • Turns OFF the output to boom LOWER EPC solenoid B.
Effect on
Machine • The boom LOWER speed is reduced to a half.

1 LOWER EPC sole-
noid B
2 wiring harness
WA800-3 20-1077
(7)
[WRK-59] Disconnection or short circuit (with power source) in bucket

TILT EPC solenoid A system
Troubleshooting
Code Disconnection or short circuit (with power source) in bucket TILT EPC solenoid A
Trouble system
WRK-59
Description of • Since there is a disconnection or short circuit (with power source) in the bucket TILT EPC
Trouble solenoid A system, bucket TILT EPC solenoid A does not operate.
Controller • Turns OFF the output to bucket TILT EPC solenoid A.
Machine

1 TILT EPC solenoid A Between P32 (male) (1) and (2) Resistance 9 – 10.2 Ω
Disconnection or
20-1078 WA800-3
(7)
[WRK-60] Grounding fault in bucket TILT EPC solenoid A system
Troubleshooting
Code Trouble Grounding fault in bucket TILT EPC solenoid A system
WRK-60
Description of • Since there is a grounding fault in the bucket TILT EPC solenoid A system, bucket TILT
Controller
Reaction • Turns OFF the output to bucket TILT EPC solenoid A.
Effect on
Machine • The bucket TILT speed is reduced to a half.

1 TILT EPC solenoid A Between P32 (male) (1) and (2) Resistance 9 – 10.2 Ω
2 wiring harness
WA800-3 20-1079
(7)

TILT EPC solenoid B system
Troubleshooting
Code Disconnection or short circuit (with power source) in bucket TILT EPC solenoid B
Trouble system
WRK-61
Description of • Since there is a disconnection or short circuit (with power source) in the bucket TILT EPC
Trouble solenoid B system, bucket TILT EPC solenoid B does not operate.
Controller • Turns OFF the output to bucket TILT EPC solenoid B.
Machine

1 TILT EPC solenoid B Between P36 (male) (1) and (2) Resistance 9 – 10.2 Ω
Disconnection or
20-1080 WA800-3
(7)
[WRK-62] Grounding fault in bucket TILT EPC solenoid B system
Troubleshooting
Code Trouble Grounding fault in bucket TILT EPC solenoid B system
WRK-62
Description of • Since there is a grounding fault in the bucket TILT EPC solenoid B system, bucket TILT
Controller
Reaction • Turns OFF the output to bucket TILT EPC solenoid B.
Effect on
Machine • The bucket TILT speed is reduced to a half.

1 TILT EPC solenoid B Between P36 (male) (1) and (2) Resistance 9 – 10.2 Ω
2 wiring harness
WA800-3 20-1081
(7)

DUMP EPC solenoid A system
Troubleshooting
Code Disconnection or short circuit (with power source) in bucket DUMP EPC solenoid
Trouble A system
WRK-63
Description of • Since there is a disconnection or short circuit (with power source) in the bucket DUMP
Trouble EPC solenoid A system, bucket DUMP EPC solenoid A does not operate.
Controller • Turns OFF the output to bucket DUMP EPC solenoid A.
Machine

1 DUMP EPC solenoid
Disconnection or
20-1082 WA800-3
(7)
[WRK-64] Grounding fault in bucket DUMP EPC solenoid A system
Troubleshooting
Code Trouble Grounding fault in bucket DUMP EPC solenoid A system
WRK-64
Description of • Since there is a grounding fault in the bucket DUMP EPC solenoid A system, bucket DUMP
Controller
Reaction • Turns OFF the output to bucket DUMP EPC solenoid A.
Effect on
Machine • The bucket DUMP speed is reduced to a half.

1 DUMP EPC solenoid
2 wiring harness
WA800-3 20-1083
(7)

DUMP EPC solenoid B system
Troubleshooting
Code Disconnection or short circuit (with power source) in bucket DUMP EPC solenoid
Trouble B system
WRK-65
Description of • Since there is a disconnection or short circuit (with power source) in the bucket DUMP
Trouble EPC solenoid B system, bucket DUMP EPC solenoid B does not operate.
Controller • Turns OFF the output to bucket DUMP EPC solenoid B.
Machine

1 DUMP EPC solenoid
Disconnection or
20-1084 WA800-3
(7)
[WRK-66] Grounding fault in bucket DUMP EPC solenoid B system
Troubleshooting
Code Trouble Grounding fault in bucket DUMP EPC solenoid B system
WRK-66
Description of • Since there is a grounding fault in the bucket DUMP EPC solenoid B system, bucket DUMP
Controller
Reaction • Turns OFF the output to bucket DUMP EPC solenoid B.
Effect on
Machine • The bucket DUMP speed is reduced to a half.

1 DUMP EPC solenoid
2 wiring harness
WA800-3 20-1085
(7)
[WRK-67] Abnormality in work equipment lever neutral caution system
Troubleshooting
Code Trouble Abnormality in work equipment lever neutral caution system
WRK-67
Description of
Trouble • A mistake is made in operation of the work equipment lever neutral system.
Controller • Turns OFF the output to the EPC solenoid. (Action to take after the error is reset: Return
Reaction the lever to NEUTRAL.)
Effect on • The work equipment cannot be operated.
Machine • The buzzer sounds.
Related
Information

Defective boom 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch
1 neutral lock switch ON. 6) Set work equipment safety lock lever in LOCK position.
and Standard Defective boom EPC 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch
Values 2 lever potentiometer ON. 6) Set work equipment lever in NEUTRAL position.
Defective bucket EPC 3) Insert T-adapter. 4) Connect connector. 5) Turn starting switch
3 lever potentiometer ON. 6) Set work equipment lever in NEUTRAL position.
20-1086 WA800-3
(7)
[WRK-68] Disconnection or grounding fault in boom lock switch system
Troubleshooting
Code Trouble Disconnection or grounding fault in boom lock switch system
WRK-68
Description of • Since there is a disconnection or a grounding fault in the boom lock (work equipment
Trouble safety lock lever) switch, the work equipment (boom and bucket) does not operate.
Controller
Reaction
Effect on • The work equipment (boom and bucket) does not operate.
Machine
Related
Information

Defective boom lock
1 switch Between P10 Boom lock switch: ON Resistance Max. 1 Ω
(female) (1)
and (2) Boom lock switch: OFF Resistance Min. 1 MΩ
Disconnection in and FS2A. 3) Connect T-adapter.
wiring harness
Wiring harness between FS2A (female)
2 (Disconnection in
wiring or defective
Possible Causes contact in connector) Wiring harness between P10 (female)
and Standard Resistance Max. 1 Ω
Values
Grounding fault in 1) Turn starting switch OFF. 2) Disconnect connectors P01 and
3 flIf this trouble
occurs, fuse (A-9) is Between P10 (female) (2) – P01 (female) Resistance Min. 1 MΩ
broken. (17) and chassis
4 equipment controller switch ON.
Between P01 Boom lock switch: ON Voltage Max. 1 V
(17) and
chassis Boom lock switch: OFF Voltage 20 – 30 V
WA800-3 20-1087
(7)
[WRK-69] Short circuit (with power source) in boom lock switch

system
Troubleshooting
Code Trouble Short circuit (with power source) in boom lock switch system
WRK-69
Description of • Since there is a short circuit (with the power source) in the boom lock (work equipment
Trouble safety lock lever) switch, the work equipment (boom and bucket) is not locked.
Controller
Reaction
Effect on • The work equipment (boom and bucket) is not locked.
Machine
Related
Information

Defective boom lock
1 switch Between P10 Boom lock switch: ON Resistance Max. 1 Ω
(female) (1)
and (2) Boom lock switch: OFF Resistance Min. 1 MΩ
Possible Causes Short circuit (with P10. 3) Connect T-adapter.
and Standard 2 power source) in
Values wiring harness Between P10 (female) (2) – P01 (female) Voltage Max. 1 V
(17) and chassis
3 equipment controller Between P01 Boom lock switch: ON Voltage Max. 1 V
(17) and
chassis Boom lock switch: OFF Voltage 20 – 30 V
20-1088 WA800-3
(7)
[WRK-70] Abnormality in bucket cylinder proximity switch system
Troubleshooting
Code Trouble Abnormality in bucket cylinder proximity switch system
WRK-70
Description of • There is a disconnection, a grounding fault, or a short circuit (with the power source) in
Trouble the bucket cylinder proximity switch system.
Controller
Reaction
Effect on • The bucket positioner does not operate (The tilt detent does not operate or stop).
Machine
Related
Information

FS2A, and LM1. 3) Connect T-adapter.
Disconnection or (20) and P40 (female) (B)
wiring harness Wiring harness between FS2A (female)
(8) and P40 (female) (A) Resistance Max. 1 Ω
Wiring harness between LM1 (female) Resistance Max. 1 Ω
(9) and P40 (female) (C)
wiring harness
Possible Causes 3 power source) in P40. 3) Connect T-adapter. 4) Turn starting switch ON.
and Standard wiring harness Between P03 (female) (20) and chassis Voltage Max. 1 V
Values
Defective bucket switch ON.
4 cylinder proximity Bucket: Below level Voltage Max. 1 V
switch Between P40 position (DUMP)
(B) and (C) Bucket: Above level Voltage 20 – 30 V
position (TILT)
switch ON.
Defective work Bucket: Below level
5 equipment controller Voltage Max. 1 V
Between P03 position (DUMP)
(20) and
chassis Bucket: Above level Voltage 20 – 30 V
position (TILT)
WA800-3 20-1089
(7)

source) in EPC lever adjustment mode input system
Troubleshooting
Code Disconnection, grounding fault, or short circuit (with power source) in EPC lever
Trouble adjustment mode input system
WRK-71
Description of • Since there is a disconnection, a grounding fault, or a short circuit (with power source) in the EPC lever adjust-
Trouble ment mode input system, the machine is not set in the adjustment mode or is kept in the adjustment mode.
Controller
Reaction
Effect on • The machine is not set in the adjustment mode.
Machine • The machine is kept in the adjustment mode. (The operation feeling of the lever is different.)
Related
Information

Disconnection or 3) Connect T-adapter.
Possible Causes 2 Grounding fault in 3) Connect T-adapter.
Short circuit (with
Defective work 3) Connect T-adapter. 4) Connect P05 (female) (2) and (3).
4 equipment controller 5) Turn starting switch ON.
20-1090 WA800-3
(7)

source) in boom angle adjustment mode input system
Troubleshooting
Code Disconnection, grounding fault, or short circuit (with power source) in boom
Trouble angle adjustment mode input system
WRK-72
Description of • Since there is a disconnection, a grounding fault, or a short circuit (with power source) in the boom angle
Trouble adjustment mode input system, the machine is not set in the adjustment mode or is kept in the adjustment mode.
Controller
Reaction
Effect on • The machine is not set in the adjustment mode.
Machine • The machine is kept in the adjustment mode. (The remote positioner stop position is irregular.)
Related
Information

Disconnection or 3) Connect T-adapter.
Possible Causes 2 Grounding fault in 3) Connect T-adapter.
Short circuit (with
Defective work 3) Connect T-adapter. 4) Connect P05 (female) (1) and (3).
4 equipment controller 5) Turn starting switch ON.
WA800-3 20-1091
(7)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................... 30- 3 TORQUE CONVERTER AND

PRECAUTIONS WHEN CARRYING TRANSMISSION ASSEMBLY
OUT OPERATION ................................... 30- 5 Removal ................................................ 30- 60
SPECIAL TOOL LIST.. ................................... 30- 8 Installation ............................................ 30- 67
SKETCHES OF SPECIAL TOOLS ................. 30-15 TORQUE CONVERTER
STARTING MOTOR Disassembly ......................................... 30- 69
Removal and Installation ..................... .30-23 Assembly .............................................. 30- 73
ALTERNATOR TORQUE CONVERTER VALVE
Removal and Installation ..................... .30-24 Disassembly and Assembly.. ............. .30- 78
ENGINE OIL COOLER TRANSMISSION
Removal and Installation ..................... .30-25 Disassembly ......................................... 30- 79
FUEL INJECTION PUMP FOR LEFT BANK Assembly .............................................. 30- 94
Removal and Installation TRANSMISSION VALVE
(with governor) ..................................... .30-26 Removal and Installation .................... 30-I 10
FUEL INJECTION PUMP FOR RIGHT BANK Disassembly and Assembly.. .............. 30-I 11
Removal and Installation TRANSFER
(without governor) ................................. 30-27 Disassembly ......................................... 30-I 15
WATER PUMP Assembly .............................................. 30-123
Removal and Installation ...................... 30-28 PTO
NOZZLE HOLDER Disassembly ........................................ .30-l 33
Removal and Installation ..................... .30-29 Assembly .............................................. 30-135
TURBOCHARGER CENTER SUPPORT
Removal and Installation ..................... .30-30 Removal ................................................ 30-138
ENGINE FRONT SEAL Installation ............................................ 30-139
Removal and Installation ..................... .30-31 Disassembly ......................................... 30-I 40
ENGINE REAR SEAL Assembly ............................................. .30-142
Removal and Installation ..................... .30-33 DRIVE SHAFT
CYLINDER HEAD Disassembly ......................................... 30-I 45
Removal .................................................. 30-35 Assembly .............................................. 30-I 47
installation .............................................. 30-39 FRONT AXLE
RADIATOR Removal ................................................ 30-I 49
Removal .................................................. 30-42 Installation ........................................... .30-l 51
Installation ............................................. .30-45 REAR AXLE
ENGINE Removal ................................................ 30-152
Removal .................................................. 30-46 Installation ........................................... .30-158
Installation .............................................. 30-52 DIFFERENTIAL
DAMPER Removal. ............................................... 30-159
Removal and Installation ..................... .30-53 Installation ............................................ 30-161
Disassembly .......................................... .30-54 Disassembly ........................................ .30-162
Assembly ................................................ 30-56 Assembly ............................................. .30-166
WA800-3 30-l
0
FINAL DRIVE PPC VALVE
Disassembly ......................................... 30-172 Removal ................................................ 30-219
Assembly .............................................. 30-175 Installation ............................................ 30-220
ORBIT-ROLL Disassembly and Assembly ................ 30-221
Removal ................................................ 30-178 WORK EQUIPMENT CONTROL VALVE
Installation ............................................ 30-179 Removal ................................................ 30-222
EMERGENCY STEERING PUMP Installation ............................................ 30-223
Removal and Installation .................... 30-180 Disassembly ......................................... 30-224
DIVERTER VALVE Assembly .............................................. 30-226
Removal and Installation .................... 30-181 CAB
ACCUMULATOR CHARGE VALVE FLOOR FRAME
Removal and Installation .................... 30-185 Removal ................................................ 30-231
Disassembly ......................................... 30-186 Installation ............................................ 30-233
Assembly .............................................. 30-187 CENTER HINGE PIN
STEERING STOP VALVE Removal ................................................ 30-234
Removal and Installation .................... 30-189 Installation ............................................ 30-240
STEERING CYLINDER WORK EQUIPMENT
Removal ................................................ 30-190 Removal ................................................ 30-244
Installation ............................................ 30-191 Installation ............................................ 30-249
STEERING VALVE BOOM FRONT END BUSH
Removal ................................................ 30-192 Replacement ......................................... 30-250
Installation ............................................ 30-193 BUCKET CYLINDER
BRAKE VALVE Removal and Installation .................... 30-251
Removal and Installation .................... 30-194 LIFT CYLINDER
SLACK ADJUSTER Removal ................................................ 30-252
Removal and Installation .................... 30-195 Installation ............................................ 30-253
Disassembly ......................................... 30-196 HYDRAULIC CYLINDER
Assembly .............................................. 30-197 Disassembly ......................................... 30-254
BRAKE Assembly .............................................. 30-256
Removal and Installation .................... 30-198 AIR CONDITIONER UNIT
PARKING BRAKE CALIPERS AIR CONDITIONER COMPRESSOR
Removal and Installation .................... 30-206 Removal and Installation .................... 30-260
Disassembly ......................................... 30-207 RECEIVER TANK
Assembly .............................................. 30-209 Removal and Installation .................... 30-261
PARKING BRAKE PAD AIR CONDITIONER CONDENSER
Removal and Installation .................... 30-211 Removal and Installation .................... 30-262
PARKING BRAKE SPRING CYLINDER TRANSMISSION AND
Removal and Installation .................... 30-212 STEERING CONTROLLER
BRAKE OIL TANK Removal and Installation .................... 30-263
Removal and Installation .................... 30-213 MAIN MONITOR
HYDRAULIC PUMP Removal ................................................ 30-264
Removal ................................................ 30-214 Installation ............................................ 30-265
Installation ............................................ 30-215 FUEL TANK
PISTON PUMP Removal ................................................ 30-266
Disassembly ...................................... 30-215-1 Installation ............................................ 30-267
Assembly ........................................... 30-215-7 COUNTERWEIGHT
SERVO CYLINDER Removal and Installation .................... 30-268
Removal and Installation .................... 30-216
HYDRAULIC TANK AND
FILTER CASE ASSEMBLY
Removal ................................................ 30-217
Installation ............................................ 30-218
30-2 WA800-3
1
3
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
(I) When removing or installing a unit assembly, the order of work and techniques used are given
for the removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked m, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in
the installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 ASSEMBLY . . .. .. . . . . . . Title of operation
A ................................................................. Precautions
the operation
related to safety when carrying out
1. xxxx (I) . .. .._....................................... Step in operation

* . . .. . . . . . . . . .. . . . . .. . . .. . . . . . .. . . . . . .. . . . . . .. . .. . . . . . . .. . . Technique or important point to remember when
removing XXXX (I).
2. a a n (2): ._........._.............._................... m Indicates that a technique is listed for use
during installation
3. 0 0 0 0 assembly (3)
. . . . . . .. . . . . . . .. .. . . . . . .. . . . . . .. . . .. . .. . .. . . . . . . .. . . See Lubricant and Coolant Table
INSTALLATION OF 0 0 0 ASSEMBLY . . .. Title of operation

l Carry out installation in the reverse
order to removal.
m ................ ............ .................... Technique used during installation
Ir . . . . . .. . . . . . .. . . . . . . .. .. . . . . . . . .. . . . . .. . .. . . . . .. Technique or important point to remember when
installing n fI n (2).
l Adding water, oil . . . . ..__......._............. Step in operation
sr .. . . . . . . .. . .. . . . . . .. . . . . . . .. . .. . . . .. . . . . . . . .. . . . Point to remember when adding water or oil
.. . . . . . .. . . .. . . . . .. . . . . . . .. . .. . . .. .. . . . . . . . .. . . . Quantity of filling oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units
are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow
these precautions when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (Al, etc.) that appear in
the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
WA800-3 30-3
Co
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
4. General tightening torque table (when using torque wrench)

* 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 flats
mm I mm
6 IO
8 13
IO 17
12 19
14 22 177 + 19 18.0 f 2.0
16 24 279 r 29 28.5 -c 3
18 27 383 r 39 39 + 4
20 30 549 -c 58 56 + 6
22 32 745 + 78 76 + 8
24 36 927 2 98 94.5 i IO
27 41 1320 k 140 135 + 15
1720 2 190 175 r 20
2210 + 240 225 + 25
2750 + 290 280 2 30
3280 + 340 335 + 35
Seal surface
5. Table of tightening torques for flared nuts SAD00483
* In the case of flared nuts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flats 1 Tightening torque
mm f mm Nm kgm
14 19 24.5 2 4.9 2.5 + 0.5
18 24 49 2 9.8 5+1
22 27 78.5 k 9.8 8+1
24 32 137.3 + 29.4 14 * 3
30 36 176.5 2 29.4 18 + 3
33 41 196.1 2 49 20 f 5
36 46 245.2 2 49 25 + 5
42 55 294.2 +. 49 30 + 5
6. Table of tightening torques for split flange bolts

* 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 flats Tightening torque
mm mm Nm kgm
IO 14 65.7 f 6.8 6.7 + 0.7
12 17 112 A 9.8 11.5 2 1
16 22 279 +. 29 28.5 + 3
30-4 WA800-3
0
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
Precautions when carrying out removal work
If the coolant contains antifreeze, dispose of it correctly.

After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws alternately.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Sleeve nut (elbow end)

r’$Fr:’ Plug (nut end)
Usethetwo items below as a set
02 07376-50210 07221-20210 (Nut),07222-00210 (Plug)

03 07376-50315 07221-20315 (Nut),07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut),07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut),07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut),07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut),07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (plug)
2) Split flange type hoses and tubes
Sleeve head
~~'a~e~t Flange (hose end) Splitflange
(tube end)
04 07379-00400 07378-10400 07371-30400

05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
DEW00401
WA8003 30-5
0
Precautions for installation operations
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pin or lock plate securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
portion with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with antifriction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
Precautions when completing the operations
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
the engine to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level.
Run the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been
removed for repair, always bleed the air from the system after reassembling the parts.
Sr For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
related parts.
Other precautions
To maintain the performance of the machine and to prevent failures, it is particularly important to
pay attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or
changing the oil, or when replacing the filters, check that the oil container and area around the
filler of the hydraulic tank are clean.
To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the
following points when disassembling or assembling.
. Before disassembling, wash the machine. Be particularly careful to completely clean the area
that is to be disassembled.
. Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
. Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for
the circuits or parts that have failed.
. When disassembling or after flushing, always mask the openings of the piping or hydraulic
equipment completely.
. Do not use seal tape for the thread of the plug mounts or connections.
If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic
equipment and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic
circuits are disassembled and assembled, also carry out thorough flushing of the hydraulic circuits.
When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump
piping, always bleed the air before starting the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.
30-6 WA800-3
0
* After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and
installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equip-
ment piping, always bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders
4 - 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the
stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then
stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more
air comes out from the plugs.
4. After completing bleeding the air, tighten the plugs.
m Plug: 11.3 + 1.5 Nm II.15 -c 0.15 kgm1
* If the engine is run at high speed from the start, or the cylinders are operated to the end of
this stroke, the air inside the cylinder will cause damage to the piston packing.
Sr After repair or long storage, follow the same procedure.
WA800-3 30-7
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

* Tools with part number790T-0000000cannot be supplied (they are items to be locally manufac-
tured).
* Necessity: n : . .. . . .. Cannot be substituted, should always be installed (used)
0: . .. . .. . Extremely useful if available, can be substituted with commercially available part
* New/remodel: N: . . . . . . .. Tools with new part numbers, newly developed for this model
R: . . . . . .. . . Tools with upgraded part numbers, remodeled from items already available
for other models
Blank: .. Tools already available for other models, used without any modification
* Tools marked 0 in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
Component T-
Isymbol Part No. Part Name “;?$s- Q'ty
Nature of work,
remarks
Removal, Installation of
1 790-331-1110 Wrench n 1 cylinder head
795-602-2200 Installer KIT n 1 Press fitting of front seal
.795-602-2210 -Installer n 1 Press fitting of oil seal
+795-502-2220 .Installer H 1 Press fitting of sleeve

2
.01050-32250 .Bolt n 1
.01050-32240 . Bolt H 6
Disassembly,
assembly of A
1.01640-22232 1.Washer /WI61 I I
engine 795-602-2300 Installer KIT n 1 Press fitting of rear seal
.795-602-2320 . installer n 1 Press fitting of oil seal
.795-502-2120 .Sleeve n 1 Press fitting of sleeve

3
~~01050-32055 / -Bolt lM5l I I
-
Press fitting of bearing in
Disassembly,
assembly of B
damper
Disassembly,
assembly of torque C
converter
30-8 WABOO-3
Neces- New/ Nature of work,

Component Symbol Part No. Part Name sity Q’ty remodeled Sketch remarks
790-201-2250 Plate ■ 1 Press fitting of shaft
5 bearing inner race
· 790-201-2760 · Spacer ■ 1
790-101-5401 Push tool KIT (C) ■ 1 Press fitting of housing

bearing outer race
· 790-101-5481 · Plate 1
6
· 790-101-5421 · Grip 1
· 01010-51240 · Bolt 1
790-101-5401 Push tool KIT (C) ■ 1 Press fitting of retainer

oil seal
Disassembly, · 790-101-5461 · Plate 1
assembly of torque C 7
converter · 790-101-5421 · Grip 1
· 01010-51240 · Bolt 1
Press fitting of pump
8 790-201-2740 Spacer ■ 1 shaft collar, bearing
790-101-5401 Push tool KIT (C) ■ 1 Press fitting of front
housing bearing outer
· 790-101-5431 · Plate 1 race
9
· 790-101-5421 · Grip 1
· 01010-51240 · Bolt 1
Check of operation of
1 799-301-1600 Oil leak tester KIT ■ 1 clutch
793T-815-1110 Push tool ■ 1 N Press fitting of clutch
2 shaft main bearing, sub
790-210-2760 Spacer ■ 1 bearing
790-101-5401 Push tool KIT (C) ■ 1 Press fitting of bushing
in cover
· 790-101-5461 · Plate 1
3
· 790-101-5421 · Grip 1
· 01010-51240 · Bolt 1
790-101-5621 Plate ■ 1 Press fitting of main

Disassembly, bearing outer race in
assembly of D 4 · 790-101-5421 · Grip ■ 1 cage
transmission
· 01010-51240 · Bolt ■ 1
790-101-5201 Push tool KIT (B) ■ 1 Press fitting of transfer

gear bearing inner race
· 790-101-5321 · Plate 1
5
· 790-101-5221 · Grip 1
· 01010-51225 · Bolt 1
790-101-5401 Push tool KIT (C) ■ 1 Press fitting of bearing

outer race in cage
· 790-101-5521 · Plate 1
6
· 790-101-5421 · Grip 1
· 01010-51240 · Bolt 1
WA800-3 30-9
1
(9)

793T-815-1120 Plate ■ 1 N Press fitting of bearing
inner race in transfer
7 790-101-5421 Grip ■ 1 output shaft cage
01010-51240 Bolt ■ 1
790-101-5401 Push tool KIT (C) ■ 1 Press fitting of oil seal in

output shaft cage
· 790-101-5491 · Plate 1
8
· 790-101-5421 · Grip 1
· 01010-51240 · Bolt 1
Disassembly,
assembly of D 790-101-5401 Push tool KIT (C) ■ 1 Press fitting of oil seal in
transmission transfer output shaft
· 790-101-5561 · Plate 1 cage
9
· 790-101-5421 · Grip 1
· 01010-51240 · Bolt 1
790-101-7200 Centering tool ■ 1 Centering of transmis-

sion and support
· 790-101-7230 · Shaft 1
10
· 790-101-7240 · Guide 1
· 01010-51230 · Bolt 1
790-101-7180 Push tool ■ 1 Press fitting of center

support bearing
1 790-101-5421 Grip ■ 1
01010-51240 Bolt ■ 1
790-101-7140 Push tool ■ 1 Press fitting of bearing

2 790-101-5421 Grip ■ 1
Disassembly, 01010-51240 Bolt ■ 1
assembly of E
center support 792-715-1300 Push tool ■ 1 Press fitting of main
bearing outer race
3 790-101-5421 Grip ■ 1
01010-81235 Bolt ■ 1
790-101-5621 Plate ■ 1 Press fitting of sub
bearing outer race
4 790-101-5421 Grip ■ 1
01010-51240 Bolt ■ 1
790-501-2000 Engine repair stand ■ 1 Disassembly, assembly

1 of differential
790-901-5110 Bracket ■ 1
790-101-2300 Push tool ● 1 Removal of pinion shaft

Disassembly, bearing
assembly of H · 790-101-2310 · Block 1
differential
2 · 790-101-2350 · Leg 2
· 790-101-2360 · Plate 4
· 790-101-2430 · Adapter 2
30-10 WA800-3
1
(9)
Nature of work,
Component Symbol Part No. Part Name
remarks
-
.02215-11622 .Nut 2
2 790-101-2102 Puller (30ton) 0 1
790-101-I 102 Hydraulic pump l 1
793T-822-1130 Push tool n 1 N 0 Press fitting of pinion

3 bearing inner race
I
793T-822-1140
I
Push tool
I
w
I
1
I
N
I
0 I
Press fitting of bearing in
I
4 793T-822-1150 Push tool w 1 N 0 sleeve
Press fitting of oil seal,
Disassembly, dust seal in cage
assembly of H
differential 5
6 sleeve round nut
bearing
7 790-425-1670 Adapter w 1
790-425-1660 Wrench w 1
-
792-633-1300 Fixture w 4 Removal, installation of
/ I I I I
brake
1 01010-81430 Bolt w 4
I I I I /
01641-21423 Washer w 4
I
Installation of floating
Disassembly,
assembly of brake J
and final drive
WAKIO-3 30-11
0
T rl
!jymbo
- - A.
Part No. Part Name lN;r-I Q’ty l,,$&(SketchI
Nature of work,
remarks
790-101-5401 Push tool KIT (C) n 1 Press fitting of bearing

and carrier spacer in
.790-101-5541 . Plate 1 planetary gear
Disassembly,
assembly of brake J 5 .790-101-5451 .Plate
and final drive
.790-101-5421 .Grip
~01010-51240 1.Bolt I /I/ I I

- -
790-101-2501 1Push puller II H II 1 II I / Press fitting of upper
I I
center hinge bearing
~790-101-2510 .Block 1
I I I I I
.790-101-2520 .Screw I 1 I
~791-112-1180 /.Nut I Ill I I

.790-101-2540 1.Washer I Ill I I
.790-101-2560 .Nut 2
790-101-7340 Push tool n 1
ml
.790-101-2102 .Puller (30ton) n 1
-
.790-101-l 102 1.Hydraulic pump IbIll I I
Disassembly,
assembly of K 2
center hinge
-
790-101-2300 Push tool n 1 Press fitting of lower
center hinge
~790-101-2310 .Plate 1
790-101-7320 Grip n 1
.790-101-2102 .Puller (30ton) n 1
~790-101-1102 .Hydraulic pump n 1

- -
30-12 WA800-3
0

793T-846-1110 Plate ■ 1 N Press fitting of lower
retainer dust seal
Disassembly, 4 · 790-101-5221 · Grip ■ 1
assembly of K
center hinge · 01010-51225 · Bolt ■ 1
Removal, installation of
5 790-450-1110 Adapter ■ 1 center hinge shaft
1 790-502-1003 Cylinder repair stand ● 1 Repair of hydraulic cylinder
790-720-1000 Expander ■ 1 Installation of piston

rings of all cylinders
2 796-720-1680 Ring ■ 1
07281-01589 Clamp ■ 1
796-720-1710 Ring ■ 1 Installation of piston

3 rings of lift cylinder
07281-02709 Clamp ■ 1
796-720-1730 Ring ■ 1 Installation of piston

4 rings of dump cylinder
07281-03209 Clamp ■ 1
790-201-1500 Push tool KIT ■ 1 Press fitting of dust seal

of steering cylinder
· 790-201-1660 · Plate 1
5
· 790-101-5201 · Grip 1
· 01010-50816 · Bolt 1
792-103-3601 Push tool ■ 1 Press fitting of dust seal

Removal, 6 of lift cylinder
installation of U 792-103-0400 Grip ■ 1
hydraulic cylinder
791-863-1140 Push tool ■ 1 Press fitting of dust seal
of dump cylinder
7 · 790-101-5221 · Grip ■ 1
· 01010-51225 · Bolt ■ 1
790-201-1702 Push tool KIT ■ 1 Press fitting of roll

bushing of steering
· 790-201-1851 · Push tool 1 cylinder
8
· 790-101-5021 · Grip 1
· 01010-50816 · Bolt 1
792-103-4102 Push tool ■ 1 Press fitting of roll

bushing of lift cylinder
9 · 790-101-5421 · Grip ■ 1
· 01010-81235 · Bolt ■ 1
792-625-1300 Push tool ■ 1 Press fitting of roll

bushing of dump
10 · 790-101-5421 · Grip ■ 1 cylinder
· 01010-81235 · Bolt ■ 1
WA800-3 30-13
1
(9)

793T-870-1110 Sleeve ■ 1 N Removal of bucket hinge
pin and bucket link pin
793T-870-1120 Plate ■ 1 N
791-745-2110 Adapter ■ 1
790-438-1110 Screw ■ 1
790-101-2540 Washer ■ 1
1
02215-11622 Nut ■ 1
01010-81655 Bolt ■ 3
01640-21626 Washer ■ 3
Removal of work 790-101-2102 Puller ■ 1
equipment pin and
removal, V 790-101-1102 Pump (30ton) ■ 1
installation of
bushing 793T-870-1130 Sleeve ■ 1 N Removal, installation of
bushing of lift arm end
793T-870-1140 Plate ■ 1 N (bucket hinge)
793T-870-1150 Plate ■ 1 N
01580-13024 Nut ■ 2
2 01643-33080 Washer ■ 2
791-650-1240 Spacer ■ 2
791-650-1230 Bolt ■ 1
790-314-1000 Puller (80ton) ■ 1
790-101-1102 Pump (30ton) ■ 1
799-703-1200 Service tool KIT ■ 1 Charging air conditioner with gas

Collection and 799-703-1110 Vacuum pump (220V) 1
reuse of air X 1
conditioner gas 790-703-1120 Vacuum pump (240V) 1
790-703-1400 Gas leak detector ■ 1
30-14 WA800-3
1
(9)
Component Symbol Part No. Part Name Neces- Q’ty New/ Sketch Nature of work,
sity remodeled remarks
1 790-501-5000 Unit repair stand 1
2 790-901-2110 Bracket 1
Y
3 790-901-1330 Plate 1
4 790-345-1020 Plate 1
(for minimum swash

1 790-445-3400 Gauge 1 plate angle) HPV
(for maximum swash

Disassembly, Z 2 790-445-3300 Gauge 1 plate angle) HPV,
assembly of piston HPF090+090 common
pump assembly
3 790-445-3500 For front 1 (HPF076+071)
4 790-445-3600 For rear 1 (HPF076+071)
1 796-720-3520 Cap 1
AA 2 796-720-2220 Socket 1
3 796-730-2120 Screwdriver 1
1 795-630-1803 Torque wrench 1

BB
2 796-720-3800 wrench 1
WA800-3 30-14-1
3
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
B2 PLATE
L;
J
-
cc
D
m
0
(5
‘8
co 5 cwwo3074
C2
- 3 El!:’ HEAT TREATMENT MATERIAL
I ---- I SS4OOP
I
PART NAME QTY
PLATE ----
V 793T-812-1110 n
D2 PUSH TOOL
cwwo3075
HEAT TREATMENT MATERIAL

---- STKMllA
PART NAME PTY
PUSH TOOL ---_
793T-815-1110 n
WA800-3 30-l 5
0
D7 PLATE
_
e
0
co
(
CWWQ
“,;“’
v 793T-815-1120 1i 1
H5 PLATE
C2
- L cwwo3077
I
-___ SS4OOP
I
PART NAME QTY
PLATE ----
I
793T-822-1110 n
30-16 WA800-3
0
H5 SPACER
CWWO3078
1 793T-822-1120 A
H3 PUSH TOOL
/v
-.-_-.__-_-_-_-.-. m
-8 ‘8
Cl
Cl 1 Cl
I- cwwo3079

---- STKMl3A
PART NAME QTY
PUSH TOOL ----
793T-822-1130 A
WA800-3 30-17
0
H3 PUSH TOOL
-
Cl
Cl
-_-___. 0
e.
150
-_____
I
-
-Cl
Cl
m
HEAT TREATMENT
--__
PART NAME
cww03080
MATERIAL
STKMl3A
QTY
PUSH TOOL --__
793T-822-1140 A
H4 PUSH TOOL
Cl
-
cww03081
- Cl
- HEAT TREATMENT MATERIAL
---- STKMlJA
50
I
PART NAME QTY
PUSH TOOL ----
v 793T-822-1150 A
30-l 8 WA800-3
0
J3 PLATE
c
r
CWWO3082
HEAT TREATMENT / MATERIAL
793T-833-1110 n
K4 PLATE
DWW05231
j
Unless otherwise specified. free from burr.
V 1 793T-846-1110 n
WA800-3 30-l 9
0
VI SLEEVE
-_-____ &
d
cu
a
c2
570
i
1 793T-870-1110 n
VI PLATE
I-
v 793T-870-1 120 ,//
30-20 WA800-3
0
v2 SLEEVE
DWW05233
---- SEE DWG
02 TUBE STKMl3A 1 15.2 @267.4XtlO PART NAME QTY
SLEEVE ----
01 PLATE SS4OOP 1 11.2 t22-
SYM. PART NAME MATERIAL OTY/SET "1;;p REMARKES 793T-870-1130 n
V2 PLATE
1
r
793T-870-1 140 n
WA000-3
V2 PLATE
-A-
T
h
0
+=T
I
J-
CWWO3162
u
-A--
12 5
---- SS4OOP
32
PART NAME QTY
PLATE --__
793T-870-1150 A
30-22 WA800-3
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR
A Disconnect the cable from the negative G-) ter-

minal of the battery.
1. Remove side cover (I).
2. Remove fuel control lever (2) together with

bracket (3).
3. Disconnect connectors (4) (ERI, 2, 3).
4. Disconnect connectors (5) (ER06, 07).
5. Disconnect cables (6) and (7).
6. Remove starting motors (8) and (9).
INSTALLATION OF STARTING
MOTOR
. Carry out installation in the reverse order to
removal.
WAN@3 30-23
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
g Disconnect the cable from the negative (-) ter-
1. Open side cover (I).
2. Disconnect connectors (2) (E20, 21, 22). m
3. Loosen locknuts (3).
4. Remove lock bolt (4).
5. Remove lock bolt (5) and turn down adjustment

bolt (6) toward the air conditioner compressor.
6. Loosen the alternator mounting bolt, then re-

move drive belt (7). m
7. Remove the mounting bolt, then remove alter-

nator (8).
INSTALLATION OF
ALTERNATOR
removal.
w Terminal mounting nut:

Terminal R: 1.9 - 2.5 Nm to.19 - 0.25 kgm1
Terminal E: 3.2 - 4.4 Nm (0.33 - 0.45 kgm1
Terminal B: 16.1 - 22.1 Nm II.65 - 2.25 kgm}
m Lock bolt:
54 - 123 Nm I5.5 - 12.5 kgm}
Adjust the deflection of the belt to the speci-

fied dimension. For details, see TESTING
AND ADJUSTING, Testing and adjusting al-
ternator belt tension.
30-24 WA800-3
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER
1. Open the left cover.
2. Loosen radiator drain valve and drain cooling

water.
Sr If the coolant contains antifreeze, dispose of
it correctly.
3. Remove fuel injection pump (1) assembly for

right bank.
* For details, see REMOVAL OF FUEL INJEC-
TION PUMP FOR RIGHT BANK (WITHOUT
GOVERNOR).
4. Remove front oil cooler assembly (2).
5. Remove rear oil cooler assembly (3).
INSTALLATION OF ENGINE OIL

COOLER
removal.
a
* Install fuel injection pump for right bank ac-
cording to INSTALLATION OF FUEL INJEC-
TION PUMP FOR RIGHT BANK.
Ir Tighten drain valve and add water to the

specified level, and then run the engine to
circulate the water then check the water level
of reservoir tank.
WA800-3 30-25
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR LEFT BANK
REMOVAL OF FUEL INJECTION

PUMP FOR LEFT BANK
(WITH GOVERNOR)
A Close valve between fuel tank and fuel filter.
1. Open left side cover.
2. Remove cover (I).
3. Remove control rods (2).
4. Disconnect injection pump lubrication tubes (3).

