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SEN06006-02

WHEEL LOADER WA470 -7


SERIAL NUMBERS 10001 and up
SHOP MANUAL

WHEEL LOADER
WA470-7
Model Serial Number

WA470-7 10001 and up

00 Index and foreword


1 00 Index and foreword

WA470-7 00-1
00 Index and foreword
Index

Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-18
Important safety notice ....................................................................................................... 00-18
How to read the shop manual.............................................................................................. 00-25
Explanation of terms for maintenance standard .................................................................... 00-27
Handling equipment of fuel system devices .......................................................................... 00-29
Handling of intake system parts........................................................................................... 00-30
Handling of hydraulic equipment.......................................................................................... 00-31
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-33
Handling of electrical equipment.......................................................................................... 00-36
How to read electric wire code............................................................................................. 00-44
Precautions when performing operation ............................................................................... 00-47
Practical use of KOMTRAX ................................................................................................. 00-51
Standard tightening torque table.......................................................................................... 00-52
List of abbreviation ............................................................................................................. 00-56
Conversion table ................................................................................................................ 00-61
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-11
Table of fuel, coolant, and lubricants .................................................................................... 01-13
10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
KVGT.................................................................................................................................. 10-6
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Cooling fan pump ............................................................................................................... 10-30
Cooling fan motor............................................................................................................... 10-39
Power train............................................................................................................................... 10-46
Power train system............................................................................................................. 10-46
Drive shaft ......................................................................................................................... 10-49
Power train piping drawing .................................................................................................. 10-50
Transmission control .......................................................................................................... 10-51
Torque converter ................................................................................................................ 10-54
Transmission ..................................................................................................................... 10-59
Transmission control valve.................................................................................................. 10-78
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .......................................... 10-81
3rd, 4th clutch ECMV.......................................................................................................... 10-88
Lockup clutch ECMV .......................................................................................................... 10-95
Main relief and torque converter relief valve.......................................................................... 10-99
Axle ................................................................................................................................ 10-101
Differential ....................................................................................................................... 10-103
Final drive ....................................................................................................................... 10-113
Steering system...................................................................................................................... 10-115
Layout of steering parts .................................................................................................... 10-115
Steering column............................................................................................................... 10-116

00-2 WA470-7
00 Index and foreword
Index

Steering pump ................................................................................................................. 10-117


Steering valve.................................................................................................................. 10-129
Orbit-roll valve ................................................................................................................. 10-143
Stop valve ....................................................................................................................... 10-149
Emergency steering motor ................................................................................................ 10-150
Emergency steering pump ................................................................................................ 10-151
Brake system ......................................................................................................................... 10-152
Layout of brake parts........................................................................................................ 10-152
Charge valve ................................................................................................................... 10-154
Brake valve ..................................................................................................................... 10-160
Slack adjuster .................................................................................................................. 10-164
Accumulator (for brake) .................................................................................................... 10-167
Brake .............................................................................................................................. 10-168
Parking brake control ....................................................................................................... 10-171
Parking brake .................................................................................................................. 10-172
Parking brake solenoid valve ............................................................................................ 10-173
Parking brake emergency release valve............................................................................. 10-176
Undercarriage and frame......................................................................................................... 10-177
Axle mount and center hinge pin........................................................................................ 10-177
Tire ................................................................................................................................. 10-178
Hydraulic system .................................................................................................................... 10-180
Hydraulic component layout .............................................................................................. 10-180
Work equipment control .................................................................................................... 10-182
Hydraulic tank.................................................................................................................. 10-183
Double type gear pump .................................................................................................... 10-186
Work equipment pump...................................................................................................... 10-187
Control valve ................................................................................................................... 10-208
CLSS .............................................................................................................................. 10-217
Hydraulic circuit diagram and names of valves.................................................................... 10-221
Accumulator charge valve................................................................................................. 10-232
Work equipment lock solenoid valve .................................................................................. 10-236
Accumulator (for PPC circuit) ............................................................................................ 10-237
Accumulator (for ECSS) ................................................................................................... 10-238
Work equipment ..................................................................................................................... 10-239
Work equipment linkage ................................................................................................... 10-239
Bucket ............................................................................................................................ 10-240
Bucket positioner and boom positioner............................................................................... 10-241
Cab and its attachments .......................................................................................................... 10-242
ROPS cab ....................................................................................................................... 10-242
Electrical system .................................................................................................................... 10-243
Engine control system ...................................................................................................... 10-243
Preheating system ........................................................................................................... 10-245
Engine power mode selector circuit ................................................................................... 10-247
Engine output limit function ............................................................................................... 10-248
Automatic warm-up function.............................................................................................. 10-249
Parking brake control system ............................................................................................ 10-250
System operating lamp function......................................................................................... 10-252
Battery disconnect switch function ..................................................................................... 10-254
Transmission controller system ......................................................................................... 10-256
Work equipment control system......................................................................................... 10-277
Machine monitor system ................................................................................................... 10-293
Rear view monitor system................................................................................................. 10-317
KOMTRAX system ........................................................................................................... 10-320
System component parts .................................................................................................. 10-323
Sensor ............................................................................................................................ 10-350
20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3

WA470-7 00-3
00 Index and foreword
Index

Standard value table for machine .......................................................................................... 20-5


Standard value table for electrical system............................................................................. 20-18
30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-8
Engine and cooling system ........................................................................................................ 30-10
Testing engine speed ......................................................................................................... 30-10
Testing boost pressure ....................................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Testing and adjusting valve clearance .................................................................................. 30-16
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-24
Testing EGR valve and KVGT oil pressures .......................................................................... 30-25
Testing fuel pressure .......................................................................................................... 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-31
Testing fuel circuit for leakage ............................................................................................. 30-33
Handling cylinder cutout mode operation.............................................................................. 30-34
Handling no injection cranking operation .............................................................................. 30-35
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-36
Testing of installed condition of cylinder head and manifolds .................................................. 30-37
Testing engine piping for damage and looseness .................................................................. 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Testing and adjusting alternator belt tension ......................................................................... 30-41
Procedures for cleaning fuel doser....................................................................................... 30-43
Writing compensation values at replacement of injector and engine controller ......................... 30-46
Power train............................................................................................................................... 30-50
Adjusting transmission output speed sensor ......................................................................... 30-50
Adjusting transmission input speed sensor ........................................................................... 30-51
Flushing procedure for torque converter and transmission hydraulic circuit.............................. 30-52
Retrieval of disabled machine due to transmission valve failure.............................................. 30-54
Testing oil leakage from axle final drive ................................................................................ 30-56
Testing drive shaft for looseness, backlash, and damage....................................................... 30-57
Testing and adjusting power train oil pressure....................................................................... 30-58
Steering system........................................................................................................................ 30-73
Testing directional lever ...................................................................................................... 30-73
Testing steering wheel ........................................................................................................ 30-74
Testing work equipment control lever ................................................................................... 30-76
Testing and adjusting steering circuit oil pressure.................................................................. 30-78
Bleeding air from steering cylinder circuit.............................................................................. 30-81
Testing and adjusting steering stopper valve......................................................................... 30-82
Brake system ........................................................................................................................... 30-83
Testing brake pedal ............................................................................................................ 30-83
Testing and adjusting brake pedal linkage ............................................................................ 30-84
Testing braking performance ............................................................................................... 30-85
Testing and adjusting of accumulator charge pressure........................................................... 30-86
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake
accumulator with nitrogen gas................................................................................ 30-88
Testing wheel brake oil pressure.......................................................................................... 30-92
Testing lowering of wheel brake pressure ............................................................................. 30-94
Testing wear of wheel brake disc ......................................................................................... 30-96
Bleeding air from wheel brake circuit.................................................................................... 30-97
Releasing remaining pressure in brake accumulator circuit .................................................... 30-99
Testing parking brake performance .................................................................................... 30-100
Testing parking brake oil pressure ..................................................................................... 30-101
Testing wear of parking brake disc ..................................................................................... 30-102

00-4 WA470-7
00 Index and foreword
Index

Method of releasing parking brake manually ....................................................................... 30-103


Hydraulic system .................................................................................................................... 30-105
Testing fan speed............................................................................................................. 30-105
Testing fan pump circuit oil pressure .................................................................................. 30-106
Bleeding air from hydraulic fan circuit ................................................................................. 30-108
Testing and adjusting work equipment EPC oil pressure ...................................................... 30-110
Testing and adjusting work equipment oil pressure.............................................................. 30-113
Bleeding air from work equipment circuit ............................................................................ 30-117
Releasing remaining pressure from work equipment circuit .................................................. 30-118
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator
with nitrogen gas ................................................................................................ 30-119
Work equipment ..................................................................................................................... 30-123
Testing and adjusting bucket position detection lever........................................................... 30-123
Testing and adjusting boom position detection lever ............................................................ 30-124
Electrical system .................................................................................................................... 30-125
Adjusting replaced, reassembled or added sensor, controller, etc. with machine
monitor .............................................................................................................. 30-125
Special functions of machine monitor ................................................................................. 30-127
Adjusting rearview camera angle ....................................................................................... 30-216
Handling voltage circuit of engine controller........................................................................ 30-217
Handling battery disconnect switch .................................................................................... 30-218
Testing diodes ................................................................................................................. 30-219
Pm clinic ................................................................................................................................ 30-220
Pm Clinic service ............................................................................................................. 30-220
Check sheet .................................................................................................................... 30-221
40 Troubleshooting............................................................................................................................ 40-1
Table of contents ........................................................................................................................ 40-2
General information on troubleshooting ...................................................................................... 40-11
Troubleshooting points ....................................................................................................... 40-11
Sequence of events in troubleshooting................................................................................. 40-13
Check before troubleshooting.............................................................................................. 40-15
Inspection procedure before troubleshooting ........................................................................ 40-17
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedures for troubleshooting ................................................................. 40-40
Symptom and troubleshooting numbers ............................................................................... 40-43
Information in troubleshooting table ..................................................................................... 40-46
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-62
T-branch box and T-branch adapter table ............................................................................. 40-98
Fuse location table ........................................................................................................... 40-104
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-107
Precautions on troubleshooting of machine monitor ............................................................ 40-110
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit .................................................................................................................... 40-112
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-117
Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-118
Failure codes table........................................................................................................... 40-119
Troubleshooting by failure code (Display of code) ...................................................................... 40-133
Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-133
Failure code [15SAL1] Release Trouble of ECMV (Forward) ................................................ 40-134
Failure code [15SALH] Malfunction of ECMV (Forward)....................................................... 40-136
Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-138
Failure code [15SBLH] Malfunction of ECMV (Reverse) ...................................................... 40-140
Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-142
Failure code [15SELH] Malfunction of ECMV (1st) .............................................................. 40-144
Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-146
Failure code [15SFLH] Malfunction of ECMV (2nd) ............................................................. 40-148
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-150

WA470-7 00-5
00 Index and foreword
Index

Failure code [15SGLH] Malfunction of ECMV (3rd).............................................................. 40-152


Failure code [15SHL1] Release Trouble of ECMV (4th) ....................................................... 40-154
Failure code [15SHLH] Malfunction of ECMV (4th) .............................................................. 40-156
Failure code [2F00MA] Failure of Parking Brake Circuit ....................................................... 40-158
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-162
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-164
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-166
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-167
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-168
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-169
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-170
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-171
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-172
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-173
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-174
Failure code [989A00] Engine Overrun Prevention Activated ............................................... 40-175
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-176
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-177
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-178
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-179
Failure code [A1U0N4] HC Desorb Request 2 .................................................................... 40-181
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-183
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-185
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-186
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-188
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-189
Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-191
Failure code [B@HANS] HYD Oil Temp. Overheat .............................................................. 40-192
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-193
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-194
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-196
Failure code [CA131] Throttle Sensor High Error................................................................. 40-198
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-200
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-202
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-204
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-206
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-208
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-210
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-212
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-214
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-216
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-218
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-220
Failure code [CA234] Eng Overspeed ................................................................................ 40-221
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-222
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-223
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-224
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-225
Failure code [CA273] PCV2 Short Error ............................................................................. 40-226
Failure code [CA274] PCV2 Open Error ............................................................................. 40-227
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-228
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-230
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-232
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-234
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-236
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-238
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-240
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-241
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-242

00-6 WA470-7
00 Index and foreword
Index

Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-244
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-246
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-248
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-249
Failure code [CA432] Idle Validation Process Error ............................................................. 40-252
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-255
Failure code [CA442] Battery Voltage High Error................................................................. 40-257
Failure code [CA449] Rail Press Very High Error................................................................. 40-258
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-259
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-261
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-263
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-265
Failure code [CA553] Rail Press High Error ........................................................................ 40-267
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-268
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-269
Failure code [CA559] Rail Press Low Error......................................................................... 40-270
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-274
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-275
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-277
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-279
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-281
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-283
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-284
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-285
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-286
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-288
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-289
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-292
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-295
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-296
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-298
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-300
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-302
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-304
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-306
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-309
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-312
Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-317
Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-319
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-322
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-324
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-326
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-328
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-329
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-331
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-333
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-335
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-337
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-339
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-340
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-342
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-344
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-346
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-348
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-350
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-352
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-353
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-355
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-357

WA470-7 00-7
00 Index and foreword
Index

Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-359


Failure code [CA2387] KVGT Servo Error .......................................................................... 40-361
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-362
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-364
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-366
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-368
Failure code [CA2732] Dosing Fuel Valve 2 High Error ........................................................ 40-371
Failure code [CA2733] Dosing Fuel Valve 2 Low Error......................................................... 40-373
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-375
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-377
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...................................................... 40-378
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-381
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-386
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-388
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-390
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-393
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-396
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-399
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-402
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-405
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-409
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-412
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-415
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-418
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-421
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-425
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-430
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-433
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-437
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-442
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-446
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-449
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-454
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-456
Failure code [D150KA] Disconnection of Emerg. Steering Relay .......................................... 40-458
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-460
Failure code [D150KY] Hot Short of Emergency Steering Relay ........................................... 40-462
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................................... 40-464
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output..................................... 40-466
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .......................................... 40-468
Failure code [D191KA] Disconnection of Neutral Output Relay............................................. 40-470
Failure code [D191KB] Ground Fault of Neutral Output Relay .............................................. 40-472
Failure code [D191KY] Hot Short of Neutral Output Relay.................................................... 40-474
Failure code [D192KA] Disconnection of ECSS Solenoid..................................................... 40-476
Failure code [D192KB] Ground Fault of ECSS Solenoid ...................................................... 40-478
Failure code [D192KY] Hot Short of ECSS Solenoid ........................................................... 40-479
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-480
Failure code [D1E6KA] Disconnection of Parking Brake Relay ............................................. 40-482
Failure code [D1E6KB] Ground Fault of Parking Brake Relay............................................... 40-484
Failure code [D1E6KY] Hot Short of Parking Brake Relay .................................................... 40-486
Failure code [D5ZHKA] Failure of Key SW C Signal ............................................................ 40-488
Failure code [D5ZHKB] Key SW C Signal Short Circuit........................................................ 40-490
Failure code [D5ZHKZ] Failure of Key SW C Signal ............................................................ 40-492
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-494
Failure code [D811MC] KOMTRAX Error............................................................................ 40-496
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-497
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-498
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-500
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-502

00-8 WA470-7
00 Index and foreword
Index

Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-503


Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-505
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-506
Failure code [DAF0MC] Monitor Error ................................................................................ 40-507
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-508
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-510
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-511
Failure code [DAFGMC] GPS Module Error........................................................................ 40-513
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-514
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-516
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-518
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-519
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-522
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-523
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-524
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-526
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .......................................... 40-529
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-531
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-532
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-534
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-536
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-537
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-538
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-539
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-540
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-541
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-546
Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................... 40-551
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...................................... 40-553
Failure code [DB90MC] BBC Error..................................................................................... 40-554
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ............................................. 40-555
Failure code [DB92KK] Solenoid Power Source Low (BBC) ................................................. 40-557
Failure code [DB95KX] Failure of 5 V Power Source 1......................................................... 40-559
Failure code [DB96KX] Failure of 5 V Power Source 2......................................................... 40-561
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) .......................................... 40-563
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)................................................ 40-564
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ................................................ 40-566
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .................................................. 40-568
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .................................................. 40-569
Failure code [DB9RMA] Inconsistency of Option Selection (BBC)......................................... 40-570
Failure code [DBE5KX] Failure of 5V Power Source............................................................ 40-571
Failure code [DBE6KX] Failure of 24 V Power Source ......................................................... 40-573
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................... 40-575
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-577
Failure code [DDB6L4] Neutral Signal Malfunction .............................................................. 40-579
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ........................................... 40-582
Failure code [DDK3KA] FNR SW Input Signal Disconnection............................................... 40-584
Failure code [DDK3KB] FNR SW Input Signal Short Circuit.................................................. 40-587
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ............................................ 40-589
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit............................................... 40-592
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................... 40-594
Failure code [DDT0L4] Failure of Shift Mode Select SW ...................................................... 40-596
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal...................................... 40-598
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ........................................... 40-600
Failure code [DDW9LD] Ground Fault of Kickdown Switch................................................... 40-602
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ................................................ 40-604
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-606
Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-608
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor........................................... 40-611

WA470-7 00-9
00 Index and foreword
Index

Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ............................................ 40-613
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor .......................................... 40-615
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ......................................... 40-617
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .................................................. 40-618
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ........................................... 40-620
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor............................................. 40-623
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ............................................ 40-625
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit........................................ 40-627
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ............................................... 40-629
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor.................................. 40-631
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor .................................... 40-633
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor...................................... 40-635
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-637
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor .................................. 40-639
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor .......................................... 40-641
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit...................................... 40-643
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-645
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ......................................... 40-646
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ............................................ 40-648
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-650
Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................... 40-652
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ........................................... 40-655
Failure code [DK55L5] Failure of FNR Lever Potentio.......................................................... 40-657
Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ............................................. 40-658
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ......................................... 40-661
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................... 40-664
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub).............................................. 40-668
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) .......................................... 40-671
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ........................................... 40-674
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....................................... 40-677
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................... 40-680
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ............................................ 40-684
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ........................................ 40-687
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................................................ 40-690
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ............................................ 40-693
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree........................................ 40-695
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub).................................................. 40-698
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub).............................................. 40-701
Failure code [DKA0KA] Failure of Boom Angle Sensor ........................................................ 40-703
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .......................................... 40-705
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...................................................... 40-707
Failure code [DKA1KA] Failure of Bucket Angle Sensor....................................................... 40-709
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit......................................... 40-711
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-713
Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-715
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-717
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-719
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-721
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-723
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-725
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-728
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-731
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-734
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .............................................. 40-736
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .......................................... 40-738
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-740
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................ 40-742
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise).................................. 40-744
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................... 40-746