I
5. Disconnect fuel hoses (4). DEW03903
II DEW03904
6. Disconnect air tube (5).
7. Disconnect fuel injection tubes (6). m
8. Remove mounting bolts at injection pump end

to remove rack control rod (7).
9. Remove coupling lock bolt (9).
10. Remove mounting bolts, then remove fuel in-

jection pump.
Ir When removing fuel injection pump, be care-
ful not to drop the key.
&I kg Fuel injection pump: 30 kg I I DEW03905
INSTALLATION OF FUEL
INJECTION PUMP FOR LEFT
BANK (WITH GOVERNOR)

removal.
DEW3906
m Sleeve nut: 24 + 1 Nm I2.4 +. 0.1 kgm}
* Check fuel injection timing according to
TESTING AND ADJUSTING FUEL INJECTION
TIMING.
30-26 WA800-3
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR RIGHT BANK
REMOVAL OF FUEL INJECTION

PUMP FOR RIGHT BANK
(WITHOUT GOVERNOR)
a Close valve between fuel tank and fuel filter.
2. Remove lower cover (I) of coupling part.
3. Disconnect injection pump lubrication tubes (2).
4. Disconnect fuel hoses (3).
5. Disconnect fuel injection tubes (4). m
6. Remove mounting bolts at injection pump end

to remove rack control rod (5).
7. Remove coupling lock bolts (6).
8. Remove mounting bolts, then remove fuel in-

jection pump.
Ir When removing the fuel injection pump, be
careful not to drop key.
& kg Fuel injection pump: 23 kg
INSTALLATION OF FUEL
INJECTION PUMP FOR RIGHT
BANK (WITHOUT GOVERNOR)

removal.
m Sleeve nut: 24 2 1 Nm 42.4 + 0.1 kgm1

* Check fuel injection timing according to
TESTING AND ADJUSTING FUEL INJECTION
TIMING.
WA800-3 30-27
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

2. Loosen drain valve and drain cooling water.

Ir If cooling water contains antifreeze, dispose
of it correctly.
3. Remove cover (I).
4. Remove corrosion resistor (2).
5. Disconnect hoses (3).
6. Disconnect bypass pipe (4).
7. Remove water pump (5).
& kg Water pump: 22 kg
INSTALLATION OF WATER
PUMP
. I 1 DEW03910
Carry out installation in the reverse order to
removal.
sr Tighten drain valve and add water to specified

level, and then run the engine to circulate water,
then check water level of reservoir tank.
30-28 WA800-3
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER
g Stop the machine on level ground and lower

the work equipment completely to the ground,
then put blocks under the wheels to prevent the
machine from moving.
1. Remove the engine hood.
2. Remove head cover mounting bolt (I), then re-

move head cover (2). m
3. Remove lock nut (4), then pull out connection

(5). m
4. Remove bolt (61, then remove holder (7). a
5. Fully screw forcing screw @ (IO mm, P = 1.5) in

the nozzle holder, then pull out nozzle holder (8)
by levering it up with a bar.
* When pulling out the nozzle holder, clean
around it so that foreign matter will not en-
ter the empty hole.
* Check that the gasket is fitted to the nozzle
end.
INSTALLATION OF NOZZLE
HOLDER

removal.
m Head cover mounting bolt:

3.9 2 0.1 Nm iO.4 = 0.1 kgm}
m Connection: 37 + 3 Nm 13.8 2 0.3 kgm1

m Lock nut: 39 2 5 Nm I4.0 + 0.5 kgm}
w Bolt: 66.2 + 7.4 Nm I6.75 + 0.75 kgm)
VVA800-3 30-29
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER
A Stolj the machine on level ground and lower

the work equipment completely to the ground.
A Disconnect the cable from the negative (-) ter-

1. Remove mufflers (I).

2. Remove handrail (2).
3. Sling and remove engine hood (3).
4. Disconnect air cleaner connecting hose.

5. Disconnect Komaclone tubes (5).
6. Remove mufflers (6).
7. Disconnect connectors (7).
8. Remove bolts (81, then remove exhaust elbows
(9).
* Check the number of the shims.
9. Remove elbows (IO).
Ir Check the number of the shims.
IO. Disconnect lubrication oil inlet hoses (II).

11. Disconnect lubrication oil outlet hoses (12).
12. Remove the mounting bolts or nuts, then re-
move turbochargers (13). m
kg
rF?l Turbocharger: 22 kg (1 piece)
CWWO2807
INSTALLATION OF
TURBOCHARGER
l Carry out installation in the reverse order to

removal.
m
* Replace the removed gaskets with new gas-
kets.
w Mounting bolt: 49 2 5 Nm I5.0 + 0.5 kgm}
30-30 WA800-3
0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
1. Remove the radiator. For details, see REMOVAL

OF RADIATOR.
2. Remove mounting bolts (I), then remove damper

and crank pulley (2).
3. Take care not to damage crankshaft (3), remove

seal (4) with a screwdriver, etc.
INSTALLATION OF ENGINE
FRONT SEAL
1. Front oil seal and sleeve

I) When the seal contact face of the crankshaft
is not worn
. Press fit the oil seal to the end of the
gear case cover by 18.lmm with tool
A2.
t Fill the space between lips on the
outside with grease (G2-LI) up to 50
- 80%.
* Tighten the mounting bolts evenly.
2) When the seal contact face of the crankshaft

is worn
. If the position of the oil seal can be
changed, press fit a new oil seal to a
place at which its lip does not touch the
worn groove.
j, Measure the position of the worn
groove, then press fit the new oil seal
with tool A2 to a place where there
is not a worn groove.
3) When the position of the oil seal cannot be

changed
. Press fit sleeve (5) to the crankshaft.
t Remove rust and mud from sleeve
fitting portion of the crankshaft.
* Thinly apply sealant (LG-7) over the
inside of sleeve (5), then install the
sleeve to the end of crankshaft (3) in
parallel by hitting it lightly with a
wooden or plastic hammer.
WA800-3 30-3 1
0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
* Press fit the sleeve to the depth of

5mm from the crankshaft end with
tool A2.
* Press fit the sleeve by tightening the
bolts alternately.
. Press fit the seal.
* Fill the space between lips on the
outside with grease (G2-LI) up to 50 A2
- 80%.
Ir Press fit front seal (6) to the depth of
13mm with tool A2.
2. Install damper and crank pulley (2).

Tighten mounting bolts (I) in the order given in
the diagram on the right.
Ir Apply engine oil (SAE-30CD) to the mount-
ing bolts.
w Mounting bolt
1st step: 74 = 20 Nm 17.5 + 2.0 kgml
2nd step: 245 - 20 Nm I25 + 2 kgml
3rd step: 745 - 20 Nm I76 + 2 kgm}
* If the mounting bolts are tightened with an
impact wrench, their threads may be bro-
ken. Accordingly, tighten them with a hand
tool.
iI2- CWW05234
Q Q
02
CWWO2813
30-32 WA800-3
0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove the torque converter and transmission.

For details, see REMOVAL OF TORQUE CON-
VERTER AND TRANSMISSION ASSEMBLY.
2. Remove mounting bolts (I), then remove fly-

wheel (2).
3. Taking care not to damage crankshaft (3), re-

move seal (4) with a screwdriver, etc.
CWWO2814
REAR SEAL
1. Rear oil seal and sleeve

is not worn
. Press fit the oil seal to the crankshaft CWWO2815
end by 21mm with tool A3.

* Fill the space between lips on the
outside with grease (G2-LI) up to 50
- 80%.
* Tighten the mounting bolts evenly.

is worn
. If the position of the oil seal can be
changed, press fit a new oil seal to a
place at which its lip does not touch the
worn groove.
* Measure the position of the worn
groove, then press fit the new oil seal
with tool A3 to a place where there
is not a worn groove.
3) When the position of the oil seal cannot be

changed
. Press fit sleeve (5) to the crankshaft.
* Remove rust and mud from sleeve
fitting portion of the crankshaft.
* Thinly apply sealant (LG-7) over the
inside of sleeve (51, then install the
sleeve to the end of crankshaft (3) in
parallel by hitting it lightly with a
wooden or plastic hammer.
CWWO2817
WA800-3 30-33
0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
* Press fit the sleeve to the depth of 14

mm from the crankshaft end with tool
A3.
* Press fit the sleeve by tightening the bolts
alternately.
4) Press fit the seal.

* Fill the space between lips on the out-
side with grease (G2-LI) up to 50 - 80%.
* Press fit front seal (6) to the depth of
21mm with tool A3.
2. Install flvwheel (2).

1) Tighten mounting bolts (1) in the order given
in the diagram on the right.
* Apply engine oil (SAE-30CD) to the
mounting bolts.
w Mounting bolt
1st step: 98 2 20 Nm {IO + 2 kgml
2nd step: 294 + 20 Nm I30 f 2 kgml
3rd step: 539 = 20 Nm 155 + 2 kgml
* If the mounting bolts are tightened with
an impact wrench, their threads may be
broken. Accordingly, tighten them with
a hand tool.
cww02818
2) Measure the radial runout and facial runout

with dial gauge 0.
@)
. Radial runout: 0.30 mm max.
. Facial runout: 0.30 mm max.
8 I
go0 6
0
10
4 3
0 0
Ooo 9
2 7
0
5
cwwo2919
30-34 WA800-3
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

a Disconnect the cable from the negative 6) ter-
1. Drain the engine cooling water.
& Engine cooling water: Approx. 310 e
2. Remove engine hood (I).
&I kg Engine hood : Approx. 300 kg
3. Disconnect clamps (3) of Komaclone tubes (2).
4. Disconnect drain tubes (4).
5. Disconnect flange bolts (5).
WA800-3
6. Remove U-bolts (6), then remove mufflers
7. Remove air intake connectors (8).
-
cwwo2994
8. Disconnect turbocharger lubrication oil *tubes (9).
9. Disconnect turbocharger drain tubes (’IO).
10. Remove turbochargers (I 1).
11. Disconnect fuel injection tube clamps (12).
12. Disconnect boost compensator tube (13).
CWWO2996
30-36 WA800-3
0
13. Disconnect electrical intake air heater wire (14).
14. Disconnect aftercooler tubes (15) and (16).
15. Temporarily sling the air intake manifold and

aftercooler assembly (18), then remove mount-
ing bolts. m
Ir Set the guide bolt to the mounting hole at
the bottom of the air intake manifold to pre-
vent the electrical intake air heater from fall-
ing.
16. Remove the air intake manifold, aftercooler (18)

and electrical intake air heater.
&I kg Air intake manifold and aftercooler as-

sembly: 50 kg
17. Remove exhaust manifold (19).
Exhaust manifold : 30 kg
18. Remove fuel injection tube (20). a
19. Remove spill tube (21). a
20. Remove air vent tube (22). m
21. Remove head cover (23). m
WA800-3
22. Remove connection tube (24).
23. Remove nozzle holder (25).
24. Remove rocker arms (26).
24 cwwo2901
25. Remove push rods (27).
26. Remove crossheads (28).
27
:wwo2902
27. Remove rocker arm housing (29). m
28. Remove the mounting bolts, then remove cylin-

der head (30). m
&I kg Cylinder head : 19 kg
30-38 WA800-3
0
INSTALLATION OF CYLINDER
HEAD

removal.
& Mounting nut: Lubricant (LM-P)

m Mounting nut: 49 + 5 Nm I5.0 f 0.5 kgm}
m Mounting bolt:
59 - 74 Nm j6.0 - 7.5 kgm}
+ Tighten the mounting bolts in the order given
& Mounting bolt: Lubricant (LM-P)

m Mounting bolt:
44 - 54 Nm I4.5 - 5.5 kgm}
+ Tighten the mounting bolts in the order given
m Fuel injection tube:

23 - 25 Nm I2.3 - 2.5 kgm}
I cwwo2905
w Spill tube: IO - 13 Nm U.0 - 1.3 kgm}
m Air vent tube:

7.8 - 9.8 Nm IO.8 - 1.0 kgm)
w Head cover: 15 - 34 Nm Il.5 - 3.5 kgm}
7 17 20 2 1 13 I 6 3 21 23 I2
w Connection tube:
34 - 39 Nm I3.5 - 4.0 kgm}
w Connection tube lock nut: CWWO2906
34 - 44 Nm I3.5 - 4.5 kgm}
WA800-3 30-39
0
w Nozzle holder mounting bolt:

59 - 74 Nm I6.0 - 7.5 kgm}
w Rocker arm mounting bolt:

93 - 103 Nm I9.5 - 10.5 kgm}
m
* Adjustment of crosshead
i) Hold upper face of the crosshead lightly and
screw in adjustment screw.
ii) After the adjustment screw comes into con-
tact with the valve stem, screw in an addi-
tional 20” (or 30” when the engine is being
reassembled).
* When the engine is disassembled and as-
sembled, be sure to adjust the crosshead.
w Crosshead: 59 2 6 Nm I6.0 + 0.6 kgm}
m Rocker arm housing:

98 = 5 Nm IlO. + 0.6 kgm1
m
* Tighten the mounting bolts in the order given
& Mounting bolt: Lubricant (LM-PI
m Mounting bolt: Tighten by 2 - 3 turns
first with the hand, then tighten further
according to the following procedure.
i) 1st step:
137 - 157 Nm I14 - 16 kgm}
ii) 2nd step:
211 - 221 Nm I21.5 - 22.5 kgm1
iii) 3rd step:
Tighten by 90” +ioOwith wrench Al.
. If wrench Al is not used, tighten the mount-

ing bolts according to the following proce- DWW05235
dure.
I Al
30-40 WASOO-3
0
Cylinder head
start mark
Tighten to 147k 10 Nm {I5 -c 1 kgml Socket 1
start
Tighten to 216 + 5 Nm I22 + 0.5 kgml
Mark bolt head, then tighten it by 90”‘:00
End
mark
Tighten bolt QJ to 66.2 f 7.4 Nm i6.75 f 0.75 kgm).
After tightening each bolt, make a punch mark Socket start
on it to indicate the number of times tightened. start mark
Socket mark
Do not use a bolt having five punch marks, but CEP0035E ,
replace it with new one.
Refilling with water

Add water up to the water filler. Run the engine
Make mark with punch
to circulate the water through the system. Then,
check the water level in the reservoir tank again.
CEW0356
WA800-3 30-41
0
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
g Stop the machine on level ground and install
the safety bar to the frame. Lower the work
equipment to the ground and stop the engine.
Then apply the parking brake and put blocks
under the wheels to prevent the machine from
moving.
a Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
Ir Disconnect the cable from the negative (-1 ter-
1. Draining water
Loosen drain valve (1) and drain cooling water.
Ir If the coolant contains antifreeze, dispose of
it correctly.
- f Cooling water: 301 e
2. Remove exhaust assembly 12) and then remove

hand guard (3), (4).
3. Remove side cover (5).
4. Remove engine hood (6).
&I kg Exhaust assembly: 44 kg (2 pieces)
fblkg Engine hood: 88 kg
5. Remove radiator grille.
l+l kg Grille: Approx. 30 kg
6. Disconnect connector (7) (CN-GRI ).

* After disconnecting the radiator water level
sensor wiring connector (CN-GOG), move the
connector towards the radiator.
30-42 WA8003
0
7. Sling radiator guard (8) temporarily, remove

mounting bolts, then lift off.
Radiator guard: Approx. 225 kg
8. Disconnect water drain hose (9) from radiator.
9. Loosen clamp of lower hose (IO).
10. Disconnect hose (I I).
11. Loosen hose clamps of tubes (12) and (13).

* Disconnect hose (14) from the radi, ator.
12. Disconnect hydraulic cooler hoses (151, (16).
WA800-3
13. Remove fan guard from radiator.
14. Remove radiator supports (18) of both sides.

m
15. Sling radiator (19) temporarily, remove mount-

ing bolts, then lift off.
Ir Raise the radiator slightly and check that the
lower and upper hoses have come out, then
lift off the radiator.
* Be careful not to let the fan hit the radiator
core.
el kg Radiator: 710 kg
30-44 WA800-3
0
INSTALLATION OF RADIATOR
removal.
w Mounting bolt: 549 2 59 Nm I56 + 6 kgml
. Refilling with water and oil

Tighten drain valve (I), then add engine cool-
ing water through the water filler of the ra-
diator to the specified level.
I& Engine cooling water: 301 e
Add oil through the oil filler of the hydraulic

tank to the specified level.
Run the engine to circulate the water and oil
through the system. Then, check the water
level and oil level again.
WA8003 30-45
0
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
A Stop the machine on level ground and install
equipment to the ground and stop the engine
and apply the parking brake, then put blocks
moving.
+ Disconnect the cable from the negative (-) ter-
* Collect the air conditioner gas (R134a) with tool
X.
1. Loosen drain valve (I 1, and drain engine cooling

water.
* If antifreeze solution is mixed in the engine
cooling water, handle the engine cooling
water as a chemical, and do not disposal of
it carelessly.
- : Engine cooling water: 301 e
2. Disconnect engine oil drain valve (2) from the

fuel tank.
3. Remove hand guards (3) and 14).
4. Remove exhaust tube (5).
5. Remove side cover (6).
6. Remove engine hood (7).
&I kg Exhaust assembly: 22 kg x 2 pieces
fhlkg Engine hood: 88 kg
Side hood: 55 kg
7. Disconnect air conditioner hose (8).
8. Disconnect heater hose clamp (9) from the bulk-

head.
9. Disconnect air conditioner hose (IO).
IO. Disconnect transmission breather (1 I).
11. Disconnect drive shaft (12). m

* After disconnecting the drive shaft, sling it
with ropes, etc.
30-46 WA8003
0
12. Loosen clamp of tube hose (13).
13. Disconnect engine stop cable (14) and electric

wiring connector (15).
- DEW04665
14. Disconnect fuel control cable (16) at servo cylin-

der end.
DEW03947 1I DEW03946
15. Loosen hose clamp between air cleaner and tur-

bocharger, and remove left and right hoses (17).
16. Sling air cleaner and bulkhead assembly (18A)

temporarily, then remove mounting bolts, and
lower.
el kg Air cleaner, bulkhead: 19.3 kg
Ir Remove bar (18B) first.
WA800-3 30-47
0
17 Disconnect hose (19) for heater from engine,

and remove clamp from bar (20), then move
hose towards front, and disconnect bar.
18. Remove air conditioner hose (21) from compres-

sor, and remove clamp from bar (20) and (22),
remove hose, then disconnect bar.
* Disconnect the both ends of fuel hoses (23),

(24).
19. Disconnect connectors (25) (CN-GRI).

* After disconnecting the radiator water level
sensor wiring, move the connector towards
the radiator.
30-48 WA800-3
0
20. Sling radiator guard (26) temporarily, then re-

move mounting bolts, and lift off.
& kg Radiator guard: 225 kg
21. Remove radiator grille.
&I kg Grille: 30 kg
22. Remove tubes (27) and (28), and disconnect hose

(29).
23. Disconnect tube (30), tube (31) (between water

pump and torque converter cooler), and tube
(32) (between torque converter cooler and en-
gine).
24. Disconnect left and right blow-by hose (33).
25. Disconnect fuel hose (34).
WA800-3
26. Disconnect ground connection cable (35).
27. Disconnect cable (36) from starting motor.
28. Disconnect connectors (37) (CN-ERI), (38) (CN-

ER2), and (39) (CN-ERS).
29. Disconnect ground connection cable (40).
CWW02934
30. Remove fan guard (41).

Sling fan temporarily and remove mounting
bolts, then secure fan to bar at top of radiator
with wire.
+ Be careful not to damage the radiator core
with the fan.
31. Sling engine temporarily, and remove left and

right front mounting bolts (42). m
30-50 WA800-3
0
32. Remove left and right rear mounting bolts (43).

a
33. Lift off engine (44).

Sr Be careful not to hit any parts when lifting
Off.
Ir Check that all hoses and wires are discon-

netted.
63kg Engine: Approx. 3,500 kg
34. Lift off fan (45) from radiator.

+ Be careful not to damage the radiator core
with the fan.
PI kg Fan: 63 kg
WA800-3 30-51
0
removal.
m Drive shaft mounting bolt:

157 - 196 Nm (16.0 - 20.0 kgm}
w Engine rear mounting bolt:

770 - 1,030 Nm (78 - 105 kgm}
w Engine front mounting bolt:

770 - 1,030 Nm {78 - 105 kgm}
30-52 WA800-3
0
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
1. Remove the engine hood and bulkhead. For de-

tails, see REMOVAL OF ENGINE .
2. Disconnect drive shaft (I). m
&I kg Drive shaft: 60 kg
3. Remove mounting bolts (2), then remove cover

(3). m
I.&lkg Cover: 113 kg
4. Loosen the upper two bolts of damper (51, then

sling temporarily and remove mounting bolts
(4). m
5. Slowly sling and lift off damper (5).
& kg Damper: 178 kg
INSTALLATION OF DAMPER
removal.
m Drive shaft mounting bolt:

157 - 196 Nm {IS - 20 kgm1
w Cover mounting bolt:

98 - 123 Nm {IO.0 - 12.5 kgml
m Damper mounting bolt:

245 - 309 Nm I25.0 - 31.5 kgml
WA800-3 30-53
0
DISASSEMBLY OF DAMPER
1. Cover
1) Remove oil seal (2) from cover (1).
2) Remove stopper snap rings (4) and (5) of
shaft (3).
3) Pull out shaft (3) from cover (1).
Ir After pulling out shaft (3), remove oil
seal (8).
Face cover (I) in the opposite direction, and

remove bearing (6) and spacer (7).
Ir Bearing (6) cannot be used again after it
has been removed. Always replace it in
the same way as oil seals (2) and (8).
DEW03993
30-54 WA800-3
0
2. Damper
1) Remove mounting bolts (91, and using forc-
ing screws, remove flange (IO).
* Tighten the 3 forcing screws evenly.
DEW03994
Ir Do not remove spacer (11) unless neces-

sary.
DEW03998
2) Remove rubber (12).
3) Remove inner body (14) and flange (15) from

outer body (13).
* Screw in the mounting bolts, tap with a
hammer and remove.
I DEW03996
WA800-3 30-55
0
ASSEMBLY OF DAMPER
1. Damper
1) Install flange (15) under outer body (13), then
install inner body (14).
* Align the bolt mounting holes of the bot-
tom flange and outer body.
& Contact surface of flange and outer
body: Gasket sealant (LG-4)
2) Assemble rubber (12) between inner body

(14) and outer body (13).
Whole surface of rubber:
Grease (G2-LI)
Outside circumference of inner body:
Grease (G2-LI)
Inside circumference of outer body:
Grease (G2-LI)
Between inner body and rubber:
Grease (G2-LI)
* Fill clearance “a” evenly at 6 places with

70 cc grease.
3) Install flange (IO), and tighten mounting bolts

(9).
9
& Contact surface of flange and outer
body: Gasket sealant (LG-4)
QZCl Mounting bolt:
278 f 31 Nm 128.3 + 3.2 kgm}
DEW03994
30-56 WA8003
0
2. Cover
I) Using tool Bl, press fit bearing (6) and spacer
(7) in cover (I).
* When press fitting the bearing, check that
the inside diameter of the spacer and
the inside diameter of the bearing are
aligned.
& Outside circumference of bearing
outer race:
Coat with adhesive (LT-2)
& Bearing: ENS grease
CWWQ3085
2) Using tool Bl and B2, press fit oil seal (8) in

cover (1).
Ir Press fit the oil seal so that the lip sur-
face is on the bearing side.
* Fill clearance a between oil seal (8) and

the bearing with grease.
Clearance a between oil seal and
bearing: ENS grease
Amount of grease: 80 g
Lip of oil seal: ENS grease
ri////h
\\\\\\\\\\\r CWWQ3086
WABOO-3 30-57
0
3) Install stopper snap ring (5) of bearing (6) to

cover (I).
4) Using tool Bl, press fit oil seal (2) in cover
(I).
Sr Press fit the oil seal so that the lip sur-
face is on the bearing side.
5) Using tool B3, press fit shaft (3) in cover (I).

& Inside of inner race of bearing (6):
Adhesive (LT-2)
6) Assemb,le snap ring (4) to shaft (3).
30-58 WA800-3
0
* Fill clearance b between oil seal (2) and

the bearing with grease.
& Clearance b between oil seal and
bearing: ENS grease
& Lip of oil seal: ENS grease
7) Remove plug (16), then fill with grease

through plug hole.
& Grease area d between bearings:
ENS grease
Amount of grease: 700 + 30 g
w Plug: 7.4 = 2.5 Nm IO.75 + 0.25 kgml
& Shaft spline portion (portion e):
Molybdenum disulphide
dry lubricant (LM-PI
(Leave to dry naturally for 2 - 3
minutes after coating, then install.)
8) Fill portion f with grease.

& Portion f: ENS grease
Ir Always keep to the specified amount for
grease in the grease areas (a, b, d, f).
* Always remove all other grease com-
pletely before using ENS grease. Do not
mix it with any other grease.
Use a different grease gun for each type
of grease.
* ENS grease Part No.: 427-12-11871 (2 kg
can)
WA800-3 30-59
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMISSION
REMOVAL OF TORQUE
CONVERTER AND
TRANSMISSION ASSEMBLY
1. Remove front, rear, right and left side covers (I)

under the cab.
2. Remove cab (2). For details, see REMOVAL OF
CAB .
w Cab: 400 kg
3. Disconnect drain hose (3) of the right-hand brake

valve.
4. Disconnect hoses (4) and (5) between the accu-
mulator and right-hand brake valve.
5. Disconnect accelerator cable (6). m
* Loosen the locknut and pull out the pin to
disconnect the cable.
6. Pull window washer hose (7) out of the floor
frame, then disconnect clamp (8) and move it
toward the frame.
7. Remove clamp (9), then disconnect left-hand

brake drain tube (IO).
9
8. Disconnect hoses (I 1) and (12) between the left-
hand brake valve and slack adjuster.
IO
9. Disconnect hoses (13) and (14) between the ac-
cumulator and left-hand brake valve.
10. Disconnect pilot hose (to shuttle valve) (15).
11. Disconnect hose (16) between the accumulator

and orbit-roll.
12. Disconnect hose (17) between the orbit-roll and
right-hand stopper valve.
13. Disconnect drain hose (18) of the orbit-roll.
left-hand stopper valve.
16. Disconnect hoses (21) and (22) between the right-
30-60 WA8QQ-3
0
17. Disconnect hoses (23) (Raise lift arm), (24)

(Dump), (25) (Lower lift arm) and (26) (Tilt) be-
tween the PPC valve and control valve.
18. Disconnect hose (27) between the PPC valve and

PPC pump.
19. Disconnect PPC valve drain hose (28).
20. Disconnect hose clamp (29).
21. Disconnect brake oil drain block (30) from the

floor frame.
22. Disconnect brake shuttle valve (31) from the floor

frame.
24. Disconnect ground cable (33).
25. Disconnect heater hose (34).

* Close the hot water outlet valve on the en-
gine side.
26. Disconnect air conditioner hose (35). m

t Collect the new Freon with tool Xl.
* Since the adapter is brittle, apply two span-
ners to it to disconnect each hose.
27. Disconnect connector (36), then remove wire

clamp (37) and move it toward the body.
Ir Connector: CN-CL2, CL3, A4, A5, A6, A7, A8A.
A8B
28. Disconnect connector (38). then remove wire

clamp (39).
j, Connector: CN-FLI, FL2, CLI, LRI, LR2, LR3,
LR4, LR5, GRE
WA8003 30-61
0
29. Remove 4 mounting nuts (40) of the floor frame

mount. m
30 Sling the floor frame (41) and lift off.

+ While slinging the floor frame slowly, check
that all the clamps and harnesses are dis-
connected.
CWWO2871
31 Remove transmission top cover (421, then re-

move bracket (43).
32. Disconnect transmission breather (44).
33. Disconnect the suction tubes of the pumps for

torque converter, transmission (45), PPC (46) and
brake (47).
34. Disconnect steering pump suction tube (48).
35. Disconnect steering pump drain hose (49).
30-62 WA800-3
0
36. Disconnect discharge tubes of the pumps for

brake (50), PPC (511, torque converter, transmis-
sion (52) and (53).
37. Disconnect switch pump suction tube (54).
38. Disconnect loader pump suction tube (55).
39. Disconnect switch pump discharge hose (56).
40. Loader pump discharge hose (57).
41. Remove bracket (58).
42. Disconnect control pump suction tubes (59) and

(60).
43. Disconnect steering pump discharge tube (61).
44. Disconnect switch pump drain hose (62) and

loader pump drain hose (63).
45. Sling upper drive shaft (63) temporarily and re-

move the mounting bolts, then lift off the shaft.
* Make match marks on the couplings.
l&lkg Upper drive shaft: 60 kg
WA8003 30-63
0
46. Disconnect emergency steering pump drain hose

(64).
47. Disconnect emergency steering pump discharge

hose (65) and suction hose (66).
49. Remove the mounting bolts, then remove emer-

gency steering pump (68).
r&Ikg Emergency steering pump: 50 kg
50. Remove hoses (69) and (70) of the sight gauge.

Sr Remove the drain hose of the engine con-
trol servo cylinder from the oil feed tube.
2953
51. Remove hose (71) of the torque converter cooler.

Ir Disconnect speedometer sensor connector
(72) (CM-CO1 1.
52. Remove transmission lubrication tube (73).
53. Remove hose (74) between the torque converter

filter and transmission.
30-64 WA800-3
0
54. Remove tube (75) between the torque converter

and torque converter cooler.
+ Disconnect torque converter oil temperature
sensor wiring (76) from the connector.
55. Remove transmission solenoid valve wiring (77)

from the connectors.
+ When removing the connector, be careful
not to damage the case of the threaded parts.
CWWO2957
56. Sling rear drive shaft (78) temporarily and re-

move the mounting bolts, then sling and lift off
the shaft. a
* When slinging the drive shaft, install suffi-
ciently long slings on left and right sides of
the transmission.
A kg Rear drive shaft: 186 kg
57. Sling center drive shaft (79) temporarily and re-

move the mounting bolts, then sling and lift off
the shaft. m
kg
LF?l Center drive shaft: 186 kg
WA800-3 30-65
0
58. Sling transmission and torque converter assem-

bly (80) temporarily.
Ir Set the slings as short as possible.
59. Remove the mounting bolts of the trunnion (81).

m
Sr Secure the trunnion to the torque converter
with wires.
* If shims are installed between the frame and
trunnion, check its quantity and thickness.
* Disconnect trunnion greasing hose (82) from
the trunnion.
60. Remove mount bracket (83) and mounting bolt

(84) on the front side. m
Ir Keep mount bracket (83) on the front side
removed.
* Be careful not to lose the pin between the
transmission and bracket.
CWWO2961
61. Moving the transmission and torque converter

(80) toward the engine, sling and lift it off slowly.
Transmission and torque converter as-

sembly: 2,880 kg
30-66 WA800-3
0
INSTALLATION OF TORQUE
CONVERTER AND
TRANSMISSION ASSEMBLY
removal.
* Adjust the length of the accelerator cable.