00-10 WA470-7
00 Index and foreword
Index

Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ............................... 40-748
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ................................. 40-750
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ...................................... 40-752
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) .......................................... 40-754
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .................................... 40-756
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt).......................................... 40-758
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ..................................... 40-760
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................ 40-762
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ..................................... 40-764
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ......................................... 40-766
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-768
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-770
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ......................................... 40-771
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid........................................... 40-773
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................................................ 40-775
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................... 40-777
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ........................................ 40-779
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ............................................. 40-781
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..................................... 40-783
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)....................................... 40-785
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ............................................ 40-787
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-789
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-791
Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-793
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ................................. 40-795
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ................................... 40-797
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ........................................ 40-799
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................... 40-801
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................ 40-803
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid...................................... 40-805
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-806
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-808
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-810
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-812
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-814
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-816
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-818
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-820
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-822
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-824
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-826
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-828
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-830
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-832
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-834
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) .................................... 40-836
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)...................................... 40-838
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ........................................... 40-840
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ........................................... 40-842
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)............................................. 40-844
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) .................................................. 40-846
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....................................... 40-848
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)......................................... 40-850
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .............................................. 40-852
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................... 40-854
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ........................................ 40-856
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ............................................. 40-858
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-860
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-863

WA470-7 00-11
00 Index and foreword
Index

Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-867


Failure code [LA00L3] Failure of Fan Reverse .................................................................... 40-869
Troubleshooting of electrical system (E-mode) .......................................................................... 40-870
E-1 Engine does not start.................................................................................................. 40-870
E-2 Manual preheating system does not work..................................................................... 40-876
E-3 Automatic preheating system does not work................................................................. 40-879
E-4 While preheating is working, preheating monitor does not light up .................................. 40-881
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .................. 40-883
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-886
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) .............................................................................................................. 40-888
E-8 LCD on machine monitor does not display properly ....................................................... 40-890
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-892
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-895
E-11 Caution LED on machine monitor is abnormal............................................................. 40-898
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly ............................................................................................................. 40-900
E-13 Two switches operation of switch panel on machine monitor does not function .............. 40-902
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-905
E-15 Rear view monitor does not light up or backlight flickers............................................... 40-907
E-16 Rear view monitor images are not displayed clearly..................................................... 40-910
E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-913
E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-916
E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-918
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position .............................................................................................................. 40-919
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light ................................................................................................................... 40-923
E-22 Air cleaner clogging indicator lamp does not light ........................................................ 40-925
E-23 Radiator coolant level caution lamp does not light ....................................................... 40-926
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil
temperature caution lamp does not light................................................................ 40-928
E-25 Indication of torque converter oil temperature gauge does not increase, or torque
converter oil temperature caution lamp does not light ............................................. 40-930
E-26 Fuel level gauge does not indicate correct level .......................................................... 40-931
E-27 Seat belt caution lamp indication is abnormal.............................................................. 40-933
E-28 Horn does not sound ................................................................................................ 40-934
E-29 Horn does not stop sounding..................................................................................... 40-937
E-30 Alarm buzzer does not sound .................................................................................... 40-939
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................ 40-940
E-32 Kickdown does not work when kickdown switch is turned ON....................................... 40-941
E-33 The hold switch does not work when it is pressed........................................................ 40-943
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake
is released and FR drive is operated..................................................................... 40-945
E-35 Transmission cut-off mode is not selected or not released............................................ 40-948
E-36 Transmission cut-off setting cannot be released .......................................................... 40-950
E-37 Directional selector (FNR) switch mode is not selected or not released ......................... 40-952
E-38 When operating engine power selection switch, engine power selection function does not
operate properly ................................................................................................. 40-954
E-39 Flow of loader pump does not increase from the minimum rate..................................... 40-956
E-40 ECSS function cannot be selected or cannot be released ............................................ 40-957
E-41 None of headlamp, clearance lamp, and tail lamp lights ............................................... 40-959
E-42 Clearance lamp and tail lamp do not light up or go out ................................................. 40-961
E-43 Both High and Low beams of headlamp do not light up or go out .................................. 40-964
E-44 Low beam of headlamp does not light up or go out ...................................................... 40-968
E-45 High beam of headlamp does not light up or go out ..................................................... 40-970
E-46 Front working lamp does not light up or go out ............................................................ 40-972
E-47 Rear working lamp does not light up or go out............................................................. 40-975

00-12 WA470-7
00 Index and foreword
Index

E-48 All of turn signal lamps and hazard lamps do not light up or go out................................ 40-978
E-49 Turn signal lamps do not light up or go out .................................................................. 40-981
E-50 Hazard lamp does not light up or go out...................................................................... 40-984
E-51 Brake lamp does not light or stays lighted ................................................................... 40-987
E-52 Backup lamp does not light up or does not go out........................................................ 40-990
E-53 Backup buzzer does not sound or continues to sound ................................................. 40-993
E-54 Front wiper does not operate ..................................................................................... 40-995
E-55 Rear wiper does not operate ..................................................................................... 40-998
E-56 Window washer does not operate ............................................................................ 40-1000
E-57 Fuel feed pump does not operate or stop automatically ............................................. 40-1003
E-58 KOMTRAX system does not operate properly........................................................... 40-1005
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 40-1007
Information described in troubleshooting table (H-mode) ................................................... 40-1007
System chart of hydraulic and mechanical systems........................................................... 40-1008
Failure mode and cause table ..........................................................................................40-1011
H-1 Machine does not move off ....................................................................................... 40-1019
H-2 Torque converter lockup clutch is not disengaged (engine stalls).................................. 40-1022
H-3 Torque converter lockup clutch is not engaged ........................................................... 40-1023
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
shift ................................................................................................................. 40-1024
H-5 Large shock is made when machine starts or gear is shifted ........................................ 40-1027
H-6 Machine starts or gear speed shifts with long time lag ................................................. 40-1029
H-7 Torque converter oil temperature is high..................................................................... 40-1031
H-8 Machine does not turn .............................................................................................. 40-1033
H-9 Turning response is poor .......................................................................................... 40-1035
H-10 Steering wheel is heavy to turn................................................................................ 40-1037
H-11 Machine sways or large shocks are made while machine turns .................................. 40-1038
H-12 Turning radius differs between right and left turns...................................................... 40-1040
H-13 Wheel brakes do not work or are weak..................................................................... 40-1041
H-14 Wheel brakes are not released or drag..................................................................... 40-1043
H-15 Parking brake does not work or it is weak ................................................................. 40-1044
H-16 Parking brake is not released or drags (including emergency release system) ............. 40-1045
H-17 Boom does not rise ................................................................................................ 40-1046
H-18 Boom moves slow or boom lacks lifting force ............................................................ 40-1048
H-19 Rising boom slows down at certain height ................................................................ 40-1050
H-20 Lift cylinders do not serve to hold bucket on ground .................................................. 40-1051
H-21 Hydraulic drift of boom is large ................................................................................ 40-1052
H-22 Boom moves up and down during operation ............................................................. 40-1053
H-23 Bucket does not tilt back ......................................................................................... 40-1054
H-24 Bucket moves slow or lacks tilt-back force................................................................ 40-1056
H-25 Bucket decelerates during tilt-back operation............................................................ 40-1058
H-26 Bucket cylinder does not hold bucket on ground ....................................................... 40-1059
H-27 Hydraulic drift of bucket is large ............................................................................... 40-1060
H-28 Bucket tilts back and forth during carrying load (work equipment valve in
HOLD) ............................................................................................................. 40-1061
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ........... 40-1062
H-30 Operating work equipment causes engine speed to lower significantly or engine to
stall ................................................................................................................. 40-1063
H-31 Large shocks are made when work equipment starts to move and stops ..................... 40-1064
H-32 When certain work equipment stalls hydraulically, other work equipment
moves ............................................................................................................. 40-1066
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces................. 40-1067
H-34 Bucket does not stop at the position which is set with remote bucket positioner ........... 40-1068
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) .................................. 40-1069
H-36 Unusual noise is heard from around fan ................................................................... 40-1070
Troubleshooting of engine (S-mode)....................................................................................... 40-1071
Information mentioned in troubleshooting table (S mode)................................................... 40-1071
S-1 When starting switch is turned to START position, engine is not cranked....................... 40-1072
S-2 The engine cranks but exhaust smoke does not come out ........................................... 40-1073

WA470-7 00-13
00 Index and foreword
Index

S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) .................................................................................................... 40-1074
S-4 Engine startability is poor .......................................................................................... 40-1075
S-5 Engine does not pick-up smoothly ............................................................................. 40-1077
S-6 Engine stops during operation ................................................................................... 40-1079
S-7 Engine runs rough or is unstable ............................................................................... 40-1081
S-8 Engine lacks power .................................................................................................. 40-1082
S-9 KDPF gets clogged in a short time ............................................................................. 40-1084
S-10 Engine oil consumption is excessive ........................................................................ 40-1086
S-11 Engine oil becomes contaminated early.................................................................... 40-1087
S-12 Fuel consumption is excessive ................................................................................ 40-1088
S-13 Oil is in coolant (or coolant spurts or coolant level goes down).................................... 40-1089
S-14 Oil pressure drops .................................................................................................. 40-1090
S-15 Fuel mixes into engine oil........................................................................................ 40-1091
S-16 Water mixes into engine oil (milky) ........................................................................... 40-1092
S-17 Coolant temperature rises too high (overheating) ...................................................... 40-1093
S-18 Unusual noise is heard ........................................................................................... 40-1094
S-19 Vibration is excessive ............................................................................................. 40-1095
S-20 Air cannot be bled from fuel circuit ........................................................................... 40-1096
S-21 Active regeneration is executed frequently ............................................................... 40-1097
S-22 Active regeneration takes a long time....................................................................... 40-1098
S-23 White smoke is exhausted during active regeneration ............................................... 40-1099
50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-17
Engine and cooling system ........................................................................................................ 50-47
Removal and installation of supply pump assembly............................................................... 50-47
Removal and installation of injector assembly....................................................................... 50-53
Removal and installation of fuel doser assembly ................................................................... 50-61
Removal and installation of cylinder head assembly.............................................................. 50-63
Removal and installation of engine hood assembly ............................................................... 50-77
Removal and installation of grille assembly .......................................................................... 50-79
Removal and installation of cooling system assembly............................................................ 50-82
Removal and installation of radiator core assembly ............................................................... 50-85
Removal and installation of aftercooler................................................................................. 50-87
Removal and installation of hydraulic oil cooler ..................................................................... 50-90
Removal and installation of power train oil cooler assembly ................................................... 50-92
Removal and installation of engine assembly ....................................................................... 50-96
Removal and installation of engine front oil seal .................................................................. 50-102
Removal and installation of engine rear oil seal................................................................... 50-105
Removal and installation of cooling fan and cooling fan motor assembly ............................... 50-110
Removal and installation of KDPF assembly....................................................................... 50-112
Disassembly and assembly of KDPF assembly .................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-126
Removal and installation of KVGT assembly....................................................................... 50-128
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-133
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-134
Removal and installation of air cleaner assembly ................................................................ 50-136
Removal and installation of air conditioner compressor belt ................................................. 50-138
Removal and installation of alternator belt .......................................................................... 50-139
Removal and installation of fuel tank assembly ................................................................... 50-140
Power train............................................................................................................................. 50-143
Removal and installation of torque converter and transmission assembly.............................. 50-143
Disassembly and assembly of transmission assembly......................................................... 50-148
Disassembly and assembly of torque converter assembly ................................................... 50-178

00-14 WA470-7
00 Index and foreword
Index

Disassembly and assembly of transmission clutch pack assembly ....................................... 50-185


Removal and installation of front axle assembly .................................................................. 50-208
Removal and installation of rear axle assembly................................................................... 50-210
Disassembly and assembly of axle housing assembly......................................................... 50-215
Disassembly and assembly of differential assembly ............................................................ 50-225
Steering system...................................................................................................................... 50-244
Removal and installation of steering valve assembly ........................................................... 50-244
Brake system ......................................................................................................................... 50-246
Removal and installation of brake charge valve assembly.................................................... 50-246
Removal and installation of parking brake disc and plate ..................................................... 50-247
Undercarriage and frame......................................................................................................... 50-250
Removal and installation of center hinge pin ....................................................................... 50-250
Removal and installation of counterweight assembly ........................................................... 50-258
Removal and installation of full-length fender assembly ....................................................... 50-260
Hydraulic system .................................................................................................................... 50-261
Removal and installation of hydraulic tank assembly ........................................................... 50-261
Removal and installation of control valve assembly ............................................................. 50-264
Removal and installation of steering pump and power train pump assembly .......................... 50-267
Removal and installation of work equipment pump and cooling fan pump assembly............... 50-269
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-271
Work equipment ..................................................................................................................... 50-278
Removal and installation of work equipment assembly ........................................................ 50-278
Cab and its attachments .......................................................................................................... 50-283
Removal and installation of operator's cab and floor frame assembly.................................... 50-283
Removal and installation of operator's cab glass (stuck window glass).................................. 50-287
Removal and installation of operator's seat assembly.......................................................... 50-295
Removal and installation of seat belt .................................................................................. 50-297
Removal and installation of air conditioner unit assembly..................................................... 50-298
Removal and installation of air conditioner compressor assembly......................................... 50-303
Removal and installation of air conditioner condenser assembly .......................................... 50-305
Electrical system .................................................................................................................... 50-307
Removal and installation of machine monitor assembly ....................................................... 50-307
Removal and installation of engine controller assembly ....................................................... 50-308
Removal and installation of work equipment controller assembly.......................................... 50-309
Removal and installation of transmission controller assembly .............................................. 50-311
Removal and installation of monitor controller assembly ...................................................... 50-312
Removal and installation of mass air flow and temperature sensor ....................................... 50-314
Removal and installation of KOMTRAX terminal assembly .................................................. 50-315
60 Maintenance standard................................................................................................................... 60-1
Table of contents ........................................................................................................................ 60-2
Engine and cooling system .......................................................................................................... 60-3
Engine related parts ............................................................................................................. 60-3
Cooling fan pump ................................................................................................................. 60-4
Cooling fan motor................................................................................................................. 60-7
Power train................................................................................................................................. 60-9
Drive shaft ........................................................................................................................... 60-9
Torque converter ................................................................................................................ 60-10
Transmission ..................................................................................................................... 60-12
Transmission control valve.................................................................................................. 60-21
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .......................................... 60-23
3rd, 4th clutch ECMV.......................................................................................................... 60-24
Lockup clutch ECMV .......................................................................................................... 60-25
Main relief and torque converter relief valve.......................................................................... 60-26
Axle .................................................................................................................................. 60-27
Differential ......................................................................................................................... 60-29
Final drive ......................................................................................................................... 60-39
Steering system........................................................................................................................ 60-41
Steering column................................................................................................................. 60-41
Steering pump ................................................................................................................... 60-42

WA470-7 00-15
00 Index and foreword
Index

Steering valve.................................................................................................................... 60-46


Steering cylinder ................................................................................................................ 60-48
Emergency steering pump .................................................................................................. 60-51
Brake system ........................................................................................................................... 60-52
Charge valve ..................................................................................................................... 60-52
Slack adjuster .................................................................................................................... 60-54
Brake ................................................................................................................................ 60-55
Parking brake .................................................................................................................... 60-57
Parking brake solenoid valve .............................................................................................. 60-58
Undercarriage and frame........................................................................................................... 60-59
Axle mount and center hinge pin.......................................................................................... 60-59
Hydraulic system ...................................................................................................................... 60-63
Hydraulic tank.................................................................................................................... 60-63
Double type gear pump ...................................................................................................... 60-64
Work equipment pump........................................................................................................ 60-65
Control valve ..................................................................................................................... 60-67
Work equipment ....................................................................................................................... 60-76
Work equipment linkage ..................................................................................................... 60-76
Bucket .............................................................................................................................. 60-80
Work equipment cylinder .................................................................................................... 60-81
80 Appendix...................................................................................................................................... 80-1
Table of contents ........................................................................................................................ 80-2
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle.................................................................................................. 80-7
Air conditioner unit ............................................................................................................... 80-9
Dual pressure switch .......................................................................................................... 80-14
Air conditioner controller ..................................................................................................... 80-15
Compressor....................................................................................................................... 80-16
Condenser ........................................................................................................................ 80-17
Receiver drier .................................................................................................................... 80-18
Sunlight sensor .................................................................................................................. 80-20
Outer temperature sensor (outside air temperature sensor) ................................................... 80-21
Procedure for testing and troubleshooting ............................................................................ 80-22
Circuit diagram and arrangement of connector pins............................................................... 80-24
System diagram................................................................................................................. 80-27
Parts and connectors layout................................................................................................ 80-30
Testing with self-diagnosis function ...................................................................................... 80-35
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-36
Testing temperature control system ..................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Check evaporator temperature sensor ................................................................................. 80-44
Testing relays .................................................................................................................... 80-46
Troubleshooting chart 1 ...................................................................................................... 80-48
Troubleshooting chart 2 ...................................................................................................... 80-49
Information in troubleshooting table ..................................................................................... 80-51
Failure code list related to air conditioner.............................................................................. 80-52
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-55
Failure code [879BKA] A/C Outer Sensor Open Circuit.......................................................... 80-57
Failure code [879BKB] A/C Outer Sensor Short Circuit .......................................................... 80-59
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-61
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-63
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ................................................ 80-65
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-67

00-16 WA470-7
00 Index and foreword
Index

Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-70


A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does
not operate).......................................................................................................... 80-73
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ........................ 80-76
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-79
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-82
Troubleshooting with gauge pressure................................................................................... 80-84
Connection of service tool................................................................................................... 80-87
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit................................................................................................................... 80-89
Handling of compressor oil.................................................................................................. 80-91
90 Diagrams and drawings................................................................................................................. 90-1
Table of contents ........................................................................................................................ 90-2
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram of power train .................................................................................. 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-11
Symbols in electric circuit diagram ....................................................................................... 90-11
Electrical circuit diagram of machine body ............................................................................ 90-15
Electrical circuit diagram of floor .......................................................................................... 90-25
Index.................................................................................................................................................................... 1

WA470-7 00-17
00 Index and foreword
Foreword, safety and general information

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

(Rev. 2012/01)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.