Adjusting length of accelerator cable.
m
* When connecting each hose, do not twist it.
* Be careful not to let dirt, dust, water, etc. in
each hose.
* Charge with new Freon gas (R134a) by us-
ing tool Xl.
w Mounting nut:
245 - 309 Nm I25.0 - 31.5 kgm1
w Upper drive shaft:

157 - 196 Nm US.0 - 20.0 kgm1
w Center drive shaft:

342 - 427 Nm I35.0 - 43.5 kgm}
w Rear drive shaft:

342 - 427 Nm i35.0 - 43.5 kgm}
w Trunnion mounting bolt:

490.4 - 608.0 Nm I50.0 - 62.0 kgm1
Sr Check the parallelism and adjust the shims.
Parallelism: 0.15 mm max.
DWW05236
WA800-3 30-67
0
1) Set the transmission to the frame, then

tighten the front and rear mounting bolts
temporarily.
2) Install tools A1, A2 and A3 to the upper and
lower center hinge pins, then install dial
gauge D10 to the coupling on the transmis-
sion side to measure the parallelism of the
coupling and shaft A1.
3) Insert the shim in the mount.
4) Position the transmission and tighten the
mounting bolts.
8
3 Bracket mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
30-68 WA800-3
1
(9)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE CONVERTER

Preparatory work
. Remove torque converter and PTO assembly.
For details, see DISASSEMBLY OF TRANSMIS-
SION.
. Set torque converter and PTO assembly (I) on
tool Cl.
Fblkg Torque converter, PTO assembly:

610 kg
CWWO3090
1. Valve
1) Remove tubes (2) and (31, and block (4).
2) Remove valve assembly (5).
3) Remove tube (6) and block (7).
DEW04036 1 1 DEW04037
2. PTO
I) Remove holder (8) and coupling (9).
2) Using eyebolts @ (Dia. = 16 mm, Pitch = 2.0

mm), sling PTO assembly temporarily.
3) Screw in forcing screws 0, and lift off PTO
assembly (IO).
WA800-3
3. Turbine . case assembly

1) Remove plug (II), and drain oil inside drive
case.
2) Leave 2 bolts on opposite sides, and remove
all remaining pump mounting bolts (12).
3) Set case side at top, and remove 2 remain-
ing mounting bolts.
4) Using eyebolts @ (Dia = 16 mm, Pitch = 2.0
mm), lift off turbine . case assembly (13).
I DEW04041
5) Disassemble turbine . case assembly as fol-

lows.
i) Remove mounting bolts, then remove
input shaft (14) and gear (15).
ii) Remove snap ring (16) and plate (17).
DEW04042 I DEW04043
iii) Using 2 forcing screws @ (Dia. = 10 mm,

Pitch = 1.25 mm) remove turbine (18).
* Use the forcing screws to push the
inner race of the bearing.
DEW04044
iv) Remove bearing (20) from case (19).

VI Remove bearing (21) from input shaft.
20 DEW04045 DEW04046
30-70
0
4. Stator
1) Remove snap ring (22).
2) Remove stator (23).
I DEW0404i 1 DEW04048
5. Puma, assemblv
I) Using tool k2, loosen nut (24).
Sr Leave the nut in position to prevent the
bearing and pump from flying off.
2) Remove 2 plugs (25) at stator shaft end.

3) Remove inner race of bearing from hole
where plug was removed, then remove
pump assembly (26).
DEW04050 I DEW04051
4) Remove bolts, then remove collar t27), pump

(28) and guide (30).
5) Remove bearing (29) from guide (30).
30
DEW04051 DEW04053
WA800-3
6. Stator shaft
I) Remove 8 mounting bolts (31).
DEW04054
2) Remove stator shaft (32) from rear housing

(33).
3) Remove seal ring (34).

4) Remove sleeve (35).
DEW04056 DEW04057
30-72 WA800-3
0
ASSEMBLY OF TORQUE CONVERTER

Preparatory work
. Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing.
. Set torque converter rear housing (33) on tool
Cl.
1. Stator shaft
1) Expand fit sleeve (35) to stator shaft.
2) Install seal ring (34) to stator shaft.
* Make the protrusion of the seal ring from
the shaft uniform.
DEW04057 DEW04056
3) Operate repair stand, rotate torque converter

case 90”, install stator shaft (32), then tighten
8 mounting bolts (31) from opposite side.
& Mounting bolt: Adhesive (LT-2)
w Mounting bolt:
275 z 29 Nm I28 f 3 kgm1
DEW04059 DEW04060
2. Pump assembly
I) Using push tool C8 (outside diameter: 195
mm), press fit bearing (29) in guide.
DEW04062
WA800-3 30-73
0
2) Install guide (30) and retainer (27) to pump

(28).
w Mounting bolt:
69 +. 5 Nm I7.0 + 0.5 kgm}
I DEW0406? I DEW04052
3) Using push tool C5, press fit inner race (36)

to stator shaft.
4) Set pump assembly (26) in position, be care-
ful not to damage the seal ring.
Ir Coat the seal ring with grease (G2-LI),
make the amount of protrusion from the
shaft uniform, and fix in position.
to stator shaft.
+ Be careful to install the inner race facing
in the correct direction.
' DEW04065
6) Set pump. Be careful not to damage the seal

ring while setting pump.
* Coat the seal ring with grease (G2-LI),
make the amount of protrusion from the
shaft uniform, and fix in position.
to stator shaft.
* Be careful to install inner race facing in
the correct direction.
DEW04066 1 1 36 cwwo3095
Statar shaft Adjustment marks
30-74 WA800-3
0
6) Using tool C2, install nut (24) to stator shaft.

& Nut: Adhesive (LT-2)
m Nut: 613 z 25 Nm 162.5 z 2.5 kgm}
3. Stator
1) Align spline, and install stator (23).
2) Install snap ring (22).
I 1 DEW04048 1 DEW04047
4. Turbine case assemblv

I) Using push tool 6, press fit bearing (20) in
case (19).
cww03097 DEW04071
2) Set turbine (18) in push tool C3 (outside di-

ameter: 105 mm, height: 165 mm).
3) Using push tool C4 (inside diameter: 110
-tzr
mm), press fit case (19) to turbine (18).
II
c3
cww03098
WA800-3 30-75
0
4) Fit plate (17) and install snap ring (16).

5) Using push tool C9 (inside diameter: 90 mm),
press fit bearing (21) in pilot.
DEW04043 cww03100
6) Install gear (15). I

7) Install pilot (14).
w Mounting bolt:
275 + 29 Nm 128 f 3 kgml
DEW04075 / DEW04076
8) Using eyebolts @ (Dia. = 16 mm, Pitch = 2.0

mm), raise turbine case assembly (131, align
oil groove of case with drain hole of pump
(2 places), then install.
9) Tighten pump mounting bolts temporarily.
IO) Rotate repair stand 90” and tighten mount-

ing bolts (12).
w Mounting bolt:
54 = 5 Nm 15.5 z 0.5 kgm}
11) Tighten drain plug (II).
12) Tighten 2 plugs (25).
w Plug: 7.4 + 2.5 Nm IO.75 t 0.25 kgml
30-76
0
5. PTO assemblv
1) Fit O-ring: then using eyebolts @ (Dia. = 16
mm, Pitch = 2.0 mm), install PTO assembly
(IO).
-f Be careful not to damage the oil seal
when installing.
* Mount PTO assembly after adjusting
mounting position. If move PTO assem-
bly after mounting, O-ring will be twisted
and gone out of groove.
2) Install coupling (9).

3) Fit O-ring and install holder (8).
w Mounting bolt:
275 +. 29 Nm I28 t 3 kgml
6. Valve assembly
1) Fit O-ring and install block (7) and tube (6).
2) Fit O-ring and install valve assembly (5).
3) Fit block (4) and install tubes (3) and (2).
w Valve assembly mounting bolt:
49 + 5 Nm j5.0 + 0.5 kgml
m Tube mounting bolt:
25 + 5 Nm j2.5 +. 0.5 kgml
I DEW04037 5 DEW04036
WA800-3 30-77
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER VALVE
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER

VALVE
DISASSEMBLY OF TORQUE CONVERTER

VALVE
1. Remove cover (1), then remove valve (2), spring

(3) and valve (4).
2. Remove cover (5), then remove spring (6), valve
(7) and washer, shim (8).
ASSEMBLY OF TORQUE CONVERTER VALVE
fl Clean all parts, and check for dirt or damage.

1. Assemble washer, shim (8), valve (7) and spring

(6), then fit O-ring and install cover (5).
2. Assemble valve (4), spring (3), and valve (2),
then install cover (1).
30-78 WA800-3
1
(8)
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF TRANSMISSION
1. Torque converter assembly
Using eyebolts, remove torque converter assem-
bly (1) from transmission assembly (2).
4 Torque converter assembly: 650 kg
2. Control valve assembly

1) Remove 11 mounting bolts.
fl The length of the bolts is different, so
check before removing.
fl Remove only the bolts marked in the
diagram.
2) Using eyebolts 1 (Dia. = 10 mm, Pitch = 1.5

mm), lift off control valve assembly (3).
4 Control valve assembly: 110 kg
3. Sleeve
Remove sleeve (4).
WA800-3 30-79
1
(8)
4. Transmission case
1) Raise transfer and transmission assembly,
and put transfer (14) at bottom.
4 Transfer, transmission assembly:

2,200 kg

mm), lift off transmission case (15).
4 Transmission case: 125 kg
5. Tie bolts
1) Using tool D1, check the operation of the
piston before disassembling.
2) Remove tie bolts (16).
30-80 WA800-3
1
(8)
6. Plate
Using eyebolts 1 (Dia. = 12 mm, Pitch = 1.75
mm), lift off plate (17).
4 Plate: 30 kg
7. Spring
Remove spring (18).
fl This spring is different from the other
springs, so keep it separately in a safe place.
8. Spring, disc, plate

Remove spring (19), disc (20), and plate (21).
fl There are springs between each plate.
9. No. 1 ring gear

Remove ring gear (22).
WA800-3 30-81
1
(8)
10. Shaft, No. 1 carrier assembly

1) Using eyebolts @ (Dia. = 12 mm, Pitch =
1.75 mm), lift off shaft and No. 1 carrier
assembly (23).
DEW04
2) Disassemble shaft and No. 1 carrier assem-

bly as follows.
i) Remove snap ring (24).
ii) Remove gear (25).
DEW04124 DEW04125
iii) Remove collar (27) from shaft and car-

rier assembly (26).
DEW04126
iv) Remove snap ring (281, then remove

shaft assembly (29) from carrier assem-
bly (30).
i!
DEW04127 DEW04128
30-82 WA800-3
0
VI Remove bearing (31).
DEW04129
vi) Remove sun gear (32).

vii) Remove bearing (33).
I DEW04130 DEW04131
viii)Remove bearing (34).

ix) Remove snap ring (35).
I DEW04132 DEW04133
x) Remove pin, then remove thrust washer

(36), planetary gear (371, needle bearing
(381, and spacer (39).
* When removing the pin, be careful
not to lose the ball.
36 3e j7
DEW04134 DEW04135
WA800-3
11. No. 2 ring gear

1) Remove mounting bolts (40), then remove
plate (41).
2) Remove ring gear (42).
12. No. 1 piston, housing

1) Using eyebolts 1 (Dia. = 12 mm, Pitch =
1.75 mm), lift off piston and housing (43).
4 Piston, housing: 65 kg
2) Remove piston (45) from housing (44).
13. Spring
Remove spring (46).

30-84 WA800-3
1
(8)
15. Guide Pin

Remove guide pin (50).
16. Ring gear

17. No.2 piston, housing

18. No. 2, 3 carrier assembly

2) Using puller, pull out bearing press-fit por-
tion of No. 2 and 3 carrier assembly (56).

1.75 mm), lift off carrier assembly (56).
4 Carrier assembly: 90 kg
4) Disassemble No. 2 and 3 carrier assembly

as follows.
i) Remove sun gear (57).
ii) Remove mounting bolts (58), then re-
move retainer (59).
WA800-3 30-85
1
(8)
iii) Remove pin, then remove thrust washer

(60), planetary gear (61), and needle bear-
ing (62).
fl When removing the pin, be careful
iv) Remove bearing (63).
19. Ring gear, plate

2) Using eyebolts (Dia. = 12 mm, Pitch = 1.75
mm), lift off plate (65).

1) Remove collar (66).
30-86 WA800-3
1
(8)

21. Spring
Remove spring (70).

23. No. 3 ring gear

WA800-3 30-87
1
(8)

25. Spring
Remove spring (78).

27. Guide pin

Remove guide pin (82).
28. Plate
Remove plate (83).
30-88 WA800-3
1
(8)
29. Shaft assembly

1) Remove shaft assembly (84).

3) Set in press, then using push tool D4 (Inside
diameter: 80 mm, Length: 400 mm), remove
bearing (86).
30. No. 4 ring gear, carrier assembly

1.75 mm), lift off ring gear and carrier as-
sembly (87).
4 Ring gear, carrier assembly: 80 kg
2) Disassemble No. 4 ring gear and carrier as-

sembly as follows.
i) Remove bearing assembly (88) from ring
gear and carrier assembly (87).
WA800-3 30-89
1
(8)
ii) Remove collar (91) from bearing (90).
DEW04172
iii) Remove mounting bolts (92), then re-

move retainer (93).
iv) Remove snap ring (94), then remove ring
gear (95).
i/
DEW04173
i DEW04174
V) Remove pin, then remove thrust washer

(961, planetary gear (97), and needle bear-
ing (98).
Ir When removing the pin, be careful
96 48
L- DEW04175 DEW04176
31. Sun gear

Remove sun gear (99).
30-90 WA8003
a
32. Cover assembly

1) Turn over transfer assembly.
4 Transfer assembly: 1,100 kg
2) Remove mounting bolts (5), then using forc-

ing screws 2 (Dia. = 12 mm, Pitch = 1.75
mm), remove cover assembly (6).
3) Remove snap ring (8) from cover (7), then

remove bushing (9).
33. Collar assembly

2) Using puller 3, remove collar assembly (11).
fl When using the puller, remove the out-
side seal ring (1 piece).
WA800-3 30-91
1
(8)
34. Inner race

Using puller 6, pull out rotating clutch assem-
bly (120), then remove inner race (121).
fl When pulling out the rotating clutch assem-
bly, fit a block under the rotating clutch to
prevent it from falling.
Serial No.: 50001 – (T/M No. 101138)
Serial No.: 50001 – (T/M No. 101138)

35. Rotating clutch assembly
1) Raise transfer assembly (122), and disassem-
ble rotating clutch assembly.
4 Transfer assembly: 1,100 kg
2) Remove flange (100) of bearing.
30-92 WA800-3
1
(8)
FINE DISASSEMBLY OF ROTATING CLUTCH

ASSEMBLY
36. No. 5 carrier assembly
1) Remove mounting bolts (101).
1.75 mm), sling carrier assembly (102), then
using forcing screws (Dia. = 12 mm, Pitch =
1.75 mm), lift off carrier assembly.
4 Carrier assembly: 65 kg
3) Disassemble carrier assembly as follows.

i) Remove snap ring (103).
ii) Remove collar (104).
iii) Remove bearing (105).
iv) Remove pin (106), then remove thrust

washer (107), planetary carrier (108), and
needle bearing (109).
fl When removing the pin, be careful
WA800-3 30-92-1
(8)
37. Sun gear, No. 5 ring gear

1) Remove sun gear (110).

39. Retainer, pressure plate

retainer (116).
2) Remove pressure plate (117).
40. Bearing
Using puller [7], remove bearing (118).
41A. Inner race

Serial No.: 50001 – (T/M No. 101138)
Remove inner race (119).
41B. Bearing
Remove bearing (119A).
WA800-3 30-93
1
(8)
ASSEMBLY OF TRANSMISSION
fl Precautions when assembling
• Coat the rotating and sliding surfaces of all
parts with engine oil (SAE10W) before in-
stalling.
• Coat the seal rings and roller bearings with
grease (G2-LI), then install them, making sure
that they are not off center.
• Align the notches on the discs when install-
ing.
• Check that the snap rings are fitted securely.
fl Clean all parts, and repair any damage.
FINE ASSEMBLY OF ROTATING CLUTCH

ASSEMBLY
fl Before assembling, coat plug (121) with LT-2

and tighten it into shaft (120) until its head is
flush with the end of shaft (120) and then bend
2 parts (parts “a”) and install pin (122).
1A. Inner race

Serial No.: 50001 – (T/M No. 101138)
Using push tool D2 (Inside diameter = 123 mm,
Length = 270 mm), press fit inner race (119).
1B. Bearing
Heat bearing (119A) and install it by shrink fit.
fl Do not heat bearing (119A) higher than
120°C.
2. Bearing
1) Install 2 seal rings to drum.
2) Press fit bearing (118).
3. Pressure plate, retainer

1) Fit seal ring to pressure plate (117), then
install to drum.
2) Fit retainer (116) and tighten mounting bolts
(115).
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
30-94 WA800-3
1
(8)

Install spring (112), disc (113), and plate (114).
fl Number of discs: 6
Number of plates: 5
5. No. 5 ring gear, sun gear

1) Install ring gear (111).
2) Install sun gear (110).
6. No. 5 carrier assembly

1) Assemble carrier assembly as follows.
i) Install needle bearing (109), planetary
gear (108), and thrust washer (107), then
knock in pin (106).
fl Be careful not to forget the ball when
installing.
ii) Heat bearing (105) and install it by shrink

fit.
fl Do not heat bearing (105) higher than
120°C.
iii) Fit 2 seal rings to collar (104) and install.
iv) Install snap ring (103).
WA800-3 30-95
1
(8)
2) Using eyebolts 1 (Dia = 12 mm, Pitch = 1.75

mm), raise carrier assembly (102) and in-
stall.
3) Tighten mounting bolts (101).
3 Mounting bolt:
110 ± 12 Nm {11.25 ± 1.25 kgm}
Serial No.: 50001 – (T/M No. 101138)

7. Rotating clutch assembly
1) Install flange (100) of bearing.
2) Raise transfer assembly (122), and connect
rotating clutch assembly.
Serial No.: 50001 – (T/M No. 101138)

8. Inner race
Using push tool D5 (inside diameter: 103 mm,
length: 70 mm), press fit inner race (121) to
rotating clutch (120).
fl Press fit the inner race at approx. 20°C, and
be extremely careful that the bearing roller
does not fall over.
30-96 WA800-3
1
(8)
8A. Collar assembly

1) Install 2 seal rings to collar.
2) Using push tool D6 (inside diameter: 83 mm),
press fit collar assembly (11).
fl Align the collar assembly exactly with
the position of the dowel pin and press
fit gradually.
WA800-3 30-96-1
(8)
9. Cover assembly
1) Set in press, then using push tool D3 (out-
side diameter: 135 mm), press fit bushing
(9) in cover (7).
3) Fit O-ring and install cover assembly (61, then

tighten mounting bolts (5).
10. Sun gear

1) Turn over transfer assembly.
&I kg Transfer assembly: 1,100 kg
2) Install sun gear (99).
DEW04212
11. No. 4 ring gear, carrier assembly

1) Assemble No. 4 ring gear and carrier as-
sembly as follows.
i) Assemble needle bearing (98) in plan-
etary gear (97), fit thrust washers (96) to
both ends and set to carrier.
7
96 DEW04213 DEW04214
WA800-3 30-97
0
ii) Fit ball (120) and push in pin (121).

installing to the shaft.
iii) Fit snap ring (94) to ring gear (95), and

install ring gear.
iv) Fit retainer (93) and tighten with mount-
ing bolts (92).
fl Check that the snap ring installed to
the ring gear is set securely between
the retainer and the carrier.
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
v) Heat bearing (90) and install it to collar

(91) by shrink fit.
fl Do not heat the bearing higher than
120°C.
fl Install a seal ring on the collar.
vi) Cool the outer race of bearing (88) and

fit bearing (88) to ring gear and carrier
assembly (87) by expansion fit.
fl Install seal rings to the ring gear and
carrier assembly.
30-98 WA800-3
1
(8)
2) Cool only the outer race of bearing (105).

Then, using eyebolts [1] (Dia. = 12 mm, Pitch
= 1.75 mm), sling and install ring gear and
carrier assembly (87) to bearing (105) by
expansion fit.
12. Plate
Align with dowel pin, and install plate (83).
13. Shaft assembly

2) Heat bearing (86) and install it to the shaft
by shrink fit.
120°C.
3) Tap shaft assembly (84), and press fit bear-

ing.
WA800-3 30-99
1
(8)
14. Guide pin

Install guide pin (82).
15. Disc, spring plate

Install disc (80), spring (79), and plate (81).
Number of plates: 4
16. Spring
Install spring (78).
springs, so be careful to distinguish it when
installing.
fl Free height of spring: 91 mm

1) Fit seal ring, then install piston (77) in hous-
ing (76).
fl Install the seal ring with the groove fac-
ing the housing as shown in the dia-
gram.
1.75 mm), align with dowel pin, raise piston
and housing (75), and install.
fl When installing, check through the clear-
ance between the piston and the trans-
fer that spring (78) has not fallen over.
18. No. 3 sun gear

Install ring gear (74).
30-100 WA800-3
1
(8)
19. Disc, spring, plate

Number of plates: 3
20. Spring
installing.
fl Free height of spring: 91 mm

ing (68).
gram.
mm), align with dowel pin, raise piston and
housing (67), and install.
ance between the piston and the hous-
ing that spring (70) has not fallen over.
3) Install collar (66).
WA800-3 30-101
1
(8)
22. Plate, ring gear

mm), align with dowel pin, then raise plate
(65) and install.
2) Install ring gear (64).
23. No. 2, 3 carrier assembly

1) Assemble No. 2 and 3 carrier assembly as
follows.
i) Heat bearing (63) and install it by shrink
fit.
120°C.
ii) Assemble needle bearing (62) in plan-

etary gear (61), and fit thrust washers
(60) to both ends, then set in carrier.
iii) Fit ball (122) and push in pin (123).
installing the shaft.
iv) Fit retainer (59) and tighten mounting

with bolts (58).
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
v) Cool only the outer race of bearing (63).
Then, using eyebolts 1 (Dia. = 12 mm,
Pitch = 1.75 mm), sling and install car-
rier assembly (56) to bearing (63).
30-102 WA800-3
1
(8)
vi) Insert seal ring in collar, then assemble

to shaft.
fl When the seal ring is assembled to
the collar, install so that the narrow
width “a” of the seal ring and collar
is at the bottom.
vii) Install sun gear (57).

viii)Install snap ring (55).

ing (53).
gram.
1.75 mm), align with dowel pin, raise piston
and housing (52), and install.
25. Ring gear

26. Guide pin

Install guide pin (50).
WA800-3 30-103
1
(8)

Number of plates: 5
28. Spring
installing.
fl Free height of spring: 108.5 mm

ing (44).
gram.
mm), align with dowel pin, raise piston and
housing (43), and install.
ance between the housing and the pis-
ton that spring (46) has not fallen over.
30. No. 2 ring gear

1) Fit snap ring (42A) to ring gear (42), and
install ring gear.
30-104 WA800-3
1
(8)
2) Fit plate (41), and tighten with mounting bolts

(40).
fl Check that the snap ring installed to the
ring gear is set securely between the
plate and the carrier.
3 Mounting bolt:
66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
31. Shaft, No. 1 carrier assembly

1) Assemble shaft and No. 1 carrier assembly
as follows.
i) Assemble needle bearing (38) and spacer
(39) in planetary gear (37), fit thrust wash-
ers (36) to both ends and set to carrier.
ii) Fit ball (124) and push in pin (125).
installing to the shaft.
iii) Install snap ring (35).

iv) Heat bearing (34) and install it by shrink
fit.
120°C.
v) Heat bearing (33) and install it by shrink

fit.
120°C.
vi) Install sun gear (32).
WA800-3 30-105
1
(8)
vii) Heat bearing (31) and install it to the

shaft by shrink fit.
120°C.
viii)Cool only the outer race of bearing (31).

Then, press fit shaft assembly (29) to the
carrier assembly (30) and install snap
ring (28).
ix) Fit seal ring and install collar (27) to shaft

and carrier assembly (26).
x) Install gear (25).

xi) Install snap ring (24).
30-106 WA800-3
1
(8)
2) Cool only the outer race of bearing (33).

Then, using eyebolts [4] (Dia. = 12 mm, Pitch
= 1.75 mm), sling and install shaft and No. 1
carrier assembly (23).
32. No. 1 ring gear


Number of plates: 5
34. Spring
installing.
fl Free height of spring: 108.5 mm
WA800-3 30-107
1
(8)
35. Plate
mm), raise plate (17) and install.
fl When installing, check through the clearance
between the plate and the piston that spring
(18) has not fallen over.
36. Tie bolts

Install 17 tie bolts (16).
3 Tie bolt: 373 ± 20 Nm {38 ± 2 kgm}
37. Piston operation check

Using tool D1, check stroke of each piston.
fl Air pressure: 0.3 – 0.5 MPa {3 – 5 kg/cm2}
Unit: mm
Piston Standard stroke
No. 1 7.6
No. 2 8.6
No. 3 7.0
No. 4 7.2
38. Transmission case

1) Fit O-ring, then using eyebolts 4 (Dia. = 12
mm, Pitch = 1.75 mm), raise transmission
case (15) and install.
30-108 WA800-3
1
(8)
39. Sleeve
1) Raise transfer and transmission assembly
and set in upright position.
kg
C+J Transfer, transmission assembly:
2,200 kg
2) Fit O-ring and install sleeve (4).
rrl!
40. Control valve assembly

1) Fit gasket, then using eyebolts @ (Dia. = 10
mm, Pitch = 1.5 mm), install control valve
assembly (3).
+ Align the hole position of the gasket at
the mating surface.
4
DEW04113
2) Tighten 11 mounting bolts. Lono bolts

* Tighten the mounting bolts uniformly in
turn so that there is no deformation of
the valve.
w Mounting bolt:
49 + 5 Nm I5.0 + 0.5 kgml
@Mountins bolts
l Mounting position of Iiftina bolts DEW04693
41. Torque converter assembly

Using eyebolts, install torque converter assem-
bly (I) to transmission (2).
DEW04 1I 1
WA800-3
DISASSEMBLY AND ASSEMBLY TRANSMISSION VALVE
REMOVAL OF TRANSMISSION
VALVE

the safety bar on the frame. Lower the work
moving.
. Disconnect the cable from the negative (-) ter-
1. Cover
Open platform cover (1).
2. Electric wiring
Disconnect transmission solenoid valve wire (2)
from transmission valve.
3. Transmission valve
Using eyebolts, lift off transmission valve (3).
Transmission valve: 96 kg
INSTALLATION OF
TRANSMISSION VALVE
1. Transmission valve
Set transmission valve (3) in mounting position,
and tighten mounting bolts.
+ Align the position of the holes of the gasket
at the mating surface exactly.
* Tighten the mounting bolts on opposite side
in turn to prevent the valve from being dis-
torted.
w Mounting bolt:
50 = 5 Nm (5.0 = 0.5 kgml
2. Electric wiring
Connect transmission solenoid valve wire (2) to
transmission valve.
* When connecting the connector, be careful
not to deform the thread case.
3. Cover
Close platform cover (I).
30-110 WA800-3
0
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION VALVE

DISASSEMBLY, ASSEMBLY OF UPPER VALVE
DEW04342
DISASSEMBLY OF UPPER VALVE

5. Remove cover (24), then remove piston (251,
Remove cover (I), then remove valve (2), shim (261, and springs (27) and (28).
spring (31, valves (4) and (51, shim (61, and * Check the number and thickness of the
springs (7) and (8). shims, and keep in a safe place.
Ir Check the number and thickness of the
shims, and keep in a safe place. 6. Using bolts (Dia. = 10 mm, Pitch = 1.5 mm),
remove stopper (291, then remove valve (30).
Remove plug (9), then remove spring (IO),
valves (11) and (121, spring (131, and valve 7. Remove cover (31), then remove boss (32).
(14).
8. Remove plug (331, then remove spring (34),
Remove plug, pull out pin (151, then remove valves (35) and (36), spring (37), and valve
stopper (16). (38).
Remove cover (171, then remove valve (18), 9. Remove cover (391, then remove valve (40)
spring (19), valves (20) and (21), and shims and spring (41).
(22) and (23).
j, Check the number and thickness of the 10. Remove plug, pull out pin (42), then remove
shims, and keep in a safe place. stopper (43).
WA800-3
ASSEMBLY OF UPPER VALVE
* Clean all parts, and check for dirt or damage.

1. Set stopper (43) in valve body (44), knock in pin

(42), and install plug.
2. Assemble spring (41) and valve (40) in valve

body (44), then fit O-ring and install cover (39).
3. Set valve (36), spring (37), and valve (38) in valve

(35), assemble valve (35) and spring (34) in valve
body (44), then fit O-ring and install plug (33).
m Plug: 128 + 20 Nm {13 + 2 kgm1
4. Fit O-ring and assemble boss (32) in valve body

(44), then align with dowel pin and install cover
(31).
5. Assemble valve (30) in valve body (44), then fit

O-ring and install stopper (29).
6. Set shim (26) in piston (25), assemble in valve

body, then fit O-ring and install cover (24).
Ir Standard shim thickness: 0.5 mm x 4
7. Set shims (22) and (23), and springs (28) and

(27) in valve (21), assemble valves (21) and (20).
spring (19) and valve (18) in valve body (44),
then fit O-ring and install cover (17).
* Standard shim thickness: 0.5 mm x 4 (both
large and small shims)
8. Set stopper (16) in valve body (44), and knock in

pin (15), then install plug.
9. Set valve (12), spring (13), and valve (14) in valve

(II), assemble valve (11) and spring (10) in valve
body (44), then fit O-ring and install plug (9).
m Plug: 128 + 20 Nm (13 + 2 kgm1
10. Set shim (6), and springs (7) and (8) in valve (5),
assemble valves (5) and (4), spring (3), and valve
(2) in valve body (44), then fit O-ring and install
cover (1).
j, Standard shim thickness: 0.5 mm x 6
30-112 WA800-3
0
DISASSEMBLY, ASSEMBLY OF LOWER VALVE
DEW04343
DISASSEMBLY OF LOWER VALVE
1. Remove solenoid valve assembly, then remove

spring (I ).
2. Remove cover (21, then using bolts (Dia. = IO

mm, Pitch = 1.5 mm), remove stopper (3).
3. Remove valve (4).
ASSEMBLY OF LOWER VALVE

1. Assemble valve (4) in valve body (5).
2. Fit O-ring and assemble stopper (3) in valve body

(51, then install cover (2).
3. Assemble spring (I) in valve body (51, and in-

stall solenoid valve assembly.
WA800-3 30-113
0
DISASSEMBLY, ASSEMBLY OF RELIEF VALVE
DISASSEMBLY OF RELIEF VALVE
1. Remove cover (I ), then remove valve (21, spring

(3), valves (4) and (51, and shim (6).
Ir Check the number and thickness of the
shims, and keep in a safe place.
2. Remove plug (7), then remove springs (8) and

(9).
ASSEMBLY OF RELIEF VALVE

1. Set springs (8) and (9) in plug (71, and install to

valve body (IO).
2. Set shim in valve (5), and assemble valves (5)

and (4), spring (31, and valve (2) in valve body
(IO), then install cover (I).
* Standard shim thickness:
0.5 mm x 12 (Main relief valve)
0.5 mm x 2 (Torque converter relief valve)
30-114 WA800-3
0
DISASSEMBLY AND ASSEMBLY TRANSFER
DISASSEMBLY OF TRANSFER
fl Clean all parts and repair any burrs.
1. Transmission assembly
Disassemble transmisison assembly.
For details, see DISASSEMBLY OF TRANSMIS-
SION.
2. Cage
1) Remove snap ring (1), then remove mount-
ing bolts (2).
2) Using forcing screws 1 (Dia. = 12 mm, Pitch
= 1.75 mm), remove cage assembly (3).
3A) Serial No.: 50001 – (T/M No. 101138)

Set in press, then using push tool D6 (out-
side diameter: 185 mm), remove bearing (5)
from cage (4).

3B) Serial No.: (T/M No. 101139) and up
Using notch “a”, remove outer race (5A)
from cage (4).
3. No. 1 gear
mm), lift off gear (6).
4 Gear: 40 kg
WA800-3 30-115
1
(8)
4. Snap ring, bearing

Serial No.: 50001 – (T/M No. 101138)
2) Remove spacer (8).
3) Using push tool 4 (outside diameter: 162
mm), remove bearing (9) form cage.

2) Remove the bolts (11 pieces). Then, using
eyebolts (2 pieces) (Dia. = 12 mm, Pitch =
1.75 mm), remove the cage assembly.
3) Using push tool 4 (outside diameter: 162
mm), remove bearing (9) form cage.
5. Cage assembly
1) Remove mounting bolts (10), then screw in
forcing screws 1 (Dia. = 12 mm, Pitch = 1.75
mm) and remove fitting portion of cage.
2) Using eyebolt 3 (Dia. = 12 mm, Pitch = 1.75

mm), lift off cage assembly (11).
fl The cage is thick, so raise it vertically.
4 Cage assembly: 40 kg
3) Remove bearing (13) from cage (12).
30-116 WA800-3
1
(8)
6. No. 3 gear
1.75 mm), lift off gear assembly (14).
4 Gear assembly: 50 kg
2) Remove bearing inner race (16) from gear

(15).
3) Remove bearing inner race (17) from gear
(15).
7. Coupling, cage assembly

1) Remove mounting bolt (18), then remove
holder (19).
fl Width across flats of mounting bolt: 55
mm
2) Remove coupling cage mounting bolts (64).
fl Make match marks on the spline of the
shaft and the coupling.
WA800-3 30-117
1
(8)
3) Screw in forcing screws @ (Dia. = 12 mm,

Pitch = 1.75 mm) and remove fitting portion
of cage.
+ Check the number and thickness of shims
(20), and keep in a safe place.
4) Using eyebolts G_! (Dia. = 12 mm, Pitch =
1.75 mm), lift off coupling and cage assem-
bly (21).
&I kg Coupling, cage assembly: 55 kg
DEW04272
5) Disassemble coupling and cage assembly as

follows.
i) Set in press, then using push tool D8
(outside diameter: 135 mm), remove cou-
pling (23) from cage (22).
DEW04274
ii) Remove oil seal (24) from cage (22).

iii) Remove bearing (25) from cage (22).
30-118 WA800-3
0
8. Strainer assembly
1) Remove cover (27).
2) Remove spring (28).
3) Remove strainer assembly (29).
9. Cage assembly
1) Turn over transfer.
4 Transfer: 770 kg

3) Screw in forcing screws 1 (Dia. = 12 mm,
Pitch = 1.75 mm) and remove fitting portion
of cage.