General precautions knowledge of welding perform the work. When


performing welding work, always wear welding
k Inappropriate handling causes an extreme gloves, apron, shielding goggles, cap, etc.
danger. Read and understand what is • Before starting work, warm up your body
described in the operation and maintenance thoroughly to start work under good condition.
manual before operating the machine. Read • Avoid continuing work for long hours and take
and understand what is described in this rests with proper intervals to keep your body in
manual before starting the work. good condition. Take a rest in a specified safe
place.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For Safety points
the locations of the safety labels and detailed 1 Good arrangement
explanation of precautions, see the operation 2 Correct work clothes
and maintenance manual.
3 Observance of work standard
• Locate a place in the repair workshop to keep
4 Practice of making and checking signals
the tools and removed parts. Always keep the
Prohibition of operation and handling by
tools and parts in their correct places. Always 5
unlicensed workers
keep the work area clean and make sure that Safety check before starting work
6
there is no dirt, water or oil on the floor. Smoke
Wearing protective goggles (for cleaning or
only in the areas provided for smoking. Never 7 grinding work)
smoke while working.
Wearing shielding goggles and protectors (for
• When performing any work, always wear the 8 welding work)
safety shoes and helmet. Do not wear loose
9 Good physical condition and preparation
work cloths, or clothes with buttons missing.
Precautions against work which you are not
1. Always wear the protective eyeglasses when 10 used to or you are used to too much
hitting parts with a hammer.
2. Always wear the protective eyeglasses when Preparation
grinding parts with a grinder, etc. • Before adding oil or making any repairs, place
• When performing any work with two or more the machine on a firm and level ground, and
workers, always agree on the working procedure apply the parking brake and chock the wheels or
before starting. While working, always keep tracks to prevent the machine from moving.
conversations of the work between your fellow • Before starting work, lower the work equipment
workers and your self on any step of the work. (blade, ripper, bucket, etc.) to the ground. If it is
During the work, hang the warning tag of not possible to lower the equipment to the
"UNDER WORKING" in the operator's ground, insert the lock pin or use blocks to
compartment. prevent the work equipment from falling. And be
• Only qualified workers must perform the work sure to lock all the work equipment control levers
and operation which require license or and hang a warning tag on them.
qualification. • When performing the disassembling or
• Keep the tools in good condition. And learn the assembling work, support the machine securely
correct way to use the tools, and use the proper with blocks, jacks, or stands before starting the
ones among them. Before starting the work, work.
thoroughly check the tools, forklift truck, service • Remove all of mud and oil from the steps or
car, etc. other places used to get on and off the machine
• If welding repairs is required, always have a completely. Always use the handrails, ladders of
trained and experienced welder with good

00-18 WA470-7
00 Index and foreword
Foreword, safety and general information

steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
the OFF (Q) position and remove the switch key. parts which must not be used with new ones.
For the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning two holes, never insert your
coolant and oil in the circuits are hot. Be careful fingers or hand into the holes. Align the holes
not to get scalded by the hot coolant and oil. with care so that your fingers are not caught in
Start the work after checking that the coolant the hole.
and oil are cooled down sufficiently. • When measuring hydraulic pressure, check that
• Start the work after the engine is shut down. Be the measuring tools are correctly installed.
sure to shut down the engine when working on • Pay attention to safety when removing and
or around the rotating parts in particular. When installing the tracks of the track type machines.
checking the machine without shutting down the When removing the track, it separates suddenly.
engine (measuring oil pressure, engine speed, The workers should not stand at either end of
oil or coolant temperature), take extreme care the track.
not to get caught in the rotating parts or the • If the engine is operated for a long time in a
working equipment. closed place which is not ventilated well, you
• The hoist or crane must be used to sling the may suffer from gas poisoning. Accordingly,
components weighing 25 kg or heavier. Check open the windows and doors to ventilate the
the slings (wire rope, nylon sling, chain and place well.
hook) for damage before the work. Use the
slings with ample capacity and install them to Precautions for slinging work and making
the proper places. Operate the hoist or crane signals
slowly to prevent the component from hitting any • Only one appointed worker must make signals
other part. Do not work with any part still raised and co-worker must communicate with each
by the hoist or crane. other frequently. The appointed signaler must
• When removing the part which is under internal make specified signals clearly at the place
pressure or reaction force of the spring, always where the signaler is well seen from the
leave two bolts in diagonal positions. Loosen operator's seat and where the signaler can see
those two bolts gradually and alternately and the working condition easily. The signaler must
release the pressure, then, remove the part. always stand in front of the load and guide the
• When removing the part, be careful not to break operator safely.
or damage the electrical wiring. The damaged 1. Do not stand under the load.
wiring may cause electrical fires. 2. Do not step on the load.
• Check the slings before starting sling work.

WA470-7 00-19
00 Index and foreword
Foreword, safety and general information

• Keep putting on the gloves during sling work. • Use the specified eye bolts and fix wire ropes,
(Put on the leather gloves, if available.) chains, etc. to them with shackles, etc.
• Measure the weight of the load by the eye and • Apply wire ropes to the middle portion of the
check its center of gravity. hook.
• Use the proper sling according to the weight of
a Slinging near the tip of the hook may cause
the load and method of slinging. If too thick wire
the rope to slip off the hook during hoisting.
ropes are used to sling a light load, the load may
The hook has the maximum strength at the
slip and fall.
middle part.
• Do not sling a load with one wire rope only. If do
so, the load may rotate or the sling gets loose
and the sling may slip off. Install two or more
wire ropes symmetrically.

k Slinging with one rope may cause turning


of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 degrees or smaller as
a rule.
• When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower • Do not use twisted or kinked wire ropes.
than that of the hook. • When slinging up a load, observe the following.
a When slinging a load with two ropes or more, 1. Wind up the rope slowly until the wire rope
the larger the hanging angle is, the larger the tensions. When putting your hands on the
tension of each rope. The figure bellow wire ropes, do not grasp them but press them
shows the variation of allowable load in kN down from above. If you grasp them, your
{kg} when hoisting is made with two ropes, fingers may be caught.
each of which is allowed to sling up to 9.8 kN 2. After the wire ropes are stretched, stop the
{1000kg} a load vertically, at various hanging crane and check the condition of the slung
angles. When the two ropes sling a load load, wire ropes, and pads.
vertically, up to19.6 kN {2000 kg} of total 3. If the load is unstable or the wire rope or
weight can be suspended. This weight is chains are twisted, lower the load and lift it
reduced to 9.8 kN {1000 kg} when the two up again.
ropes make a hanging angle of 120 degrees. 4. Do not lift up the load at an angle.
If the two ropes sling a 19.6 kN {2000 kg} • When lowering a load, pay attention to the
load at a hanging angle of 150 degrees, each following.
rope is subjected to a force as large as 39.2 1. When lifting down a load, stop it temporarily
kN {4000 kg}. at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.

Precautions for using mobile crane


a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.

• When installing wire ropes to an angular load,


apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.

00-20 WA470-7
00 Index and foreword
Foreword, safety and general information

Precautions for using overhead traveling crane Nominal


diameter of rope Allowable load
k The hoist or crane must be used to sling the mm kN ton
components weighing 25 kg or heavier. A
12 12.7 1.3
part weighing 25 kg or heavier in
14 17.3 1.7
"disassembly and assembly" section is
16 22.6 2.3
indicated with the symbol of 4 . 18 28.6 2.9
20 35.3 3.6
• Before starting work, check the wire ropes,
25 55.3 5.6
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter 30 79.6 8.1
for electric shock prevention, crane collision 40 141.6 14.4
prevention device, and energizing warning lamp, 50 221.6 22.6
and check the following safety items. 60 318.3 32.4
• Observe the signals for sling work.
• Operate the hoist at a safe place. a The allowable load is calculated as one sixth of
• Be sure to check the directions of the direction the breaking load of the rope to be used (safety
indication plate (north, south, east and west) and coefficient: 6).
the operating button. Precautions for disconnecting and connecting
• Do not sling a load at an angle. Do not move the hoses and tubes in air conditioner circuit
crane while the slung load is swinging.
• Do not raise or lower a load while the crane is Disconnection
moving longitudinally or laterally. k When replacing the air conditioner unit, air
• Do not drag a sling. conditioner compressor, condenser or
• When lifting up a load, stop it just after it leaves receiver drier, etc., collect the refrigerant (air
the ground and check safety, and then lift it up. conditioner gas: R134a) from the air
• Consider the travel route in advance and lift up a conditioner circuit before disconnecting the
load to a safe height. air conditioner hoses.
• Place the control switch in a position where it will
not be an obstacle to work and passage. a Ask a qualified person for collecting, adding and
• After operating the hoist, do not swing the filling operations of the refrigerant (air
control switch. conditioner gas: R134a).
• Remember the position of the main switch so
that you can turn off the power immediately in an a Never release the refrigerant (air conditioner
emergency. gas: R134a) to the atmosphere.
• Shut down the main switch when the hoist stops k If refrigerant gas (air conditioner gas: R134a)
because of a blackout. When turning on a switch gets in your eyes, you may lose your sight.
which is turned OFF by the ground fault circuit And if it touches your skin, you may suffer
interrupter for electric shock prevention, check from frostbite. Put on protective eyeglasses,
that the devices related to that switch are not in gloves and working cloth with long sleeves
operating condition. while collecting the refrigerant or filling the
• If you find an obstacle around the hoist, stop the air conditioner circuit with the refrigerant.
operation.
• After finishing the work, stop the hoist at the • When loosening the nuts fixing air conditioner
specified position and raise the hook to at least hoses and tubes, be sure to use two wrenches;
two meters above the floor. Do not leave the use one wrench to fix and use the other one to
sling attached to the hook. loosen the nut.
Selecting wire ropes Connection
• Select adequate ropes depending on the weight • When installing the hose for the air conditioner
of the parts to be hoisted, referring to the table circuit, take care not to allow invasion of dirt,
below dusts and water into the hose.
Wire ropes (standard "Z" twist ropes without • Check that the O-rings are fitted to the joints
galvanizing) (JIS G3525, Type 6x37-A) when connecting the air conditioner piping.
Nominal • Once an O-ring is used, it is deformed and
diameter of rope Allowable load deteriorated. Accordingly, do not reuse it.
mm • When removing the O-rings, use a soft tool so
kN ton
that the piping is not damaged.
10 8.8 0.9

WA470-7 00-21
00 Index and foreword
Foreword, safety and general information

• Check that the O-ring is not damaged or


deteriorated.
• Apply compressor oil for refrigerant (R134a) to
the O-ring.
a However, do not apply oil to the threaded
portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL ZXL100PG (equivalent to
SYSTEMS PAG46)
SANDEN SP-10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.

For tightening torques, see "Others",


"Precautions for disconnection and connection
of air conditioner piping".

00-22 WA470-7
00 Index and foreword
Foreword, safety and general information

Fire prevention (ALL-0000-001-K-27-A)

Action if fire occurs (ALL-0000-17A-K-01-A)


• Turn the starting switch to the OFF position to
shutdown the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful 9 J D 0 1 7 2 0
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature 9 J D 0 1 7 2 1
environment).
When wearing cotton-work-gloves, wear rubber • Fire caused by accumulation or attachment
gloves under them. of flammable material
• Remove any dry leaves, chips, pieces of
Prevent fire (ALL-0000-17B-K-03-A) paper, coal dust, or any other flammable
• Fire caused by fuel, oil, coolant or window materials accumulated or attached to or
washer fluid around the engine exhaust manifold, muffler,
Do not bring any flame or fire close to flammable or battery, or on the undercovers.
substances such as fuel, oil, coolant or window • To prevent fires from being caught, remove
washer fluid.There is danger that they may catch any flammable materials such as dry leaves,
fire. Always observe the following. chips, pieces of paper, coal dust, or any
• Do not smoke or use any flame near fuel or other flammable materials accumulated
other flammable substances. around the cooling system (radiator, oil
• Shut down the engine before adding fuel. cooler) or on the undercover.
• Do not leave the machine when adding fuel • Fire coming from electric wiring
or oil. Short circuits in the electrical system can cause
• Tighten all the fuel and oil caps securely. fire. Always observe the following.
• Be careful not to spill fuel on overheated • Keep all the electric wiring connections clean
surfaces or on parts of the electrical system. and securely tightened.
• After adding fuel or oil, wipe up any spilled • Check the wiring every day for looseness or
fuel or oil. damage. Reconnect any loose connectors or
• Put greasy rags and other flammable refasten wiring clamps. Repair or replace any
materials into a safe container to maintain damaged wiring.
safety at the workplace. • Fire caused by piping
• When washing parts with oil, use a non- Check that all the clamps for the hoses and
flammable oil. Do not use diesel oil or tubes, guards, and cushions are securely fixed
gasoline.There is danger that they may catch in position.
fire. If they are loose, they may vibrate during
• Do not weld or use a cutting torch to cut any operation and rub against other parts. There is
pipes or tubes that contain flammable liquids. danger that this may lead to damage to the
• Determine well-ventilated areas for storing oil hoses and cause high-pressure oil to spurt out,
and fuel. Keep the oil and fuel in the leading to fire and serious personal injury or
specified place and do not allow death.
unauthorized persons to enter. • Fire around the machine due to highly heated
• When performing grinding or welding work exhaust gas
on the machine, move any flammable This machine is equipped with KDPF (Komatsu
materials to a safe place before starting. Diesel Particulate Filter).

WA470-7 00-23
00 Index and foreword
Foreword, safety and general information

KDPF is a system for purifying soot in exhaust


gas. The exhaust gas discharged during the
purification process (regeneration) can be higher
temperature than that of existing models. Do not
bring any flammable material close to the outlet
of the exhaust pipe.
• If there are thatched houses, dry leaves or
pieces of paper around the job site, set the
system to the "Regeneration Disable" before
starting operation to prevent fire hazard of
highly heated exhaust gas caused by KDPF
regeneration.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.

Dispose of waste materials (ALL-0000-99A-K-02-A)


To prevent pollution, pay full attention to the way to
dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.

Some kinds of rubber and plastics may produce


poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.

00-24 WA470-7
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Foreword, safety and general information

How to read the shop manual (ALL-0320-010-A-01-A)

(Rev. 2012/01)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.

Composition of shop manual


• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
described.
Tightening The tightening torques that require special attention during assembly
3 torque work are described.

WA470-7 00-25
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Foreword, safety and general information

Symbol Item Remarks


The places to be coated with adhesives, etc. during assembling are
2 Coat
indicated.
Oil, coolant The places to which oil is supplied and the quantity of the oil are
5 indicated.

6 Drain The places from which oil is drained and quantity of the oil are indicated.

Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

00-26 WA470-7
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Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

(Rev. 2012/01)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.

Standard dimension and tolerance


• To be accurate, the finished dimension of a part
is slightly different from one to another.
• To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
• The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
• The standard dimension and tolerance are
indicated by attaching the symbols of + or - and
a number on the right side of the standard
dimension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance. Standard interference
• Indication of dimension of rotating shaft and hole • When the diameter of a hole of a part shown in
and their related drawing. the given standard dimension and tolerance
Example: table is smaller than that of the shaft to be
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
• When some parts are repaired, the value of the parts can not be used any longer. This value
performance/function is set to the standard is called "repair limit".
value. • If a part is worn to the repair limit, it must be
replaced or repaired.

WA470-7 00-27
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Foreword, safety and general information

• The performance and function of the products


lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.

Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.

Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.

00-28 WA470-7
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Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.

Use care for working environment


• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.

How to clean parts when dirt is stuck


• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.

Precautions for replacing fuel filter cartridge


• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.

WA470-7 00-29
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Foreword, safety and general information

Handling of intake system parts (PC220-A900-2A4-K-00-A)

(Rev.2012/01)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.

Be careful of working environment


• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.

00-30 WA470-7
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Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

(Rev. 2012/01)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.

Be careful of working environment


• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.

Disassembly and maintenance work in the field


• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.

Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never leave the openings of the
pipes and hoses without being covered or Replacing hydraulic oil while its temperature is
high
plugged with cloth as foreign material may enter
• When the hydraulic oil is warm, it flows easily. In
them or environment may be polluted by the oil
addition, sludge can also be drained from the
leaked. Do not discard the waste oil somewhere
circuit together with the oil. So, it is better to
or other. Hand it over to your customer for
change the hydraulic oil while it is warm. When
disposal, or dispose it by yourself.
changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.

WA470-7 00-31
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Foreword, safety and general information

Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.

Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.

00-32 WA470-7
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Foreword, safety and general information

Method of disconnecting and connecting of push-pull type coupler (ALL-


C930-001-P-00-A)
(Rev. 2012/01)

k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.

k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1 (ALL-C930-925-P-01-A)

Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move toward the hose,
however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.

WA470-7 00-33
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Foreword, safety and general information

Type 2 (ALL-C930-925-P-02-A)

Disconnection Connection
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)

00-34 WA470-7
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Foreword, safety and general information

Type 3 (ALL-C930-925-P-03-A)

Disconnection Connection
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)

WA470-7 00-35
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Foreword, safety and general information

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

(Rev. 2012/01)

• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".

Precautions for handling electric equipment

Handling wiring harnesses and connectors


• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.

Main failures occurring in wiring harness


Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. The corroded or oxidized harness may be broken.
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately ten
times.

00-36 WA470-7
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Foreword, safety and general information

blow it with compressed air and spray it with


electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.

High-pressure water entering connector


• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.

Entry of water, mud or dirt when disconnecting a


connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or

WA470-7 00-37
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Foreword, safety and general information

• Check that there is no oil, dirt or water stick


to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.

3. Action to take after removing connectors


• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.

Connecting connectors
1. Check the connector visually.

00-38 WA470-7
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Foreword, safety and general information

• If the connector clamp is removed, be sure to • If there is any oil or dirt on the wiring harness,
return it to its original position. And check wipe it off with a dry cloth. Avoid washing by
that it is securely installed. using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.

Deutsch connector (DT8-pin, DT12-pin)


Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).

2. Dry the inside of the connector with a dryer.


If water gets inside the connector, use a dryer to
dry the connector.
a Hot air from the dryer can be used, but
regulate the time to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.

3. Perform a continuity test on the connector.


After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
Drying wiring harness

WA470-7 00-39
00 Index and foreword
Foreword, safety and general information

2. While pressing lock (L2), pull out connector (1).


Handling of connectors used on engine

Slide, lock type (Type 1) (FRAMATOME-3,


FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).

Connection
1. Insert the connector securely until a click is
heard. Connection
1. Insert the connector securely until a click is
Slide, lock type (Type 2) (FRAMATOME-24) heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.

00-40 WA470-7
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Foreword, safety and general information

Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
Push lock type (1) (BOSCH-3) Push lock type (2) (SUMITOMO-4)
Disconnection Disconnection
1. While pressing lock (C), pull out connector (3) in 1. While pressing lock (C), pull out connector (4) in
the direction of the arrow. the direction of the arrow.
• 114 series Connection
1. Insert the connector securely until a click is
heard.

• 107 series

Push lock type (3) (AMP-3)


Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
Example) Fuel pressure sensor in common rail:
PFUEL etc (AMP-3)

a If the lock is located on the underside, use


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

WA470-7 00-41
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Foreword, safety and general information

Example) Injection pressure control valve of


supply pump: PCV (SUMITOMO-2)

Connection
1. Insert the connector to the end while aligning its
Example) Speed sensor of supply pump: G grove to the other.
(SUMITOMO-3) 2. Turn housing (H1) in the direction of the arrow
until it "clicks".
a Pull the connector straight up.

Connection Handling controller


• The electronic circuits for control including the
1. Insert the connector securely until a click is
microcomputers are assembled in the controller.
heard.
These electronic circuits in the controller must
Turn-housing type (Round green connector) be handled with care as they control the
(CANNON-4) machine.
Disconnection • Do not place objects on top of the controller.
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.

• Cover the control connectors with tape or a vinyl


bag. Never touch the connector contacts.
• During rainy weather, do not leave the controller
in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high

00-42 WA470-7
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Foreword, safety and general information

temperature even for a short period of time.


(Place it on a suitable dry stand.)

• Precautions when performing arc welding


When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.

Precautions for troubleshooting electrical


circuits
• Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.

WA470-7 00-43
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Foreword, safety and general information

How to read electric wire code (ALL-E500-030-P-00-A)


(Rev. 2012/01)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.

Type, symbol, and material


• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
Type 2
Heat-
resistant low- (Safety factor:
Heat-resistant cross
voltage wire AEX linked polyethylene -50 to +110 Wiring at high-temperature
for place
automobile

00-44 WA470-7
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Dimension
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 —
Coating D

AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard — — — — — — — — —
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25


Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D

CAVS Standard — 1.6 — 1.8 — 2.1

a "f" of nominal No. denotes "flexible".

WA470-7 00-45
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Color codes table


(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".

Types of circuits and color codes


Type of wire AVS, AV, CAVS AEX
Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of — — —
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Appendix Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —

00-46 WA470-7
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Precautions when performing operation (ALL-1160-927-A-00-A)

(Rev. 2012/01)
• When performing "removal or installation" and "disassembly or assembly" of the components, observe the
following general cautions.

Precautions for removal work


• If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
a Precautions when handling piping during disassembly
Use the plugs indicated below for the pipes disconnected at the disassembly.
Face seal type hoses and tubes
Nominal No. Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
Split flange type hoses and tubes
Nominal No. Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

WA470-7 00-47
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If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part No.
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

Precautions for installation work


• Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the
threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end four to five times.
3. Operate the hydraulic cylinder three to four times to the end of its stroke.

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a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.

WA470-7 00-49
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Precautions at the time of completing work


Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Check of installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Check of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Cooling system for water leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Fuel system for fuel leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

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Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)


(Rev. 2012/01)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)

Merit of using KOMTRAX


• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice tool for the user and operator.

How to use KOMTRAX practically


With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.

How to operate KOMTRAX


For the operating method of each screen of KOMTRAX, see "KOMTRAX basic operation manual".

WA470-7 00-51
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Standard tightening torque table (ALL-M140-03B-P-01-A)

(Rev. 2012/01)

Table of tightening torque for bolts and nuts


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

a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (Nm) (kgm)
6 10 5.9 to 9.8 0.6 to 1.0
8 12 13.7 to 23.5 1.4 to 2.4
10 14 34.3 to 46.1 3.5 to 4.7
12 17 74.5 to 90.2 7.6 to 9.2
Fig. A Fig. B

a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)

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Table of tightening torque for split flanged bolts


a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (Nm) (kgm)
10 14 59 to 74 6.0 to 7.5
12 17 98 to 123 10.0 to 12.5
16 22 245 to 309 25 to 31.5

Table of tightening torque for O-ring boss piping joints


a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})
Nominal No. diameter across flats
(mm) mm Range Target
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 Varies 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 depending 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 on type of 128 to 186 {13.0 to 19.0} 157 {16.0}
10, 12 33 connector. 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}

Table of tightening torque for O-ring boss plugs


a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})
Nominal No. diameter across flats
(mm) mm Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

WA470-7 00-53
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Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Tightening torque (Nm {kgm}) Taper seal Face seal
Width
Nominal across Nominal No. - Thread root
No. of Thread size threads per
flats Range Target diameter
hose (mm) (mm) inch, type of (reference)
thread
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16 -18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16 -16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16 -16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16 -12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —

Table of tightening torque for face seal joints


a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Outer Tightening torque (Nm {kgm}) Face seal
Width
diameter of Nominal No. - Thread root
across flats
pipe Range Target threads per inch, diameter
(mm)
(mm) type of thread (Reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16 -18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16 -16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16 -16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1-3/16 -12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.

00-54 WA470-7
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Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —

Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the
torque shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material In cast iron or steel In aluminum
Tightening torque Tightening torque
Thread diameter (inch)
(Nm) (kgm) (Nm) (kgm)
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

WA470-7 00-55
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List of abbreviation (ALL-0360-005-A-00-A)


(Rev. 2012/09)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text(marked witha).
• This list of abbreviations consists of 2 parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of abbreviations used in the shop manual


Purpose of use (major
Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Function with which when the tires skid
Anti-skid Brake Travel and brake (wheels stop rotating), the brakes are
ABS System released, and when the wheels start to rotate,
(HD, HM)
the brakes are applied again.
Automatic Idling
AISS Engine Automatic setting function of at idle speed
Setting System
Function that a lever can perform the steering
Advanced Joystick Steering operations, shifting gear speed operation and
AJSS Steering System changing direction operation instead of a
(WA)
steering wheel.
Function that the retarder works automatically
Automatic Retarder Travel and brake with a certain braking force when the
ARAC
Accelerator Control (HD, HM) accelerator pedal is released while the
machine travels downhill.
Function that the retarder works automatically
with a certain braking force so that the
Automatic Retarder Travel and brake machine travels with the speed not exceeding
ARSC Speed Control (HD, HM) the speed set by the operator when the
accelerator pedal is released while the
machine travels downhill.
Function with which, when the rear wheels
Automatic Spin Travel and brake spin on soft ground surfaces, this function
ASR Regulator (HD, HM) automatically uses the optimum braking force
to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake Valve that bypasses part of the brake cooling
Brake cooling oil oil to reduce the load on the hydraulic pump
BCV
control valve (HD) when the retarder is not being used.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine
Crankcase Depression Regulator valve that is installed to the KCCV
CDR Engine ventilator It is not used independently and
Regulator
described CDR valve.
System that can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Oil pressure
Sensing System (provides better combined operation
comparing to OLSS).
Function to maintain optimum fuel injection
amount and fuel injection timing by using
CRI Common Rail Injection Engine
engine controller to perform electronic control
of supply pump, common rail, and injector.
Electronic control device that uses the signals
Electronic Control from the sensors on the machine to indicate
ECM Electronic control system
Module the optimum actuation to the actuators .
(Same as ECU)

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Purpose of use (major


Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
System that ensures smooth high-speed
Electronically Travel travel by using hydraulic spring effect of
ECSS Controlled Suspension
(WA) accumulator to absorb vibration of machine
System
during travel
Electronic control device that uses the signals
from the sensors on the machine to indicate
ECU Electronic Control Unit Electronic control system the optimum actuation to the actuators .
(Same as ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas Engine combustion chamber in order to reduce
EGR
Recirculation combustion temperature and to control
emission of NOx.
Equipment System that allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on monitor.
Electromagnetic Electromagnetic proportional control
EPC Oil pressure Mechanism that actuator works in proportion
Proportional Control
to current
Structure that protects operator's head from
Falling Object Cab and canopy falling objects. (Structure to protect operator)
FOPS
Protective Structure
Performance standardized in ISO 3449
Forward-Neutral- Operation
F-N-R Forward - NEUTRAL - REVERSE
Reverse
Communication Global Positioning System Satellite
Global Positioning
GPS System (KOMTRAX 、KOMTRAX positioning system that is used to determine
Plus) the current location on the earth
Steering function that uses a combination of
Hydrostatic Steering Steering hydraulic motor and bevel shaft to control
HSS System difference in travel speed of right and left
(D) tracks to turn machine without using steering
clutch.
Hydraulic transmission system that uses a
Hydro Static Transmission combination of hydraulic pump and hydraulic
HST motor to shift gear steplessly without using
Transmission (D, WA)
gears.
Valve that adjusts fuel intake amount at inlet
Inlet Metering Actuator Engine port of pump in order to control fuel discharge
IMA
amount of supply pump. Same meaning as
IMV
Valve adjusting fuel intake amount at inlet port
IMV Inlet Metering Valve Engine of pump in order to control fuel discharge
amount of supply pump. Described IMV (IMA)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.
This filter is used to capture soot in exhaust
Komatsu Catalyzed Engine gas.
KCSF
Soot Filter
It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine This is built in KDPF or assembled with the
Oxidation Catalyst
muffler.
This component with built-in KDOC (catalyst)
Komatsu Diesel Engine and KCSF (soot-capturing filter)
KDPF
Particulate Filter
purifies exhaust gas.

WA470-7 00-57
00 Index and foreword
Foreword, safety and general information

Purpose of use (major


Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
It is installed in place of the currently used
muffler.
Function that recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Liquid Display Image display equipment such
LCD Liquid Crystal Display Machine monitor as the monitor which assembles in the liquid
crystal element.
Light Emitting Diode Semi-conductor element
LED Light Emitting Diode Electronic parts that emits light when the voltage is applied in
the normal direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Oil pressure pump and controls discharge amount
according to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
It means the intake air flow of the engine. It is
Engine not used independently but used together with
MAF Mass Air Flow
the sensor. The mass air flow sensor may be
called MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Device actuated to open electric or hydraulic
NC Normally Closed Electric and hydraulic circuits that are normally closed if not
actuated.
Device actuated to close electric or hydraulic
NO Normally Open Electric and hydraulic
circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Oil pressure actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Oil pressure A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
Valve installed at inlet port of pump to adjust
Pre-stroke Control Engine fuel intake amount in order to control fuel
PCV
Valve discharge amount of supply pump.
Proportional pressure control Mechanism that
Proportional Pressure Oil pressure actuator works in proportion to hydraulic
PPC
Control pressure
Piston Pump and Oil pressure
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
Power Tilt and power Work equipment Function that performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)

00-58 WA470-7
00 Index and foreword
Foreword, safety and general information

Purpose of use (major


Abbrevia- Actual word spelled applicable machine (*), or Explanation
tion out equipment/device)
Structure that protects operator fastening seat
belt from being crushed when machine tips
Roll-Over Protective Cab and canopy over (Structure to protect operator when
ROPS:
Structure machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
International unit
SI Unit Unit system that is employed worldwide, and
system
"one unit against one factor"
Actuator that moves a part with a movable iron
SOL Solenoid Electric core in the coil (solenoid), which is moved by
energizing the coil.
Two Way Valve Hydraulic and electric Solenoid valve that switches the direction of
TWV
flow.
Variable Flow Turbocharger variable in route of exhaust
VFT Engine
Turbocharger passage.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature

WA470-7 00-59
00 Index and foreword
Foreword, safety and general information

Abbreviation Actual word spelled out


T/C Torque Converter
T/M Transmission

00-60 WA470-7
00 Index and foreword
Foreword, safety and general information

Conversion table (ALL-2150-931-A-00-A)


(Rev. 2012/01)

Method of using the conversion table


• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit
from millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
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 get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 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

WA470-7 00-61
00 Index and foreword
Foreword, safety and general information

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 2.847 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

Kilograms to pounds
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

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

00-62 WA470-7
00 Index and foreword
Foreword, safety and general information

l to U.K. Gallons
1 l= 0.21997 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

WA470-7 00-63
00 Index and foreword
Foreword, safety and general information

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

00-64 WA470-7
00 Index and foreword
Foreword, safety and general information

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

WA470-7 00-65
00 Index and foreword
Foreword, safety and general information

00-66 WA470-7
SHOP MANUAL

WHEEL LOADER
WA470-7
Model Serial Number

WA470-7 10001 and up

01 Specification
2 01 Specification

WA470-7 01-1
01 Specification
Table of contents

Table of contents (ALL-0310-002-A-00-A)


01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-5
Weight table ...................................................................................................................... 01-11
Table of fuel, coolant, and lubricants .................................................................................... 01-13

01-2 WA470-7
01 Specification
Specification drawing

Specifications (ALL-2111-001-A-00-A)

Specification drawing (WA470_7-2110-931-A-00-A)

WA470-7
Item Unit
(in P mode)
Machine weight (with BOC) kg 23,510
Operating load kg 6,720
Bucket capacity (heaped, with BOC) m3 4.2
Engine model - Komatsu SAA6D125E-6 diesel engine
Rated horsepower
• SAE J1995 [Gross] (*1) kW {HP} / 204 {273}/ 2,000 {2,000}
• ISO 14396 min-1 {rpm} 204 {273}/ 2,000 {2,000}
• ISO 9249/ SAE J1349 [Net] (*2) 203 {272}/ 2,000 {2,000}
A Overall length (with BOC, additional weight) mm 8,825
B Overall height mm 3,500
C Overall height with bucket at max. height mm 5,960
D Overall width mm 3,010
E Min. ground clearance mm 525
F Bucket width mm 3,170
G Dumping clearance (*3) Bucket tip / BOC tip mm 3,270/3,185
H Dumping reach (*3) Bucket tip / BOC tip mm 1,190/1,235
I Dumping angle deg. 45
Bucket tip / BOC tip mm 7,615/7,650
Min. turning radius
Center of outside tire mm 6,630
Allowable towing load kN {kg} 171 {17,400}
1st (forward/reverse) 7.6/7.9
locked up travel speed 2nd (forward/reverse) 13.2/13.7
(P mode) km/h
3rd (forward/reverse) 23.6/24.3
4th (forward/reverse) 38.3/39.0
*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: Indicates the value when the tilt down angle of bucket is 45 degrees.

WA470-7 01-3
01 Specification
Specification drawing

a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
194 kW {260 HP}/ 2,000 min-1 {2,000 rpm}
a BOC: Abbreviation for Bolt On Cutting edge

01-4 WA470-7
01 Specification
Specifications

Specifications (WA470_7-2111-931-A-00-A)

Machine model WA470-7


Serial No. 10001 and up
Machine weight kg 23,510
Machine weight (front wheel) in SAE
kg 10,600
travel posture
Machine weight (rear wheel) in SAE
kg 12,910
travel posture
Performance
Machine model WA470-7
Serial No. 10001 and up
Bucket capacity (heaped) m3 4.2
Operating load kg 6,720
E mode P mode
Forward 1st 6.6 7.6
When traveling in torque converter drive mode

Forward 2nd 11.4 13.1


km/h
Forward 3rd 19.6 22.9
Forward 4th 30.8 36.2
Reverse 1st 6.8 7.9
Reverse 2nd 11.7 13.5
Reverse 3rd 20.2 23.6

km/h
Reverse 4th 31.7 37.3
Travel speed

Forward 1st 6.6 7.6


Forward 2nd 11.5 13.2
When traveling with torque converter locked up

km/h
Forward 3rd 20.4 23.6
Forward 4th 33.1 38.3
Reverse 1st 6.8 7.9
Reverse 2nd 11.8 13.7
Reverse 3rd 21.1 24.3
Reverse 4th

km/h
34.2 39.0

Maximum rim pull


• Forward 170 {17,300} 192 {19,600}
kN {kg}
• Reverse 160 {16,300} 181 {18,500}
Gradeability deg. 25

WA470-7 01-5
01 Specification
Specifications

Machine model WA470-7


Serial No. 10001 and up
Minimum turning radius (center of
mm 6,630
outside tire)
Turning radius (cutting edge tip/BOC tip)
mm 7,615/7,650
in SAE travel posture

a BOC: Abbreviation for Bolt On Cutting edge

01-6 WA470-7
01 Specification
Specifications

Dimension
Machine model WA470-7
Serial No. 10001 and up
Overall length (with BOC) mm 8,825
Overall width (machine body) mm 3,010
Bucket width (with BOC) mm 3,170
Overall height (top of cab) mm 3,500
Overall height with bucket at max.
mm 5,960
height
Wheelbase mm 3,450
Tread mm 2,300
Min. ground clearance mm 525
Max. hinge pin height mm 4,360
Dumping clearance (*1)
mm 3,270/3,185
(cutting edge tip/BOC tip)
Dumping reach (*1)
mm 1,190/1,235
(cutting edge tip/BOC tip)
Steering angle deg. 35
Tilt back angle of bucket (travel posture/
deg. 50/65
max. height)
Tilt down angle of bucket (max. height) deg. 45
Digging depth, 10 deg. (cutting edge tip/
mm 265/315
BOC end)
*1: Indicates the value when the tilt down angle of bucket is 45 degrees.
a BOC: Abbreviation for Bolt On Cutting edge

WA470-7 01-7
01 Specification
Specifications

Engine
Machine model WA470-7
Serial No. 10001 and up
Model SAA6D125E-6
4-cycle, water-cooled, in-line vertical, direct injection,
Type with turbocharger, air-cooled aftercooler, and water-
cooled EGR
No. of cylinders – bore x stroke mm 6 - 125 x 150
Total piston displacement l {cc} 11.04 {11,040}
Rated horsepower
Performance (In P mode)

• SAE J1995 [Gross] (*1) kW {HP}/min- 204 {273}/ 2,000 {2,000}


1 {rpm} 204 {273}/2,000 {2,000}
• ISO 14396
• ISO 9249/ SAE J1349 [Net] (*2) 203 {272}/ 2,000 {2,000}
Nm {kgm}/
Max. torque (*1) 1,307 {133}/ 1,450 {1,450}
min-1 {rpm}
Fuel consumption rate at rated g/kWh
224 {165}
horsepower {g/HPh}
Max. speed with no load min-1 {rpm} 2,170 ± 50
Min. speed with no load min-1 {rpm} 800 (+ 50/0)
Starting motor 24 V, 7.5 kW
Alternator 24 V, 50 A
Battery (*3) 12 V, 140 Ah, 2 pieces
*1: Indicates the value of the basic engine (without cooling fan).
*2: Indicates the value at the minimum cooling fan speed.
*3: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine rated horsepower is indicated in the net value and gross value. The gross denotes the
flywheel horsepower measured on the basic engine unit, while the net denotes the value measured of an
engine under the condition essentially the same as that when it is installed on a machine.
a Following shows the rated horsepower (net) at the maximum cooling fan speed.
194 kW {260 HP}/ 2,000 min-1 {2,000 rpm}
Power train
Machine model WA470-7
Serial No. 10001 and up
Torque converter 3-element, 1-stage, 2-phase
Counter-shaft, power shift, helical and spur gear,
Transmission constant mesh type
Multiple disc, hydraulically actuated, modulation
Reduction gear system Spiral bevel gear, oil bath lubrication type
Differential Straight bevel gear type
Planetary gear single reduction type, oil bath
Final drive lubrication type
Axle
Machine model WA470-7
Serial No. 10001 and up
Drive wheel Front and rear wheel drive
Front axle Fixed to frame, semi-float type
Rear axle Center pin support, semi-float type

01-8 WA470-7
01 Specification
Specifications

Tire
Machine model WA470-7
Serial No. 10001 and up
Size 26.5R25 AA L - 3
Rim size 22.00 - 25WTB
Inflation pressure
• Front wheel kPa 450 {4.5}
• Rear wheel {kg/cm2} 350 {3.5}
Brake
Machine model WA470-7
Serial No. 10001 and up
4-wheel braking, braking with independent front and
Braking method
rear wheel systems
Main

Brake type Sealed, wet disc type


Operation type Hydraulically operated type
Operating method With hydraulic booster
Braking method Transmission output shaft braking
Parking