1.75 mm), lift off cage assembly (31).
WA800-3 30-119
1
(8)
10. No. 2 gear assembly

mm), lift off gear assembly (34).
4 Gear assembly: 50 kg
2) Remove bearing inner races (36) and (37)

from gear (35).
11. Bearing
Remove bearing (38).
30-120 WA800-3
1
(8)
12. Cage assembly

2) Using forcing screws 1 (Dia. = 12 mm, Pitch
= 1.75 mm), remove cage assembly (40).

4) Remove cover (43) from cage (41).
13. Coupling assembly

holder (45).
fl Width across flats of mounting bolt: 55
mm
2) Lift off coupling assembly (46).
fl Support the block under the shaft.
3) Remove inner race (48) from coupling (47).
WA800-3 30-121
1
(8)
14. Cage assembly

1) Remove mounting bolts (49), then screw in
forcing screws (Dia. = 12 mm, Pitch = 1.75
mm) and remove fitting portion of cage.
mm), lift off cage assembly (50).
3) Remove oil seal (52) from cage (51).

4) Remove snap ring (53) from cage (51), then
remove bearing (54).
15. No. 4 gear, shaft assembly

1) Using holder (45) and mounting bolts (44),
lift off No. 4 gear and shaft assembly (55).
4 No. 4 gear, shaft assembly: 90 kg
2) Lift off gear (57) from shaft (56).
4 Gear: 60 kg
3) Remove spacer (58) from shaft (56).
30-122 WA800-3
1
(8)
ASSEMBLY OF TRANSFER
1. No. 4 gear, shaft assembly
1) Install spacer (58) to shaft (56).
2) Raise gear (57) and install to shaft (56).
3) Using holder (45) and mounting bolts (44),

raise No. 4 gear, shaft assembly (55) and
install.
fl Support the block under the shaft.
2. Cage
side diameter: 245 mm), press fit bearing
(54) in cage (51), and install snap ring (53).
2) Using push tool (outside diameter: 195 mm),

press fit oil seal (52) in cage (51).
2 Oil seal: Grease (G2-LI)
fl Apply gasket sealant to the oil seal fit-
ting face. Spread it thinly to the inside of
the housing hole and wipe off the pro-
jected part.
WA800-3 30-123
1
(8)
3) Fit O-ring, then using eyebolts @ (Dia. = 12

mm, Pitch = 1.75 mm), raise cage assembly
(50) and install.
4) Tighten with mounting bolts (49).
DEW04296
\Y DEW04295
3. Coupling
1) Set in press, then using push tool D8 (inside
diameter: 135 mm), press fit inner race (48)
in coupling (47).
L-
cwwo3114
2) Raise coupling assembly (46) and install.

3) Fit O-ring and holder (45), and tighten with
mounting bolts (44).
w Mounting bolt:
2,210 + 150 Nm I225 +. 15 kgm}
DEW04293 DEW04292
4. Cage assembly
1) Fit O-ring and install cover (43) to cage (41).
DEW04306
30-124 WA800-3
a
2) Using push tool D6 (outside diameter: 165

mm), press fit bearing (42) in cage (41).
3) Fit cage assembly (40) and tighten with

mounting bolts (39).
5. Bearing
Using push tool D6 (outside diameter: 165 mm),
press fit bearing (38).
6. No. 2 gear assembly

diameter: 85 mm), press fit inner race (37) in
gear (35).
gear (35).
2 Inner race: Adhesive (LT-2)
fl After press fitting, wipe off the projected
adhesive.
WA800-3 30-125
1
(8)
fl After press fitting, when the inner race

is at the room temperature, check that
the clearance between the gear and in-
ner race is 0.04 mm or less at 2 places.

mm), raise gear assembly (34) and install.
7. Cage assembly
(33) in cage (32).

(31) and install.
30-126 WA800-3
1
(8)

Serial No.: 50001 – (T/M No. 101138)
2) Using push tool D6 (outside diameter: 175

mm), press fit bearing (9).
9. Strainer assembly
1) Turn over transfer.
4 Transfer: 700 kg
2) Install strainer assembly (29).
WA800-3 30-127
1
(8)
3) Install spring (28).

fl Insert the spring securely in the groove
at the top of the strainer.
4) Fit O-ring and install cover (27).
10. Coupling, cage assembly

1) Install collar (26).
2) Assemble coupling and cage assembly as

follows.
i) Set in press, then using push tool D8
(outside diameter: 220 mm), press fit
bearing (25) in cage (22).
ii) Using push tool D8 (outside diameter:

195 mm), install oil seal (24) in cage (22).
2 Oil seal: Grease (G2-LI)
fl Apply gasket sealant to the oil seal
fitting face.
Spread it thinly to the inside of the
housing and wipe off the projected
part.
30-128 WA800-3
1
(8)
iii) Set in press, then using push tool D8

(outside diameter: 160 mm), press fit
coupling (23) in cage (22).
11. Adjusting coupling, cage assembly

mm, pitch = 1.75 mm), raise coupling and
cage assembly (21) and install.
fl Install the front and rear couplings of
the output shaft to the splines so that
the phase difference will be 10° or less
when the output shaft is assembled.
2) Fit holder (19), and tighten with mounting
bolt (18), then measure clearance between
cage and case with feeler gauge C.
3 Mounting bolt:
2,210 ± 150 Nm {225 ± 15 kgm}
3) Remove mounting bolt (18) and holder (19),

then using forcing screw 1 (Dia. = 12 mm,
Pitch = 1.75 mm), insert shim (20) with thick-
ness of measured clearance + (0 ± 0.05) mm.
4) Tighten coupling cage mounting bolt (64).

5) Fit holder (19) and tighten with mounting
bolt (18).
3 Mounting bolt:
2,210 ± 150 Nm {225 ± 15 kgm}
WA800-3 30-129
1
(8)
12. No. 3 gear

gear (15).

diameter: 85 mm), press fit inner race (16)
to gear (15).
3) After press fitting, when the inner race is at

the room temperature, check that the clear-
ance between the gear and inner race is
0.04 mm or less at 2 places.
2 Inner race: Adhesive (LT-2)
After press fitting, wipe off the pro-
jected adhesive.

1.75 mm), raise gear assembly (14) and in-
stall.
30-130 WA800-3
1
(8)
13. Cage assembly

(13) in cage (12).

(11) and install.
14. Bearing
1) Turn over the transfer.
4 Transfer: 700 kg
2) Install bearing (9) to the case by expansion
fit.
3) After installing the bearing, tighten the bolts
(11 pieces).
15. No. 1 gear

1) Install spacer (8).
1.75 mm), raise gear (6) and install.
WA800-3 30-131
1
(8)
16. Cage assembly

Serial No.: 50001 – (T/M No. 101138)
1A) Set in press, then using push tool D6 (out-
side diameter: 210 mm), press fit bearing (5)
in cage (4).

1B) Set in press, then using push tool D6 (out-
side diameter: 210 mm), press fit outer race
(5A) in cage (4).

3) Fit cage assembly (3) and tighten with
mounting bolts (2).
17. Transmission assembly

Assemble transmission assembly.
For details, see ASSEMBLY OF TRANSMISSION.
18. Adjusting speedometer sensor

1) Screw in sensor (68) until it contacts outside
surface of gear (69).
fl Before installing the sensor, check that
the gear is at the outside surface com-
pared with the mounting surface.
2) After sensor (68) contacts gear (69), turn it
back 3/4 – 1 turn and secure with locknut
(70).
fl Be careful that the outlet direction of the
sensor harness is not the opposite direc-
tion to the sensor connector clamp.
2 Sensor thread: Adhesive (LT-2)
3 Sensor locknut:
39 ± 10 Nm {4 ± 1 kgm}
30-132 WA800-3
1
(8)
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY OF PTO
Preparatory work
. Remove PTO. For details, see DISASSEMBLY
OF TORQUE CONVERTER.
Sr The procedure for disassembly and assembly of

the gear and shaft assemblies is the same, but
for gear and shaft assemblies I, II, III and IV, the
shaft and bearing are different.
u w DEW04082
1. Retainer
I) Using forcing screws @ (Dia. = 10 mm, Pitch
= 1.25 mm), remove retainer (I).
2) Remove oil seal (2).
DEW04083 1 1 DEW04084
2. Snap ring
Remove snap ring (3).
I DEW04085
3. Bearing
1) Turn over PTO case assembly (4).
2) Remove bearing (5).
DEW04086
WA800-3 30- 133

0
4. Shaft assembly
I) Remove snap ring (6).
2) Using push tool @ (outside diameter: 60
mm), tap shaft assembly and remove.
*
DEW04087 DEW04088

4) Set shaft assembly in position, then using
push tool 0, pull out bearing (8) from shaft
(9).
* Push tool @
Unit: mm
Gear, shaft assembly No. Push tool outside diameter
I, II, III I 70
IV 65
5. Inner race
Remove inner race (IO).
6. Spacer, gear
I) Lift up gear (11) and remove.
* Gear (I I) must be installed facing in the
correct direction, so remember the di-
rection.
------&
DEW04091

I) Turn over case.
3) Turn over case again, and remove bearing
(14).
\ ?-- ’
DEW04093 I DEW04094
30- 134 WA800-3

0
ASSEMBLY OF PTO
Preparatory work
. Clean all parts, and check for dirt or damage.
* The procedure for disassembly and assembly of

the gear and shaft assemblies is the same, but
for gear and shaft assemblies I, II, III and IV, the
shaft and bearing are different.
III
DEW04082
1. Bearing, snap ring

1) Using push tool @ (outside diameter = 115
mm), press fit bearing (14).
DEW04096
2. Spacer, gear
1) Install spacer (12).
2) Set gear (11) in position.
* Be careful to install gear (I I) facing in
the correct direction.
\-------’
/------ _L DEW04097
WA800-3
3. Shaft assembly
1) Using push tool 0, press fit bearing (8) in
shaft.
Ir Push tool @
Unit: mm
Gear, shaft assembly No. Push tool inside diameter
I, II, III I 80
IV 75
DEW04100
2) install snap ring (7)

3) Using push tool 0, press fit shaft assembly
(9).
* Push tool @
Unit: mm
Gear, shaft assembly No. Push tool outside diameter
DEW04101
4. Snap ring
Install snap ring (3).
5. Bearing
Using push tool @ (outside diameter: 145 mm),
press fit bearing (5) in case.
DEW04103 rr DEW04104
6. Retainer
I) Press fit oil seal (2) to retainer.
& Oil seal press-fitting surface:
Gasket sealant (LG-4)
2) Fit O-ring, then using guide bolts 0 (Dia. =
IO mm, Pitch = 1.25 mm), install retainer (1).
& Lip of oil seal: Grease (G2-LI)
DEW04105 DEW04106
30-136 WA800-3
0
7. Inner race
1) Turn over PTO case assembly (4).
2) Set bottom of shaft on stand @I.
* Set the PTO case assembly so that there
is no play.
DEW04107
3) Using push tool @ (inside diameter: 70 mm),

press fit inner race (15).
DEW04108
I DEW04109
4) Install snap ring (6). 1

Sr Check that the gear rotates smoothly.
DEW04110
WAKD3 30-137
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
REMOVAL OF CENTER SUPPORT

a Stop the machine on level ground and turn the
steering wheel fully to the left lock. Lower the
work equipment to the ground and stop the en-
gine. Then apply the parking brake and put
blocks under the wheels.
1. Drive shaft
1) Lift off center drive shaft (I). m
r+ kg Center drive shaft: 186 kg
2) Lift off front drive shaft (2). m

* Move the drive shaft towards the front
differential, move the center support end
to the side and remove the pilot portion
at the differential end.
EYIkg Front drive shaft: 173 kg
DEW04346
2. Center support
Sling center support (3) temporarily, remove
mounting bolts, then lift off. m
* If there are shims inserted between the
center support and frame, check the number
of shims and use as a guide when assem-
bling.
+ When lifting off, be careful not to damage
the steering cylinder rod.
&I kg Center support: 169 kg

DEW04347
30- 138 WA800-3
0
r
INSTALLATION OF CENTER SUPPORT
removal.
m Center drive shaft:

342 - 427 Nm I35.0 - 43.5 kgm}
m Front drive shaft:

342 - 427 Nm j35.0 - 43.5 kgm1
w Center support mounting bolt:

820 - 1,030 Nm I84 - 105 kgm}
t Check the parallelism and adjust the shims.
Parallelism: 0.15 mm max.
1) Set the center support to the frame, then
tighten the mounting bolts temporarily.
2) Install tools Al, A2 and A3 to the upper and
lower center hinge pins, then install dial
gauge @ to the coupling on the center sup-
port side to measure the parallelism of the
coupling and shaft.
3) Adjust the shims on the center support
mounting face. Center suvpor
4) Position the center support and tighten the I DEW04107

-
mounting bolts.
m Center support mounting bolt:
820 - 1,030 Nm I84 - 105 kgm}
II center SUPPort
DEW04708
WA800-3 30-139
0
DISASSEMBLY OF CENTER SUPPORT

1. Retainer
Remove mounting bolts (2) of retainer (1).
* Rotate the coupling and remove all mount-
ing bolts.
* Turn over the center support.
DEW04351
2. Coupling
Remove center bolt (3), then remove holder (4),
O-ring and coupling (5).
* Check the number and thickness of the shims
between the holder and shaft.
3. Retainer
Remove mounting bolts, then remove retainer
(6).
Ir Remove the O-ring at the mating face of
retainer (6) and case (7).
I DEW04353
4. Shaft
I) Set shaft and case assembly (8) on press
stand.
2) Remove shaft (9) with press.
* Be extremely careful as the shaft will
drop out suddenly.
DEW04354
30- 140
0
3) Remove bearing cone (IO) and retainer (I)

from shaft.
Ir Remove O-ring (11) from retainer.
I DEW04355
5. Oil seal
Remove oil seal (12) from retainers (1) and (6).
1, 6 12
I DEW04356 1
6. Case
Remove bearing cup (13) from case.
I DEW04357 1
I I
WA800-3 30-141
0
ASSEMBLY OF CENTER SUPPORT

1. Bearing cup
Install bearing cup (13) to the case.
2. Oil seal
Install oil seals (12) to retainers (I) and (6) with
tool El.
& Outside of oil seal: Grease (G2-LI)
DEW04357
3. Bearing cone
1) Install retainer (I) to the shaft, then press fit
bearing cone (IO) with tools B, C and Cl.
* After installing the bearing, check that
there is not a clearance at the shaft end.
& Lip of seal: Grease (G2-LI)
6 Inner circumfernce of bearing:
Grease (G2-LI)
2) Install O-ring (I I) to the retainer.
1.b i2 CWWOJ128
4. Case
I) Install case (7) to the shaft.
2) Press fit bearing cone (14) with tool E2, then
install O-ring (15).
* Fill the inner circumference of the case
with grease.
Sr When press fitting bearing (14), be care-
E2
ful not to apply excessive force.
30-142 WASOO-3
0
5. Retainer
1) Secure retainer (6) to case (7).
+ Be careful not to get the O-ring caught.
m Mounting bolt:
110.8 2 11.8 Nm Ill.3 + 1.2 kgml
I DEW04353
2) Tighten retainer (I) with mounting bolts (2).

Sr Be careful not to get the O-ring caught.
w Mounting bolt:
110.8 + 11.8 Nm Ill.3 + 1.2 kgm}
DEW04351
6. Coupling
1) Select shim as follows.
. Rotate case (7) and tighten bolt (3) until
starting torque is (7.9 - 11.8 Nm IO.8 -
1.2 kgm)).
. Measure clearance “a” between holder
(4) and shaft (9) at holes in holder at 3
places, take the average clearance, and
select shims of a thickness equal to the
average clearance + 0.1 to 0.15.
Ir To measure the clearance, first meas-
ure the thickness of the holder. h DEW04360
2) Assemble coupling (5), install O-ring (161,

shim (17) selected above, and holder (9),
then tighten bolt (3).
* Rotate the case and tighten the bolts to
the specified torque.
m Mounting bolt:
2,750 = 290 Nm (280 = 30 kgm1
(width across flats: 55 mm)
DEW04361
WA800-3 30-143
0
* Align the spline of the shaft and cou-

COUPI ins
pling so that the match marks are
/
aligned.
Match marks
7. End play
Check that end play is within specified range.
Ir End play: 0.05 - 0.15 mm
* Carry out greasing after installing the center
support to the chassis.
lEW04363
30-144 WA800-3
0
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE SHAFT

1. Splined yoke
Loosen retainer (I) and remove splined yoke
(2).
DEW04364
2. Bearing
Remove mounting bolts (3), then remove bear-
ing assembly (4).
Sr Make match marks on the yoke and bearing.
DEW04365
3. Bearing cap
1) Remove bearing cap (5) from bearing as-
sembly.
* Remove strap (6) of cap.
I DEW04366
2) Remove bearing (7), seal (8) and Delrin

washer (9) from bearing cap.
DEW043 867 DEW04366
WA800-3
4. Sleeve yoke
I) Remove mounting bolts (11) from sleeve
yoke (IO), then remove bearing assembly
(4).
* Make match marks on the yoke and bear-
ing.
DEW04369
2) Remove bearing cap (5) from bearing as-

sem bly.
I DEW04370
3) Remove bearing (7), seal (8), and Delrin

washer (9) from bearing cap.
DEW04367
9’ DEW04371
30-146 WA800-3
0
ASSEMBLY OF DRIVE SHAFT

1. Bearing cap
I) Install bearing (71, and seal (8) to bearing
cap (5).
& Bearing, seal: Grease (G2-LI)
DEW04372
2) Assemble Delrin washer (9) and bearing cap

(5) to bearing assembly (4).
& Bearing cap: Grease (G2-LI)
DEW04373
2. Bearing
Assemble bearing assembly (4) to sleeve yoke
(IO).
* Align the match marks correctly.
Ir Wipe the mounting face of the bearing cap
with a clean cloth.
w Mounting bolt:
385 + 41 Nm I39.3 2 4.2 kgml
DEW04374
3. Splined yoke
1) Assemble bearing (7) and seal (8) in bearing
cap (5).
& Bearing seal: Grease (G2-LI)
7
0
&
9
DEW043 DEW04366
WA800-3 30- 147

0
2) Assemble Delrin washer (9) and bearing cap

(5) to bearing assembly (4).
* Do not weld the strap. The heat when
welding will damage the bearing.
DEW04375
3) Assemble bearing assembly (4) to splined

yoke (2).
* Align the match marks carefully.
* Wipe the mounting face of the bearing
cap with a clean cloth.
w Mounting bolt:
385 + 41 Nm 139.3 2 4.2 kgm1
DEW04376
4) Align match marks, insert splined yoke in

sleeve yoke (IO), and secure with retainer
(I).
* Check that the yokes are facing in the
same direction.
* If the spline is worn, replace the whole
drive shaft assembly.
1 DEW04377
z Upper drive shaft

w Bearing cap mounting bolt (11):
214 + 7 Nm (21.8 f 0.7 kgm1
DEW04378
30-148 WA800-3
0
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL OF FRONT AXLE

moving.
. Block the rear tires and apply the parking brake

securely.
. Inset-t blocks @ between the top face (I) of the
rear axle housing and frame (2). (both left and
right) DEW04379
. Jack up the machine and set blocks @ under

the front frame on the left and right.
DEW04380
1. Tires, wheels
Sling left and right tires and wheels (3) tempo-
rarily, remove mounting nuts, then lift off.
63kg Tire, wheel: 3,505 kg
2. Drive shaft
Lift off front drive shaft (4). m
* Make match marks on the drive shaft cou-
pling to act as a guide when assembling.
* Move the drive shaft towards the front dif-
ferential, then move the center support end
to the side and remove the pilot portion at
the differential end.
elkg Front drive shaft: 173 kg
DEW04382
WA800-3
Brake hoses
Disconnect brake hoses (5) and (6) from connec-
tion of tube.
Ir Fit covers after disconnecting the piping.
Parking brake hose

Disconnect hose (7) from parking brake cylin-
der. E-J
* Check that the parking brake is actuated-
* Disconnect the air hoses from the left and
right parking brake cylinder.
CWW02967
Front axle
I) Sling axle (8) temporarily, remove mounting
bolts, then use hoist and jack to maintain
balance, and lower on top of roller. m
el kg Front axle: 8,190 kg
+ Fix chains around the axle as shown in

the figure.
DEW04385
2) Pull out front axle (8) from chassis.
50x50x850(x4)
DEW04710
30-150 WA800-3
0
INSTALLATION OF FRONT AXLE

removal.
w Front drive shaft:

343 - 427 Nm I35.0 - 43.5 kgml
* Bleed air from the parking brake cylinder.

Bleeding air from each portion.
m Front axle mounting bolt:

3,170 - 3,870 Nm {323 - 395 kgml
WA800-3 30-l 51
0
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL OF REAR AXLE

moving.
. Disconnect the cable from the negative (-) ter-

. Put blocks under the front wheels to prevent the
machine from moving, and apply the parking
brake securely.
1. Counterweight
1) Remove left and right steps (I), and covers
(2) and handrail (3).
2) Electric wiring, battery cables

. Remove battery cable (4) from left and
right battery relays.
. Disconnect wiring (5) for left and right
lights at connector.
. Disconnect wiring (6) for left and right
relays at connector.
. Disconnect cable (7).
. Disconnect cable (8) for left and right
ground connections.
3) Remove under cover (9). a

4) Remove left and right mounting bolts (IO),
then lift counterweight (11) off. m
& kg Counterweight (II): 2,500 kg
30-152
0
REAR AXLE
DISASSEMBLY AND ASSEMBLY
* Pull out the disconnected battery cables

and wirings (12) and (13) to the left and
right from holes.
2. Fuel tank
1) Loosen drain valve and drain fuel.
- : Fuel : 1,200 1
2) Remove engine oil drain valve (141, cooling

water drain valve (15) of torque converter
cooler, and cooling water drain valve (16)
from fuel tank.
DEW04392
3) Disconnect fuel hoses (17) and (18).

* Remove the clamps of the fuel hoses,
left and right engine blowby hoses and
engine block water drain hoses.
+Jg----p
4) Disconnect wiring (19) for fuel unit from con-
nector.
19 k2J
\*
IgJ fi cwwo2971
WA800-3
30-153
0
5) Sling fuel tank (20) temporarily, remove

mounting bolts, then lift off. m
Fix the lifting tool to the lifting hooks, be
careful to maintain the balance, and lift
off slowly.
Check that all the fuel has been drained.
Lay a pallet under the tank, set blocks in
position in line with the fuel tank, then
pull out the fuel tank from the chassis.
For details, see REMOVAL OF FUEL
TANK.
& kg Fuel tank : 786 kg
3. Frame support
Jack up rear frame and set stand under frame.
Sr Inset-t blocks @ between the top face of the
rear axle housing and frame (both left and
right).
* For safety, put steel sheets under the stand. and
Steel sheet
DEW04396 DEW04711
4. Tire, wheel
Sling left and right rear tire and wheel (21) tem-
porarily, remove mounting nuts, then lift off.
m
& kg Tire, wheel : 3,565 kg
5. Drive shaft
Sling rear drive shaft (22) temporarily, remove
mounting bolts, then lift off. a
Sr Use a lifting tool of ample length for the
drive shaft, and lift up from both ends of the
transmission.
&I kg Rear drive shaft : 186 kg
DEW04399
30-154
0
6. Brake piping
1) Remove cover (23). m
2) Disconnect tube (24) from slack adjuster.
3) Remove support lubrication tube (25).
7. Rear axle, support

1) Remove mounting bolts, then remove thrust
cover (26). m
& kg Thrust cover : 119 kg
Sr Remove grease tube.
* Thrust cover (26) is heavy, so handle it

as follows and use fixed signals when
removing.
. Leave one bolt in position at the bot-
tom, and use this bolt as a pivot to
rotate the cover carefully.
. Hold the cover with a pallet, remove
the 1 remaining bolt, then remove
the cover carefully.
I DWW05237
0
\ o o 0
0 0 0
o”
0
\o 0
0 0
0 0
0
0
21
0
0 0 O
cwwo2977
WA&XI-3 30-155
0
2) Remove thrust washer (271, thrust plate (28)

and thrust washer (29).
E?lkg Thrust plate : 76 kg
3) Sling rear axle temporarily.

Sr Fit a chain around the axle and be care-
ful to maintain the balance.
DEW04404
4) Secure front support (30) to rear axle with

wire, and remove front support mounting
bolts. m
CWWO2980
5) Move rear axle approx. 250 mm to front,

remove from rear support, then using hoist
and jack to maintain balance, lower rear axle.
&I kg Rear axle and support : 7,986 kg
* Lay steel sheets under the part being

lowered, and lower one end of the axle
on to the roller.
6) Pull out rear axle and support (31) from the
body.
I cwwo2991
30-156 WA800-3
0
8. Front support
1) Remove front support (32) from rear axle.
Ir Be careful not to damage the O-ring (or
seal).
&I kg Front support : 286 kg
2) Remove retainer (33), O-ring (or seal) (34),

and bushing (35) from front support (32).
* For machines where the bushing and
support are stuck together, remove bush-
ing (35) in the procedure for Step 10.
9. Rear support
Remove O-ring (or seal) (36) and bushing (37)
from rear support.
* For machines where the bushing and sup-
port are stuck together, remove bushing (37)
in the procedure for Step 10.
10. Procedure for removing bushing

1) Insert tip of a knife between bushing and
support, separate bushing and support
around whole circumference, then remove
bushing.
* If the adhesive is hard, and it is difficult
to separate the bushing and support,
heat the bushing to 100°C with boiling
water or with a small torch, then try again
to separate the bushing and support.
2) Coat adhesion portion (where it is held to

the support) with adhesive removing liquid,
wait for 2 - 3 minutes, then remove adhe-
sive.
& Portion with hardened adhesive :
Adhesive removing liquid
(part No. 427-48-11890)
WA8003 30-157
0
INSTALLATION OF REAR AXLE

removal.
m Undercover mounting bolt:

490 - 608 Nm I50 - 62 kgm}
m Counterweight mounting bolt:

1,510 - 1,910 Nm I155 - 195 kgm1
w Fuel tank mounting bolt:

1,510 - 1,910 Nm I155 - 195 kgml
w Hub nut: 736 - 912 Nm I75 - 93 kgm}
w Rear drive shaft:

343 - 427 Nm (35.0 - 43.5 kgm}
Sr Bleed air from the rear brake. For details,

see TESTING AND ADJUSTING, Bleeding air
from each portion.
& Thrust washer: Lubricant (G2-LI)

w Thrust washer mounting bolt:
824 - 1,030 Nm I84 - 105 kgm}
w Thrust cover:
824 - 1,030 Nm I84 - 105 kgm}
& Bushing: Lubricant (G2-LI)

w Retainer mounting bolt:
157 - 196 Nm I16 - 20 kgml
w Front support mounting bolt:
3,170 - 3,870 Nm I323 - 395 kgm}
30-l 58 WA800-3
0
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
REMOVAL OF DIFFERENTIAL
1. Remove axle assembly and set on block 0. For
details, see REMOVAL OF AXLE ASSEMBLY.
r5lkg Front axle assembly: 8,190 kg
el kg Rear axle assembly: 7,700 kg
2. Remove drain plug of final case and drain plug

at bottom of differential case, and drain oil from
final drive case.
Ir There is a large amount of oil drained, and
the oil spurts out suddenly, so be careful DEW04418
when draining.
- : Final drive case: Approx. 360 .t
3. Remove final drive case cover (2).
DEW04419
4. Remove snap ring, then remove sun gear (3).

* When removing the sun gear, pull out the
torque shaft slightly to remove.
5. Raise torque shaft (4), and pull out from spline

of differential assembly.
J, Remove the torque shaft on the opposite
side in the same way.
WA800-3 30- 159

0
6. When removing front differential assembly, re-

move parking brake assembly as follows.
1) Loosen the adjustment bolt, and remove the
plate.
2) Pull out pin, and remove cylinder assembly
(7).
3) Remove brake pad assembly (8).
4) Remove cover (9) and disc (IO), then remove
bracket. m
7. Remove holder, then remove coupling (II).

m
* Check the number and thickness of the shims
assembled inside the holder, and keep in a
safe place.
& kg Coupling: 40 kg
8. Remove mounting bolts, pull out differential as-

sembly (II) slightly, then using lifting hooks @
adiust balance with bar and remove differential
assembly.
Differential assembly: 1,250 kg a
a When pulling out the differential assembly,

support the bottom of the differential as-
sembly with a garage jack.
30-160 WANI@3
0
INSTALLATION OF
DIFFERENTIAL
removal.
Disc mounting bolt: Adhesive (LT-2)

Disc mounting bolt:
549 = 59 Nm I56 = 6 kgm1
Holder mounting bolt: Adhesive (LT-2)

Holder mounting bolt:
2,750 t 290 Nm I280 + 30 kgm}
Adjustment of shim of shaft

* Adjust the shim of the shaft when the differ-
ential or axle housing is replaced.
1) install shaft (12) and tighten the mounting
bolts evenly, then measure the clearance be-
tween the axle housing and shaft.
* Do not assemble shims.
w Mounting bolt:
3.9 z 1.0 Nm IO.4 2 0.1 kgm1
2) Prepare shim having thickness of measured
clearance a + 0.1 k 0.05 mm, then insert it.
* Thickness of shim: Clearance a + (0.1 i
0.05 mm)
w Mounting bolt:
280 + 29 Nm i28.5 +. 3.0 kgm1

w Mounting bolt:
932 2 98 Nm I95 f 10 kgm}
WA800-3 30-161
0
DISASSEMBLY OF DIFFERENTIAL
. Preparatory work
Set differential assembly (1) to tools HI.
fblkg Differential assembly: 1,250 kg
1. Remove case (2).
L&lkg Case: 45 kg
2. Remove oil seal (3) from case.
DEW04429 DEW04430
3. Fit the coupling (4) temporarily, and remove pin-

ion and cage assembly (5).
Coupling, pinion, cage assembly: 180 kg
* Check the number and thickness of the

DEW04431
4. Disassemble pinion and cage assembly as fol-

lows.
1) Remove coupling, and sling cage (6) tempo-
rarily, then using tools H2 and 0, pull out
bearing (7), and remove cage.
* If tools H2 and @ are not used, support
the flange surface of the cage, push the
pinion shaft with a press to disassem-
ble.
DEW04433
30-l 62 WA800-3
0
2) Remove outer race (8).

3) Remove bearing (11) from pinion shaft (IO).
5. Remove left and right locks, then loosen the nut

(12) with a bar to a point where it can be turned
by hand.
DEW04434 DEW04435
6. Remove mounting bolts (13), then remove cap

(14).
DEW04436
7. Remove differential gear case assembly (15).
Differential gear case assembly: 1,250 kg
DEW04437 DEW04438
8. Disassemble differential gear case assembly as

follows.
case (171.
Case: 85 kg
2) Remove bearing (18) and thrust washer from

case.
DEW04439
WA800-3 30-163
3) Remove bevel gear (19).

4) Remove pinion gear assembly (20) together
with cross shaft (21).
Pinion gear, cross shaft: 110 kg
I DEW04440 nFWO4441
+ Disassemble pinion gear assembly as follows.

1) Raise lock plate, hold pinion gear assembly
(20) with press, then using wrench H6, loosen
lock nut (22) and remove.
2) Push shaft (23) with press, and remove pin-
ion gear (24) and bearing (25).
DEW04443

4) Remove bearing (27) from shaft.
DEW04444 DEW04445
DEW04446
30-164 WA800-3
0
5) Remove outer races (28) and (29).
0 0 0
DEW04449
9. Remove bevel gear (30).
10. Remove thrust washer (31).
11. Remove mounting bolts, and using eyebolts (Dia.

= 24 mm, Pitch = 3.0 mm), remove bevel gear.
&I kg Bevel gear: 320 kg
DEW04447 DEW04448
WA800-3 30-165
0
ASSEMBLY OF DIFFERENTIAL
+ Coat the rotating surfaces of the bearing roller,
inner race and outer race rollers with engine oil
before installing.
1. Using the eyebolts Dia. = 24 mm, Pitch = 3.0

mm), install the bevel gear.
6 Mounting bolt: Adhesive (LT-2)
w Mounting bolt:
932 + 98 Nm {95 2 10 kgm]
2. Install thrust washer (31).

J, Align the thrust washer with the dowel pin DEW04448 DEW04447
when installing.
3. Install bevel gear (30).
* Assemble pinion gear as follows.

1) Install outer races (29) and (28).
DEW04446
2) Press fit bearing (27) in shaft.
0 0
DEW04450 DEW04445
3) Assemble collar (26).
0 0 0
DEW04449
I
30- 166 WA8003

0
4) Assemble pinion gear (24) and bearing (25)

in shaft.
5) Fit lock plate and tighten lock nut (22) with
wrench 0.
Jr Bend the lock plate securely.
m Lock nut:
981 + 98 Nm {IO0 f 10 kgm1
24
DEW04451 CWWO3130
Ir Assemble differential gear case assembly as fol-

lows.
1) Assemble pinion gear assembly (20) in cross
shaft (21), and install to case.
Jr Align the notch in the pinion gear with
the cross shaft dowel pin when install-
ing.
2) Install bevel gear (19).
* Move the bevel gear and check that the
pinion gear assembly rotates smoothly.
3) Install thrust and bearing to case.
* Align the thrust with the dowel pin when DEW04452
installing.
4) Install case, and tighten mounting bolts.
m Mounting bolt:
932 + 98 Nm (95 f 10 kgm1
I DEW04441 DEW04440
4. Tighten nut (12) temporarily, and put differen-

tial gear case assembly (15) in differential case.
* Align the nut with the groove in the differ-
ential case, then check that it rotates
smoothly by hand.
I DEW04437 DEW04453
WA800-3 30-167
0
5. Install cap (14) and tighten mounting bolts (13).

& Mounting bolt: Adhesive (LT-21
w Mounting bolt:
932 = 98 Nm I95 = 10 kgm}
j, Check the match mark on the bearing cap
when installing.
Ir When tightening the bolts, rotate the bevel
gear 20 - 30 times to settle the bearing be-
fore tightening.
DEW04436
* Adjust the preload of the bevel gear as follows.