Brake type Wet disc type


Actuating method Actuation with spring, hydraulic release
Steering
Machine model WA470-7
Serial No. 10001 and up
Steering method Articulation type
Actuating method Hydraulic operation type
Hydraulic system
Machine model WA470-7
Serial No. 10001 and up
Power train pump
• Type Gear type
• Discharge cm3/rev 80+32
Steering pump
• Type Variable displacement swash plate piston type
Hydraulic pump

• Discharge cm3/rev 90
Work equipment pump
• Type Variable displacement swash plate piston type
• Discharge cm3/rev 120
Cooling fan pump
• Type Variable displacement swash plate piston type
• Discharge cm3/rev 30
Emergency steering pump
• Type Gear type
• Discharge cm3/rev 21

WA470-7 01-9
01 Specification
Specifications

Hydraulic system
Machine model WA470-7
Serial No. 10001 and up
Type Double-acting piston type
Steering cylinder

Cylinder bore mm 90
Piston rod outside diameter mm 50
Stroke mm 441
Max. distance between pins mm 1,296
Min. distance between pins mm 855
Type Double-acting piston type
Lift cylinder

Cylinder bore mm 140


Cylinder

Piston rod outside diameter mm 95


Stroke mm 764
Max. distance between pins mm 2,167
Min. distance between pins mm 1,403
Type Double-acting piston type
Bucket cylinder

Cylinder bore mm 160


Piston rod outside diameter mm 100
Stroke mm 575
Max. distance between pins mm 1,795
Min. distance between pins mm 1,220
Work equipment control valve
• Type 2-spool type
Control valve

MPa {kg/
• Set pressure 34.3 {350}
cm2}
Steering valve
• Type Spool type
MPa {kg/
• Set pressure 24.5 {250}
cm2}
Cooling fan motor
Motor

• Type Fixed displacement, swash plate, piston type


• Motor capacity cm3/rev 28
Work equipment
Machine model WA470-7
Serial No. 10001 and up
Link type Z-bar link
Shape of bucket cutting edge Straight cutting edge with BOC

a BOC: Abbreviation for Bolt On Cutting edge

01-10 WA470-7
01 Specification
Weight table

Weight table (WA470_7-2120-931-A-00-A)

k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model WA470-7
Serial No. 10001 and up
Engine (excluding coolant and oil) 1,486
Cooling assembly (including fan, frame, and air conditioner condenser)
(excluding coolant and oil) 369
• Cooling sub assembly (excluding fan, cooling fan motor, frame, coolant,
and oil) 204
• Radiator (1 piece) 33
• Aftercooler 25
• Oil cooler 7
• Air conditioner condenser 3
• Cooling fan motor 14
Torque converter oil cooler 25
Cooling fan pump 25
Transmission (including torque converter)
Without lockup clutch 1,148
With lockup clutch 1,193
Front drive shaft 33
Center drive shaft 40
Rear drive shaft 20
Front axle
With conventional differential 1,238
With limited slip differential 1,250
Rear axle
with conventional differential 1,168
With limited slip differential 1,180
Axle pivot (rear axle) 144
Tire and rim assembly (26.5 - R25 AA L - 3) (1 piece) 655
• Tire (26.5R25 AA L - 3) (1 piece) 415
• Rim (22.00-25WTB) (1 piece) 240
Power train pump 20
Work equipment pump 103
Steering pump 40
Work equipment control valve 108
Work equipment EPC valve 4
Brake valve 7
Steering valve 24
Emergency steering motor 13
Emergency steering pump 3
Steering cylinder assembly (1 piece) 37
Lift cylinder assembly (1 piece) 185
Bucket cylinder assembly 206
Front frame 1,852
Rear frame 1,735
Counterweight 1,595
Additional weight 385

WA470-7 01-11
01 Specification
Weight table

Unit: kg
Machine model WA470-7
Serial No. 10001 and up
Engine hood assembly (including hydraulic tank, hydraulic tank mounting
bracket, hood, grille assembly, and upper portion of bulkhead) 690
• Food body (excluding hydraulic tank hydraulic tank mounting bracket) 428
• Hood 38
• Side door (1 piece) 47
• Grille 87
• Mask 25
• Hydraulic tank (excluding hydraulic oil) 168
• Hydraulic tank mounting bracket 68
Fuel tank (excluding fuel) 194
Boom (including bushings) 1,470
Bucket link 89
Bell crank 390
Bucket (3,170 mm wide, including BOC side guard) 2,023
Operator's cab (including floor assembly) 1,078
Operator's seat 50
Air conditioner unit 5
Battery (1 piece) 45

a BOC: Abbreviation for Bolt On Cutting edge

01-12 WA470-7
01 Specification
Table of fuel, coolant, and lubricants

Table of fuel, coolant, and lubricants (WA470_7-RA19-05A-K-00-A)

a For details of notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.

WA470-7 01-13
01 Specification
Table of fuel, coolant, and lubricants

Unit: l
Refill point Specified capacity Refill capacity
Engine oil pan 47 38
Transmission case 76 65
Hydraulic oil system 270 173
Axle (front / rear) 57/56 57/56
Cooling system 80 ―
Fuel tank 380 ―

01-14 WA470-7
SHOP MANUAL

WHEEL LOADER
WA470-7
Model Serial Number

WA470-7 10001 and up

10 Structure and function


3 10 Structure and function

WA470-7 10-1
10 Structure and function
Table of contents

Table of contents (ALL-0310-002-A-00-A)


10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
KVGT.................................................................................................................................. 10-6
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-15
EGR cooler........................................................................................................................ 10-17
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Cooling fan pump ............................................................................................................... 10-30
Cooling fan motor............................................................................................................... 10-39
Power train............................................................................................................................... 10-46
Power train system............................................................................................................. 10-46
Drive shaft ......................................................................................................................... 10-49
Power train piping drawing .................................................................................................. 10-50
Transmission control .......................................................................................................... 10-51
Torque converter ................................................................................................................ 10-54
Transmission ..................................................................................................................... 10-59
Transmission control valve.................................................................................................. 10-78
Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV .......................................... 10-81
3rd, 4th clutch ECMV.......................................................................................................... 10-88
Lockup clutch ECMV .......................................................................................................... 10-95
Main relief and torque converter relief valve.......................................................................... 10-99
Axle ................................................................................................................................ 10-101
Differential ....................................................................................................................... 10-103
Final drive ....................................................................................................................... 10-113
Steering system...................................................................................................................... 10-115
Layout of steering parts .................................................................................................... 10-115
Steering column............................................................................................................... 10-116
Steering pump ................................................................................................................. 10-117
Steering valve.................................................................................................................. 10-129
Orbit-roll valve ................................................................................................................. 10-143
Stop valve ....................................................................................................................... 10-149
Emergency steering motor ................................................................................................ 10-150
Emergency steering pump ................................................................................................ 10-151
Brake system ......................................................................................................................... 10-152
Layout of brake parts........................................................................................................ 10-152
Charge valve ................................................................................................................... 10-154
Brake valve ..................................................................................................................... 10-160
Slack adjuster .................................................................................................................. 10-164
Accumulator (for brake) .................................................................................................... 10-167
Brake .............................................................................................................................. 10-168
Parking brake control ....................................................................................................... 10-171
Parking brake .................................................................................................................. 10-172
Parking brake solenoid valve ............................................................................................ 10-173
Parking brake emergency release valve............................................................................. 10-176
Undercarriage and frame......................................................................................................... 10-177
Axle mount and center hinge pin........................................................................................ 10-177
Tire ................................................................................................................................. 10-178
Hydraulic system .................................................................................................................... 10-180
Hydraulic component layout .............................................................................................. 10-180
Work equipment control .................................................................................................... 10-182
Hydraulic tank.................................................................................................................. 10-183

10-2 WA470-7
10 Structure and function
Table of contents

Double type gear pump .................................................................................................... 10-186


Work equipment pump...................................................................................................... 10-187
Control valve ................................................................................................................... 10-208
CLSS .............................................................................................................................. 10-217
Hydraulic circuit diagram and names of valves.................................................................... 10-221
Accumulator charge valve................................................................................................. 10-232
Work equipment lock solenoid valve .................................................................................. 10-236
Accumulator (for PPC circuit) ............................................................................................ 10-237
Accumulator (for ECSS) ................................................................................................... 10-238
Work equipment ..................................................................................................................... 10-239
Work equipment linkage ................................................................................................... 10-239
Bucket ............................................................................................................................ 10-240
Bucket positioner and boom positioner............................................................................... 10-241
Cab and its attachments .......................................................................................................... 10-242
ROPS cab ....................................................................................................................... 10-242
Electrical system .................................................................................................................... 10-243
Engine control system ...................................................................................................... 10-243
Preheating system ........................................................................................................... 10-245
Engine power mode selector circuit ................................................................................... 10-247
Engine output limit function ............................................................................................... 10-248
Automatic warm-up function.............................................................................................. 10-249
Parking brake control system ............................................................................................ 10-250
System operating lamp function......................................................................................... 10-252
Battery disconnect switch function ..................................................................................... 10-254
Transmission controller system ......................................................................................... 10-256
Work equipment control system......................................................................................... 10-277
Machine monitor system ................................................................................................... 10-293
Rear view monitor system................................................................................................. 10-317
KOMTRAX system ........................................................................................................... 10-320
System component parts .................................................................................................. 10-323
Sensor ............................................................................................................................ 10-350

WA470-7 10-3
10 Structure and function
Engine related parts

Engine and cooling system (ALL-R401-001-K-00-A)

Engine related parts (WA470-A001-041-K-00-A)

1. Air cleaner

10-4 WA470-7
10 Structure and function
Engine related parts

2. KDPF (*1)
3. KVGT (*2)
4. Alternator
5. Engine mount
6. EGR cooler (*3)
7. Starting motor
8. Engine oil filter
9. Engine controller
10. KCCV ventilator (*4)
11. Vibration damper
*1: For KDPF, see "KDPF".
*2: For KVGT, see "KVGT".
*3: For the EGR cooler, see "EGR cooler".
*4: For the KCCV ventilator, see "KCCV ventilator".

WA470-7 10-5
10 Structure and function
KVGT

KVGT (ENG125-AA10-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and denotes the variable displacement
turbocharger.
a The shape is subject to machine models.

10-6 WA470-7
10 Structure and function
KVGT

1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation (ENG125-AA10-044-K-00-A)

1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speed but also at
low engine speed. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
• To obtain a high EGR ratio especially at low engine speed, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speed.
• The turbine impeller (T) drives the blower impeller (C) via a shaft to send a large amount of air to the
cylinders for combustion. When the air flow from KVGT (2) increases, more fuel can be injected, and the
engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.

WA470-7 10-7
10 Structure and function
KVGT

a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.

• Exhaust gas enters from (C) of turbine housing (4), and flows out from (D) through section (P). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area varies when push rod (8) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the front cover, and also controls the right/left slide of push rod (8).
• Exhaust gas flows through vanes (6) and rotates turbine impeller (11), the torque of which rotates blower
impeller (10) via shaft (9). This works as a compressor and the air entered from (A) is compressed and
sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speed), push
rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by KVGT speed sensor (2).

When nozzle ring is closed


• At low engine speed, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed.)
• When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine
increases and the turbocharger speed increases.

10-8 WA470-7
10 Structure and function
KVGT

When nozzle ring is open


• At high engine speed, exhaust gas inlet passage (P) is widened (L2).
• As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).

a Nozzle ring (7), vane (6) and rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
Hydraulic actuator operation
• Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to the front cover.
• The force for the movement is the oil pressure supplied from boost pump (12).
a The shape is subject to machine models.

WA470-7 10-9
10 Structure and function
KVGT

• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).

1. Air cleaner
2. Mass air flow and temperature sensor

10-10 WA470-7
10 Structure and function
KVGT

3. KVGT
4. KVGT speed sensor
5. KVGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler and EGR valve)
11. EGR valve lift sensor
C. Blower impeller
T. Turbine impeller

KVGT control system


• Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and
KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil
pressure controlled by EPC valve (8), and then move the piston.
• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure
sensor, and automatically controlling the fuel injection and the KVGT.
• The KVGT is protected by controlling its speed to prevent overspeed.

Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.

Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Returning coolant flows from the center housing to the radiator.

WA470-7 10-11
10 Structure and function
EGR system piping drawing

EGR system piping drawing (ENG125-A9J0-04D-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation


a The shape is subject to machine models.

1. KVGT
2. EGR valve
3. Air intake connector
4. Intake manifold
5. Exhaust manifold
6. EGR cooler
7. Mixing connector
Function (ENG107-A9J0-042-K-00-A)

• EGR valve (driven hydraulically)


Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is
higher than the boost pressure, the exhaust gas flows to the air intake side.

10-12 WA470-7
10 Structure and function
EGR system piping drawing

• EGR cooler
Cools the exhaust gas.
Engine coolant is used for cooling.
• Air intake connector
Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
• Each sensor
Controls the EGR according to the operating condition.
Troubleshoots the system.
• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.

WA470-7 10-13
10 Structure and function
EGR system circuit diagram

EGR system circuit diagram (ENG125-A9J0-052-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR cooler
6. EGR valve
7. Hydraulic actuator (power piston)
8. EPC valve (for EGR valve)
9. EGR valve lift sensor
10. Exhaust manifold
11. Boost pump
12. Intake manifold
13. Charge (boost) pressure and temperature sensors
14. Engine controller
15. Mixing connector
C: Blower impeller
T: Turbine impeller
Operation (ENG125-A9J0-044-K-00-A)

• The engine controller outputs signals for opening EGR valve (6) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (10)
through EGR piping to EGR cooler (5).
• The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in
mixing connector (15), and then flows into intake manifold (12).

10-14 WA470-7
10 Structure and function
EGR valve

EGR valve (ENG125-A9K1-041-K-00-A)

a The shape is subject to machine models.

1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
6. EGR valve lift sensor
7. EPC valve (for EGR)
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
Structure
• The EGR valve consists of the EGR gas flow control mechanism and the EPC valve .
• An EPC valve is provided for EGR valve control, and an EPC valve for KVGT control is installed to front
cover.

WA470-7 10-15
10 Structure and function
EGR valve

Operation (ENG107-A9K1-044-K-00-A)

• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
• Spool (4) is pressed to the right by the force of spring (5), and EGR valve (1) is closed by the force of
spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
• When force (Fp) becomes larger than force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas
will flow to the intake side.
• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4).
• The valve position is controlled by the engine controller by controlling the spool position with the control
pressure of the EPC valve.
• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
• Position of spool (4) is sensed by the EGR valve lift sensor.

10-16 WA470-7
10 Structure and function
EGR cooler

EGR cooler (ENG125-A9L0-041-K-00-A)

a The shape is subject to machine models.

1. Header plate
4. Shell
A: EGR gas inlet
B: EGR gas outlet (to EGR valve)
C: Coolant inlet
D: Coolant outlet
E: Air vent
F: Air vent

2. Flat tube
3. Inner fin
Operation (ENG125-A9L0-044-K-00-A)

• The EGR gas enters from (A) and flows through 9 flat tubes (2).

WA470-7 10-17
10 Structure and function
EGR cooler

• Coolant enters from (C) and flows around flat tube (2) in shell (4) and then goes out from (D).
• The EGR gas is effectively cooled by flat tubes (2) with inner fins (3) and flows out from EGR gas outlet
(B).

10-18 WA470-7
10 Structure and function
KCCV layout drawing

KCCV layout drawing (ENG125-A180-04D-K-00-A)

KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation


a The shape is subject to machine models.

1. KCCV ventilator
2. KVGT
3. Check valve
4. CDR valve
A: Blowby gas
B: Engine oil-free blowby gas (to KVGT)
C: Engineoil that C is separated (to oilpan)
• Formerly blowby gas (A) was discharged to the atmosphere as is. However, the tightened exhaust gas
regulation no longer permits releasing blowby gas to the atmosphere.
• Since blowby gas (A) contains engine oil components, which may cause the following problems when
recirculated to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to adherence of engine oil

WA470-7 10-19
10 Structure and function
KCCV layout drawing

Operation (ENG125-A180-044-K-00-A)

a The figure on the left shows the traditional flow of blowby gas that has been discharged to the atmosphere.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.

1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
• Separated engine oil (C) flows through a check valve and falls to the oil pan.

10-20 WA470-7
10 Structure and function
KCCV ventilator

KCCV ventilator (ENG125-A18H-041-K-00-A)

a The shape is subject to machine models.

1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
A: Blowby gas inlet (engine breather)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlets
Function (ENG125-A18H-042-K-00-A)

• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
• Warmed engine coolant is conducted to the locations that pose potential problem of freezing to prevent it
from happening.

WA470-7 10-21
10 Structure and function
KCCV ventilator

Operation (ENG107-A18H-044-K-00-A)

• Blowby gas enters from (A). The larger drops of oil mist are removed from the blowby gas when it flows
through the impactor (5) holes in filter (6).
• Smaller drops of oil mist are removed by filter (6).
• Removed oil flows down along the case wall to oil drain port (C) and then flows to the oil pan.
• The CDR valve operates when the pressure inside the crankcase becomes negative, to prevent excessive
negative pressure in the crankcase.
• Crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
• When the engine controller determines that the filter is clogged from crankcase pressure sensor (3)
signals, failure code CA555 is issued. If the pressure increases further, failure code CA556 is issued.
• Relief valve (4) is installed in case (1). It operates to protect the KCCV ventilator and engine when filter (6)
is blocked.
CDR valve (ENG107-A18A-041-K-00-A)

CDR: Abbreviation for Crankcase Depression Regulator

1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.

10-22 WA470-7
10 Structure and function
KDPF

KDPF (ENG125-A9H0-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter


a The shape is subject to machine models.

1. Inlet unit
2. KDOC inlet temperature sensor
3. KDOC outlet temperature sensor
4. KCSF unit
5. Aggregate connector box
6. KDPF outlet temperature sensor
7. Outlet unit
8. KDPF differencial pressure sensor port
9. KDPF differencial pressure sensor
10. KDPF differential pressure sensor port
11. KDOC unit
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
• The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11)
that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and
outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit
(4).

WA470-7 10-23
10 Structure and function
KDPF

• KDOC unit (11) consists of a ceramic honeycomb coated with oxidation catalyst material. By using this
ceramic honeycomb, it regenerates (*1) NO (nitrogen monoxide) to NO2 (nitrogen dioxide) in exhaust gas.
• The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
• The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
• The KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
• Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
• Temperature signals from these three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
• The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Denotes to purification (oxidation) processing of soot.
k While engine is running and for some time after engine is stopped, the surface of KDPF and
nearby piping are extremely hot. Be careful not to get burned when working near the KDPF.

Function (ENG125-A9H0-042-K-00-A)

A: Flow of exhaust gas


1. KDOC(oxidation catalyzer)
2. KCSF
3. Sealing (made of ceramics)
4. Cell
5. Ceramics honeycomb
• The KDPF purifies the exhaust gas by catching most of the granulous or chain-like soot formed by the PM
(particulates in air such as soot) included in the exhaust from the engine.
• KCSF (2) is made of ceramic.

10-24 WA470-7
10 Structure and function
KDPF

• Inside the KCSF (2), there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) are naturally oxidized and burned away by the effect of KDOC (1)
(oxidation catalyzer), in operating conditions with relatively high exhaust gas temperatures. (This is
referred to as "passive regeneration".)
• On the other hand, when the exhaust temperature is relatively low, in conditions such as continued low
load operations, the deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF (2) differential pressure sensor signals.
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. (This operation is called "exhaust temperature-raising
control")
• As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
• Fuel is injected from (fuel doser) installed to the outlet portion of turbocharger. (Fuel dosing) Fuel that is
injected into this piping mixes with exhaust gas and combusts (oxidizes) soot by the action of KDOC (1).
• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
the KCSF (2) will increase.
• If the soot deposit in the KCSF (2) exceeds a certain level, it will be necessary to perform "manual
stationary regeneration" to burn away (oxidize) the soot in the KCSF (2).
• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration"
Displaying KDPF regeneration (HM400-A9H0-042-K-00-A)

a Regeneration refers to a new function used for purifying (oxidizing) soot accumulated in the soot collection
filter (KCSF) inside the KDPF.
1. Passive regeneration
When the engine exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will
be stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration (increase of engine exhaust temperature + fuel dosing)
1) Automatic regeneration
This is the regeneration process started automatically when the soot deposit exceeds a certain level.
At this time, the engine controller performs the exhaust temperature-raising control mode (*1) and fuel
dosing (*2). Another type of automatic regeneration is performed by the engine controller at certain
intervals, regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGTare controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process.
2) Manual stationary regeneration
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request, on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service)
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.

WA470-7 10-25
10 Structure and function
KDPF

• When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KDOC. If some of the conditions for automatic drying are not
met, manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping KDPF
regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the KDPF,
leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is low.
Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGTautomatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes and
the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low temperatures,
white smoke may come out from the exhaust pipe for a short time, but this is normal. Be sure to
perform regeneration at a well ventilated place since carbon monoxide can be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be smelled
from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at the
exhaust pipe can exceed 650°C. Make sure that there is no flammable material near the exhaust
system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe, and pay
sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
KDOC_In KDOC_Out KDPF_Out
(KDOC inlet temperature (KDOC outlet (KDPF outlet
sensor) temperature sensor) temperature sensor)
Not regenerating (idling) 100 to 250°C
Regenerating (under
exhaust temperature-raising 100 to 250°C 400 to 550°C
control: 1,000 rpm)

10-26 WA470-7
10 Structure and function
Cooling system

Cooling system (WA470-B000-041-K-00-A)

1. Accumulator charge valve


2. Reservoir tank
3. Cooling fan, brake pump

WA470-7 10-27
10 Structure and function
Cooling system

4. Aftercooler outlet hose


5. Radiator cap
6. Radiator inlet hose
7. Aftercooler inlet hose
8. Power train oil cooler inlet
9. Coolant drain valve
10. Cooling fan motor
11. Fan guard
12. Radiator
13. Cooling fan
14. Hydraulic oil cooler inlet hose
15. Aftercooler
16. Condenser
17. Power train oil cooler
18. Power train oil cooler outlet
19: Hydraulic oil cooler outlet hose
20. Radiator outlet hose
21. Hydraulic oil cooler

10-28 WA470-7
10 Structure and function
Cooling system

Specifications (WA470-B000-030-K-00-A)

Power train oil


Radiator Oil cooler Aftercooler
cooler
Core type AL WAVE-5 AL WAVE AL WAVE PTO-OL
100 x 558 x 20
Fin pitch (mm) 6.0/2 6.0/2 6.0/2 layers
(*1)
Total heat dissipation
area (m2) 84.28 x 2 8.16 25.24 2.152
Pressure valve cracking
88.3 ± 14.7
pressure ― ― ―
{0.9 ± 0.15}
(kPa {kg/cm2})
Vacuum valve cracking
0 to 4.9
pressure ― ― ―
{0 to 0.05}
(kPa {kg/cm2})
1: Indicates the element size.

WA470-7 10-29
10 Structure and function
Cooling fan pump

Cooling fan pump (WA500-B450-041-K-00-A)

P1: Pump discharge port


PAEPC: EPC output pressure pickup plug
PE: Control piston pressure input port
PEPC: EPC valve source pressure input port
PH: Pump discharge pressure output port
PS: Pump suction port
T0: Drain port
1. Servo valve
2. Air bleeder
3. EPC valve
4. Control current input connector

10-30 WA470-7
10 Structure and function
Cooling fan pump

1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
11. Ball retainer

WA470-7 10-31
10 Structure and function
Cooling fan pump

Structure
• Cylinder block (7) is supported on shaft (1) by spline (a).
• Shaft (1) is supported by each bearing at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) pivot on ball retainer (11).
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while blocking the pressurized oil.
• This plane is designed so that the oil pressure is balanced correctly.
• The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (7)
through valve plate (8).
Specifications (WA470-B450-030-K-00-A)

Model LPV30
Type Variable displacement swash plate type piston pump
Theoretical discharge (cm3/rev) 30
Fan drive pressure (MPa {kg/cm2}) 10.9 {111}
Rated speed (rpm) 2,282

Function (WA380-B450-042-K-00-A)

• The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.
• It is possible to change the delivery by changing the swash plate angle.

10-32 WA470-7
10 Structure and function
Cooling fan pump

Operation (WA380-B450-044-K-00-A)
Operation of pump

• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) pivots on ball retainer (11), and accordingly angle (a) between center line (X) of rocker
cam (4) and the axial direction of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
• Pistons (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Oil in amount of (F) minus (E) goes in and out of each cylinder.
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.
• In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge
stroke.

WA470-7 10-33
10 Structure and function
Cooling fan pump

• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
• Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 deg.)
• The pump delivery is in proportion to swash plate angle (a).

10-34 WA470-7
10 Structure and function
Cooling fan pump

Control of delivery

• When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
delivery (Q) is increased.
• Swash plate angle (a) is changed by servo piston (10).
• Servo piston (10) reciprocates linearly according to the signal pressure of the servo valve.
• This straight line movement is transmitted to rocker cam (4).
• Rocker cam (4) supported with ball retainer (11) pivots on ball retainer (11).

WA470-7 10-35
10 Structure and function
Cooling fan pump

Servo valve (WA470-B4H0-041-K-00-A)

P: EPC valve source pressure port


PE: Control piston pressure port
PH: Pump discharge pressure port
T: Drain port
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
8. Spring
9. Pilot valve

10-36 WA470-7
10 Structure and function
Cooling fan pump

Function (PC400-B4H0-042-K-00-A)
• The servo valve controls the pump so that the input current (i) to the EPC valve relates to pump delivery
(Q) as shown in the figure below.

Operation (PC400-B4H0-044-K-00-A)
• The output pressure of the EPC valve enters piston chamber (C) and pushes piston (6).
• Piston (6) pushes spool (5) and moves to a position where it is balanced with the spring.
• Land (PE) of the servo piston pressure passage is connected to pump delivery pressure passage (PH)
through the notch of spool (5), so the pump delivery pressure is transmitted to servo piston (10).
• Rocker cam (9) is pushed up by servo piston (10), and then its position is fed back and lever (2) moves to
compress spring (8).

WA470-7 10-37
10 Structure and function
Cooling fan pump

• If spool (5) is pushed back, the pump delivery circuit and servo piston circuit are disconnected.
• The pressure in the servo piston chamber decreases and rocker cam (9) moves toward the maximum
swash plate angle.
• These processes are repeated until the swash plate stabilizes at an angle where the EPC output pressure
is balanced with the force of spring (8).
• As the EPC output pressure increases, the swash plate angle decreases. As the EPC output pressure
decreases, the swash plate angle increases.

10-38 WA470-7
10 Structure and function
Cooling fan motor

Cooling fan motor (WA380-B5L0-041-K-00-A)

P: From fan pump


T: To oil cooler
TC: To hydraulic tank

WA470-7 10-39
10 Structure and function
Cooling fan motor

1. Output shaft
2. Case
3. Thrust plate
4. Piston assembly
5. Cylinder block
6. Valve plate
7. End cover
8. Center spring
9. Check valve
10. Pilot valve
11. Reversible valve spool
12. Safety valve
13. Cooling fan speed sensor
Specifications (WA470-B5L0-030-K-00-A)

Model LMF28
Capacity (cc/rev) 28.0
Rated speed (rpm) 1,300
Rated flow rate (l/min) 36.4
Check valve cracking pressure (MPa {kg/
0.044 {0.45}
cm2})

10-40 WA470-7
10 Structure and function
Cooling fan motor

Hydraulic motor (WA380-B5N0-042-K-00-A)

• This hydraulic motor is called a swash plate axial piston motor. It converts the energy of the pressurized oil
sent from the hydraulic pump into rotary motion.
• This fan motor is installed within the blade width as shown in the figure.

Principle of operation (HM300-B5N0-04B-K-00-A)

• The pressurized oil sent from the pump flows through valve plate (3) into cylinder block (5).
• This oil can flow to only one side of the (Y - Y) line connecting the top dead center and bottom dead center
of the stroke of piston (4).
• The pressurized oil sent to one side of cylinder block (5) pushes each piston (4) (two or three pistons).
• A single piston generates force F1 [F1 (kg) = P (kg/cm2) x xD2 / 4 (cm2)].
• This force acts on thrust plate (2).
• Since thrust plate (2) is fixed at specific angle (a) to output shaft (1), the force is divided into components
(F2) and (F3).
• Of those components, radial component (F3) generates torque (T = F3 x ri) against the (Y - Y) line
connecting the top dead center and bottom dead center.
• The total of these torque [T = s (F3 x ri)] rotates cylinder block (5) through piston (4).
• Cylinder block (5) is connected to output shaft (1) with spline.
• Output shaft (1) rotates to transmit the torque.

WA470-7 10-41
10 Structure and function
Cooling fan motor

10-42 WA470-7
10 Structure and function
Cooling fan motor

Suction valve (HM300-B6D0-001-K-00-A)


Function (HM300-B6D0-042-K-00-A)
• When the pump stops, the pressurized oil does not flow into the motor any more.
• Since the motor continues to rotate with the force of inertia, the pressure on the outlet side of the motor
increases.
• When the oil stops flowing in from inlet port (P), suction valve (1) sucks in the oil on the outlet side and
supplies it to port (MA), compensating for the lack of oil on that side to prevent cavitation.

Operation (WA500-B6D0-044-K-00-A)

When pump is started

• The pressurized oil from the pump is supplied to port (P), increasing the (MA) side pressure.
• The starting torque is generated in the motor, and the motor starts rotating.
• The pressurized oil on the motor outlet (MB) side returns to the tank through port (T).

WA470-7 10-43
10 Structure and function
Cooling fan motor

When pump is stopped

• When the engine stops, the pump input speed becomes 0 rpm.
• The pressurized oil from the pump is not supplied to port (P).
• As the pressurized oil is not supplied to (MA) side of the motor, the motor speed decreases gradually to
stop.
• When the motor shaft is rotated by the force of inertia while the oil flow in port (P) is decreasing, the oil in
port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent cavitation.
Reversible valve (WA500-B6E0-041-K-00-A)

The rotating direction of the fan motor changes from the normal rotation to the reverse rotation, or from the
reverse rotation to the normal rotation corresponding to the current data which controls the pilot valve.
• When changing from the normal rotation to the reverse rotation:

The solenoid valve controls the spool position according to the command current which is output from
controller in proportion to the set rate. While the command current passes the neutral range area, the fan
becomes neutral and the fan speed decreases sufficiently. As a result, the direction of the fan changes to
reverse rotation smoothly.
• The fan rotation changes similarly from reverse to normal.

10-44 WA470-7
10 Structure and function
Cooling fan motor

Safety valve (ALL-B6G0-001-K-00-A)

Function (PC400-B6G0-042-K-00-A)
• When the engine is started, the pressure in port (P) of the fan motor is increased in some cases.
• Safety valve (1) is provided in order to protect the fan system circuit.

Operation (WA500-B6G0-044-K-00-A)

• If the pressure in port (P) rises above the cracking pressure of safety valve (1), valve (2) of safety valve (1)
opens to release the pressurized oil into port (T).
• This operation prevents the generation of the abnormally high pressure in port (P).

WA470-7 10-45
10 Structure and function
Power train system

Power train (ALL-C100-001-K-00-A)

Power train system (WA470-C100-041-K-00-A)

1. Transmission
2. Torque converter
3. Engine
4. Rear axle
5. Rear drive shaft
6. Center drive shaft
7. Front drive shaft
8. Front axle

10-46 WA470-7
10 Structure and function
Power train system

Power train system

1. Front axle
2. Differential
3. Wet-type multiple-disc brake

WA470-7 10-47
10 Structure and function
Power train system

4. Final drive
5. Front drive shaft
6. Center drive shaft
7. Parking brake (wet-type multiple-disc)
8. Transmission (counter-shaft type)
9. Rear drive shaft
10. Rear tire
11. Final drive
12. Wet-type multiple-disc brake
13. Differential
14. Rear axle
15. Engine
16. Torque converter
17. Steering pump
18. Power train pump
19. Work equipment pump
20. Cooling fan pump
21. Flange bearing
22. Front tire
Function (WA470-C100-042-K-00-A)

• The power of engine (15) is transmitted to torque converter (16) through the flywheel.
The torque converter converts the received torque to the torque corresponding to the fluctuation of the
load by using oil as a medium, and transmits it to the input shaft of transmission (8). The engine power is
also transmitted through the pump drive gear of the torque converter to work equipment pump (19),
cooling fan pump (20), steering pump (17), and power train pump (18) to drive those pumps.
• Transmission (8) selects one from the four gear speeds each in the forward and reverse directions by
operating the six hydraulic clutches with the directional and gear shift valves among the transmission
valves.
• Parking brake (7) is a wet-type multiple-disc brake to stop the machine. It is installed on the front side of
the output shaft and actuated by the solenoid valve which is operated with the parking brake switch.
• The power of transmission (8) is transmitted to the front and rear axles.
The power for the front side is transmitted through center drive shaft (6), flange bearing (21), and front
drive shaft (5) to front axle (1).
The power for the rear side is transmitted through rear drive shaft (9) to rear axle (14).
• The powers transmitted to front axle (1) and rear axle (14) is reduced in speed by the pinions of
differentials (2) and (13), and then transmitted to the respective sun gear shafts through the differentials.
• The power of each sun gear is further reduced in speed by final drives (4) and (11), and then transmitted
through the axle shafts to tires (10) and (22).

10-48 WA470-7
10 Structure and function
Drive shaft

Drive shaft (WA470-D510-041-K-00-A)

1. Front drive shaft


2. Flange bearing
3. Center drive shaft
4. Rear drive shaft
Function (WA380-D510-042-K-00-A)

• The power from the transmission output shaft is transmitted through center drive shaft (3), front drive shaft
(1), and rear drive shaft (4) to the front and rear axles.
• The relative positions of the transmission and front and rear axles change due to articulation of the
machine body, or impacts received from the road surface during traveling, or impacts during operations,
etc. The drive shafts absorb the fluctuation of their angle and length by the universal joints and flange
bearings (2) so that the power is transmitted even when the machine receives the above impacts and
when the positions of the components change.

WA470-7 10-49
10 Structure and function
Power train piping drawing

Power train piping drawing (WA470-C150-041-K-00-A)

1. Power train pump


2. Hydraulic tank
3. Power train oil cooler
4. Last chance filter
5. Transmission ECMV
6. Power train mount
7. Oil filler pipe
8. Oil filter
9. Transmission assembly

10-50 WA470-7
10 Structure and function
Transmission control

Transmission control (WA470-CN20-041-K-00-A)

WA470-7 10-51
10 Structure and function
Transmission control

1. Machine monitor
2. Parking brake switch
3. Kickdown switch
4. Hold switch
5. Transmission cut-off and transmission cut-off set switch
6. Monitor controller
7. Transmission controller
8. Relay
9. Fuse box
10. Transmission cut oil pressure sensor
11. Brake valve
12. Directional lever and gear speed switch
13. Transmission ECMV
14. Transmission output speed sensor
Function (WA380-CN20-042-K-00-A)

No. Function Operation


Selection of FORWARD,
1 The travel direction can be selected with the directional lever.
REVERSE or NEUTRAL
2 Selection of gear speed The gear speed can be selected with the gear speed switch.
The gear speed can be shifted down by pushing the kickdown switch
without operating the gear shift lever. In the manual shift mode, only the
3 Kickdown forward 2nd is shifted down. In the automatic shift mode, the gear speed is
shifted down according to the gear speed and travel speed before the
switch is operated.
If the hold switch is pushed in the automatic shift mode, the current gear
speed is maintained and is not shifted up even if the travel speed
4 Hold
increases. Even if the travel speed decreases, the gear speed is not
shifted down.

10-52 WA470-7
10 Structure and function
Transmission control

When the transmission cut-off switch is turned "ON", the transmission is


5 Transmission cut-off set in neutral with the adjusted pressing distance of the L.H. brake pedal.
Transmission cut-off function is used to adjust the pressing distance of the
6 Transmission cut-off setting L.H. brake pedal to set the transmission in neutral.
The transmission cut-off function can be turned ON/OFF. While this
Transmission cut-off function is turned "OFF", the L.H. brake pedal works as a normal brake
7
selection pedal.
The transmission is kept in neutral while the parking brake is applied.
8 Neutralizer Seizure of the parking brake is prevented with this function when the
operator starts the machine by mistake while the parking brake is applied.
Even if the starting switch is operated, the engine does not start, that is,
9 Neutral safety the machine does not start, while the directional lever is not in the "N
(NEUTRAL)" position.
While the machine is traveling in reverse, the backup lamp and backup
10 Alarm buzzer are turned on to give a warn around the machine.

WA470-7 10-53
10 Structure and function
Torque converter

Torque converter (WA470-CD00-041-K-00-A)

1. Pilot
2. Flywheel
3. Lockup clutch housing
4. Boss
5. Turbine
6. Drive case
7. Stator
8. Pump
9. PTO gear
10. PTO drive gear (number of teeth: 97)
11. Stator shaft
12. Guide
13. Input shaft

10-54 WA470-7
10 Structure and function
Torque converter

14. Free wheel


15. Race
16. Lockup clutch disc
17. Lockup clutch piston
Specifications (WA470-CD00-030-K-00-A)

Type 3-element, 1-stage, 2-phase


Stall torque ratio 2.14

WA470-7 10-55
10 Structure and function
Torque converter

Power transmitting route (WA470-CD00-052-K-00-A)


When lockup clutch is "disengaged"

Drive case (3), boss (9) and turbine (8) are separated and the torque converter works as an ordinary torque
converter.
Power from engine
O
Flywheel (1)
O
Clutch housing (2)
O
Drive case (3), pump (5), and PTO drive gear (6) rotate as one unit
O
Oil is used as a medium
O
Turbine (8) and boss (9)
O
Transmission input shaft (10)
• The power transmitted to PTO drive gear (6) is then transmitted through PTO gear (7) to drive the pump.