I) Using tool D7, measure distance D.
2) Adjust with the nut so that the increase in
distance D is 0.39 2 0.15 mm.
* The increase becomes the amount of
deflection of the case from before giving
preload to after giving preload.
DEW04454
Ir If the increase deflection is greater than

the standard distance, return to the po-
sition before adjusting with the adjust-
ment nut.
When returning the adjustment nut, ro-
tate the bevel gear, and tap the bearing
cap and bevel gear with a plastic ham-
mer to check that there is no clearance
at “b”. Then adjust again.
DEW04455
* Assemble pinion and cage assembly as follows.
P!/
1) Install bearing (11) to pinion shaft (IO).
Ir Check that there is no clearance between
the bearing inner race and the pinion.
2) Install outer race (8) to cage.
I’ ’ IO
DEW04435 DEW04434
30-168 WA800-3
0
3) Install pinion shaft to cage (6).

4) Install bearing (7).
DEW04456
5) Install coupling (4), and tighten holder with

mounting bolt to 323.6 + 19.6 Nm {33 & 2.0
kgm} temporarily, then measure clearance
between holder and pinion.
Ir Add 0.11 mm to the measured value for
the clearance to decide the shim thick-
ness.
---Clearance
DEW04720
6) Insert shim and rotate cage while tightening

holder mounting bolts to specified tighten-
ing torque.
w Mounting bolt:
2,750 = 290 Nm I280 f 30 kgml
DEW04457
* Rotate the cage 20 - 30 times, then using

push-pull scale 0, check the starting torque.
Ir Starting torque: 22.6 + 6.9 Nm t2.3 + 0.7
kgm)
DEW04458
WA8QO-3 30-169
0
+ Check that the bearing roller big end and

inner race lip are in contact.
There must be
no clearance
DEW04721
6. Fit O-ring and assemble shim, then install pin-

ion and cage assembly (5) to differential case.
* If the shim was disassembled, assemble the
same number and thickness of shims that
was removed.
w Mounting bolt:
549 = 59 Nm (56 f 6 kgml
7. Adjusting tooth contact, backlash

* Adjust backlash as follows.
1) Move bevel gear with adjustment nut. I DEW04461
When adjusting the bevel gear, do not

change the preload of the bearing.
Always turn the adjustment nuts at both
ends the same amount in the same di-
rection.
2) Put dial gauge H7 at right angles in con-
tact with the face of the tooth at the
outside of the bevel gear.
Turn the adjustment nut and adjust until
the movement of the gauge indicator is
0.43 - 0.61 mm.
Sr Adjust at 3 or 4 places. Keep the pin-
ion gear locked when measuring.
+ Adjust tooth contact as follows.
I) Adjust the position of the bevel pinion by
changing the shims between the differential
case and bearing cage.
2) Adjust tooth contact between pinion gear
and bevel gear.
For details, see Adjusting tooth contact.
30-170 WA800-3
0
3) Adjust tooth contact

Coat face of 7 or 8 teeth of bevel pinion
lightly with red lead (minimum).
Hold the bevel gear by hand to brake it,
and rotate the bevel pinion forward and
backward and inspect the pattern left on
the teeth.
Adjust the tooth contact as follows.
Tooth contact Cause Procedure for adiustment
Correct contact Adjust the bevel pinion by adjusting the shims

The tooth contact pattern at the bevel pinion cage.
should start from about 5 Adjust the bevel gear in the same way as when
mm from the toe of the adjusting backlash.
bevel gear and cover
about 50% of the length
of the tooth.
It should be in the center
DEW00910 of the tooth height.
Bevel pinion is too far 1. Reduce shims at bevel

from bevel gear. pinion to bring closer to
bevel gear.
2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly. ? r DEW00908
DEW00904
Bevel pinion is too close 1. Increase shims at bevel

to bevel gear. pinion to move away
from bevel gear.
2. Move bevel gear closer
to bevel pinion and
adjust backlash correctly.
_r
f DEW00905
DEW00909
Bevel gear is too close to 1. Reduce shims at bevel

bevel pinion. pinion to bring closer to
bevel gear.
2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly.
Bevel gear is too far from 1. Increase shims at bevel

bevel pinion. pinion to move away
from bevel gear.
2. Move bevel gear closer
to bevel pinion and
adjust backlash correctly.
! DEW00909
8. After adjusting tooth contact and backlash, in-

stall left and right locks.
WA800-3 30-171
0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL DRIVE

the safety bar on the frame.
Lower the work equipment to the ground and
stop the engine. Then apply the parking brake
and put blocks under the wheels to prevent the
1. Loosen wheel nut, jack up machine with work

equipment, insert stand under axle, then sling
wheel assembly temporarily, remove wheel nut,
and lift off wheel assembly (I).
& kg Wheel assembly: 3,565 kg
2. Remove drain plug of final drive case, and drain

oil from final drive case.
Ir There is a large amount of oil drained, and
the oil spurts out suddenly, so be careful
when draining.
--_-_-
:
-.
- Final drive case: Approx. 360 e
3. Remove final drive case cover (2).
z
4. Remove snap ring, then remove sun gear (3).
Sr Pull out the torque shaft approx. 150 mm, I Y
Snaprina
then push in the sun gear approx. 10 mm,
and remove the snap ring.
DEW0472;
1
5. Remove torque shaft (4).
Torque shaft: 105 kg
* Remove retainer (5).
30-172 WA8003
0
6. Remove 3 hexagonal bolts, then using eyebolts

@ (Dia. = 12 mm, Pitch = 1.75 mm), lift off car-
rier case assembly (6).
+ When pulling out the carrier case assembly,
insert a bar in the casting hole at the bottom
of the case, and adjust the balance when
pulling out.
&I kg Carrier case assembly: 390 kg
* Disassemble carrier case assembly as fol-

lows.
1) Remove mounting bolts (7). then remove
retainer (8).
2) Using a copper hammer, knock out shaft,
then remove pinion gear (9) and bearing
form carrier case.
3) Remove the bearing from pinion gear,

then remove cup (II), spacer (12), and
snap ring (13).
* Keep the bearing and cup as set.
DEW04468
7. Using tool Jl, secure wheel hub (14) and float-

ing seal case (15).
Jr Secure tool A at 4 places on opposite sides
to prevent uneven contact of the floating
seal.
WA800-3
8. Remove retainer (161, then remove shim (17). r

Sr Check the number and thickness of the
_I
I
I
DEW04470 DEW04471
9. Lift off ring gear assembly (18).

* When pulling out the ring gear assembly,
of the case, and adjust the balance when
pulling out.
& kg Ring gear assembly: 240 kg
10. Remove lock plate, then remove ring gear (20)

from ring gear hub (19).
r&lkg Ring gear hub: 95 kg
Ring gear: 150 kg
20
DEW04473
30-174 WA800-3
0
ASSEMBLY OF FINAL DRIVE

Install ring gear (20) to ring gear hub (191, and
secure with lock plate.
m Mounting bolt:
113 f 10 Nm III.5 + 1.0 kgm}
Sr Clean all the grease and oil from the bolt
thread and mounting hole.
DEW04473
Adjust wheel bearing as follows.

1) Align ring gear assembly (18) with spline of
axle shaft, and tighten retainer (16) with 4
bolts temporarily.
* Measure thickness of the retainer before
installing.
Ir Remove tool A, rotate the hub 5 - 6

times, then tighten the mounting bolts
uniformly to the specified torque.
w Mounting bolt:
78.5 + 4.9 Nm 18.0 f 0.5 kgm1
2) Using calipers @ or depth micrometer

through measuring hole of retainer, meas-
ure distance “a” from retainer to end face of
axle shaft.
Measure at 2 places and take the aver- a

age.
Difference C between measured values
= a - b + 0.3 mm (Round the measure-
lr
ment up to the nearest 0.1 mm).
Select the combination of shims to give
the required thickness with the minimum
number of shims.
WA&XI-3
3) Using tool Jl, secure wheel hub (14) and

floating seal case (15).
* Secure tool Jl at 4 places on opposite
sides to prevent uneven contact of the
floating seal.
4) Remove retainer, and fit selected shim (17)

and retainer, then tighten mounting bolts.
* Remove tool Jl, rotate the hub 5 - 6
times, then tighten the mounting bolts
uniformly to the specified torque.
6
w
Mounting bolt: Adhesive (LT-2)
Mounting bolt:
932 = 98 Nm I95 + 10 kgm)
0
* After tightening the bolts, rotate the hub
and check for any abnormality in the ro-
tation of the bearing rollers.
\
3. Assemble planetary carrier as follows.
1) Install snap ring (13) and spacer (12) to pin-
ion gear.
2) Press fit cup (I I), and assemble the bearing.
DEW04468
3) Set pinion gear (9) and bearing in carrier

case, assemble shaft, then press fit shaft with
copper hammer.
4) Tighten retainer (8) with mounting bolts.
J=$& Mounting bolt: Adhesive (LT-2)
m Mounting bolt:
275 f 29 Nm I28 = 3 kgm}
DEW04467
30-176 WA800-3
0
4. Fit O-ring, then using eyebolts 0 (Dia. = 12 mm,

Pitch = 1.75 mm), raise carrier case assembly
(6), align tooth faces of planetary gear and ring
gear, then set in mounting position and tighten
3 hexagonal bolts.
* When installing the carrier case assembly,
-_--
of the case to adjust the balance when in-
stalling.
ZL
5. Raise torque shaft (5) and set in mounting posi-
tion temporarily.
-_
Snaprina
6. Align spline and push torque shaft (5) in mount-
ing position of differential assembly.
* Leave the torque shaft protruding approx.
150 mm, install the snap ring to the sun 5
gear, then push in completely.
7. Install retainer (4) and sun gear (3), and secure

with snap ring.
* When aligning the tooth faces of the sun I DEW04722
gear and carrier gear, raise the torque shaft

slightly to align.
8. Fit O-ring and install final case cover (2).
9. Tighten drain plug of final case, and add oil

until it flows out from level plug.
Final drive case: Approx. 360 t
DEW04419
10. Raise wheel assembly (I), install to wheel hub,

then temporarily tighten nuts.
Jack up machine with work equipment, remove
stand from under axle, then lower machine.
11. Tighten wheel nuts fully.

w Wheel nut: 824 t 88 Nm I84 f 9 kgm1
WA800-3
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL
REMOVAL OF ORBIT-ROLL
a Stop the machine on level ground and lower
a Disconnect the cable from the negative C-1 ter-
1. Remove cover (I) from the steering column.
2. Loosen joint lock bolt (2).
3. Remove cover (3) under the cab.
4. Disconnect hose (4) of the accumulator.
5. Disconnect hose (5) of the right-hand stop valve.
6. Disconnect hose (6) of the left-hand stop valve.
7. Disconnect drain hose (7).
30-178 WA800-3
0
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL
8. Remove mounting bolt (8), then remove orbit-

roll (9) and bracket together. m
I _~--
__--
I----- ~-
9. Loosen lock bolt (IO), then remove joint (II).
IO. Remove bolt (12), then remove bracket (13) from

orbit-roll (9).
INSTALLATION OF ORBIT-ROLL
removal.
w Joint lock bolt:

55.9 + 7.8 Nm {5.7 f 0.8 kgm}
m Bracket mounting bolt:

51.9 + 7.8 Nm I5.3 + 0.8 kgml
. Bleeding air
Bleed air from the steering circuit. For details,
from each portion.
WA800-3 30- 179

0
DISASSEMBLY AND ASSEMBLY EMERGENCY STEERING PUMP
REMOVAL OF EMERGENCY
STEERING PUMP
A Lower the work equipment completely to the
ground, then put blocks under the wheels to
prevent the machine from moving.
1. Disconnect hoses (I) and (2) of the diverter valve.
2. Disconnect return hose (3).
3. Remove mounting bolt (4), then remove

emergency steering pump (5).
& kg Emergency steering pump: 49 kg
INSTALLATION OF
EMERGENCY STEERING PUMP
l Carry out installation in the reverse order
to removal.
. Bleeding air
Bleed air from the emergency steering circuit.
Bleeding air from each portion.
30- 180 WABOO-3

0
DISASSEMBLY AND ASSEMBLY DIVERTER VALVE
REMOVAL OF DIVERTER VALVE

a Lower the work equipment completely to the
a Gradually loosen the cap of the hydraulic tank

to release the pressure from the tank.
1. Disconnect hose (I) of the hydraulic tank.
2. Disconnect tube (2) of the steering valve.
3. Disconnect hoses (3) and (4) of the emergency

steering pump.
4. Disconnect tube (5) of the hydraulic tank.
5. Disconnect connector (6) (ROI ).
6. Disconnect hose (7) of the steering pump.
7. Disconnect hose (8) of the hydraulic tank.
8. Remove the mounting bolt, then remove diverter

valve (9).
& kg Diverter valve : Approx. 70 kg
INSTALLATION OF DIVERTER
VALVE
removal.
. Bleeding air
Bleed air from the circuit. For details, see TEST-
ING AND ADJUSTING, Bleeding air from each
portion.
WA800-3 30-181
0
DISASSEMBLY OF DIVERTER
VALVE
r
1. Remove mounting bolt (I), then disconnect se-
lector valve (3) from check valve (2).
2. Disassembly of check valve

I) Remove spring (5) and check valve (4) from
valve body (2).
2) Remove cover (6) from valve body (21, then I

remove spring (7) and check valve (8).
3) Remove O-ring (9) and backup ring (IO) from
cover (6).
4) Remove cover (I I) from valve body (21, then

5) Remove O-ring (14) from cover (II), then
remove backup ring (15).
30-182 WA800-3
0
3. Disassembly of selector valve

1) Remove O-ring (17) and spool (18) from valve
body (3).
2) Remove cover (19) from valve body, then

remove spring (20) and retainer (21).
3) Remove O-ring (22) from cover (19).
ASSEMBLY OF DIVERTER
VALVE
1. Assembly of check valve
1) Assemble check valve (8) and spring (7) to
valve body (2).
2) Install backup ring (IO) and O-ring (9) to cover
(6), then install them to valve body (2).
I CWWQ2996
3) Assemble check valve (13) and spring (12) 11

to valve body (2).
4) Install backup ring (15) and O-ring (14) to
cover (II), then install them valve body (2).
2
WA800-3
5) Assemble check valve (4) and spring (5) to

valve body (2).
6) Install the O-ring to selector valve body (3).
then install bolt (I) to check valve (2).
w Mounting bolt: 98.1 Nm {IO kgm}
3 cww03000
2. Assembly of selector valve

1) Install spool (17) to valve body (3).
2) Install O-ring (18) to valve body (3), then
install cover (16).
w Mounting bolt:
98 - 123 Nm IlO. - 12.5 kgm}
19 cww03001
3) Assemble retainer (21) and spring (20) to

valve body (3).
4) Install O-ring (22) to cover (191, then install
them to valve body (3).
w Mounting bolt:
58.8 - 73.6 Nm 16.0 - 7.5 kgm}
I cww03002
i
30-184 WABOO-3
0
DISASSEMBLY AND ASSEMBLY ACCUMULATOR CHARGE VALVE
REMOVAL OF ACCUMULATOR
CHARGE VALVE
A Lower the work equipment completely to the
A Disconnect the cable from the negative (-1 ter-

A Depress the brake pedal at least 100 times to

release the pressure from the accumulator.
1. Remove tube (1) of the accumulator.
2. Disconnect hose (2) of the brake tank.
4. Disconnect hose (4) of the hydraulic tank.
5. Disconnect tube (5) of the brake pump.
6. Remove mounting bolt, then remove accumula-

tor charge valve (6).
INSTALLATION OF
ACCUMULATOR CHARGE
VALVE
removal.
. Bleeding air
portion.
WA8003 30-185
0
DISASSEMBLY OF
ACCUMULATOR CHARGE
VALVE
1. Remove PPC relief valve (2) from valve body (I).
2. Remove O-ring (3) and 2 backup rings (4) from

the PPC relief valve.
3. Remove plug (6) from valve body (I), then re-

move spring (8) and spool (9).
IO I
4. Remove the O-ring from plug (6). CWWO2884
5. Remove bushing (IO) from valve body (I).
6. Remove snap ring (II), filter (12) and O-ring

(13) from bushing (IO).
7. Remove locknut (14) from valve body (I), then

remove adjustment screw (15).
8. Remove retainer (161, spring (17), shim (18) and

O-ring (19) from adjustment screw 115).

move retainer (21), piston (22) and valve seat
(23).
10. Remove O-ring (24) from plug (20).
11. Remove locknut (14) from valve body (I), then

remove adjustment screw (15).
12. Remove ball (251, spring (261, shim (18) and O-

ring (19) from adjustment screw (15).
move orifice (28).
14. Remove snap ring (29) from valve body (I ), then

remove filter (30).
30-186 WA800-3
0
ASSEMBLY OF
ACCUMULATOR CHARGE
VALVE
1. Insert filter (30) in valve body (I), then install
snap ring (29).
2. Install orifice (28) to valve body (I).

6 Orifice: Loctite (#241)
w Orifice: 3.14 - 3.9 Nm IO.32 - 0.40 kgml
3. Install oluo (27).

&’ Plig: ThreeBond (#I3051 ‘29 CWWO2885
4. Install O-ring (19) to adjustment screw (15), then

set shim (18), spring (26) and ball (25). and in-
stall them to valve body (I).
5. Install locknut (14) to adjustment screw (15).

w Locknut: 9.8 - 11.8 Nm 11.O - 1.2 kgm1
6. Install valve seat (231, piston (22) and retainer

(21) to valve body (I). install O-ring (24) to Plug
(201, then install them.
& Plug: 30.4 - 37.3 Nm 13.1 - 3.8 kgml
7. Assemble O-ring (19) to adjustment screw (15).

Set shim (18) and spring (17) and retainer (16),
then install them to valve body (I).
8. Install locknut (14) to adjustment screw (15).

w Locknut: 9.8 - 11.8 Nm 11.O - 1.2 kgm}
9. Insert filter (12) in bushing (IO), then install snap

ring (II).
10. Install O-ring (13) to bushing (IO), then install

them to valve body (I).
w Bushing: 29.4 - 39.2 Nm I3.0 - 4.0 kgm}
io ._ ‘I C WWO2884
WA8003 30-187
0
11. Assemble spring (7) to spool (8), then insert

them in valve body (1).
12. Install O-ring (9) to plug (6), then install them to

valve body (1).
w Plug: 53.9 - 68.6 Nm (5.5 - 7.0 kgml
13. Install O-ring (51, backup ring (4) and ring (3) to
PPC relief valve (2), then install them to valve
body (1).
m PPC relief valve: 79 - 88 Nm {8 - 9 kgml
30-188 WA800-3
0
DISASSEMBLY AND ASSEMBLY STEERING STOP VALVE
REMOVAL OF STEERING STOP

VALVE
A Stop the machine on level ground and lower
1. Disconnect hose (I) of the steering valve.
2. Disconnect hose (2) of the orbit-roll.
4. Remove mounting bolt (4), then remove steer-

ing stop valve (5).
INSTALLATION OF STEERING
STOP VALVE
removal.
Ir Check the stop valve. For details, see TESTING

AND ADJUSTING, Adjustment of stop valve.
WABOO-3 30-189
0
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER
1 3
g Fully extract the piston rod of the steering cylin- 0
der to be removed and lower the work equip-
ment completely to the ground, then put blocks
moving. \
I\(‘ I
1. Remove bolt (I) and loosen bolt (2), then slowly \
turn cover (3) toward the rear of the machine
body. ;:% ,7>
,
‘-__-
* Turn the cover around bolt (2). i\ CWWO2823
* Since the available space is narrow, work

carefully.
2. Remove mounting bolts (4) and (51, then re-

move plate (6).
3. Disconnect the remote tube, then remove grease

nipple (7).
4. Remove bolt (3). then remove plate (9).
5. Remove taper bushings (IO) and (II), then pull

out pin (12). m
6. Start the engine, then retract piston (13).

* Check the number of the shims.
7. Temporarily sling steering cylinder (14).
8. Disconnect hose (15) on the bottom side.
9. Disconnect hose (16) on the head side.
30-190 WA800-3
0
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
10. Remove bolts (17) and (181, then remove plate

(19).
11. Disconnect the remote tube, then remove grease

nipple (20).
12. Remove bolt (211, then remove plate (22).
13. Remove taper bushings (23) and (24), then pull

out pin (25). m
14. Sling and remove steering cylinder (14). CWWO2827
li When slinging, be careful not to interfere

with the remote grease tube, etc.
Sr Check the number of the shims.
kg
cE?l Steering cylinder : 210 kg
CYLINDER
removal.
I) Do not put grease or other lubricants on the

contact faces of the pin and taper bushing.
2) When installing the taper bushing, set its slit
in the lateral direction of the machine body.
a When aligning the position of the pin hole, use
a bar. Never insert your fingers in the pin hole.
* Adjust the clearance of the cylinder mounting
portions to the following values.
. Bottom side: a, b = 3 mm max.
. Head side: a, b = 1 mm max.
Bottom DWWO5238
Head DWW05244
WA800-3 30-191
0
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING VALVE

a Stop the machine on level ground and install
moving.
g Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then operate
the steering wheel and the control levers 2 - 3
times to release the remaining pressure in the
hydraulic piping.
1. Step
Remove step (1) on cab front.
2. Hydraulic piping
Disconnect the following tubes from steering
demand valve.
. Remove tube (2) between steering demand
valve (Pz port) and switch pump.
valve (PI port) and steering pump.
valve (P, B port) and work equipment valve.
* Remove the bolts of bracket (5) for fix-
ing tube (4) in advance.
valve (A port) and steering cylinder.
valve (B port) and steering cylinder.
valve (T port) and return port of hydraulic
oil tank.
. Remove tubes (9) and (IO) between orbit-
roll and steering demand valve pilot circuit.
* Remove the tube clamp in advance.
A \l h DGW04485
30-192 WA8003
0
DISASSEMBLY AND ASSEMBLY STEERING VALVE

Sling steering demand valve temporarily, remove
mounting bolts (II), then remove steering de-
mand valve (12).
Steering demand valve: 66 kg
4. Bracket
Remove bracket (13) from steering demand valve
(12).
DGW04487
VALVE
removal.
Refilling with oil

. Add oil through the oil filler of the hydraulic
. Before starting the engine, bleed air from the

steering pump, switch pump and work equip-
ment pump.
* See TESTING AND ADJUSTING.
+ Run the engine to circulate the oil through

the system. Then, check the oil level again.
WA800-3 30- 193

0
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

1. Remove the U-bolt, then disconnect drain tube

(2).
Ir Move the drain tube and hose toward the
frame.
2. Disconnect hose (3) of the front brake.
3. Disconnect hose (4) of the shuttle valve.
4. Disconnect pilot hose (5) (of the shuttle valve).
6. Pull out snap pin (9), then pull out pins (7) and
(8).
* Be careful not to lose L-pin (IO).
7. Remove pedal (11).

J
8. Remove boot (12).

1
CWWO2845
9. Remove 4 bolts (13). then remove brake valve

(14).
Ir This work must be done by two workers.
Remove the valve under the floor frame.
INSTALLATION OF BRAKE
VALVE
removal.
. Bleeding air
portion.
A\ CWW02847
30- 194
0
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER
the work equipment completely to the grouna,
1. Disconnect tubes (1) and (2) of the brake valve.

* After removing the tubes, loosen the clamp.
2. Disconnect hoses (3) and (4) of the brakes on

left and right sides.
3. Remove mounting bolt (51, then remove bracket

(6) and slack adjuster (7) together.
INSTALLATION OF SLACK
ADJUSTER
removal.
. Bleeding air
portion.
WA8003 30- 195

0
DISASSEMBLY OF SLACK ADJUSTER

1. Bleeder
Remove bleeder (2) from body (I).
I CEW00911
2. Cylinder
Remove mounting bolts, then disconnect body
(I) from cylinders (3) and (4).
g Cylinder has spring tension inside. Carefully

remove them holding two parts together.
3. Piston
1) Remove spring (5) and O-ring (6).
2) Push out piston (7) and remove O-ring.
Ir Gently push out the piston with a rod
(diameter IO mm) when remove it.
* Pay attention not to give damage to
screw portion with the rod.
CEW00913 CEW00914
4. Poppet
* Do not disassemble poppet unless neces-
sary.
If disassembled, replace poppet and cylin-
der as assembly.
1) Remove cover (8) from cylinder (4), then re-
move plug (9), spring (IO) and poppet (II).
Ir Remove the poppet by air blowing
through the oil hole of the cylinder.
* Hold the oil port of the cylinder by hand
and pay attention not to blow air hard.
sr If replace poppet (II) or cylinder (41,
replace them as a set.
CEW00915
2) Remove O-ring (12) from the poppet.
30- 196 WA800-3
0
ASSEMBLY OF SLACK ADJUSTER

Poppet
1) Fit O-ring (12) to poppet (II).
2) Install poppet (II), spring (IO), plug (9) and
cover (8), then assemble into the cylinder
(4).
CDW00916
8 9 IO II
CEW00917
Piston
1) Fit O-ring (13) to piston (7).
2) Insert piston (7) into cylinder (4).
* Confirm that the piston moves smoothly.
CEW00918 CEW00919
3. Cylinder
1) Install O-ring (6) and spring (5) to cylinder.
* Spring installation load: 43.1N (4.4 kg1
CEW00920
2) Install cylinders (4) and bracket (3) to body

(I).
4. Bleeder
Install bleeder (2).
WA800-3
DISASSEMBLY AND ASSEMBLY BRAKE
REMOVAL OF BRAKE
moving.
1. Remove ring gear.

For details see DISASSEMBLY OF FINAL DRIVE.
2. Disconnect brake tube (1).

DEW04536
3. Sling wheel hub (2) temporarily, remove mount-

ing nut, then remove wheel hub. m
* Bearing (3) will fall out, so remove the bear-

ing while removing the wheel hub.
&I kg Bearing: 45 kg
&I kg Wheel hub: 90 kg
4. Sling brake (4) temporarily, and remove mount-

ing bolts, then remove brake.
Sr Bearing (5) will fall out, so remove the bear-
ing while removing the brake.
& kg Bearing: 43 kg
Brake : 380 kg
INSTALLATION OF BRAKE o-
0
DEW04538
removal.

m Mounting bolt:
549 = 59 Nm (56 + 6 kgm1
a Mounting bolt: Adhesive (LT-2)

w Mounting bolt:
932 = 98 Nm I95 + 10 kgm}
30-198 WA800-3
0
DISASSEMBLY OF BRAKE
1. Remove mounting bolts, and screw in eyebolts
@ (Dia. = 16 mm, Pitch = 2.0 mm), then lift off
cylinder assembly (1).
L+lkg Cylinder assembly: 140 kg
Ir Disassemble cylinder as follows.

I) Screw in eyebolts @ (Dia. = 16 mm, Pitch
= 2.0 mm), push in spring with bar 0,
then pull out pin (2).
2) Remove spring (3), shaft (4), and washer.
DEW04541 DEW04542
3) Remove piston (5).
DEW04543
2. Removal plate and disc

I) Remove stopper bolt, then remove plate (6).
WA800-3
2) Remove disc (7).
3. Remove tool Jl.
Screw in eyebolts @ (Dia. = 16 mm, Pitch = 2.0

mm), then lift off outer drum (8).
& kg Outer drum: 240 kg

9
Knock out retainer (IO) through removal hole in
inner gear (9), then remove together with float-
ing seal (I I).
6. Remove mounting bolts, then remove hub (12)

from outer drum.
30-200
0
7. Remove oil seal (13).
8. Remove floating seal (14).
WA800-3 30-201
0
ASSEMBLY OF BRAKE
1. Using tools J2, install floating seal (14) to hub.
+ When assembling the floating seal, clean the
surface of the O-ring with alcohol and as-
semble without twisting.
* Use a new part for the O-ring.
DEW04549
2. Install oil seal (13).

Ir Tap the oil seal with a plastic hammer to
install uniformly.
& Lip of oil seal: Grease (G2-LI)
3. Fit O-ring and install hub (12) to outer drum.

Ir Use a new part for the O-ring.
xQ.= Mounting bolt: Adhesive (LT-2)
m Mounting bolt:
549 r 59 Nm 156 + 6 kgm}
II
DEW04548
4. Using tools 52, install floating seal (11) to re-

tainer (IO).
* When assembling the floating seal, clean the
surface of the O-ring with alcohol and as-
semble without twisting.
I DEW04551
30-202 WABOO-3
0
5. Fit O-ring to inner gear (9), align with dowel pin

and install retainer (IO) together with floating
seal (11).
Sr When installing the retainer to the inner gear,
tap the end of face of the retainer with a
copper hammer to install.
Ir Use a new part for the O-ring.
IO
‘11
4548
6. Using eyebolts @ (Dia. = 16 mm, Pitch = 2.0

mm), install outer drum (8) to inner gear.
t Coat the sliding surface of the floating seal
thinly with engine oil, and be careful not to
damage the floating seal when installing the
outer drum.
Sr Center the inner gear and outer gear, and
tighten with tool Jl.
7. Using tool Jl, fix inner gear and outer gear.

Sr Center the inner gear and outer gear, and
tighten with tool Jl.
8. Assemble disc (7) and plate (6).

* Align the notched teeth at 6 places around
the circumference of the disc and plate when
assembling.
WA&XI-3
30-203
0
9. Fit O-ring and tighten stopper bolts of disc and

plate.
Ir Assemble cvlinder as follows. I 1

1) Assemble seal rings to cylinder and pis-
ton, and set piston (5) at bottom.
+ Coat to each seal ring with engine
oil. Sea I
0
Cross-sectional
L-Lf-- -
DEW04724
I DEW04543
2) Assemble washer, shaft (41, and spring

(3) to piston from cylinder end.
3) Screw in eyebolts @ (Dia. = 16 mm, Pitch
= 2.0 mm), compress spring with bar 0,
then install pin (2) in shaft.
I DEW04542 DEW04541
J
30204 WA800-3
0
IO. Fit O-ring, then screw in eyebolts @ (Dia. = 16

mm, Pitch = 2.0 mm), install cylinder assembly
(I).
w Mounting bolt:
549 t. 59 Nm I56 I 6 kgml
\- ‘/ DEW04540
WA8003 30-205
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS
REMOVAL OF PARKING BRAKE

CALIPERS
1. Release the parking brake and turn adjustment

bolt (I) counterclockwise to set the yoke free.
2. Pull out pin (3), then disconnect the yoke from

adjuster (4).
cww03005
3. Remove cover (5).
4. Apply the parking brake, then disconnect I-lose

(6).
Ir Before disconnecting the hose, check that
any pressure is not remaining in the brake
cylinder.
5. Remove the mounting bolt, then remove spring

cylinder (7).
6. Remove plate (8).

* Remove cover (9).
Ir After removing the plate, remove pad
Ir Sling the calipers so that they will not fall.
7. Remove parking brake calipers (11).

Ir The parking brake calipers must be removed
by two workers.
elkg Parking brake caliper : 40 kg
INSTALLATION OF PARKING
BRAKE CALIPERS
removal.

w Mounting bolt:
820 - 1,030 Nm I84 - 105 kgm}

w Mounting bolt:
490 - 608 Nm t50 - 62 kgm}
. Bleeding air
Bleed air from the parking brake circuit. For de-
tails, see TESTING AND ADJUSTING, Bleeding
air from each portion.
30-206 WA800-3
0
DISASSEMBLY OF PARKING BRAKE CALIPERS

1. Remove snap ring (I), then pull out adjuster (2).
DEW04560
2. Remove washers (3) and (41, and seal (5).
DEW04561
3. Remove bolt, then remove cap (6) and gasket

(7).
U I
DEW04562
4. Remove piston shaft (8) and thrust bearing (9)

from piston.
I DEW04563
WA800-3 30-207
0
5. Remove piston (11) and piston seal (12) from

calipers (IO).
IO
DEW04564
30-208 WAND3
0
ASSEMBLY OF PARKING BRAKE CALIPERS

1. Assemble piston seal (12) in calipers (IO), and
insert piston (I I).
& Piston, piston seal: Grease (G2-LI)
IO
DEW04564
2. Screw piston shaft (8) into piston, and install

thrust bearing (9).
* Be careful to install the thrust bearing facing
in the correct direction.
6 Thrust bearing: Grease (G2-LI)
DEW04563
3. Fit gasket (7) and install cap (6).

m Mounting bolt:
177 + 20 Nm I18 1: 2 kgm1
DEW04562
4. Install seal (5) and washers (3) and (4).

* Fit the seal securely in the groove.
& Seal: Grease (G2-LI)
3 4
DEW04561
WA800-3 30-209
0
5. Assemble adjuster (2) and secure with snap ring

(1).
DEW04560
30-210 WA800-3
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD

PAD
Then put blocks under the wheels to prevent
the machine from moving.
-k Turn the main switch ON, and release the
parking brake.
1. Turn adjustment bolt (I) in counterclockwise di-

rection to increase clearance between pad and
cww03001
disc.
2. Remove cover (2). m
3. Loosen mounting bolts of plate (3). m

* Sling to prevent calipers (4) from falling.
4. Move plate to side carefully so that pad does

not fall, then remove pad (5).
* When removing the front pad, first remove
the rear pad and move the calipers to the
front, then remove the front pad.
+ Remove the pad of the parking brake calipers
on the right side in the same way.
BRAKE PAD
removal.
u
w Mounting bolt:
490 - 608 Nm I50 - 62 kgm}
a
m Mounting bolt:
820 - 1,030 Nm I84 - 105 kgm}
. Bleeding air
tails, see TESTING AND ADJUSTING.
WA800-3 30-211
0
DISASSEMBLY AND ASSEMBLY PARKING BRAKE SPRING CYLINDER

SPRING CYLINDER

1. Release the parking brake and turn adjustment

bolt (I) counterclockwise to set the yoke (2) free.
2. Pull out pin (31, then disconnect yoke (2) from

adjuster (4).
3. Apply the parking brake, then disconnect hose

(5).
Ir Check that no pressure is remaining in the
brake cylinder.
* After removing the hose, cover the hole to
prevent dust from entering.
4. Remove the mounting bolt (61, then remove park-

ing brake spring cylinder (7).
BRAKE SPRING CYLINDER
removal.
. Bleeding air
tails, see TESTING AND ADJUSTING, Bleeding
air from each portion.
30-212 WA800-3
0
DISASSEMBLY AND ASSEMBLY BRAKE OIL TANK
REMOVAL OF BRAKE OIL TANK

a Lower the work equipment completely to the
1. Drain oil from the brake oil tank.
- : Brake oil: 27 e
2. Remove front cover (I) and side covers (2) and

(3).
4. Remove suction tube (5).
5. Disconnect hose (6) of the parking brake sole-

noid valve.
6. Disconnect hoses (7) and (8) of the charge valve.