10-56 WA470-7
10 Structure and function
Torque converter

When lockup clutch is "engaged"

Drive case (3), boss (9), and turbine (8) are connected and the torque converter is locked up.
Power from engine
O
Flywheel (1)
O
Clutch housing (2)
O
Drive case (3), pump (5), and PTO drive gear (6) rotate as one unit
O
Lockup clutch (4)
O
Boss (9)
O
Transmission input shaft (10)
• The power transmitted to PTO drive gear (6) is then transmitted through PTO gear (7) to drive the pump.

WA470-7 10-57
10 Structure and function
Torque converter

Oil flow (WA470-CD00-044-K-00-A)

• The oil flows through the main relief valve and its pressure is regulated to the set pressure or below by the
torque converter relief valve. It then flows in inlet port (A), goes through the oil passages of stator shaft (1)
and guide (2), and flows into pump (3).
• The oil is given centrifugal force by pump (3) and flows in turbine (4) to transfer its energy to turbine (4).
• The oil from turbine (4) is sent to stator (5) and flows into pump (3) again. However, a part of the oil flows
between turbine (4) and stator (5), and through outlet port (B) to the oil cooler to be cooled, and then
lubricates the transmission.

10-58 WA470-7
10 Structure and function
Transmission

Transmission (WA470-CF00-041-K-00-A)

WA470-7 10-59
10 Structure and function
Transmission

A: From power train pump (for torque converter)


B: From torque converter oil cooler
C: Torque converter outlet oil pressure pickup port
D: To power train oil cooler
E: To power train pump
F: From power train pump (for lubricating oil)
1. Work equipment hydraulic pump and cooling fan pump mounting port
2. Steering and power train pump mounting port
3. Oil filler pipe mounting port
4. Front coupling
5. Torque converter
6. Transmission control valve (left valve assembly)
7. Transmission input speed sensor
8. Parking brake indicator switch
9. Rear coupling
10. Oil level gauge
11. Transmission oil filter
12. Transmission case (front)
13. Main relief valve and torque converter relief valve
14. Transmission case (rear)
15. Drain plug
16. Transmission output speed sensor
17. Transmission lubricating oil temperature sensor
18. Breather
19. Torque converter outlet port oil temperature sensor
20. Transmission cntrol valve (right valve assembly)
21. Torque converter in let pressure sensor
22. Torque converter out let pressure sensor

10-60 WA470-7
10 Structure and function
Transmission

1. Input shaft
2. Torque converter
3. F clutch
4. R clutch
5. 4th clutch
6. Rear coupling
7. Output shaft
8. Output gear (number of teeth: 52)
9. Parking brake
10. Front coupling
11. Transfer gear 2
12. Lower shaft
13. Transfer shaft 2
14. 3rd clutch
15. middle shaft
WA470-7 10-61
10 Structure and function
Transmission

16. Transfer gear 1


17. 2nd clutch
18. Upper shaft
19. 1st clutch

1. PTO gear A(number of teeth: 85)


2. PTO gear B(number of teeth: 85)
3. Strainer

10-62 WA470-7
10 Structure and function
Transmission

F, 1st clutch (WA470-CF82-041-K-00-A)

A: F clutch oil port


B: 1st clutch oil port
C: Lubricating oil port
1. Upper shaft
2. 1st clutch gear (number of teeth: 35)
3. 1st clutch
4. F and 1st cylinders
5. F clutch
6. F clutch gear (number of teeth: 51)

WA470-7 10-63
10 Structure and function
Transmission

R, 2nd clutch (WA470-CFJ1-041-K-00-A)

A: R clutch oil port


B: 2nd clutch oil port
C: Lubricating oil port
1. Middle shaft
2. Transfer shaft 1 (number of teeth: 64)
3. 2nd hub
4. 2nd clutch
5. R and 2nd cylinders (number of teeth: 50,62)
6. R clutch
7. R gear (number of teeth: 51)

10-64 WA470-7
10 Structure and function
Transmission

3rd, 4th clutch (WA470-CFK1-041-K-00-A)

A: 3rd clutch oil port


B: 4th clutch oil port
C: Lubricating oil port
1. Lower shaft
2. 3rd cylinder
3. 3rd clutch
4. 3rd gear (number of teeth: 48)
5. 4th gear (number of teeth: 36)
6. 4th clutch
7. 4th cylinder

Structure (WA470-CF60-041-K-00-A)
• The transmission employs the counter-shaft, constant mesh type gear mechanism and the disc clutches
and has "forward 4-speeds and reverse 4-speeds".
• The transmission selects one rotating direction and one gear speed by fixing two of the six disc clutches
hydraulically by the operation of the ECMV in the counter-shaft type constant mesh gear mechanism.
• The transmission transmits the power received by the transmission input shaft to the output shaft by
changing the gear speed (forward 1st to 4th or reverse 1st to 4th) with any combination of the forward or
reverse clutch, and one of four speed clutches.

Number of plates and discs used


Clutch name Number of plates Number of discs
F clutch 15 14
R clutch 15 14
1st clutch 13 12
2nd clutch 13 12
3rd clutch 10 9
4th clutch 13 12

Combinations of clutches for each gear speed and reduction ratios


Gear speed Clutches to be used Reduction ratio
Forward 1st F x 1st 3.886
Forward 2nd F x 2nd 2.196
Forward 3rd F x 3rd 1.218
WA470-7 10-65
10 Structure and function
Transmission

Gear speed Clutches to be used Reduction ratio


Forward 4th F x 4th 0.737
Neutral - -
Reverse 1st R x 1st 3.760
Reverse 2nd R x 2nd 2.125
Reverse 3rd R x 3rd 1.179
Reverse 4th R x 4th 0.713

10-66 WA470-7
10 Structure and function
Transmission

Disc clutch (HM300-CF60-001-K-00-A)


Operation (WA470-CF60-044-K-00-A)

When clutch is "engaged" (locked)

• The oil sent from the ECMV is supplied with pressure through the oil passage of shaft (1) to the back of
piston (2), and pushes piston (2) to the right.
• Piston (2) presses plates (3) against discs (4) to stop rotation of discs (4) with the friction force between
them.
• As the internal teeth of discs (4) are meshed with clutch gear (5), shaft (1) and clutch gear (5) transmit the
power in one piece.
• The oil is drained through oil drain hole (6), but it does not affect the operation of the clutch since its
quantity is far less than the quantity of the supplied oil.

When clutch is "disengaged" (released)

• When the oil sent from the ECMV is shut off, the oil pressure applied to the back of piston (2) decreases.
• Piston (2) is pushed back to the left by the reactive force of wave spring (7).
• The friction force between plates (3) and discs (4) is lost and shaft (1) and clutch gear (5) are released.
• When the clutch is disengaged, the oil on the back of the piston is drained by the centrifugal force through
oil drain hole (6) to prevent partial engagement of the clutch.
a Oil drain hole (6) is provided only in the 3rd and 4th clutches.

WA470-7 10-67
10 Structure and function
Transmission

Power transmitting route (HM300-CF60-001-K-01-A)

Forward 1st (WA470-CF60-044-K-01-A)

10-68 WA470-7
10 Structure and function
Transmission

F clutch (5) and 1st clutch (9) are fixed hydraulically.


Power from torque converter o (from bottom left) o (from bottom center)
O O O
Input shaft (1) 1st clutch (9) Output gear (24)
O O O
Input shaft gear (2) 1st clutch gear (10) Output shaft (25)
O O
F gear (3) Transfer shaft 1 (13)
O O
F clutch (5) Transfer gear 1 (14)
O O
F/1st cylinder (7) Transfer gear 2 (23)
O O
(to top center)o (to top right) o

WA470-7 10-69
10 Structure and function
Transmission

Forward 2nd (WA470-CF60-044-K-02-A)

10-70 WA470-7
10 Structure and function
Transmission

F clutch (5) and 2nd clutch (11) are fixed hydraulically.


Power from torque converter o (from bottom left) o (from bottom center)
O O O
Input shaft (1) 2nd clutch (11) Output shaft (25)
O O
Input gear (2) 2nd hub (12)
O O
F gear (3) Transfer shaft 1 (13)
O O
F clutch (5) Transfer gear 1 (14)
O O
F/1st cylinder (7) Transfer gear 2 (23)
O O
R/2nd cylinder (8) Output gear (24)
O O
(to top center)o (to top right) o

WA470-7 10-71
10 Structure and function
Transmission

Forward 3rd (WA470-CF60-044-K-03-A)

10-72 WA470-7
10 Structure and function
Transmission

F clutch (5) and 3rd clutch (16) are fixed hydraulically.


Power from torque converter o (from bottom left) o (from bottom center)
O O O
Input shaft (1) 3rd gear (15) Output gear (24)
O O O
Input gear (2) 3rd clutch (16) Output shaft (25)
O O
F gear (3) 3rd cylinder (17)
O O
F clutch (5) Lower shaft (21)
O O
F/1st cylinder (7) Transfer shaft 2 (22)
O O
R/2nd cylinder (8) Transfer gear 2 (23)
O O
(to top right) o (to top right) o

WA470-7 10-73
10 Structure and function
Transmission

Forward 4th (WA470-CF60-044-K-04-A)

10-74 WA470-7
10 Structure and function
Transmission

F clutch (5) and 4th clutch (19) are fixed hydraulically.


Power from torque converter o (from bottom left) o (from bottom center)
O O O
Input shaft (1) 4th gear (18) Output gear (24)
O O O
Input gear (2) 4th clutch (19) Output shaft (25)
O O
F gear (3) 4th cylinder (20)
O O
F clutch (5) Lower shaft (21)
O O
F/1st cylinder (7) Transfer shaft 2 (22)
O O
R/2nd cylinder (8) Transfer gear 2 (23)
O O
(to top right) o (to top right) o

WA470-7 10-75
10 Structure and function
Transmission

Reverse 1st (WA470-CF60-044-K-05-A)

10-76 WA470-7
10 Structure and function
Transmission

R clutch (6) and 1st clutch (9) are fixed hydraulically.


Power from torque converter o (from bottom left) o (from bottom center)
O O O
Input shaft (1) R/2nd cylinder (8) Transfer gear 2 (23)
O O O
Input gear (2) F/1st cylinder (7) Output gear (24)
O O O
R gear (4) 1st clutch (9) Output shaft (25)
O O
R clutch (6) 1st gear (10)
(The output rotation is reversed by O
transmitting the power of input gear Transfer shaft 1 (13)
(2) without through the upper shaft)
O
Transfer gear 1 (14)
O O
(to top center)o (to top right) o

WA470-7 10-77
10 Structure and function
Transmission control valve

Transmission control valve (WA470-CJA0-041-K-00-A)


Left valve assembly

A: R clutch oil pressure pickup port


B: 2nd clutch oil pressure pickup port
C: 3rd clutch oil pressure pickup port
D: From parking brake emergency release valve
E: To parking brake
F: Parking brake indicator switch mounting location
G: Parking brake oil pressure pickup port
H: Transmission lubricating oil pressure pickup port
1. R clutch ECMV
2. 2nd clutch ECMV
3. 3rd clutch ECMV
4. Parking brake solenoid valve
5. Last chance filter

10-78 WA470-7
10 Structure and function
Transmission control valve

Right valve assembly

A: Lockup clutch oil pressure pickup port


B: F clutch oil pressure pickup port
C: 1st clutch oil pressure pickup port
D: 4th clutch oil pressure pickup port
1. Lockup clutch ECMV
2. F clutch ECMV
3. 1st clutch ECMV
4. 4th clutch ECMV

WA470-7 10-79
10 Structure and function
Transmission control valve

Function (WA470-CJA0-042-K-00-A)

• The oil from the pump flows through the oil filter into the transmission control valve assembly and then is
divided into the main relief circuit and clutch actuation circuit.
• The oil regulated its pressure by the main relief valve and flowed into the clutch operating circuit goes
through the last chance filter, then operates the clutch and parking brake. The oil relieved from the main
relief valve is supplied to the torque converter.
• When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according to
the command current from the transmission controller to reduce the gear shifting shocks. The ECMV also
keeps the clutch pressure constant during travel.
• If the F or R, and one of the 1st to 4th clutch ECMVs are selected, the regulated oil pressure is supplied to
the selected clutches and the desired gear speed is obtained.
• The lockup ECMV is actuated when the machine travels in the 2nd, 3rd, or 4th gear speed and its travel
speed exceeds the travel speed set by the transmission controller.
• This machine uses three types of the ECMVs, which have the following identifications and differences.
Identifi-
Fill switch
Stamp on name plate cation Mark Clutches to
color Flow detection valve (operating pressure:
(A) (C) be used
MPa {kg/cm2})
(B)
Installed F, R, 1st,
L******* ― ― Not installed
(0.20 {2.0}) 2nd
Installed
Q******* Pink S Installed 3rd, 4th
(0.24 {2.45})
K******* ― ― Not installed Not installed L/U
L/U: Indicates lockup clutch ECMV.

• Table of ECMV
operation
ECMV
F R 1st 2nd 3rd 4th L/U
F1 Q Q
F2 Q Q Q
F3 Q Q Q
Gear speed

F4 Q Q Q
R1 Q Q
R2 Q Q Q
R3 Q Q Q
R4 Q Q Q
L/U: Indicates lockup clutch ECMV.

10-80 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Forward and reverse clutch ECMV and 1st and 2nd clutch ECMV (WA470-CJJ0-
041-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve


a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function (HM300-CJJ0-042-K-00-A)

• The ECMV consists of a pressure control valve and a fill switch.


• Pressure control valve

WA470-7 10-81
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

The proportional solenoid receives the current from the transmission controller, and this valve converts it
into oil pressure.
• Fill switch
This switch detects that the clutch is filled with oil and has the following functions.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting the signals (fill signals) to the controller to notify that the oil pressure is applied while oil
pressure is applied to the clutch.

Range A: Before shifting gear (oil is drained)


Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

ECMV and proportional solenoid


• Each ECMV is equipped with one proportional solenoid.
The proportional solenoid generates thrust shown below according to the command current from the
controller.
Oil pressure is generated as shown below by applying the thrust generated by the proportional solenoid to
the pressure control valve spool.
Accordingly, the thrust is changed by controlling the command current to operate the pressure control
valve and control the flow and pressure of the oil.

10-82 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Proportional solenoid current - thrust characteristics

Proportional solenoid thrust - oil pressure characteristics

ECMV and fill switch


• Each ECMV is equipped with one fill switch.
When the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. This signal
allows the oil pressure to build up.

WA470-7 10-83
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Operation of ECMV (HM300-CJJ0-044-K-00-A)

• ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relationship among the proportional solenoid command current for ECMV, clutch input pressure, and
fill switch output signal is shown below.

Range A: Before shifting gear (oil is drained)


Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

10-84 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Before shifting gear [when oil is drained] (range A in chart)

• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).

WA470-7 10-85
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Filling phase (range B in chart)

• When the current flows to proportional solenoid (1) while there is no oil in the clutch, the hydraulic force
balanced with the solenoid force is applied to chamber (B) to push pressure control valve (3) to the left. As
a result, pump port (P) is connected with clutch port (A) and the oil starts filling the clutch. When the clutch
is filled with the oil, oil pressure sensing valve (4) operates and fill switch (5) is turned "ON".

10-86 WA470-7
10 Structure and function
Forward and reverse clutch ECMV and 1st and 2nd
clutch ECMV

Pressure build-up (range C in chart)

• When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).

WA470-7 10-87
10 Structure and function
3rd, 4th clutch ECMV

3rd, 4th clutch ECMV (WA470-CJJ0-041-K-01-A)

a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Flow detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate
Function (WA470-CJJ0-042-K-00-A)

• The ECMV consists of a pressure control valve and a fill switch.


• Pressure control valve
The proportional solenoid receives the current from the transmission controller, and this valve converts it
into oil pressure.
• Fill switch

10-88 WA470-7
10 Structure and function
3rd, 4th clutch ECMV

This switch detects that the clutch is filled with oil and has the functions explained later.
1. Outputs a signal (a fill signal) to the controller to notify that filling is completed when the clutch is filled with
oil.
2. Keeps outputting the signals (fill signals) to the controller to notify that the oil pressure is applied while oil
pressure is applied to the clutch.

Range A: Before shifting gear (oil is drained)


Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

ECMV and proportional solenoid


• Each ECMV is equipped with one proportional solenoid.
The proportional solenoid generates thrust shown below according to the command current from the
controller.
Oil pressure is generated as shown below by applying the thrust generated by the proportional solenoid to
the pressure control valve spool.
Accordingly, the thrust is changed by controlling the command current to operate the pressure control
valve and control the flow and pressure of the oil.

WA470-7 10-89
10 Structure and function
3rd, 4th clutch ECMV

Proportional solenoid current — thrust characteristics

Proportional solenoid thrust — hydraulic pressure characteristics

ECMV and fill switch


• Each ECMV is equipped with one fill switch.
When the clutch is filled with oil, the fill switch is turned "ON" by the pressure of the clutch. This signal
allows the oil pressure to build up.
Operation of ECMV (WA470-CJJ0-044-K-00-A)

• ECMV is controlled by the command current sent from the controller to the proportional solenoid and the
fill switch output signal.
The relation between the proportional solenoid command current for ECMV, clutch input pressure, and fill
switch output signal is shown below.

10-90 WA470-7
10 Structure and function
3rd, 4th clutch ECMV

Range A: Before shifting gear (oil is drained)


Range B: Clutch is being filled
Range C: Pressure is being adjusted
Range D: Clutch is being filled (triggering period)
Point E: Filling is started
Point F: Filling is finished
a The logic is designed so that the controller does not recognize completion of filling even if the fill switch is
turned "ON" during the triggering period (Range D).

WA470-7 10-91
10 Structure and function
3rd, 4th clutch ECMV

Before shifting gear [when oil is drained] (range A in chart)

• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).
Fill switch (5) is turned OFF at this time since the oil pressure is not applied to pressure sensing valve (4).