Ir There is a clamp on the tank side.
7. Remove the mounting bolts, then sling and re-

move brake oil tank (9).
&I kg Brake oil tank: 36 kg
INSTALLATION OF BRAKE OIL

TANK
removal.
. Refilling with oil

Add oil to the center of the upper sight gauge.
Ir Bleed air from the brake line, referring to
TESTING AND ADJUSTING, Bleeding air
from each portion. Then, check the oil level
again.
WA800-3
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL OF HYDRAULIC
PUMP

1. Remove step (I) from the rear of the cab.
_
I CWWO2857
2. Loader pump
I) Disconnect suction tube (2).
2) Disconnect hose (3) of the main control valve.
3) Disconnect drain hose (4).
4) Disconnect hose (5) of the E.S valve.
5) Remove bracket (6), then disconnect control
pump discharge tube (7).
6) Remove mounting bolts (8), then sling loader
pump (9) and lift it off.
& kg Loader pump : Approx. 160 kg
3. Switch pump
1) Disconnect suction tube (10).
2) Disconnect hose (11) of the steering valve.
switch pump (14).
&I kg Switch pump : 160 kg
4. 4-units (T/C, T/M, PPC, brake) pump

1) Disconnect suction tubes (15) and (16) of the
T/C and T/M pumps.
2) Disconnect suction tube (17) of the PPC
pump.
3) Disconnect suction tube (18) of the brake
pump.
30-214 WA800-3
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
4) Disconnect tube (19) of the accumulator

charge valve.
5) Disconnect tube (20) of the PPC.
6) Disconnect tubes (21) and (22) of the T/C
and T/M.
7) Remove mounting bolts (231, then remove
4-unit pump (24).
& kg 4-unit pump : 60 kg
5. Steering pump
1) Disconnect suction tube (25).
3) Disconnect tube (27) of the steering valve.
4) Remove the mounting bolts, then remove
steering pump (28).
+ Disconnect the hose between the top of
the pump and the diverter valve.
& kg Steering pump : 145 kg
INSTALLATION OF HYDRAULIC
PUMP
removal.
. Bleeding air
Bleed air from the hydraulic line. For details,
from each portion.
WA800-3 30-215
0
DISASSEMBLY AND ASSEMBLY PISTON PUMP
DISASSEMBLY OF PISTON
(HPF076+071)
PUMP ASSEMBLY
HPV090+090, HPF076+071
fl The disassembly procedure is the same for both

the front and rear pumps, so the procedure for
disassembly of the front pump is given below.
If there are any differences, the different part is
explained.
Preparatory work
Set pump assembly to tool Y1.
(HPV090+090)
1. ES valve assembly, hoses (HPV090+090 only)
1) Remove ES valve assembly (3).
2) Remove hoses (4) and (5).
2. Rear pump assembly

1) Sling rear pump assembly (7).
2) Remove 4 nuts at front pump end, then re-
move rear pump assembly (7).
fl It separates between the end caps.
fl Only the HPV090+090 has a gear pump.
Disassembly of pump
fl The front pump is disassembled as it is, but for

rear pump assembly (7), install plate Y4 and
disassemble.
30-215-1 WA800-3
3
3. Impeller
1) Remove bolt (15), then remove plate (9) and
shim (17).
fl Check the number and thickness of the
2) Remove impeller (8).
4. Servo valve assembly (HPV090+090 only)

Remove servo assembly (12).
fl For the HPF pump, remove the cover.
5. End cap
1) Remove snap ring (13), then remove washer
(14).
2) Remove inner race (20) and bearing (21).

3) Remove end cap (23).
4) Remove valve plate.
fl It is stuck to the cylinder block, so be
careful not to scratch or damage it.
Note: If the cylinder block and valve plate are
to be used again, keep them in a safe
place as a set.
5) Remove outer race and bearing from end
cap.
WA800-3 30-215-2
3
6. Valve plate
Remove valve plate (45).
fl It is stuck to the cylinder block, so be careful
not to scratch or damage it.
Support cylinder block and shaft, and remove
pump sub-assembly (49).
8. Servo piston
1) Using forcing screw 1 (Thread dia.=10 mm,
Pitch=1.5 mm) and nut 2, remove cap (27)
and shim (28).
2) Remove spring (31).
fl The spring and forcing screw are for the
HPV090+090 only.
3) Screw in forcing screw and remove cap (29)

and shim (30).
4) Remove servo piston (32).
fl The servo pistons for the front and rear
pumps are different parts, so mark them
with a distinguishing mark.
fl With the HPF pump, there is a spacer on
the right side as seen from the rear of
the pump.
30-215-3 WA800-3
3
Disassembly of pump sub-assembly
9. Cylinder, shaft
1) Set pump sub-assembly (49) in vice.
fl Be careful not to damage the flange sur-
face of the cradle.
2) Remove slider (38) and cylinder block (35).
3) Screw in forcing screw and remove housing

(40) and shim.
fl Check the number and thickness of the
fl The control pump is installed to the rear

pump. Therefore, collar (10) assembled to
the pilot pump must be removed.
(HPV090+090 only)
fl Remove the cover of the HPF pump.
4) Knock out drive shaft assembly (41) from

piston end and remove.
10. Piston
Remove 4 screws (56), then remove retainer
bearing (57), shoe retainer (58), spacer (59), and
piston (60).
WA800-3 30-215-4
3
When using pump drive shaft and cylinder block

again
• Removal of bearing from pump drive shaft

1) Remove snap ring (55), then remove washer
(54), inner race A (53), and bearing (68).
2) Using bearing race puller 3, remove inner

race B (52).
• Disassembly of cylinder block

30-215-5 WA800-3
3
2) Remove washer (36) and spring (37) from

cylinder block (35).
WA800-3 30-215-6
3
ASSEMBLY OF PISTON PUMP

ASSEMBLY
HPV090+090, HPF076+071
Precautions when assembling
1) Clean all parts and remove all burrs.

2) Coat the rotating and sliding surfaces of all
parts with engine oil (EO-10CD) before as-
sembling.
fl Always use the following parts as a set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate
fl The disassembly procedure is the same for
both the front and rear pumps, so the proce-
dure for disassembly of the front pump is
given below.
If there are any differences, the different part
is given.
1. Cradle, piston assembly

1) Fit dowel pin, then install rocker cam stop-
per (64) to cradle (65).
2 Stopper bolt:
Thread tightener (LT-2)
(Loctite #262)
3 Stopper bolt:
13.24 ± 1.47 Nm {1.35 ± 0.15 kgm}
2) Fit dowel pin to cradle, set rocker cam (62)

in position, then install plate (63).
fl Set the side of the rocker cam with the
groove facing the oil hole in the cradle.
2 Plate bolt:
(Loctite #262)
3 Plate bolt:
30.89 ± 3.53 Nm {3.15 ± 0.35 kgm}
fl After tightening the bolts, check that the
rocker cam moves smoothly.
30-215-7 WA800-3
3
3) Select spacer thickness as follows.

i) Assemble piston (60) to shoe retainer
(58), then set on surface plate 4 and
measure dimension a to top of shoe re-
tainer.
ii) Select spacer size as follows.
Measured dimension a + (0.03 to 0.07 mm)
fl There are 3 types of spacer.
4) Fit spacer (59) selected in Steps 5)-i) and ii),

then install piston (60), shoe retainer (58),
and retainer bearing (57).
2 Bearing retainer bolt :
(Loctite #262)
3 Bearing retainer bolt :
13.24 ± 1.47 Nm {1.35 ± 0.15 kgm}
5) Hold rocker cam (69) in position, pull piston

(60) with a force of 19.6 – 29.4 N {2 – 3 kg},
and measure clearance x between piston
shoe and rocker cam.
fl When measuring, measure at position b
or c of rocker cam (69), and measure for
all 9 pistons.
fl Clearance x : 0.03 – 0.07 mm
fl If clearance x is not within the standard
range, carry out the spacer adjustment
again.
WA800-3 30-215-8
3
2. Shaft assembly
1) Press fit inner race B (52) (inside diameter
45 mm) to shaft (41) using press.
2) Fit bearing (68) and install inner race A (53).
3) Select washer as follows.

i) Install snap ring (55).
fl Check that the snap ring is not de-
formed or damaged, and remove any
burrs.
Install with the cut inside portion fac-
ing away from the inner race.
ii) Use clearance gauge to measure clear-
ance d between snap ring (55) and inner
race.
fl Push the snap ring securely into the
groove on the opposite side from the
inner race.
iii) Select washer of following thickness and
install.
Thickness = measured thickness + (0 to
0.1 mm)
fl Check that there is no play between
snap ring (55) and washer (54).
There are 3 types of washer.
Washer: 2.0 mm, 2.1 mm, 2.2 mm
30-215-9 WA800-3
3
4) Install drive shaft (41) to cradle (65).
5) Install oil seal (50) to housing (40).

2 Lip of oil seal : Grease (G2-LI)
6) Fit O-ring and shim (39), and install hous-

ing (40) to cradle.
3 Mounting bolt:
30.89 ± 3.43 Nm {3.15 ± 0.35 kgm}
fl Wind the shaft with tape to prevent dam-
age to the lip surface of the oil seal.
fl Install the cover of the rear pump.
3 Cover mounting bolt:
110.32 ± 12.26 Nm {11.25 ± 1.25 kgm}
fl Do not install the control pump to the rear

pump at this point. If it is installed, it will be
impossible to prevent the shaft from turn-
ing when adjusting the bearing end play.
7) Select housing shim as follows.
i) Push in drive shaft (41) completely, then
measure end face dimension e of cradle
and bearing outer race.
ii) Measure dimension f of housing (40).
WA800-3 30-215-10
3
iii) Select shim of following thickness.

fl Shim thickness =
f – e = g + (0.05 to 0.15) mm
fl This will produce a clearance of 0.05
to 0.15 mm at portion h.
fl With the rear pump, install collar (66) to con-

trol pump (67), then measure dimension j of
collar. (HPV090+090 only)
fl Measure the dimension of the collar portion
of the cover on the HPF pump.
3. Cylinder block
Align with drive shaft and piston, and install
cylinder block (35).
fl The valve plate forms a set with the cylinder
block, so always mark with a distinguishing
mark and keep as a set.
fl Install the spring and washer inside the cyl-
inder block after adjusting the bearing
preload.
30-215-11 WA800-3
3
fl The length from the center is different for the

side where the spring is fitted and the side where
no spring is fitted.
WA800-3 30-215-12
3
4. Servo piston (HPV090+090 only)

1) Install pump case (33) to tool Y1.
2) Install servo piston (32).
fl The servo pistons for the front and rear
pumps are different parts, so be careful
not to mistake them when installing.
fl See the diagram on the next page.
3) Adjust servo piston stroke as follows.

i) Align groove k for servo valve arm of
servo piston with dowel pin, then set on
tool Z.
fl The right side as seen from the rear
(the side with the spring, the top
when mounted on the machine) is
the maximum angle side.
Note: Use the same tool and turn it
over for the rear pump.
ii) Measure dimension n between servo pis-

ton and case.
iii) Measure dimension p of cap (29).
iv) Calculate shim thickness from dimension
p of cap and dimension n of servo as
follows to give a clearance of ± 0.05 mm.
Shim thickness: p – n = q ± 0.05 mm
fl Keep the adjusted shim and the cap
as a set.
fl When adjusting the minimum angle side,

replace tool Z with the minimum angle tool,
and repeat the procedure in Steps i) – iv)
above.
Note that the direction of the case is the
opposite from the maximum angle.
30-215-13 WA800-3
3
4. Servo piston (HPF pump only)

1) Install servo piston (32).
fl When installing the servo piston, set the
shallow notch on the inside (the end
where the spring is installed on the HPV
pump) facing the left side as seen from
the rear of the pump.
2) Position servo piston as follows.
i) Align with servo piston groove k and
dowel pin, then set tool Z in position.
fl It is offset from the center to the left
side as seen from the rear of the
pump.
ii) Measure dimension n between servo pis-
ton and case.
iii) Measure dimension p of cap (29).
iv) Calculate shim thickness from dimension
p of cap and dimension n of servo as
follows.
Shim thickness: p – n = q ± 0.05 mm
fl Keep the adjusted shim and the cap
as a set.
fl Assemble a spacer on the right side
as seen from the rear of the pump,
and measure. When measuring, push
the spacer securely against the pis-
ton.
WA800-3 30-215-14
3
1) Install slider (38) and O-ring.
fl Fit the O-rings to the pilot portion and
the joint portion.
2) Install 2 joints to case.
fl Set with the small hole facing the cradle.
3) Align slider with servo piston, support cylin-
der block and shaft, then install pump sub-
assembly (49).
fl Be careful not to get the O-ring caught.
3 Mounting bolt:
112.78 ± 9.81 Nm {11.5 ± 1 kgm}
fl For the rear pump, set on the other plate
and assemble.
6. Adjusting of bearing end play

1) Install following parts to end cap.
i) Install bearing (48) (outer diameter 42
mm).
2 Bearing mounting surface:
Grease (G2-LI)
ii) Install outer race (46) to end cap (42).
fl Be careful not to damage the rolling
surface of the roller.
30-215-15 WA800-3
3
iii) Coat with engine oil, align with pin and

bearing, then install valve plate (45).
iv) Install joint (44).
fl Set with the small hole facing the
case.
Install the joint with only one hole to
the suction port end.
2) Install end cap (42) to case (33).

3 Mounting bolt:
68.65 ± 4.9 Nm {7 ± 0.5 kgm} (front)
3 Mounting nut:
235.36 ± 19.61 Nm {24 ± 2 kgm} (rear)
3 Stud bolt:
132.39 ± 14.71 Nm {13.5 ± 1.5 kgm}
(Tighten the nut of the stud bolt.)
3) Install bearing (21) and inner race (20).
4) Assemble any one of 5 types of washer (14),

then install snap ring (13).
5) Select and install washer so that clearance r
between snap ring and washer is 0 – 0.01
mm.
WA800-3 30-215-16
3
6) Set dial gauge 2 to case, move shaft to

front and rear, and measure end play.
fl End play: 0.1 – 0.3 mm
fl If the end play is not within the standard
range, carry out the shim selection again.
7) After completion of measurement, remove
end cap.
fl Be careful not to drop the valve plate
when removing the end cap.
fl With the rear pump, after tightening the

bolts, for holding the cradle bearing in posi-
tion, install the control pump, set dial gauge
2 to the end cap, and measure.
fl HPV090+090 only
7. End cap
1) Assemble spring (37) and washer (36) to cyl-
inder block (35), then install snap ring (34).
fl Be careful not to damage the contact
surface of the valve plate.
2) Install end cap.
fl For details, see Steps 6-1)-iii), iv), and 2).
3) Fit bearing (21), inner race (20), spacer (18),

boss (16), shim (15), and plate (14), and
tighten bolt (13).
2 Bolt: Thread tightener (LT-2)
3 Bolt: 68.65 ± 4.9 Nm {7 ± 0.5 kgm}
30-215-17 WA800-3
3
fl With the rear pump, fit an O-ring and install

control pump assembly (40). (HPV090+090
only)
3 Mounting bolt:
112.78 ± 9.81 Nm {11.5 ± 1 kgm}
8. Servo piston cap (HPV090+090 only)

1) Install spring (31).
fl Install to the right side as seen from the
rear of the pump (the top when installed
on the machine). (The rear pump is the
same.)
2) Fit shim (30) and O-ring, and install cap (29).

3) Fit shim (28) and O-ring, then using forcing
screw 3 (Thread dia.=10 mm, Pitch=1.5 mm)
and nut 4, install cap (27).
fl Use a forcing screw for HPV090+090 only.
fl Be careful not to change the cap and
shim set when installing.
3 Mounting bolt:
68.65 ± 4.9 Nm {7 ± 0.5 kgm}
9. Servo valve (HPV090+090 only)

Fit O-ring and align arm with piston, then install
servo valve assembly (12).
fl Be careful not to drop the O-ring. Tighten
the bolts gradually on opposite sides in turn.
3 Mounting bolt:
30.89 ± 3.43 Nm {3.15 ± 0.35 kgm}
WA800-3 30-215-18
3
10. Adjusting impeller shim

1) Install impeller (8) to coupling (26).
2 Mounting bolt:
3 Mounting bolt:
4.9 ± 0.49 Nm {0.5 ± 0.05 kgm}
2) Adjust clearance between impeller and end

cap portion s as follows.
i) Measure thickness t of plate (9).
ii) Assemble plate (9) to coupling (26), and
install impeller.
fl Check that the impeller and portion
s of the end cap are in contact.
iii) Measure dimension from end face of
coupling to end face of plate (9).
iv) Measure dimension from end face of
coupling to end face of shaft (41).
v) Calculate shim thickness from dimen-
sions t, u, and v as follows.
Shim thickness =
v – (u + t) + (0.5 ± 0.1) mm
vi) Assemble shim selected in Steps i) – v),
then install impeller (8).
2 Mounting bolt:
3 Mounting bolt:
66.19 ± 7.35 Nm {6.75 ± 0.75 kgm}
vii) Check clearance w between impeller and
end cap.
fl Clearance w: 0.5 ± 0.1 mm
fl If it is not within the standard range,
adjust the shims again.
3) Check for interference of impeller (8) and rear

end cap as follows.
i) Measure dimension x of rear cap end face.
ii) Measure protrusion dimension y of impeller
vane from front end cap.
iii) Check that measured dimension is x > y.
fl If the above dimensions are y > x, there is
no clearance at portion a. This means that
the impeller vane will contact the rear end
cap, so repeat Step 10-2) and carry out ad-
justment of shim (17) again.
30-215-19 WA800-3
3
4) Install selected spacer (10) to rear pump.

5) Fit selected spacer (9) to front pump and
install impeller (8).
11. Rear pump assembly

1) Install each O-ring to front and rear end caps.
2) Raise rear pump assembly (7), then align
spline and install.
3 Mounting nut:
235.36 ± 19.61 Nm {24 ± 2 kgm}
3 Stud bolt:
132.39 ± 14.71 Nm {13.5 ± 1.5 kgm}
fl Only HPV090+090 has a gear pump.
(HPV090+090)
12. ES valve assembly, hoses (HPV090+090 only)
1) Fit O-ring and install ES valve assembly (3).
2) Install hoses (4) and (5).
(HPF076+071)
fl Checking quality after completion of assem-

bly
After completing assembly of the pump as-
sembly, use a test stand (A type or C type)
and check the quality.
fl For details of the procedure for checking the
quality, see the Testing Method.
WA800-3 30-215-20
3
CHECKING CONTACT BETWEEN CYLINDER BLOCK

AND VALVE PLATE, AND ROCKER CAM AND CRADLE
1. Checking contact between cylinder block and

valve plate.
1) Make a centering tool for the cylinder block
and valve plate.
fl The tool can be made of a soft material
such as plastic or bakelite.
2) Remove grease from the parts to be checked.
fl Do not wipe with a cloth.
3) Set the tool in position, and coat the cylin-
der block side with inspection paint.
fl Apply the paint thinly.
4) Put the valve plate on top, push with a force
of 39 – 49 N {4 – 5 kg}, and rotate 2 – 3
times.
5) Remove the valve plate, transfer the contact
surface to tape, and check the contact sur-
face.
fl The standards for the contact surface are as
follows.
Valve plate a. Seal Min. 80%
Cylinder block a. Seal Min. 80%
2. Checking contact between rocker cam and

cradle.
1) Remove grease from the parts to be checked.
fl Do not wipe with a cloth.
2) Set the tool in position, and coat the cradle
side with inspection paint.
fl Apply the paint thinly.
3) Put the rocker cam on top, push with a force
of 39 – 49 N {4 – 5 kg}, and move 2 – 3 times
from the stopper contact position to the
maximum angle.
4) Remove the rocker cam, transfer the contact
surface to tape, and check the contact sur-
face.
fl The standards for the contact surface are as
follows.
Pump Contact Contacr b
Model Dimension a from a to
surface
ouside
HPV090 72 mm Min. 80% Min. 50%
fl If there is no contact at the center but only

at the outside, the contact is no good.
Reference:
If the contact is not within the contact standard
value, when carrying, always lap both parts to-
gether.
fl Parts with scratches cannot be reused.
30-215-21 WA800-3
3
DISASSEMBLY AND ASSEMBLY SERVO CYLINDER
REMOVAL OF SERVO
CYLINDER

then apply the parking brake and stop the en-
gine.
1. Open step (I).
2. Disconnect drain hose (2) of the transmission.
3. Disconnect hose (3) of the oil filter.
4. Pull out the pin of cable (4) of the fuel pump,

then disconnect the cable.
5. Pull out the pin of cable (5) of the accelerator

pedal, then disconnect the cable.
6. Remove spring (6).

+ If the position of the bracket changes, the
engine speed may change. Accordingly, mark
off the position of the bracket with a pen
before removing it.
8. Remove the mounting bolt from bracket (7), then

remove servo cylinder (8).
* Mark off the position of the servo cylinder
so that it will be installed to the same posi-
tion.
INSTALLATION OF SERVO
CYLINDER

removal.
* Check the engine speed. For details, see DE-

PRESSING ANGLE OF ACCELERATOR PEDAL.
30-216 WA800-3
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK AND FILTER CASE
REMOVAL OF HYDRAULIC TANK AND FILTER CASE ASSEMBLY

* Observe the following points to protect the hy-

draulic equipment when disassembling and as-
sembling it.
. Before disassembling any part, clean the ma-
chine body, particularly around that part.
. When disassembling and assembling the hy-
draulic equipment, do not let dust in the
hydraulic circuit.
. Perfectly clean the parts, particularly the cir-
cuits and parts in the trouble section.
. Before disassembling or after cleaning the
hydraulic equipment, mask the all openings
of the piping and hydraulic parts.
g Loosen the oil filler cap to release the pressure

from the hydraulic tank, then operate the steer-
ing wheel and work equipment control lever 2 -
3 times to release the pressure from the piping.
1. Draining oil
Remove plug (I), then loosen plug (2) and drain
hydraulic oil.
- : Hydraulic oil: Approx. 550 l?
2. Remove step (3) on the top of the hydraulic

tank.
& kg Step: 150k g
3. Remove ladder (4) from hydraulic tank (11).
l&lkg Ladder: 45 kg
4. Disconnect tube (5) between the hydraulic tank

and hydraulic pump from the hydraulic tank.
5. Disconnect tube (6) between the hydraulic tank

and PPC pump from the hydraulic tank.
WA800-3 30-2 17
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK AND FILTER CASE
6. Disconnect tubes (7) and (8) between the hy-

draulic tank and diverter valve from the hydrau-
lic tank.
7. Disconnect return tube (9) between the work

equipment valve and hydraulic tank from the
hydraulic tank.
8. Disconnect return tube (IO) between the oil

cooler and hydraulic tank from the hydraulic
tank.
9. Temporarily sling hydraulic tank and filter case

assembly (11).
10. Remove mounting bolts (12) and (13), then re-

move hydraulic tank and filter case assembly
(II). m
& kg Hydraulic tank and filter case assembly:

900kg
CWWO3010
INSTALLATION OF HYDRAULIC
TANK AND FILTER
removal.
w Mounting bolt:
820 - 1,030 Nm (84 - 105 kgm1

I) Add hydraulic oil to the specified level.
2) Before starting the engine, bleed air from
the steering pump, switch pump and loader
pump. (For details, see TESTING AND AD-
JUSTING, Bleeding air from each portion.)
3) Run the engine to circulate the oil through
the system. Then, check the oil level again.
Q Hydraulic oil: Approx. 550 f?
CWWO3012
30-218 WA8003
a
DISASSEMBLY AND ASSEMBLY PPC VALVE
REMOVAL OF PPC VALVE

moving.
* Observe the following points to protect the hy-

draulic equipment when disassembling and as-
sembling it.
. Before disassembling, clean the machine
body, particularly around disassembling por-
tions.
. When disassembling and assembling the hy-
draulic equipment, do not let dust get into
the hydraulic circuit.
. Perfectly clean the parts, particularly the cir-
cuits and parts in the trouble section.
. Before disassembling or after cleaning the
hydraulic equipment, mask the all openings
of the piping and hydraulic parts.
a Loosen the oil filler cap to release the pressure

from the hydraulic tank, then operate the work
equipment control lever over TILT and NEUTRAL
at least 40 times to release the pressure from
the accumulator and piping.
Cover
Remove the cover form the rear of the cab and
console box cover (I) from the right side of the
operator’s seat.
Remove nut (2), then disconnect rod (3).
3. Pull out pin (4), then disconnect plate (5) from

lever (7).
4. Remove nut (6), then remove lever (7).

* Similarly, remove the nut and lever on the
opposite side.
WA800-3 30-2 19
0

control valve. (Identification color: Yellow)

control valve. (Identification color: Blue)
7. Disconnect hose (IO) between the PPC valve and

control valve. (Identification color: Green)
8. Disconnect hose (1 I) between the PPC valve and

control valve. (Identification color: Red)

accumulator. (Identification color: White)
IO. Disconnect PPC valve drain hose (13).
11. Remove mounting bolt (141, then remove PPC

valve (15).
Sr Plug the disconnected hoses to prevent dirt
from entering them.
INSTALLATION OF PPC VALVE

removal.

Add oil to the specified level of the hydraulic
tank.
30-220 WA800-3
0
DISASSEMBLY OF PPC VALVE

1. Remove bolt (I), then remove plate (2).
2. Remove seal (3), then remove Collar (4).
3. Remove piston (5).
4. Disassembly of piston
Remove the following parts from piston assem-
bly (6).
1) Push down retainers (8), and remove collar
(7).
2) Remove retainers (8), main spring (9), spring
(IO), shim (II), and piston (12).
5. Remove snap ring (13).
6. Remove retainer (14), spring (15), and valve (16)

from body (17).
ASSEMBLY OF PPC VALVE

1. Assembly of piston
Assemble the following parts to piston (12).
1) Assemble shim (II), spring (IO), and main
17
spring (9).
2) Push down retainer (8), and install collar (7).
2. Assemble valve (16), spring (15), and retainer

(14) to body (17).
3. Install snap ring (13).
4. Assemble piston assembly (6).
5. Install piston (5), then install collar (4) and seal

(3).
6. Align with dowel pin, and install plate (2), then

install bolt (1).
w Bolt: 44.1 1 4.9 Nm 14.5 z 0.5 kgm1
WA800-3 30-221
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT CONTROL VALVE
REMOVAL OF WORK EQUIPMENT CONTROL VALVE

moving.
To keep the hydraulic circuits clean and to pro-

tect the hydraulic equipment, be careful of the
following points when disassembling or assem-
bling.
. Before disassembling, wash the machine. Be
particularly careful to completely clean the
area that is to be disassembled.
. Do not let dirt or dust get into the hydraulic
circuits when disassembling or assembling.
. Carry out thorough flushing of the parts, and
be particularly careful to do this thoroughly
for the circuits or parts that have failed.
. When disassembling or after flushing, always
mask the openings of the piping or hydrau-
lic equipment completely.
I - - 11
g Loosen the filler cap to remove the pressure in
the hydraulic oil tank, and repeat shifting the ‘I
operation lever for the work equipment between
TILT and NEUTRAL 40 times or more to remove
DEW04589
the remaining pressure in the accumulator and
the pipings.
1. Cover
Remove cover (I) from the front frame.
2. Hydraulic piping
Disconnect the following hydraulic piping from
work equipment control valve.
. Hoses (IA) and (2) between steering demand
valve and work equipment control valve. Dis-
connect them on the side of the work equip-
ment control valve.
. Hoses (3) and (4) between work equipment
control valve and bucket cylinder. Discon-
nect them on the side of the work equip-
ment control valve.
. Tubes (7) between work equipment control
valve and the hydraulic oil tank. Disconnect
them on the side of the work equipment
control valve.
* Remove the clamp before removing the
tube.
. Tubes (5) and (6) between work equipment
control valve and the lift cylinder. Discon-
nect them on the side of the work equip-
ment control valve.
* Remove the clamp before removing the
tube.
* Cover pipings disconnected with blind
plugs to prevent dust in them.
30-222
0
3. PPC piping
Disconnect the following PPC pipings from the
work equipment control valve.
. Tubes (8) and (9) between PPC valve and
the dump spool piston
. Tubes (IO) and (11) between PPC valve and
the lift spool piston
. Hose (12) between work equipment control
valve and the hydraulic oil tank
Ir Cover pipings disconnected with blind
plugs to prevent dust in them.
Ir Attach tag plate and others to tubes dis-
connected to distinguish attaching posi-
tions.
4. Work equipment control valves

Screw eyebolts into work equipment control
valves, remove mounting bolts, then raise work
equipment control valves (13) and (14) and re-
move to outside of frame.
&I kg Work equipment control valve:

90 kg (I piece)
* When raising the valve, be careful not to hit

the valve against the frame. Also be careful
not to get your fingers caught.
INSTALLATION OF WORK
EQUIPMENT CONTROL VALVE
DEW04594
Refilling with oil

Add oil through the oil filler of the hydraulic tank
to the specified level.
* Before starting the engine, bleed air from the

piston pump circuit. For details, see TESTING
AND ADJUSTING.
j, After bleeding air, run the engine to circulate
the hydraulic oil through the system. Then, check
the oil level again.
. Bleeding air
Bleed air from the brake system.
Ir For the air bleeding procedure, see TEST- ~ DEW04595
ING AND ADJUSTING.
WA800-3 30-223
0
DISASSEMBLY OF WORK EQUIPMENT CONTROL VALVE

1. Remove hose (21, T-piece (3) and valve (4) from
valve body (I).
2. Remove hose (51, T-piece (6) and joint (7) from

valve body (1).
3. Remove suction valve (8) and 2 safety valves (9)

having the suction tube from valve body (I).
+ Since the safety valve cannot be adjusted
actually, do not disassemble it.
4. Remove plug (IO) from the valve body. I 9 cww03017
5. Remove main relief valve (II) from valve body

(I).
6. Remove plate (12) from valve body (I), then

IS
7. Remove flange (15) from valve body (I), then
remove spring (16), seal (17) and valve (18).
cwwo:1018
8. Remove elbows (19) and (20) from cases (21)

20
and (26).
26
9. Remove case (21) from valve body (I), then re- 20

move springs (22) and (23), retainer (24) and 26
spool (25).
21
10. Remove case (26) from valve body (1). then re-
move springs (27) and (28) and retainer (29).
11. Remove plug (30) from valve body (I). 19

I 22 il cww03019
12. Loosen nut (33) of main relief valve (I I), then

divide it into holder (31A) and sleeve (32A).
31A
I 32A cww03020
30-224 WA800-3
0
13. Remove nut (33) from holder (31A).
14. Remove nut (34) from holder (31A), then re-

move screw (351, retainer (36). spring (37) and
puppet (38).
CWWQ3021
15. Remove seat

sleeve (32A).
(39) and backup ring (40) from
I 32A
16. Remove snap ring (41) from sleeve (32A), then

remove valve (42), spring (43) and backup ring
(44).
* If sleeve (32) or valve (42) has any trouble,
replace as a set, since those parts are not
supplied independently.
12
CWWO3022
WA800-3 30-225
0
ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE

1. Assembly of sleeve (32A)
1) Install backup ring (441, spring (43) and valve
(42) to sleeve (321, then secure them with
snap ring (41).
2) Install the O-ring to seat (39), then install
them and backup ring (40) together to sleeve
(32).
42
2. Assembly of holder (31A)

1) Install the O-ring and puppet (38), spring (37),
retainer (36) and screw (35) to holder (31).
2) Install nut (33) to holder (31A).
3. Install holder (31A) to sleeve (32A), then lock

them with nut (33).
4. Insert retainer (29), springs (28) and (27) in valve 32A cww03020
body (1). Install the O-ring to case (26), then

install them to the valve body.
20 27 20 23
5. Insert spool (25), retainer (24) and springs (23) 26
and (22). Install the O-ring to case (21), then
install them to the valve body. 20
26
6. Install elbows (19) and (20) to cases (21) and
(26). 21
m Elbows (19), (20):
90.7 +. 12.3 Nm 19.25 r 1.25 kgml
19
7. Install plug (30) to valve body (I).
m Plug (30): 152 = 24 Nm j15.5 z 2.5 kgml 22 21 cww03019
30-226 WA8003
0
8. Insert valve (18), seal (17) and spring (16) in

valve body (I), then install the O-ring to flange
(15).
9. insert check valve (14) and spring (13) in valve

body (I), then install the O-ring to plate (12).
10. Install main relief valve (11) to valve body (I).

w Main relief valve (II):
324 2 44 Nm I33.0 f 4.5 kgm)
11. Install plug (IO) to valve body (I).

m Plug (IO): 68.6 2 9.8 Nm j7.0 = 1.0 kgm1
12. Install safety valve (9) having the suction tube

to valve body (I).
m Safety valve having suction tube (9):
186 +. 10 Nm {I9 f 1 kgm}
13. Install suction valve (8) to valve body (I).

m Suction valve (8):
186 z 10 Nm I19 f 1 kgm1
14. Install joint (7) and T-piece (6) to valve body (I),
then connect hose (5) between elbow (20) and
T-piece (6).
+ When clamping the hose, be careful not to
twist it.
15. Install valve (4) and T-piece (3) to valve body

(I),then connect hose (2) between elbow (19)
and T-piece (3).
w Valve (4): 68.7 = 9.8 Nm I7.0 2 1.0 kgml
w T-pieces (31, (6):
34.3 + 4.9 Nm 13.5 2 0.5 kgm}
w Hoses (21, (5):
49.0 z 19.0 Nm (5.0 + 2.0 kgml
w Joint (7): 34.3 = 4.9 Nm 13.5 + 0.5 kgm1
WA800-3 30-227
0
DISASSEMBLY AND ASSEMBLY CAB
REMOVAL OF CAB
a Stop the machine on level ground, install the
safety bar on the frame, and put blocks under
the wheels to prevent the machine from mov-
ing.
1. Remove covers (1) at bottom of floor frame.
2. Remove right cover (2) inside cab.
I II . I\ L CEW01056
3. Disconnect electric wiring connectors (3).

Connectors: CN-CLI, CL2, CL3
4. Disconnect window washer hose (4).
CEW01057
5. Remove 2 steering post lock bolts (5).
CEW01058
30-228 WA800-3
0
6. Remove plastic mounting bolts and pull up rub-

ber boot (6) at bottom of steering post.
7. Remove 4 bolts (7), then tip steering post over

fully towawds operator’s seat.
Sr At the same time, set the colum tilt lever to
the unlock position and tip the steering cot-
umn over fully towards the operator’s seat.
1--t-1-1-
1, <c
_’ +__+_
1
-- CDW01060
8. Remove 2 cab mounting bolts (8) and 4 mount-

ing bolts (9) each at intermediate position and
rear.
9. Raise cab assembly (IO) slowly and keep hori-

zontal when lifting off. a
Ir Be careful that there is no interference with
the electric wiring at the rear right of the
floor frame.
Ir Cover the steering post and plastic cover
with a sheet to prevent any damage.
Cab: 400 kg
CWW03669
WA800-3
INSTALLATION OF CAB
removal.
m
. When installing the cab assembly, do not
forget to install the seal.
* Coat the seal uniformly with adhesive.
6 Seal: Adhesive Kemedyne 366E)
30-230 WA800-3
0
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

a Disconnect the cable from the negative W ter-
1. Remove front, rear, right and left side covers (I 1

under the cab.
2. Remove cab (2). For details, see REMOVAL OF

CAB .
&I ks Cab :400 kg
3. Disconnect drain hose (3) of the right-hand brake

valve.
4. Disconnect hoses (4) and (5) between the accu-

mulator and right-hand brake valve.
5. Disconnect accelerator cable (6). m

* Loosen the locknut and pull out the pin to
disconnect the cable.
6. Pull window washer hose (7) out of the floor

frame, then disconnect clamp (8) and move it
toward the frame.
7. Remove clamp (9), then disconnect left-hand

brake drain tube (IO).
8. Disconnect hoses (11) and (12) between the left-

9. Disconnect hoses (13) and (14) between the ac-

cumulator and left-hand brake valve.
11. Disconnect hose (16) between the accumulator

and orbit-roll.

right-hand stopper valve.
13. Disconnect drain hose (18) of the orbit-roll.

left-hand stopper valve.
16. Disconnect hoses (21) and (22) between the right-

WA800-3
17. Disconnect hoses (23) (Raise lift arm), (24)

(Dump), (25) (Lower lift arm) and (26) (Tilt) be-
tween the PPC valve and control valve.

PPC pump.
19. Disconnect PPC valve drain hose (28).
21. Disconnect brake oil drain block (30) from the

floor frame.
22. Disconnect brake shuttle valve (31) from the floor

frame.
24. Disconnect ground cable (33).
25. Disconnect heater hose (34).

* Close the hot water outlet valve on the en-
gine side.
26. Disconnect air conditioner hose (35). m

Sr Collect the new Freon with tool Xl.
t Since the adapter is brittle, apply two span-
ners to it to disconnect each hose.

clamp (37) and move it toward the body.
* Connector: CN-CL2, CL3, A4, A5, A6, A7, A8A,
A8B

clamp (39).
* Connector: CN-FLI, FL2, CLI, LRI, LR2, LR3,
LR4, LR5, GRE
30-232 WA800-3
0
29. Remove 4 mounting nuts (40) of the floor frame

mount. 11
30. Sling and lift off floor frame (41).

+ While slinging the floor frame slowly, check
that all the clamps and harnesses are dis-
connected.
& kg Floor frame : 240 kg
CWWO2871
INSTALLATION OF FLOOR
FRAME
removal.
Adjust the length of the accelerator cable.

Adjusting length of accelerator cable.
When connecting each hose, do not twist it.

Be careful not to let dirt, dust, water, etc. get
into hoses.
Charge with new Freon gas (R134a) by us-
ing tool Xl.
m Mounting nut:
245 - 309 Nm I25.0 - 31.5 kgm}
. Bleeding air
Bleed air from the brake circuit, steering circuit
and PPC circuit. For details, see TESTING AND
ADJUSTING, Bleeding air from each portion.
WA800-3 30-233
0
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN
* Before starting the work, remove the bucket.

moving.
from the hydraulic tank, then operate the work
equipment control lever over TILT and NEUTRAL
at least 40 times to release the pressure from
the accumulator and piping.
Ir Disconnect the cable from the negative (-1
terminal of the battery.
1. Floor frame
Remove the floor frame . For details, see RE-
MOVAL OF FLOOR FRAME .
2. Steering cylinder pin

Remove lock plates (I) of the right-hand and
left-hand steering cylinder pins, then pull out
the pins (2) downward. m
Ir Remove the bushings.
3. Hydraulic piping
Disconnect the following hoses from the joints
on the rear frame side.
. Hose (3) between switch pump and steering
valve
. Hose (4) between loader pump and work
equipment valve
. Hose (5) between steering pump and steer-
ing valve
. Hose (6) between oil cooler and steering
valve
. Hose (7) between work equipment valve and
hydraulic tank
. Hose (8) between diverter valve and steer-
ing valve
4. Drive shaft
Sling and remove center drive shaft (9). m
r+ kg Center drive shaft: 186 kg
30-234 WA800-3
0
5. PPC piping, brake piping

Disconnect the following hoses from the tubes.
. Hoses (IO) (Raise lift arm), (11) (Lower lift
arm), (12) (Dump) and (13) (Tilt) between
PPC valve and control valve
. Hoses (14) and (15) between brake valve and
slack adjuster
. Hose (17) between parking brake solenoid
valve drain hose (16), parking brake sole-
noid valve and accumulator charge valve
. Hoses (18) (right side) and (19) (left side)
between stop valve and steering valve
Ir Attach a tag to each hose for identifica-
tion.
Ir Disconnect the clamps of each hose.
/r-----
6. Supporting of frame
I) Adjust the height of the rear frame with hy-
draulic jacks, and place blocks 0.
* Apply the hydraulic jacks and place the
blocks on left and right sides of the
frame.
2) Place blocks @ under the front frame by
using jacks.
3) Place blocks @ under the counterweight.

4) Move the hydraulic hoses to the right side
of the machine by using lever blocks.
7. Lower hinge pin

I) Remove the mounting bolts, then remove
retainer (39). 11
* Check the quantity and thickness of the
shims inserted between the retainer and
frame.
2) Install eyebolts to lower hinge pin (21), then

lift off pin.
&I kg Lower hinge pin: 68 kg
* Remove bolt (22) of the hinge pin, and

install the eyebolt.
8. Upper hinge pin

1) Remove mounting bolts (24) and (2% then
remove retainer (26). m
--_(
c;
.26
I 24 cww03031
2) Install eyebolt K5 to upper hinge pin (27),

and lift off.
& kg Upper hinge pin: 40 kg
CWWO3032
30-236 WA8003
0
9. Disconnecting frame
Remove safety bar, pull out front frame to front
and disconnect frames.
Be careful not to let the spacer at the upper
of the lower hinge bite into the rear frame.
Be careful to maintain the balance when car-
rying out the operation.
Move the frame about 100 mm at a time.
Remove spacer (28) from the rear frame.
IO. Lower hinge

I) Remove mounting bolt, then remove retainer
(29). m
* There are shims between the retainer and
the frame, so check the number and
thickness of the shims, and keep in a
safe place.
2) Remove dust seal (30) from retainer.
3) Remove spacer (31) from front frame.
WA8003 30-237
0
4) Remove plate (32) from front frame, then

remove dust seal (33).
I cww03039
Upper hinge
I) Remove retainer (35). m
* There are shims between the retainer and
the frame, so check the number and
thickness of the shims, and keep in a
safe place.
I cwwo3039
2) Remove dust seal (36) from retainer.
CWWO3040
30-238 WA800-3
0
3) Remove plate (37) from front frame, then

remove dust seal (38).
I CWWO3042 1
WA%OO-3 30-239
0
INSTALLATION OF CENTER
HINGE PIN
removal.
* Adjust clearance d to the specification val-

ues with shims.
Clearance d: 3.0 max.
a When aligning the position of the pin hole,
use a bar. Never put your fingers on the pin
hole. DEW04652
w Drive shaft mounting bolt:

343 - 427 Nm I35.0 - 43.5 kgm}
& Outer circumference of lower hinge pin:

Lubricant iG%LI)
Install the retainer to the lower hinge pin
without using shims, then tighten it to the
specified torque.
Jack up the front frame until the spacer
reaches the rear frame hinge.
Tap the lower hinge pin head with a copper
hammer so that the mounting bolt will be
tightened to the specified torque, then
tighten the bolt to the specified torque.
Before installing the retainer, measure its
thickness to select shims.
w Mounting bolt:
927 2 103 Nm I94.5 = 10.5 kgm}
Remove the all outside mounting bolts and
measure clearance c between the retainer
and frame at three holes, then calculate the
average.
Select shims so that the average clearance
will be 0.08 - 0.18mm.
The thickness of the shims must not exceed
the clearance measured at the three places.
Remove the grease from the mounting bolts
and mounting holes completely.
w Mounting bolt:
927 = 103 Nm I94.5 z 10.5 kgm}
30-240 WA800-3
0
Insert the upper hinge pin and tap its head

with a copper hammer lightly three times to
fit it.
Do not apply grease to the fitting faces of
the spacer, frame and spacer pin.
a Outside of hinge pin:
Lubricant (G2-LI)
Tap the upper hinge pin head with a copper
hammer so that the mounting bolt will be
tightened to the specified torque, then
tighten the bolt to the specified torque.
If the mounting bolt cannot be tightened to
the specified torque, grease may be sticking
to the spacer. In this case, clean the spacer,
then tighten again.
6 Adhesive: (LT-2)
w Mounting bolt:
549 2 59 Nm 456 + 6 kgm}
m
Ir Press fit the bearing and spacer to the front
frame with tool K3.
Ir Be careful that the bearing is not at an an-
gle.
* Fill inside of the bearing with grease suffi-
ciently.
* When installing the bearing, be sure to re-
member to install the spacer.
* The clearance of the bearing is adjusted, so
do not change the combination of bearing
and the spacer. When replacing, replace as
a set.
* Press fit so that the lip of the dust seal is
facing outside.
6 Dust seal lip face: Lubricant (G2-LI)
cwwo3044
WA800-3
* Tighten the 10 mounting bolts of the retainer,

and measure clearance b between the re-
tainer and hinge at 4 places. Then, select
shims so that clearance b will be 0.08 -
0.18mm less than the measured value.
Ir The thickness of the shims must not exceed
the clearance measured at the four places.
+ After selecting shims, tighten the retainer to
b
w Mounting bolt (For adjusting shims):
245 + 25 Nm t25.0 + 2.5 kgm}
w Mounting bolt: DEW04645
927 2 103 Nm (94.5 + 10.5 kgm1

facing outside.
& Dust seal lip face: Lubricant (G2-LI)
* Install the spacer with the more chamfered
side on the bearing side.
4 Inside of spacer: Lubricant (G2-LI)
m
sr Install tool Kl to the top of the front frame
upper hinge, then set the bearing. Press fit
the bearing to the press fit part from above.
* Be careful that the bearing is at an angle.
* Fill inside of the bearing with grease suffi-
ciently.
* When installing the bearing, be sure to re-
member to install the spacer.
* The clearance of bearing h is adjusted, so
do not change the combination of it and the
spacer. When replacing, replace as a set.
facing outside.
6 Dust seal lip face: Lubricant (G2-LII To
DWWO5240
30-242 WA800-3
0
Tighten the six mounting bolts of the re-

tainer, and measure clearance a between the
retainer and hinge at four places. Then, se-
lect shims so that clearance b will be 0.08 -
a
0.18mm less than the measured value.
The thickness of the shims must not exceed
the clearance measured at the four places.
After selecting shims, tighten the retainer to
m Mounting bolt (For adjusting shims):
78.5 + 7.9 Nm 18.0 + 0.8 kgml
m Mounting bolt: DEW04640
549 2 59 Nm (56 r 6 kgml

Press fit so that the lip of he dust seal is
facing outside.
6 Dust seal lip face: Lubricant (G2-LI)

Add oil through the oil filler of the hydraulic
%# Hydraulic oil: Approx. 550 !?I
Before starting the engine, bleed air from

the piston pump circuit. For details, see
TESTING AND ADJUSTING.
After bleeding air, run the engine to circu-
late the hydraulic oil through the system.
Then, check the oil level again.
. Bleeding air
Bleed air from the brake system.
+ For the air bleeding procedure, see TEST-
ING AND ADJUSTING.
. Charging with gas

Charge the air conditioner with gas (R134a).
Standard quantity of gas to be supplied:
1.5 - 1.6kg
Before charging with the gas, be sure to
evacuate the system by the repeated evacu-
ation method.
Be sure that Freon liquid stay out of the
refrigerating system, and prevent mistakes
such as placing the Freon can upside down.
Do not start the compressor before charging
the system with the gas.
Check that proper quantity of the gas is sup-
plied.
Check the quantity of the compressor oil.
(Standard quantity of oil: 150’:’ CC ND-OIL81
WA800-3 30-243
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT

moving.

from the hydraulic tank, then operate the steer-
ing wheel and work equipment control lever 2 -
3 times to release the pressure from the piping.
1. Bucket link
I) Move cord ring (I) toward the bucket.
2) Temporarily sling bucket link (4) and remove
lock bolt (3). Then, slowly pull mounting pin
(2) out of the bucket link, and disconnect
bucket link. II
el kg Mounting pin: 87 kg
* Check the quantity of shims (5) between

the bucket link and bucket, and use it as
the standard value for assembly.
2. Bucket
1) Move cord ring (6) toward the bucket.
2) Remove lock bolts (7) of the pins on left and
right sides, then slowly pull out mounting
pins (8). a
&I kg Mounting pin: 72 kg
* Check the quantity of shims (9) between

the bucket and lift arm, and use it as the
standard value for assembly.
4) Move the machine in reverse to disconnect
the bucket.
30-244 WA800-3
0
3. Bucket link
Temporarily sling bucket link (4) and slowly pull
out the mounting pin, then lift out the bucket
link from the bell crank.
Sr Remove the cord ring from the joint in ad-
vance.
* Insert mounting pin (IO) in the pinhole of
the bell crank and tighten the lock bolt lightly.
kg
LF?l Bucket link: 449 kg
4. Dump cylinder
1) Put block @ between the bell crank and lift
arm to lock the bell crank.
Sr When the dump cylinder pin is removed,
the bell crank falls down toward the ma-
chine. Accordingly, be sure to lock the
bell crank.
W04659
2) Temporarily sling dump cylinder (II) and

slowly pull out mounting pin (121, then dis-
connect the cylinder rod and bell crank.
Ir Disconnect grease hose (13) from the pin.
t Do not pull out the pin completely. After
disconnecting the dump cylinder, insert
the pin in the bell crank mounting por-
tion, then install the lock bolt.
3) Raise the dump cylinder and lock it with the

lever block.
Ir Be sure to lock the cylinder for safety.
DEW04661
WA8003
5. Lift cylinder pin

1) Raise the lift arm until pin (14) exceeds the
height of the fender, then temporarily sling
the lift arm and bell crank.
2) Disconnect grease tube (15) from the mount-
ing pin.
& kg Lift arm and bell crank:

Approx. 9,560 kg
3) Support lift cylinder (16) on the lever block

at the rear and remove the lock bolt, then
slowly pull the pin out of the cylinder.
Sr After removing the lift cylinder, insert
both mounting pins (17) in the lift arm
pinholes and tighten the lock bolts lightly.
6. Lift arm and bell crank

1) Remove boom kick-out switch (18).
Ir Remove the cover, then remove the
switch.
2) Remove stays for the lights on left and right

sides.
* Disconnect connectors (19) (CN-FOI, 02,
03, 04) on left and right sides in advance.
3) Disconnect both grease tubes (20) from
mounting pins, then remove grease nipple
(21).
30-246
0
4) Slowly pull out left and right mounting pins

(22), then sling and remove lift arm and bell
crank (23).
* If shims are installed between the front
frame and lift arm, check its quantity.
* Sling right and left mounting pins and
lift them off.
Mounting pin: 159 kg
7. Bell crank
Slowly pull out the mounting pin, then sling the
bell crank (24) from lift arm and lift it off.
* Do not pull out mounting pin (25) completely.
After removing the bell crank, sling and lift
off the mounting pin.
&l kg Bell crank: 1,792 kg
Mounting pin: 179 kg
8. Dust seal and bushing

1) Pull dust seal (27) and bushing (28) out of
lift arm (26).
Sr Remove dust seal (29) and bushing (30)
from the joint of the lift arm and frame.
CWWO3060
2) Pull dust seal (31) and bushing (32) out of

bell crank (24).
I CWWO3061
WA8003 30-247
0
3) Remove dust seal (33) and bushing (34) from

bucket link (4).
* Remove dust seal (35) and bushing (36)
from the joint of the bell crank and ring.
* If the pin cannot be pulled out easily Sol t Sleeve Plate

because of its wear after long use, make
and use tool VI.
Puller
DWW@~'lAI
30-248 WA8003
0
INSTALLATION OF WORK
EQUIPMENT
removal.
g When aligning the position of the pin hole, use

a bar. Never put your fingers on the pin hole.
Ir When installing the pins and bushings, ap-
ply grease to them.
& Pin, bushing: Lubricant (G2-LI)
m
* Assemble shims evenly in a and b.
Ir Reduce the clearance to below 1.5 mm.
a
* Assemble shims evenly in a and b.
* Reduce the clearance to 1.5 mm or less.
. Supplying grease
Supply grease to each mounting portion.
WA800-3 30-249
0
DISASSEMBLY AND ASSEMBLY BOOM FRONT END BUSH
REPLACEMENT OF BOOM
FRONT END BUSH
1. Pulling out bushing

1) Clean the lift arm end.
2) Remove dust seal (I).
3) Set tool V2.
4) Pull out bushing (2) by operating the puller.
5) After bushing (2) comes out by the stroke,
tighten the puller piston and add the spacer,
then tighten the nut.
* Stroke of puller: 15 mm
2. Press fitting of bushing

1) Set tool V2. I 2. \
Sleeve
2) Press fit bushing (2) by operating the puller.

+ Check that bushing (2) is press fitted
evenly while operating the puller.
3) After bushing (2) is press fitted by the stroke,
tighten the puller piston and add the spacer,
then tighten the nut.
4) Install dust seal (I).
I DWW05242
Sleeve Plate
Sc;ew
DWW05243
30-250 WA800-3
0
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER
1. Disconnect grease hose (I).
2. Remove lock bolt (2), then remove pin (3).

* Temporarily sling the cylinder.
j, Start the engine and retract the piston.
A After retracting the piston, stop the engine
and release the pressure from the piping.
3. Disconnect bucket positioner piping connector

(4) (FO5).
4. Disconnect hose (5) on the head side.
5. Disconnect hose (6) on the bottom side.
6. Remove clamp (8), then disconnect and remove

grease tube (7).
7. Remove lock bolt (9), then remove pin (IO).
8. Sling bucket control cylinder (11) and lift it off.

Ir Check the quantity of the shims.
r+ kg Bucket control cylinder : 1,110 kg
INSTALLATION OF BUCKET
CYLINDER
a ‘7’ 9 6 CWWO2834
removal.
A When aligning the position of the pin hole, use

a bar. Never insert your fingers in the pin hole.
. Adjustment of shim
Adjust the clearance on each side of the bottom
to 1.5 mm or less.
WA800-3
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
REMOVAL OF LIFT CYLINDER

the safety bar to the frame, then put blocks un-
der the wheels to prevent the machine from
moving.
1. Remove the bucket. For details, see REMOVAL

OF BUCKET.
2. Remove fender (I).
&I kg Fender : 200 kg
3. Raise the lift arm until the pin on the cylinder

head side can be pulled out, then sent stand 0.
g After stopping the engine, lower the lift arm
slowly to eliminate the load on the lift cylin-
der.
Loosen the cap of the hydraulic tank slowly
to release the pressure from the hydraulic
tank.
4. Temporarily sling lift cylinder (3).

* Be careful not to damage the tubes.
5. Remove lock bolt (4), then pull out pin (5).
30-252 WAND3
0
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
6. Retract piston rod (6).
7. Disconnect hose (7) on the bottom side and hose

(8) on the head side.
8. Remove lock bolt (91, then pull out pin (IO).
9. Sling lift cylinder (3) and lift it off. a

* Check the quantity of the shims.
&I kg Lift cylinder : Approx. 1,000 kg

3
0
WO2841
INSTALLATION OF LIFT
CYLINDER
removal.
Match the holes on the bottom side by as-

sembling shims so that the clearance be-
tween the cylinder and frame will be in the
specified range.
Clearance a + b = 1.0 mm max.
a When aligning the position of the pin hole,
use a bar. Never put your fingers in the pin
hole.
CWWO2843
WA800-3
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC CYLINDER

1. Cylinder assembly
I) Set cylinder assembly (I) on Tool Ul.
2) Remove mounting bolts (2) of head cover.
3) Pull out piston rod (3) from cylinder.

When pulling out the rod, the oil remain-
ing inside the cylinder will come out, so
catch it in a container.
If the piston rod cannot be pulled
smoothly out of the cylinder, rotate the
piston rod slightly when pulling out.
l&l kg Steering cylinder piston rod assembly:

88 kg
kg
cE?l Dump cylinder piston rod assembly: DEW04599
520 kg
Lift cylinder piston rod assembly: 1

450 kg
* Remove the cylinder from tool Ul.
2. Piston rod
1) Remove spacer mounting bolts (41, then re-
move spacer (5).
2) Pull out piston (6) and head cover (19).
3) Remove O-ring (8) and backup rings (7) and
(9) from piston rod (3).
3 DEW04600
30-254 WA800-3
0
e
3. Piston
1) Remove wear ring (10) from piston (6). II a
2) Remove piston ring (II).
IO DEW04601
4. Head cover
1) Remove O-ring (12) and backup ring (13).
2) Remove snap ring (14), then pull out dust
seal (15), rod packing (16), backup ring (171,
and bushing (18) from head cover (19).
I4 I5 I6 I7
DEW04602
WA800-3 30-255
0
ASSEMBLY OF HYDRAULIC CYLINDER

-k Coat the sliding surfaces of all parts with hy-
draulic oil before installing. Be careful not to
damage U-packings, dust seals or O-rings when
installing.
1. Head cover
I) Press fit bushing (18) in head cover (19), and
install backup ring (17), rod packing (161,
dust seal (151, and snap ring (14).
* Be careful not to deform the bushing
when press fitting.
Ii I5 -16 ‘I7
2) Install backup ring (13) and O-ring (12) to DEW04602
head cover (19).
* Do not try to force the backup ring into
position. Warm it in warm water (50 to
SOT) before fitting it.
2. Piston U2
\
I) Set piston ring (11) on tool U2 and expand
it.
+ Set the piston ring on the expander and
turn the handle 8-10 times to expand
the ring.
2) Remove piston ring (I I) from tool, and in-

stall on piston (6).
3) Using tool U3, tighten piston ring (II).
;I!
4) Install wear rings (IO) to piston (6).
II 6
io DEW04601
30-256 WA800-3
0
3. Piston rod
1) Install head cover (19) to cylinder rod (3).
2) Install O-ring (8) and backup rings (7) and
(9) to rod.
Sr Coat the backup ring with grease to pre-
vent it from protruding, and assemble it
carefully.
& Backup ring, O-ring:
Grease (G2-LI)
3)
4)
Install piston (6).
Set spacer (5) in position, and tighten spacer
mounting bolts (4).
/J-T-T!
3 7, 8, 9 DEW04 600
* Remove all oil and grease from the

mounting bolts and mounting holes.
& Mounting bolt:
Adhesive (Locktite 262)
w Mounting bolt:
110 f 12 Nm (11.25 t 1.25 kgm}
(Steering cylinder)
w Mounting bolt:
277 f 32 Nm I28.25 + 3.25 kgm}
(Lift, dump cylinder)
I DEW04599
4. Cylinder assembly
I) Set cylinder in tool Ul.
2) Assemble piston rod (3) in cylinder.
3) Tighten head cover mounting bolts (2).
* Coat the O-ring and backup ring on the
cover side with grease.
Q%KI Steering cylinder mounting bolt:
461 2 14 Nm I47.0 + 14.5 kgm}
m Dump cylinder mounting bolt:
2,450 f 250 Nm I250 z 25 kgm}
w Lift cylinder mounting bolt:
1,550 = 170 Nm I157.5 2 17.5 kgm}
4) Remove cylinder assembly (I) from tool Ul.
ui
cwwo3133
WA800-3
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT

1. Remove the cab. For details, see REMOVAL OF

CAB .
2. Connect refrigerant collector Xl to adapter (I)

of the air conditioner compressor hose, then
collect the new Freon gas (R134a).
3. Remove operator’s seat (2).
&I kg Operator’s seat : 40 kg
4. Remove cover (3).
5. Remove air conditioner unit cover (31, console

box cover (4) and box (5).
6. Remove fuse box (6) from the air conditioner

unit, then move it toward the right-hand con-
sole box.
7. Disconnect connectors (7) (LC3) and (8) (LC2).
8. Disconnect two refrigerant tubes (9).
30-258
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
9. Disconnect two heater hoses (IO).

* Be careful, since the tube on the unit side is
soft.
10. Remove mounting bolt (ll), then remove air

conditioner unit (12).
* Remove the air conditioner unit by pulling it
out to the left.
INSTALLATION OF AIR
CONDITIONER UNIT
removal.
. Charging with gas

Charge the air conditioner circuit with new Freon
gas (R134a) by using refrigerant charger Xl.
WA800-3 30-259
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
a Disconnect the cable from the negative (-) ter-

1. Collect the new Freon gas (Rl34a) with tool Xl.
2. Disconnect connector (1) (CN-E08).
3. Disconnect two hoses (2).
4. Loosen locknut (3) and drive belt adjustment w CWWO2874

nut (4).
5. Loosen mounting bolt (5).
6. Loosen adjustment nut (41, then remove drive

belt (6) from the pulley.
7. Remove bolt (7), then disconnect block (8) from

the air conditioner compressor.
8. Remove four mounting bolts (91, then remove

air conditioner compressor (IO).
INSTALLATION OF AIR
removal.
l Charging with gas

Charge the air conditioner with new Freon gas
(R134a) by tool Xl.
30-260 WA8003
0
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
REMOVAL OF RECEIVER TANK

a Disconnect the cable from the negative (-1 ter-
g Collect the new Freon gas (R134a). For details,
see REMOVAL OF AIR CONDITIONER COMPRES-
SOR .
1. Open snap (I).
2. Disconnect hose (2) of the air conditioner con-
II r----l
denser.
3. Disconnect hose (3) of the air conditioner unit. CWWO2877
4. Remove two U-bolts (41, then remove receiver

tank (5).
INSTALLATION OF RECEIVER
TANK
removal.
m
+ Before connecting each hose, check that the
O-ring is free from damage and deteriora-
tion.
. Charging with gas

* Charge the air conditioner circuit with air
conditioner gas (R134a) by using refrigerant
charger Xl.
WA800-3 30-261
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
a Stop the machine on level ground and put blocks

moving.
A Disconnect the cable from the negative (-) ter-
1. Collect the new Freon gas (R134a). For details,

see REMOVAL OF AIR CONDITIONER COMPRES-
SOR .
2. Right-hand condenser
1) Disconnect connectors (I ).
* Connectors: CN-BIO, CN-Bll
2) Disconnect hose (2) between both condens-
ers. @YJ
3) Disconnect hose (3) of the air conditioner
compressor.
Sr Since the adapter is brittle, apply two
spanners to it to disconnect each hose.
4) Remove the mounting bolts, then remove
right-hand condenser (4).
3. Left-hand condenser
I) Disconnect connectors (5).
Ir Connectors: CN-B12, CN-B13
2) Disconnect hose (6) between the right-hand
condenser and receiver tank. a
3) Disconnect hose (7) between both condens-
ers.
Sr Since the adapter is brittle, apply two
spanners to it to disconnect each hose.
4) Remove the mounting bolts (8), then remove
left-hand condenser (9).
INSTALLATION OF AIR

removal.
* When connecting each hose, do not twist it.

* Be careful not to let dirt, dust, water, etc. in
each hose.
* Charge the air conditioner circuit with new
Freon gas (R134a) by using tool Xl.
30-262 WA800-3
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION AND STEERING CONTROLLER
REMOVAL OF TRANSMISSION
AND STEERING CONTROLLER
a Disconnect the cable from the negative (-) ter-

1. Open the right-hand door of the cab, then re-

move the cover out of the control stand case.
2. Disconnect connectors (I), (2), (3), (4), (5) and

(6).
(1) = Cl, (2) = C3B, (3) = C3A, (4) = C4, (5) = C2,
(6) = C5
3. Remove mounting bolts (7), then remove trans-

mission and steering controller (8).
INSTALLATION OF
TRANSMISSION AND
STEERING CONTROLLER
removal.
WA800-3 30263
0
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
REMOVAL OF MAIN MONITOR

moving.

1. Removal of surrounding steeling column

I) Remove dashboards (I) and (2).
2) Remove steering post covers (3) and (4).
3) Remove steering post cover (5).

4) Remove steering post cover (6) and mount-
ing bolt cap (7), then remove the bolt.
5) Remove steering post cover (8) and mount-

ing bolt cap, then remove mounting bolt (9).
+ Turn down the steering post cover for-
ward.
2. Remove bracket (IO) on the back side of the

main monitor.
30-264 WA800-3
0
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
3. Remove main monitor (11) and eight mounting

bolts (12).
Ir When removing the main monitor, be care-
ful not to give a large shock to it.
4. Disconnect connectors (131, (14), (15) and (16)

from the main monitor (1 I), then remove the
main monitor. a
(13) = CN-LO5
(14) = CN-LO7
(15) = CN-LO6
(16) = CN-LO8
DEW01309
INSTALLATION OF MAIN 15 14 13
MONITOR
removal.
a
* Apply the locks of the connectors securely.
WA800-3 30-265
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

1. Drain the fuel.
- : Fuel: Approx. 1,300 k?
2. Remove step (I) and covers (2) and (3).
3. Disconnect engine oil drain valve (4), torque con-

verter cooling water drain valve (5) and cooling
water drain valve (6) from the fuel tank.
4. Remove side cover 17).
5. Remove handrail (8).
6. Remove fuel cut valve cover (9).
7. Remove step (IO).
8. Disconnect fuel hoses (11) and (12).

* Disconnect the hoses on the engine side.
9. Disconnect fuel gauge connector (13) (CN-R05).

* This connector is just above the drain valve.
13
l-
\*
Q
6 cww03070
30-266
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
10. Remove cover (14) installed between the fuel

tank and counterweight.
11. Temporarily sling fuel tank (15), then remove

mounting bolts (16). a
& kg Fuel tank : 786 kg
I I
12. Set block @ under the fuel tank.
13. Slowly lower fuel tank (15).

* Pull the fuel tank out of under the machine
body.
INSTALLATION OF FUEL TANK

removal.
w Fuel tank mounting bolt:

1,520 - 1,910 Nm II55 - 195 kgm}
. Bleeding air
Bleed air from the fuel line. For details, see TEST-
portion.
WA800-3 30-267
0
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
g Stop the machine on level ground, install the
safety bar on the frame, and put blocks under
the wheels to prevent the machine from mov-
ing.
1. Sling counterweight (I), then remove mounting

bolts, and lift off.
* When lifting off the couterweight, be careful
to maintain the balance.
L+lkg Counterweight: 2,500 kg

2876
INSTALLATION OF
COUNTERWEIGHT
removal.
m Counterweight mounting bolt:

1,510 - 1,910 Nm I155 - 195 kgm1
30-268 WA800-3
0
40 MAINTENANCE STANDARD
Engine mount ............................................... 40- 2

Transmission mount ................................... 40- 3
Damper ......................................................... 40- 4
Torque converter charging, PPC and
brake pump ........................................... 40- 6
Torque converter ......................................... 40- 8
Torque converter regulator valve ............. 40- 9
Transmission ............................................... 40-10
Transfer ........................................................ 40-13
Transmission control valve ....................... 40-14
Drive shaft .................................................... 40-19
Center support ............................................ 40-20
Differential.................................................... 40-21
Final drive .................................................... 40-24
Axle mount .................................................. 40-26
Center hinge pin ......................................... 40-28
Steering column ......................................... 40-30
Steering demand valve ............................... 40-32
Diverter valve ............................................. 40-34
Steering cylinder mount ............................ 40-35
Emergency steering pump ........................ 40-36
Brake valve .................................................. 40-38
Slack adjuster ............................................. 40-40
Brake ............................................................. 40-42
Parking brake ............................................... 40-44
PPC valve ..................................................... 40-46
PPC relief valve ............................................ 40-48
Control pump ............................................. 40-49
Steering pump ......................................... 40-49-1
Switch pump ........................................... 40-49-2
Main piston pump ................................... 40-49-3
Main control valve ....................................... 40-50
Hydraulic cylinder ........................................ 40-52
Bucket linkage .............................................. 40-54
Bucket positioner and boom kick-out ........ 40-56
WA800-3 40-1
40-1
(6)
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
40-2 WA800-3
MAINTENANCE STANDARD TRANSMISSION MOUNT
TRANSMISSION MOUNT
A-A
m 927*103Nm
(94.5i10.5koml
----L-/ SEW01595
Unit: mm
-
No. Check item Criteria
T Remedy
Clearance
Clearance between trunnion and limit
1 torque converter case
230 -0.100 +0.072 0.100 -

Replace
-0.172 0 0.242
Clearance between O.D. of shaft 0 +0.035

2 0 - 0.065
and I.D. of rubber cushion 63 -0.030 0
Clearance between O.D. of rubber +0.115 +0.054 -0.115 -

3 97
cushion and I.D. of bracket hole +0.080 0 -0.026
4 Thickness of mount shim

Standard shim thickness: 1.5 mm (parallelism
of transmission
of coupling mating joint
output shaft and sensor of sensor pin: Max. 0.5 mm)
I
WA800-3 40-3
MAINTENANCE STANDARD DAMPER
DAMPER
40-4 WA800-3
MAINTENANCE STANDARD DAMPER
Unit: mm
No. Check item Criteria

T Remedy
-
~ Clearance
Clearance between bearing and limit
1 shaft
95 +0.015 0 -0.035 -
0.025
+0.003 -0.020 -0.003
Clearance between bearing and 170 0 -0.008 -0.033 -

2 housing 0.030
-0.025 -0.033 0.017
Clearance between inner body 94.3 +0.035 +0.099 0.029 -

3 0.1 Replace
and shaft +0.013 +0.064 0.086
I I
Standard size Tolerance Repair limit
4 Wear of surface in shaft and oil seal
0
115 -0.140
-0.087
Wear of surface in sleeve and oil 0

5 140 -0.160
seal -0.100
6 Backlash of spline 0.068 - 0.263
WA800-3 40-5
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
m 1128*9.8Nm
I
(1 1.5-t Okami
/ ’ I I \ I- \ \ \
Torque cunverter charging PUMP Torque cunverter charolna DUIW PPC PUrnP / Brake PUIIP
I-
SAR(4)-112 SARb-100 SARCI) -32 SAR (1)-14 SWWO3858
40-6 WA800-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
Unit: mm
No. Check item Criteria Remedy
Model Standard clearance Clearance limit
SAR4 – 112 0.11 – 0.16 0.19
Clearance between gear case and

1 side plate, gear SAR3 – 100 0.13 – 0.18 0.22
SAR1 – 32 0.10 – 0.15 0.19
SAR1 – 14 0.10 – 0.15 0.19
SAR4 – 112 0.06 – 0.140 0.20
Clearance between inside diameter SAR3 – 100 0.06 – 0.149 0.20

2 of plain bearing and outside Replace
diameter of gear shaft
SAR1 – 32 0.06 – 0.119 0.20
SAR1 – 14 0.06 – 0.149 0.20
SAR4 – 112 21 –0
–0.5
14 –0
SAR3 – 100 –0.5
3 Insertion depth of pin
SAR1 – 32 10 –0
–0.5
SAR1 – 14 10 –0
–0.5
4 Rotating torque of spline shaft 20.6 – 36.3 Nm {2.1 – 3.7 kgm} –

Standard Repair limit
Model Revolution Discharge discharge discharge
(rpm) pressure (¬/min) (¬/min)
2.9 MPa
SAR4 – 112 2200 {30 kg/cm2} 242 222
Discharge 2.9 MPa
– Oil: EO10-CD SAR3 – 100 2200 {30 kg/cm2} 210 183 –
Temperature: 45 – 55°C
2.9 MPa
SAR1 – 32 2200 {30 kg/cm2} 68 57
9.8 MPa
SAR1 – 14 2200 {100 kg/cm2} 29 24
WA800-3 40-7
40-7
(6)
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
1 279.5*29.4Nm
\ \ /
SEW01598
Unit: mm

Inside diameter of seal ring surface Repair
1
of retainer 170 +0.040 170.5 chrome
0 plating or
replace
inside diameter of seal ring surface +0.035
2 85 85.1
of sleeve 0
0
Width 4.45 4.05
-0.1
Width and thickness
3
of seal ring
Thickness 6.0 20.1 5.5 Replace
4 Backlash of PTO gear (Drive gear) 0.20 - 0.52
WA800-3
MAINTENANCE STANDARD TORQUE CONVERTER REGULATOR VALVE
TORQUE CONVERTER REGULATOR VALVE
A-A
SEW01599
Unit: mm
Criteria Remedy
I
No. Check item
-
Tolerance
Standard Standard Clearance
size clearance limit
Clearance between poppet and
1 Shaft Hole
spool
22 -0.020 +0.021 0.020 -

0.08
-0.030 0 0.051
40 -0.035 +0.016 0.035 -

2 Clearance between spool and body 0.08
-0.045 0 0.061
Replace
Standard size Repair limit
Free Installation Installation Free Installation

3 Poppet spring length length load length load
22.4 N 20.6 N
43.9 21 42
12.28 kg} 12.1 kg1
107.9 N 98.1 N
4 Spool spring 172 92 {I1 kg1 167 {lo.0 kg}
-
WA800-3 40-9
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION (1/2)
5 16 6 15 17 7 8 9 13
12 1 2 10 11 14 3 4
kgm 66.7±6.9Nm kgm 6.7±6.9Nm kgm 66.7±6.9Nm kgm 66.7±6.9Nm
{6.8±0.7kgm} {6.8±0.7kgm} {6.8±0.7kgm} {6.8±0.7kgm}
kgm 110.3±12.3Nm SEW01600
{11.25±1.25kgm}
40-10 WA800-3
(8)
Unit: mm
No. Remedy
Standard size
3 clutch springs (12 pieces)
4
-
5 5 plates for R clutch

61.4 59.5
I I
Thickness of assembled 6 discs and

6 61.4 59.0
5 plates for F clutch
Thickness of assembled 4 discs and _

7 3 plates for 2nd clutch 39.0 37.4

8 50.8 48.8
4 plate for 1st clutch

9 61.4 59.0
5 plates for 3rd clutch
Thickness of 1 disc 5.4 20.1 5.0

IO
-
Thickness of 1 plate 5.8 kO.1 5.3 Replace
11
Wear of seal ring for

1;
input shaft

14
2nd carrier
Wear of seal ring for F

carrier
Wear of seal ring for R

carrier
-0.01
Width 3.0 2.6
-0.03
idler shaft
Thickness 4.0 kO.12 3.85
WA800-3 40-11
TRANSMISSION (2/2)
1 2 3 4 5 6 7 8 9 10
SEW01601
Unit: mm
Backlash between reverse sun

1 gear and planetary gear 0.15 – 0.40
Backlash between reverse plan-

2 etary gear and ring gear 0.15 – 0.39
Backlash between forward sun

3 gear and planetary gear 0.15 – 0.40
Backlash between forward

4 planetary gear and ring gear 0.15 – 0.40
Backlash between sun gear and

5 planetary gear 0.15 – 0.40
Replace
Backlash between planetary gear
6 and ring gear 0.15 – 0.40
Backlash between 2nd sun gear

7 and planetary gear 0.15 – 0.40
Backlash between 2nd planetary

8 gear and ring gear 0.15 – 0.39
Backlash between 1st sun gear

9 and planetary gear 0.15 – 0.40
Backlash between 1st planetary

10 gear and ring gear 0.15 – 0.39
40-12 WA800-3
(8)
MAINTENANCE STANDARD TRANSFER
TRANSFER
Serial No.: 50001 – (T/M No. 101138)
Unit: mm

Oil seal sliding surface of output
1 shaft coupling (R) –0
170 –0.10 169.8
Oil seal sliding surface of output 0

2 shaft coupling (F) 170 –0.10 169.8
Standard clearance Clearance limit Replace

Clearance between output cover
3 and case –0.05 – 0.05
1 After installed shim
Backlash between input gear and
4 idler gear 0.23 – 0.59
Backlash between output gear and

5 idler gear 0.23 – 0.59
Backlash between 2nd shaft gear

6 and 3rd shaft gear 0.23 – 0.59
WA800-3 40-13
(8)
MAINTENANCE STANDARD TRANSFER
Unit: mm

Oil seal sliding surface of output
1 shaft coupling (R) –0
170 –0.10 169.8
Oil seal sliding surface of output 0

2 shaft coupling (F) 170 –0.10 169.8
Standard clearance Clearance limit Replace

Clearance between output cover
3 and case –0.05 – 0.05
1 After installed shim
Backlash between input gear and
4 idler gear 0.23 – 0.59
Backlash between output gear and

5 idler gear 0.23 – 0.59
Backlash between 2nd shaft gear

6 and 3rd shaft gear 0.23 – 0.59
40-13-1 WA800-3
(8)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

1) UPPER VALVE
14
12
I1
I5
4
3
SWWO3652
40-14 WA800-3
Unit: mm
Clearance between pilot reducing

1 valve spool and body
Clearance between valve -0.035 +0.013 0.035 -

2 priority 28 0.08
and body -0.045 0 0.058
Clearance between return -0.035 +0.013 0.035 -

3 quick
valve spool and body 19 -0.045 0 0.058 0.08
Clearance between -0.035 +0.016 0.035 -

4 modulating
valve spool and body 35 -0.045 0 0.061 0.08
Clearance between valve -0.035 +0.013 0.035 -

5 spool and body reducing 28 -0.045 0 0.058 0.08
en lubrication valve
Replace
Large 1 (One shim will charge the pressure by 37.3 kPa (0.38 kg/cm21
15 Thickness of shim for
modulating valve
Small 1 (One shim will charge the pressure by 41.2 kPa IO.42 kg/cm?
Adjust
16 Thickness of shim for priority valve 3 (One shim will charge the pressure by 136.3 kPa Il.39 kg/cm?
I I
,7 Adjustment of shim for reducing

One shim will charge the pressure by 28.4 kPa to.29 kg/cm?
valve
,8 Adjustment of shim for lubrication

One shim will charge the pressure by 3.9 kPa IO.04 kg/cm*)
valve I
WA800-3 40-15
2) LOWER VALVE
40-l 6 WA80Q-3
Unit: mm
I I
Clearance between forward spool

and body
22 -0.035 +0.013 0.035 -

-0.045 0 0.058 0.08
Clearance between first speed spool -

2 22 -0.035 +0.013 0.035 0.08
and body -0.045 0 0.058
Clearance between second speed -0.035 +0.013 0.035 -

3 22 0.058 0.08
spool and body -0.045 0
Clearance between third speed -0.035 +0.013 0.035 -

4 22 0.058 0.08
Clearance between reverse spool -0.035 +0.013 0.035 -

5 22 0.058 0.08
and body -0.045 0
Replace
Clearance between main relief valve -0.035 +0.016 0.035 -
6 45 0.061 0.08
Clearance between torque converter -0.035 +0.016 0.035 -

7 relief valve spool and body 45 -0.045 0 0.061 0.08
Springs for FORWARD, REVERSE, Free 1 Installation Installation Free Installation

8 first, second, and third speeds length length load length load
78 45 113.8 N 75 107.9 N
Ill.6 kg) 111 kg)
206.5 143 517.8 N 200 492.3 N

9 Torque converter relief valve spring 152.8 kg} 150.2 kg)
185 138 681.6 N 179 647.2 N

10 Main relief valve spring (inner) 169.5 kg) 166.0 kg}
160 97 926.7 N 155 880.6 N

11 Main relief valve spring (outer) 189.8 kg}
194.5 kg}
Standard shim thickness: 6.0

12 Thickness of main relief valve shim (One shim will charge the pressure 11.8 kPa CO.12 kg/cmz})
Adjust
Standard shim thickness: 1.0
13 Thickness of T/C relief shim (One shim will charge the pressure 6.9 kPa CO.07 kglcm21)
WA800-3 40-17
SOLENOID VALVE
I
II I I
40-18 WA800-3
DRIVE SHAFI-
MAINTENANCE STANDARD
DRIVE SHAFT
WA800-3
40-l 9
MAINTENANCE STANDARD CENTER SUPPORT
CENTER SUPPORT
A-A
2746+294Nm
1280*30bml SEW01607
Unit: mm
I
Clearance
limit
Clearance between case and
bearing
0.011
Replace
Clearance between case and
2 0.011
bearing
Clearance between coupling shaft

3 -0.024
and bearing
Clearance between coupling shaft

4
and bearing

Wear of oil seal surface Repair
0 chrome
160 -0.100 -0.20
plating or
I
replace
0
Wear of oil seal surface
-0.100
End play of coupling shaft End play 0.05 - 0.15 Replace
40-20 WA800-3
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (l/Z)
927*103Nm
2746*294Nm 1st step :3.9!1.ONm (0.4iO.lkml

1280*30bml (When measuring cIearance(no shim))
2nd step '279.5*29.4Nmi28.5*3.0kml
(shim Installed)
SWWO3859
Unit: mm

1 Thickness of side 9ear washer
9.0 8.5
Replace
2 Thickness of pinion 9ear washer
sleeve 10.75 10.25
3 Wear of oil seal surface 0

150
-0.100
WA800-3 40-2 1
DIFFERENTIAL (2/2)
40-22 WA8003
Unit: mm

-
Clearance of bearing outer race in

1 differential gear assembly
280 0 +0.036 -0.016 -

-0.035 -0.016 0.071
Clearance of bearing inner race in +0.074 0 -0.049 -

2
differential gear assembly 180 +0.049 -0.025 -0.099
Clearance of outer race of 0 -0.046 -

3 pinion 215 -:.030 _
shaft bearing -0.046 0.030
Clearance of inner race of pinion 0 0 -0.020 -

4 shaft bearing 120 -0.022 -0.020 0.022
Clearance of outer race of pinion 0 0 -0.052 -

5 shaft bearing 290 -0.035 -0.052 0.035
Clearance of inner race of +0.040 0 -0.015 -

6 I shaft bearing pinion 160 +0.015 -0.025 -0.065 I
Clearance of differential 0 -0.028 -0.003 -
, outer race bearing pinion gear 160 -0.025 -0.068 -0.068 I
8 Clearance of differential pinion gear -0.028 -
inner race bearing
Clearance of differential pinion gear 0 -0.028 -0.010 -

_
9 outer race bearing 140 -0.018 -0.068 -0.068
Clearance of differential +0.013 0 -0.028 -

,. inner race bearing pinion gear 90 -0.009 -0.015 0.009 Replace
Clearance between differential 330 0 +0.057 0 - 0.114 _

11
carrier and cage -0.057 0
Clearance between and 0 +0.030 _

12 spider 70 0 - 0.060
differential pinion bushing -0.030 0
13 1 Backlash of bevel gear 0.43 - 0.61
14 Backlash of differential gear 0.31- 0.40
Free rotating torque of pinion gear 22.6 Nm I2.3 kgm}

15
Preload of pinion bearing 21 kN {2,140 kg)
I
Free rotating torque of bevel gear 25.5 Nm I2.6 kgm)
16 I
Preload of side bearing 28 kN {2,860 kg)
17 Rear face runout of bevel gear 0.13
,8 Standard thickness of shims for

Clearance “a” + (0.1 * 0.05)
stop shaft
2.0
WA800-3 40-23
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1520+24.5Nm
i15.5~2.5ksml
926.7*103.ONm(94.5+10.5kom)
(Final value)
SWW03RfiO
40-24 WA800-3
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
No Check item Criteria Remedy
Clearance between planetary shaft

1 and bearing
Clearance between planetary gear 180 0 -0.028 -0.003 -

2 and bearing -0.025 -0.068 -0.068
Clearance between axle housing -0.017 0 -0.018 -

3 300 0.069
and bearing -0.069 -0.035
Clearance between wheel hub and 0 -0.045

4 460 -0.108-O _
bearing -0.045 -0.108
I I
Clearance between axle housing -0.018 0 -0.022 -

5 320 0.075 Replace
and bearing -0.075 -0.040
Clearance between wheel hub and 0 -0.045

6 480 -0.108 - 0 _
bearing -0.045 -0.108
Standard size Tolerance I Repair limit

I
7 Thickness of retainer at ring gear
hub mount
30 +o. 1 29.6
I I
Standard clearance Clearance limit

Backlash between planet gear and
8
sun gear
0.26 - 0.58 1 .o
Backlash between planet gear and

9 0.30 - 0.78 1.2
ring gear /
Thickness of standard shim for
10 wheel hub 2.0
-
WABOO-3 40-25
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
\ \
\.\
I
,/’ \x
\ ,’
/’
--___,
‘____A
A-A
WA800-3
40-26
MAINTENANCE STANDARD AXLE MOUNT
Unit: mm
Clearance of shaft and hole

(Front support side)
(Before press-fit bushing)
I I I I
-0.068 +I.021 0.323 -
2 (Front support side) 460 -0.165 1.186 1.6
+0.255
(After press-fit bushing)
+4.800 +o. 155 -4.80 -
3 (Rear support side) 470.2 co.800 0 -0.645
- (Before press-fit bushing)
st,nd;;z
i :‘.il 1o.E;ran!e
Replace
(Rear su~t~ort side)
4
(After press-fit bushing)
460 1.6
--+++I+
5 Thickness of thrust washer
6 rhickness of thrust plate
7 Thickness of rear bushing 5 I +O.l
8 Thickness of front bushing 5 +o. 1

I
-
WA800-3 40-27
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
,’
,/ L--______n ” I
‘? ,
‘\ -.\ ,/”
I
0-l \ -. ,/”
\
‘-__-l --___,
A-A
40-28 WA800-3
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm

-
I I
Clearance between lower hinge pin

and bushing
Clearance between lower hinge pin -0.043 +0.063 0.043 -

2 and (small) 146.05 1.0
spacer -0.068 0 0.131

3 and bearing 146.05 -0.068 0 0.093

4 and spacer (large) I 146.05 -0.068 0 0.131 1.0
Clearance between lower hinge -0.050 +0.077 0.050 -

spacer (large) and bushing 206.0 -0.122 0 0.199
Clearance between front frame and +0.025 -0.067 -0.138 -

upper hinge bearing 234.95 0 -0.113 -0.067
Clearance between upper hinge pin -0.043 +0.063 0.043 -

and rear frame 127 -0.068 0 0.131
Clearance between upper hinge pin I -0.043 +0.025 0.043 -

8 and bearing 127 -0.068 0 0.093
Replace
Clearance between front frame and co.025 -0.078 -0.155 -
9 lower hinge bearing 304.8 0 -0.130 -0.078
Clearance between rear frame and -0.043 +0.063 0.043 -

10 bushing 170 -0.068 0 0.131
Clearance at press-fitted part of seal +0.310 +0.063 -0.310 -

11 of upper hinge pin 146.05
+0.210 0 -0.147
Clearance at press-fitted part of seal _ co.260 +0.072 -0.260 -

12 of lower hinge pin 210
+0.160 0 -0.088
Clearance between lower hinge CO.186 +0.063 -0.186 -

13 161.0 _
bushing and frame (upper) +O. 146 0 -0.083
Clearance between lower hinge +0.242 +0.072 -0.242 -

14 bushing and frame (lower) 226.0
+0.196 0 -0.124

15 Height of lower hinge spacer (small)
73 +o. 1
16 Height of lower hinge spacer (large) 155.5 +o. 1
Thickness for lower hinge and

17 retainer 32 ~0.8
Shim thickness for lower hinge and

18 retainer 1.93
I
Shim thickness for lower hinge and Adjust
19 retainer 2.20
I
Shim thickness for upper hinge and
20 2.31
retainer I
WA%OO-3 40-29
MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
A-A 0-B
Unit: mm
Tolerance
size clearance limit Replace
Clearance between steering shaft
1 Shaft Hole bushing
and column bushing
0 +0.150 0.050 -
19
-0.080 +0.050 0.230
40-30 WA800-3
MAINTENANCE STANDARD STEERING DEMAND VALVE
STEERING DEMAND VALVE
L
A
rl
f
c
A T
i ‘1
A-A
40-32 WA800-3
MAINTENANCE STANDARD STEERING DEMAND VALVE
E-B
6 6
c-c SVWQ3601
Unit: mm
Free Installation Installation Free Load

1 Steering spool return spring limit
length length load length
74.5 N 58.8 N
41.8 38.0
t7.6 kg} - (6 kg)
8.8 N 7.0 N
2 Load check valve spring 20.9 13.2
IO.9 kg} - (0.71 kg}
410 N 328 N
3 Demand spool return spring 90.8 83.0 Replace
141.8 kg) - l33.4 kg}
182.4 N 145.1 N
4 Surge cut relief valve spring 24.0 22.19 08.6 kg} - (14.8 kg}
182.4 N 145.1 N
5 Main relief valve spring 24.0 22.19 118.6 kg) - (14.8 kg}
590 N 471 N
6 Overload relief valve spring 39.5 35.7 160.2 kg1 - t40.8 kg}
8.8 N 7.0 N
7 Check valve return spring 20.9 13.2 (0.9 kg> - fO.71 kg}
WA800-3 40-33
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
4)
--
I I
0 0
0 0
0
0
0
2
0-f ;
0
0
O-
O-
---
'0
0
0 0
0
0
0
0 0 0
0 0
> 3
SEW01614
Unit: mm
-
1 Clearance between body and spool
Replace
Spool spring
Check valve spring
Check valve spring
WA800-3
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
‘\
“\
\ -.___, ,/’
/ A-A
2 B-B ‘1 SWWO3660
Unit: mm
Tolerance
size clearance limit
Clearance between mounting pin
and bushing connection of steering Shaft Hole
cylinder rod and frame
-0.036 +0.307 0.256 -

110 .-0.090 +0.220 0.397 1 .o
Clearance between mounting pin

-
and bushing at connection
2 steering cylinder bottom andof frame 110 -0.036
-0.090
+0.020
0
0.036
0.110
1.0
I I
Standard clearance
Width of boss Width of hinge Replace
(Clearance a + b)
Connection of steering cylinder and
3
front frame
0
g3 -0.2 116 + 1.5 0.5 - 3.7
I /
Connection of steering cylinder rod After adjusting with

4 110+06 116 + 1.5
and rear frame 0 I shim: Less than 1.0
I I I

5 Width of spacer
I 10.5 20.5
WA800-3 40-35
MAINTENANCE STANDARD EMERGENCY STEERING PUMP
EMERGENCY STEERING PUMP

Model SAM(3)lOO + 100
A-A
‘2
\
Q= 277*32Nm
(28.25* 3.25kml
SWWO3661
Unit: mm
Pump model Standard clearance Clearance limit

Clearance between gear case and
side plate gear
SAM(3)lOO 0.10 - 0.15 0.19 Replace
I I I
)
Clarance between inside diameter of plain
2 bearinq and outside diameter of clear shaft
3 Insertion depth of pin
4 Rotating torque of spline shaft 13.7 - 23.5 Nm Il.4 - 2.4 kgml

Pump model Revolution Pressure discharge discharge
Discharge (rpm) Wmin) (Eimin)
Oil: EOIO-CD
Temperature: 45 to 55°C 20.6 MPa
SAM(31100 + 100 2000 352 312
210 kg/cm2
40-36 ‘NA800-3
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
RIGHT AND LEFT (Serial No.: 50001 – 50025)
RIGHT (Serial No.: 50026 and up)
40-38 WA800-3
(6)
Unit: mm
Tolerance
Clearance between pedal mount size clearance limit
1 Shaft Hole
hole and bracket hole
–0.025 +0.1 0.175 –
10 –0.075 +0 0.025 0.25
–0.025 +0.1 0.175 –

2 Clearance between roller and pin 10 –0.075 +0 0.025 0.25

3 Outside diameter of roller
0
30 29.2
–0.5
Standard size Repair limit Replace

4 Control spring
length height load length load
30.6 N
34 30 {3.12 kg} 33
0N
5 Control spring 46 46 {0 kg} 45
60.8 N
6 Return spring 86.2 58 {6.2 kg} 78
17.7 N
7 Spring 17 16.5 {1.8 kg} 16.2
16.7 N
8 Return spring 31.5 19.5 {1.7 kg} 28
WA800-3 40-39
(6)
LEFT (Serial No.: 50026 and up)
Unit: mm
Tolerance
Clearance between pedal mount size clearance limit
1 Shaft Hole
hole and bracket hole
–0.025 +0.1 0.175 –
10 –0.075 +0 0.025 0.25
–0.025 +0.1 0.175 –

2 Clearance between roller and pin 10 –0.075 +0 0.025 0.25

3 Outside diameter of roller
0
30 29.2
–0.5
Replace

4 Control spring
length height load length load
3.82 N
34 33.5 {0.39 kg} 33
12.8 N
5 Control spring 47.7 46 {1.3 kg} 46.7
60.8 N
6 Return spring 86.2 58 {6.2 kg} 78
16.7 N
7 Return spring 31.5 19.5 {1.7 kg} 28
40-39-1 WA800-3
(6)
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
55.9*6.9Nm
i5.7*0.7ksml
SEW01620
Unit: mm
Clearance between body and piston
80 -0.030 +0.074 0.030 -

-0.076 0 0.150 0.250
Standard size Repair limit Replace

2 Slack adjuster spring
length length load length load
117.7 N
246 88 _
{I2 kg}
123.6 N
3 Check valve spring 44.8 38
(12.6 kg} -
40-40 WAND3
MAINTENANCE STANDARD BRAKE
BRAKE
926.7*103.ONm D 549.2*58.8Nm
94.5*l0.5bml (56*6kad
\ I98
I \ \ \
40-42 WA800-3
MAINTENANCE STANDARD BRAKE
Unit: mm
-

Return spring length length load length load
999.3 N 887.5 N
114.0 98.8 (101.9 kg) 112.3 190.5 kg)
/
2 Thickness of plate
2.4 2.15
(:
3 Thickness of disc
4 Total thickness of plate and disc
Reolace
I
5 Wear of contact surface of oil seal
0
-0.175 I
Wear of surface
piston seal
in contact with
585
+O.llO
0 I
Wear of surface in contact with +0.110
630
piston seal 0
I
Deformation of friction surface of
8
plate and disc
Max. 0.45 0.70
/
9 Backlash between outer gear and 0.21 - 0.64

plate
Backlash between inner gear and 0.21 - 0.64

10
WA800-3
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
I 5
A-A
Z
SWWO3663
40-44 WA800-3
MAINTENANCE STANDARD PARKING BRAKE
Unit: mm
Remaining thickness
1 Wear of pad of friction material 22.2 3.7 Replace
Including backing
plate 31.7 12.7
2 Face runout of disc 0.6 1.2

1
-0.10
3 Wear of rod connecting pin 12.7 Rebuild
-0.17
Thickness of plate
must be under 23 mm
4 Wear of disc 25 +0.7
(Thickness of disc)
Less than 23 mm Replace
I I / , I
Clearance between pad and disc

5 1.06 +0.18 2.1
(Total of both sides)
Adjust
Clearance between brake body and
6 0.36 - 1.0
plate
WA800-3 40-45
MAINTENANCE STANDARD PPC VALUE
PPC VALVE
44 I *4.9Nm
145tOSksml
309*34Nm
1315t035kemI
SVWO3605
40-46 WA800-3
MAINTENANCE STANDARD PPC VALUE
Unit: mm
Centering spring
(Bucket dump, boom lower)
WA800-3
MAINTENANCE STANDARD PPC RELIEF VALVE
PPC RELIEF VALVE
Unit: mm

1 Main valve spring length length load length load
Replace
19.6 N 15.7 N
47 27 {2.0 kg} - Il.6 kg}
58.4 N 47.1 N
2 Poppet spring 33.6 30.5 15.95 kg} - 14.8 kg}
WA800-3
MAINTENANCE STANDARD CONTROL PUMP
CONTROL PUMP (BAR025)
SEW01624
Unit: mm

I

1 Top clearance of gear
0.090 - o.i30 0.145
Replace
2 Side clearance of gear 0.055 - 0.075 0.105
Clearance between gear shaft and

3 0.045 - 0.076 0.13
bushing
Standard Reparr lrmrt
Pump model Revolution Pressure drscharge
Discharge discharge
(rpm) Wminl WWl) _
Oil: EOlO-CD
2.9 MPa
Temperature: 45 to 55°C BAR25 3,200 68
{30 kg/cm*} 72
Tightening torque for housing case

110.3 2 12.3 Nm III.25 21.25 kgm)
mounting bolt
WA800-3 40-49
MAINTENANCE STANDARD STEERING PUMP
STEERING PUMP
MODEL: HPF76+71
40-49-1 WA800-3
(6)
MAINTENANCE STANDARD SWITCH PUMP
SWITCH PUMP
MODEL: HPF90+90 Serial No.: 50001 – 50025
MODEL: HPF95+95 Serial No.: 50026 and up
2-STAGE HYDRAULIC SYSTEM SPECIFICATION

MODEL: HPV95+95
WA800-3 40-49-2
(6)
MAINTENANCE STANDARD MAIN PISTON PUMP
MAIN PISTON PUMP

Serial No.: 50001 – 50025
MODEL: HPV90+90

MODEL: HPV95+95
40-49-3 WA800-3
(6)
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

Serial No.: 50001 – 50021
40-50 WA800-3
(6)
Unit: mm

1 Spool return spring length length load length load
431.5 N 345.2 N
69.9 63.0 {44.0 kg} – {35.2 kg}
0N
2 Spool return spring 77.0 77.0 {0 kg} – –
61.6 N 49.0 N
3 Spool return spring 79.7 78.5 {6.28 kg} – {5.0 kg}
Main valve spring of relief valve 86.3 N 69.0 N
(Serial No.: 50001 – 50014) 52.4 38.0 {8.80 kg} – {7.04 kg}
4
(Large) (Serial No.: 50015 and up) 12.0 12.1 {0.57 kg} – {0.46 kg}
Replace
18.8 N 14.7 N
5 Check valve spring 78.2 52.0 {1.92 kg} – {1.5 kg}
6.9 N 5.9 N
6 Suction valve spring of safety valve 27.9 18.0 {0.70 kg} – {0.6 kg}
6.9 N 5.9 N
7 Suction valve spring 27.9 18.0 {0.70 kg} {0.6 kg}
137.3 N 109.8 N
8 Float selector valve spring 53.0 42.1 {14.0 kg} {11.2 kg}
49.0 N 39.2 N
9 Unloader valve spring 82.7 47.0 {5.0 kg} {4.0 kg}
319.7 N 256.0 N
10 Pilot poppet spring of relief valve 30.7 26.9 {32.6 kg} {26.1 kg}
11 (Small) (Serial No.: 50015 and up) 10.45 6.3 {0.236 kg} {0.19 kg}
WA800-3 40-51
(6)
40-51-1 WA800-3
(6)
Unit: mm

1 Spool return spring length length load length load
431.5 N 345.2 N
69.9 63.0 {44.0 kg} – {35.2 kg}
0N
2 Spool return spring 77.0 77.0 {0 kg} – –
61.6 N 49.0 N
3 Spool return spring 79.7 78.5 {6.28 kg} – {5.0 kg}
4 (Large) 12.0 12.1 {0.57 kg} – {0.46 kg}
18.8 N 14.7 N
5 Check valve spring 78.2 52.0 {1.92 kg} – {1.5 kg} Replace
6.9 N 5.9 N
6 Suction valve spring of safety valve 27.9 18.0 {0.70 kg} – {0.6 kg}
6.9 N 5.9 N
7 Suction valve spring 27.9 18.0 {0.70 kg} {0.6 kg}
137.3 N 109.8 N
8 Float selector valve spring 53.0 42.1 {14.0 kg} {11.2 kg}
49.0 N 39.2 N
9 Unloader valve spring 82.7 47.0 {5.0 kg} {4.0 kg}
319.7 N 256.0 N
10 Pilot poppet spring of relief valve 30.7 26.9 {32.6 kg} {26.1 kg}
11 (Small) 10.45 6.3 {0.236 kg} {0.19 kg}
WA800-3 40-51-2
(6)
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
-
Steering
Bucket
Boom
461*1<2Nin(470il45kam
24521245Nm
1545*172Nm
1250*25kPml
~1575*175k~m1
m Steerins:110\3~12,3Nm(1125*1,25kami
Bucket
Boom
:277*32Nm
:277232Nm
{2625+325ksml
(2825*325k~mI
SWWO3863
Unit: mm
No Iqemedy
1
Clearance between piston rod
and bushing
-
Replace
bushing
Clearance between piston rod

2
mounting pin and bushing
Clearance between cylinder

3 bottom mounting pin and
bushing
4 Cylinder bore Replace
40-52 WA800-3
MAINTENANCE STANDARD BUCKET LINKAGE
BUCKET LINKAGE
18’
2
6
\
b a b
D-D’,5 E-E’q
a
v G-G 17
b
40-54 WA800-3
MAINTENANCE STANDARD BUCKET LINKAGE
Unit: mm
Clearance between pin and bushing

at boss ends of bucket link
-
Clearance between pin and bushing -0.043 +0.434 0.390 -
2 at joint of boom and bucket 180 -0.106 +0.347 0.540 1.0
Clearance between pin and bushing -0.050 +0.435 0.370 -

1.0 Replace
3 at joint of boom and frame 200 -0.122 +0.320 0.557 also if
Clearance between pin and bushing at other parts
-0.043 +0.395 0.338 -
4 joint of bucket cylinder rod and bellcrank 180 -0.106 +0.295 0.501 1.0 are biting
into pin
Clearance between pin and bushing at -0.043 +0.395 0.338 -
5 joint of bucket cylinder bottom and frame 180 -0.106 +0.295 0.501 1.0

6 joint of bellcrank and boom 200 -0.122 +0.320 0.557 1.0
-
7 joint of boom cylinder bottom and frame 180 -0.106 +0.295 0.501 1.0
-
8 joint of boom cylinder rod and boom 180 -0.106 to.295 0.501 1.0
Width between Standard clearance Insert shims

Width of hinge on both sides
bosses (Clearance a + b)
9 Joint of bucket cylinder and bellcrank to make
+ 0.1 + 0.8 clearance on
213 o 210 0 1.4 - 3.8 both left and
right sides
less than 1.5
10 Joint of boom and frame 214 + 0.8 210 * 2.9 0.3 - 7.7 mm.
+ 1.5
11 Joint of boom and bucket 259 0 254 + 4.9 0.1 - 11.4
+ 1.5
12 Joint of bucket link and bucket 259 0 254 + 3 2.0 - 9.5
+I
13 Joint of bellcrank and bucket link 253 o 250 : ; 2.0 - 5.0
insert shims
+ 0.8
14 Joint of boom cylinder and frame 214 & 0.8 210 0 2.4 - 4.8 on both sides
to make
clearance on
15 Joint of bellcrank and boom 358 5 0.5 355 r 0.5 2.0 - 4.0 both left and
right sides
+ 0.8 less than 1.5
16 Joint of frame and bucket cylinder 213 ? 0.8 210 0 2.2 - 4.0
mm
-
+ 0.8
17 Joint of boom cylinder and boom 213 + 1.5 210 0 0.7 - 4.5
I
18 Wear of bucket tooth Replace
45 0
WA800-3 40-55
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
d
88.3*34.3Nm
(9.0+3.5keml
!===a 0
==
1
P
SVWO3RIfi
Unit: mm
1 Clearance of bucket position switch 3-5
2 Clearance of boom kick-out switch 3-5 Adjust
Clearance between bucket

3 0.5 - 1
positioner protector and switch
40-56 WA800-3
90 OTHERS
Electric circuit diagram (1/16) .................................................................... 90- 3

Electric circuit diagram (5/16) .................................................................... 90-11
Electric circuit diagram (10/16) .................................................................. 90-21
Electric circuit diagram (Remote boom positioner) ................................. 90-35
WA800-3 90-1
(6)
OTHERS ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM [1/16]

STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION (1/5) [FOR MECHANICAL GOVERNOR ENGINE]
WA800-3 90-3
5

WA800-3 90-5
5

WA800-3 90-7
5

WA800-3 90-9
5

WA800-3 90-11
5

STEERING WHEEL SPECIFICATION, STEERING WHEEL AND JOYSTICK STEERING SPECIFICATION (1/6) [FOR ELECTRONIC GOVERNOR ENGINE]
WA800-3 90-13
5

WA800-3 90-15
5

WA800-3 90-17
5

WA800-3 90-19
5

WA800-3 90-21
5

WA800-3 90-23
5

AJSS (ADVANCED JOYSTICK STEERING SYSTEM) SPECIFICATION (1/5)
WA800-3 90-25
5

WA800-3 90-27
5

WA800-3 90-29
5

WA800-3 90-31
5

WA800-3 90-33
5
ELECTRIC CIRCUIT DIAGRAM (REMOTE BOOM POSITIONER)
WA800-3 90-35
(6)
DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186
DATE: FOR INTERNAL USE ONLY -- No. PMR
NAME OF COMPANY: CITY:
) STATE OR PROVINCE::
’ DEPARTMENT: COUNTRY:
; NAME: FAX NO:
ANUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service
ANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:
ANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:
SOOK DESCRIPTION
IACHINE MODEL 8 S/N:
IANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS:
‘ROBLEM:
,ttach photo or sketch.

more space is needed, use another sheet.
FOR INTERNAL USE ONLY
:ORRECTIVE ACTION:
m
PROPFREV.WPD 071:

Shop Manual WA800-3

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Shop Manual WA800-3

Загружено:

Авторское право:

Доступные форматы

SEBM013409

WA800-3 50001 and up

• WA800-3 mount the SA12V140-1 engine.

01 GENERAL ........................................................................ 01-1

10 STRUCTURE AND FUNCTION ...................................... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

40 MAINTENANCE STANDARD ......................................... 40-1

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

‡ 00- 1 (9) ‡ 00-22 10-15 10-41 10-65-1 (6)

Time of Time of Time of Time of Time of

10-79-5 (5) 10-111 (6) 10-137-1 (6) 10-161 10-177-22 (4)

Time of Time of Time of Time of Time of

20- 2 20-115 20-153 20-224 (7) 20-245

Time of Time of Time of Time of Time of

20-410 (5) 20-514 20-610 20-724 20-852 (5)

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

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

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

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

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

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

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})