10-92 WA470-7
10 Structure and function
3rd, 4th clutch ECMV

Filling phase (range B in chart)

• When a current flows in proportional solenoid (1) while the clutch piston is not pressurized, the thrust of
the solenoid pushes ball (6) to the left to throttle the drain circuit.
• Oil pressure balanced with the thrust of the solenoid is applied to chamber (B) to move pressure control
valve (3) to the left.
• The oil flows into the clutch chamber through pump port (P) and orifice (a) of flow detection valve (4).
• Differential pressure is generated between the upstream and downstream over orifice (a) of flow detection
valve (4), and then flow detection valve (4) moves to the left.
• When the clutch chamber is filled with the oil and the oil does not flow from pump port (P) to clutch port (A)
any more, the differential pressure over orifice (a) of flow detection valve (4) is lost.
• Flow detection valve (4) is pushed back to the right by the oil pressure generated by the area difference
between clutch port (A) side and drain port side of flow detection valve (4) to turn ON fill switch (5).

WA470-7 10-93
10 Structure and function
3rd, 4th clutch ECMV

Pressure build-up (range C in chart)

• When a current flows in proportional solenoid (1), the solenoid generates thrust in proportion to the current.
The pressure builds up until the thrust of the solenoid is balanced with the sum of the thrust generated by
the oil pressure in clutch port and the reaction force of pressure control valve spring (2).

10-94 WA470-7
10 Structure and function
Lockup clutch ECMV

Lockup clutch ECMV (HM300-CDT8-041-K-00-A)

a ECMV: Abbreviation for Electronic Control Modulation Valve


a Do not disassemble this ECMV since it needs to be adjusted for maintaining the performance after
assembly.

A: To clutch
P: From pump
T: Drain
Dr: Drain
P1: Clutch oil pressure pickup port

1. Proportional solenoid connector


2. Sleeve
3. Proportional solenoid
4. Pressure control valve
5. Name plate
Function (WA470-CDT8-042-K-00-A)

• This valve is used for adjusting the clutch oil pressure to the set pressure and selecting a clutch.
Since the modulation waveform is used for the pressure application characteristics to the clutch, the
lockup clutch is engaged smoothly and the gear shift shocks are reduced. In addition, generation of a
peak torque in the power train is prevented. As a result, the operator comfort improves and the power train
durability increases.

WA470-7 10-95
10 Structure and function
Lockup clutch ECMV

When torque converter drive mode changes to direct drive mode

When gear is shifted (traveling in direct drive mode)

10-96 WA470-7
10 Structure and function
Lockup clutch ECMV

Operation (WA380-CDT8-044-K-00-A)

When clutch is "disengaged" (released)

• While no current is flowing to the proportional solenoid (1), pressure control valve (3) drains the oil from
clutch port (A) through drain port (T).

WA470-7 10-97
10 Structure and function
Lockup clutch ECMV

When clutch is "engaged" (locked)

• When the current flows to proportional solenoid (1), the hydraulic force balanced with the solenoid force is
applied to chamber (B) to push pressure control valve (3) to the left. As a result, pump port (P) is
connected to clutch port (A) and the oil starts filling the clutch.
• When the clutch is filled with oil, the thrust of the solenoid is balanced with the sum of the thrust generated
by the oil pressure in clutch port and the reaction force of pressure control valve spring (2), thus the
pressure is adjusted.

10-98 WA470-7
10 Structure and function
Main relief and torque converter relief valve

Main relief and torque converter relief valve (WA380-C156-041-K-00-A)

1. Body
2. Piston
3. Torque converter relief valve
4. Piston
5. Main relief valve
A: Drain (torque converter relief)
B: Drain
C: From pump
D: Drain
E: To torque converter
P1: Main relief oil pressure pickup port
P2: Torque converter relief oil pressure pickup port
Function (WA470-CJ10-042-K-00-A)

Main relief valve


• The main relief valve regulates the oil pressure in the transmission and parking brake oil circuits to the set
pressure.
Set pressure: 2.55 MPa {26.0 kg/cm2} (at engine rated speed)
Torque converter relief valve
• The torque converter relief valve maintains the torque converter inlet pressure below the set pressure to
protect the torque converter from abnormally high pressure.
Set pressure: 0.91 MPa {9.31 kg/cm2} (cracking pressure)

WA470-7 10-99
10 Structure and function
Main relief and torque converter relief valve

Operation (WA380-CJ10-044-K-00-A)
Operation of main relief valve

• The oil from the hydraulic pump flows to port (C) through the filter. Then it flows to chamber (F) through
orifice (a) in main relief valve (1).

• When the oil pressure in the circuit exceeds the set pressure, the oil in chamber (F) pushes piston (2) and
the reaction force pushes main relief valve (1) leftward. This connects ports (C) and (E).
Then, the oil from the pump flows through port (E) into the torque converter.

Operation of torque converter relief valve

• The oil relieved through the main relief valve flows through port (E) into the torque converter. It also flows
through orifice (b) in torque converter relief valve (3) into chamber (G).
• When the oil pressure to the torque converter exceeds the set pressure, the oil in chamber (G) pushes
piston (4) and the reaction force of the piston pushes torque converter relief valve (3) rightward to connect
ports (E) and (A).
Then, the oil in port (E) is drained through port (A).

10-100 WA470-7
10 Structure and function
Axle

Axle (HM300-DA00-001-K-00-A)

Front axle (WA470-DA20-041-K-00-A)

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler pipe and level plug
8. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder

WA470-7 10-101
10 Structure and function
Axle

Rear axle (WA470-DAC0-041-K-00-A)

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/ level plug
8. Brake oil port
9. breather
10. Brake wear gauge
11. Drain plug
12. Air bleeder

10-102 WA470-7
10 Structure and function
Differential

Differential (HM300-DC10-001-K-00-A)

Front conventional differential (WA470-DC70-041-K-00-A)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

WA470-7 10-103
10 Structure and function
Differential

Rear conventional differential (WA470-DCD0-041-K-00-A)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

10-104 WA470-7
10 Structure and function
Differential

Operation (WA380-DC10-044-K-00-A)

• The power from the engine is transmitted to the front and rear axles through the torque converter,
transmission, and drive shafts.
• The power to be transmitted is changed in direction 90 degrees and in transmitting speed by bevel pinion
(1) and bevel gear (5) in the axle housing, and then transmitted to sun gear shaft (2) through pinion (4).
• The power of the sun gear is further reduced in transmitting speed by the planetary gear type final drives,
and then transmitted to the axle shaft and wheels.
When machine is traveling straight

• When the machine is traveling straight, the right and left wheels rotate at the same speed. Accordingly,
pinions (4) in the differential assembly do not rotate and the power of carrier (6) is transmitted through
pinions (4) and side gears (3) to the right and left sun gear shafts (2) evenly.

WA470-7 10-105
10 Structure and function
Differential

When machine is turning

• When the machine is turning, the right and left wheels rotate at different speeds. Accordingly, pinions (4)
and side gears (3) in the differential rotate and transmit the power of carrier (6) to right and left sun gear
shafts (2), depending on the difference in rotation speed between the right and left wheels.

10-106 WA470-7
10 Structure and function
Differential

Front limited slip differential (WA470-DCH3-041-K-00-A)

(if equipped)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

WA470-7 10-107
10 Structure and function
Differential

Rear limited slip differential (WA470-DCH4-041-K-00-A)

(if equipped)

1. Pinion
2. Shaft
3. Bevel gear
4. Sun gear shaft
5. Bevel pinion
6. Side gear

10-108 WA470-7
10 Structure and function
Differential

Operation (WA470-DCH2-042-K-00-A)

1. Washer
2. Disc
3. Plate
4. Pressure ring
5. Cover
6. Side gear
7. Shaft
8. Pinion
9. Bevel gear
10. Case
The power from the transmission is transmitted through bevel gear (9) to case (10), pressure ring (4), shaft (7),
pinion (8), and side gears (6), and then distributed to the right and left shafts. On the back of each side gear
(6), the brake mechanism consisting of discs (2) and plates (3) is installed. It generates braking torque in
proportion to the torque transmitted from pressure rings (4) to shaft (7).
Since the braking torque restricts the rotation of side gears (6) and case (10), side gears (6) on the right and
left sides do not rotate freely and the operation of the differential is restricted.

WA470-7 10-109
10 Structure and function
Differential

<Mechanism of generating braking torque to right and left side gears (6)>

Shaft (7) is supported on the cam surfaces made on the surfaces of pressure rings (4) that are facing each
other. The power (= torque) from pressure rings (4) is transmitted to shaft (7) through the cam surfaces. Force
Fa to separate right and left pressure rings (4) is generated by inclination of the cam surfaces in proportion to
the transmitted torque.
This separating force (Fa) acts on the brakes on the back of right and left side gears (6) to generate braking
torque.

<When machine is traveling straight>

When the driving forces of the right and left wheels are balanced

[When road conditions (friction coefficient) under the right and left wheels and the loads on wheels are even
and the center of load on the bucket is not shifted]
The power from the transmission is distributed evenly by the differential gear to the right and left. Since the
tire slip limits on the right and left sides are the same under this condition, both tires slip and the differential
does not operate even if the power from the transmission exceeds the tire slip limit.
No load is applied to the brake on the back of each side gear.

10-110 WA470-7
10 Structure and function
Differential

When the driving forces of the right and left wheels are unbalanced

[When the road conditions (friction coefficient) under the right and left wheels and the loads on wheels are
uneven and either of the wheels slips more easily than the other]
Example 1. Either wheel is on soft ground during digging work
Example 2. Either wheel is on snow and the other is on asphalt during snow plowing work
Example 3. The loads on the right and left wheels are unbalanced during travel on a slope
The power from the transmission is distributed evenly by the differential gear to the right and left. If the driving
force exceeds the tire slip limit on the more slippery side, the excessive driving force is transmitted to the
brake on the opposite side (locked side) and given to the tire on the locked side through the brake on the back
of the side gear and the case.
Only when this excessive driving force exceeds the braking force, the differential operates.
Difference of wheel driving force by type of differential when either wheel slips
Wheel driving force (slipping wheel is set as 1)
Slipping wheel Locked wheel Total (ratio)
Limited Slip Differential 1 2.64 3.64 (1.82)
Conventional differential 1 1 2 (1)

On a road surface where either wheel slips easily, the Limited Slip Differential increases the driving force by
1.82 times compared to the conventional differential.

WA470-7 10-111
10 Structure and function
Differential

Since the differential gear in the Limited Slip Differential is the same as the one used in the conventional
differential, it can smoothly generate the rotational difference between the inside and outside wheels that is
caused by turning.

10-112 WA470-7
10 Structure and function
Final drive

Final drive (WA470-DF10-041-K-00-A)

a The figure shows the front axle.

1. Planetary gear
2. Planetary carrier
3. Axle shaft
4. Ring gear
5. Sun gear shaft

WA470-7 10-113
10 Structure and function
Final drive

Operation (WA380-DF10-044-K-00-A)

a The figure shows the front axle.

• The final drive finally reduces the speed to transmit the power from the engine and increases in drive
power.
• Ring gear (4) is press-fitted to the axle housing and fixed with the pin.
• The power transmitted from the differential through sun gear shaft (5) is reduced in speed and increased
in drive power by the planetary gear mechanism.
• The increased drive power is transmitted through planetary carrier (2) and axle shaft (3) to the wheels.

10-114 WA470-7
10 Structure and function
Layout of steering parts

Steering system (ALL-F000-001-K-00-A)

Layout of steering parts (WA470-DT00-04D-K-00-A)

1. Steering cylinder (R.H.)


2. Steering valve
3. Orbitrol valve
4. Stop valve (R.H.)
5. Steering pump
6. Hydraulic tank
7. Emergency steering motor (if equipped)
8. Emergency steering pump (if equipped)
9. Stop valve (L.H.)
10. Steering cylinder (L.H.)

WA470-7 10-115
10 Structure and function
Steering column

Steering column (WA380-F171-041-K-00-A)

1. Steering wheel
2. Steering column
3. Steering tilt lock lever
4. Short column
5. Orbit-roll valve

10-116 WA470-7
10 Structure and function
Steering pump

Steering pump (WA470-F220-041-K-00-A)

P1: Pump discharge port


PD: Drain port
PS: Pump suction port
P1L: Pump pressure input port
PD2: Drain plug
PEN: Control pressure pickup plug
PLS: Load pressure input port
POP: External pilot pressure input port

WA470-7 10-117
10 Structure and function
Steering pump

PEPC: EPC source pressure input port


1. Pump body
2. Servo valve
3. Air bleeder
Pump body

PA: Control source pressure output port


PD4: Drain port
PD5: Drain port
PE: Control pressure input port
PEPC: EPC source pressure input port

10-118 WA470-7
10 Structure and function
Steering pump

1. Bearing
2. Shaft
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap

WA470-7 10-119
10 Structure and function
Steering pump

10. Shoe retainer


11. Servo piston
12. Spring
13. Oil seal
14. Ball retainer

Structure
• Cylinder block (6) is supported by spline (a) on shaft (1).
• Shaft (1) is supported by each bearing at the front and rear.
• The tip of piston (5) shapes a spherical concave and integrates with shoe (4) by gripping it.
• Piston (5) and shoe (4) form a spherical bearing.
• Rocker cam (3) is supported by case (2) and ball retainer (9) and has flat surface (A), and shoe (4) is
always pressed against this surface while sliding in a circular pattern.
• Shoe (4) leads high-pressure oil to form a static pressure bearing for its sliding.
• Piston (5) moves relatively in the axial direction in each cylinder chamber of cylinder block (6).
• Cylinder block (6) rotates relatively to valve plate (7) while sealing the pressurized oil.
• This plane is designed so that the oil pressure is balanced correctly.
• The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (6)
through valve plate (7).
Specifications (WA470-F220-030-K-00-A)

Model LPV90
Type Variable displacement swash plate type piston pump
Theoretical delivery (cm3/rev) 90
Rated delivery pressure: (MPa {kg/
24.5 {250}
cm2})
Rated speed (rpm) 2,280

Function (WA380-F220-042-K-00-A)

• The engine rotation and torque transmitted to the pump shaft is converted into the hydraulic energy and
the pressurized oil corresponding to the load is discharged.

10-120 WA470-7
10 Structure and function
Steering pump

• It is possible to change the delivery by changing the swash plate angle.


Operation (WA470-F220-044-K-00-A)
Operation of pump

• Cylinder block (6) rotates together with shaft (1) and shoe (4) slides on plane (A).
• Rocker cam (3) pivots on ball retainer (9), and accordingly angle (a) between center line (X) of rocker cam
(3) and the axis of cylinder block (6) changes.
• Angle (a) is called the swash plate angle.

• While angle (a) is made between center line (X) of rocker cam (3) and the axis of cylinder block (6), plane
(A) works as a cam for shoe (4).
• Piston (5) reciprocates inside cylinder block (6) and a difference is made between volumes (E) and (F) of
the cylinder chamber in cylinder block (6).
• Oil in amount of (F) minus (E) is sucked in and discharged from piston (5).
• Oil is discharged while cylinder block (6) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.
• In the figure, chamber (F) is at the end of the suction stroke and chamber (E) is at the end of the discharge
stroke.

WA470-7 10-121
10 Structure and function
Steering pump

• When center line (X) of rocker cam (3) matches the axis of cylinder block (6) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (6) is zero.
• Suction and discharge of pressurized oil is not performed in this stage. Namely pumping action is not
performed. (Actually, however, a zero swash plate angle never occurs.)
• The pump delivery is in proportion to swash plate angle (a).

Control of delivery

• When swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
delivery (Q) is increased.
• Swash plate angle (a) is changed by servo piston (11).
• Servo piston (11) reciprocates linearly according to the signal pressure from the PC valve and LS valve.
• This linear motion is transmitted to rocker cam (3).
• Being supported by ball retainer (9) on case (2), rocker cam (3) slides in the direction of rotary movement.

10-122 WA470-7
10 Structure and function
Steering pump

Servo valve (WA380-F2J0-041-K-00-A)

P1: Pump delivery pressure port


PE: Control pressure output port
T: Drain port
PEPC: EPC source pressure input port

WA470-7 10-123
10 Structure and function
Steering pump

PC valve
T: Drain
PA: Pump pressure input
PPL: PC valve output pressure
PM: PC mode selector pressure
1. Lever
2. Spring
3. Retainer
4. Seat
5. Spool
6. Sleeve
7. Piston
8. Seal
9. Piston
LS valve

10-124 WA470-7
10 Structure and function
Steering pump

PA: Pump pressure input


PE: Control piston pressure
PLS: LS pressure input
PPL: PC valve output pressure
PPLS: LS pump pressure input
10. Nut
11. Plate
12. Plug
13. Spring
14. Seat
15. Spool
16. Plug

LS valve (WA380-F2R0-001-K-00-A)

Function (WA380-F2R0-042-K-00-A)
• The LS valve controls the pump delivery according to the travel of the control lever, or the flow demanded
by the actuator.
• The LS valve detects the flow rate demanded by the actuator from differential pressure (dPLS) between
inlet pressure (PPLS) and outlet pressure (PLS) of the control valve and controls pump delivery (Q) of the
main pump. [(PPLS) is called the LS pump pressure, (PLS) the LS pressure, and (dPLS) the LS
differential pressure.]
• In other words, pressure loss [= LS differential pressure (dPLS)], which occurs when oil flows through the
passage in control valve spool, is detected, and pump delivery (Q) is controlled to maintain the pressure
loss at a constant level. Through this operation, pump can deliver the proper volume of oil as demanded
by the actuator.
• Main pump delivery pressure (PP), LS pump pressure (PPLS) and LS pressure (PLS) are transmitted into
the LS valve. Pump delivery (Q) changes as shown in the following figure according to the LS differential
pressure (dPLS).

WA470-7 10-125
10 Structure and function
Steering pump

PC valve (WA380-F2S0-001-K-00-A)

Function (WA380-F2S0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depending on the delivery pressure) even if the travel of
the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed
the engine horsepower, when pump delivery pressure (PA) is high.
• In other words, the PC valve decreases the pump delivery when the actuator load is increased and the
pump delivery pressure rises, and increases it when the pump delivery pressure lowers.
• If command current (X) sent to EPC valve increases further, the relationship between pump pressure (PP)
and pump delivery (Q) is shifted parallel in proportion to the thrust of EPC valve solenoid.
• That is, since the thrust of the EPC valve solenoid is added to the left-hand thrust caused by the pump
pressure applied to spool (6), the relationship between pump pressure (PA) and (Q) is shifted from [1] to
[2] as (X) increases.

Operation (WA380-F2S0-044-K-00-A)

Action of spring
• The spring force of spring (3) in the PC valve is determined by the angle of the swash plate.
• When servo piston (9) moves to the right, spring (3) is compressed through lever (2) and the spring force
changes.

When pump pressure (PA) is low


• The pressing force of piston (10) is decreased and spool (6) is a little closer to the right (Fig. 1). At this time,
port (C) is connected to port (D) and the pressure transmitted to the LS valve becomes drain pressure
(PT).
• When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes drain pressure
(PT) and servo piston (9) moves to the left.
• Consequently, the pump delivery is increased.
• As servo piston (9) moves, lever (2) moves to the left and spring (3) expands and the spring force is
decreased. Consequently, spool (6) moves to the left and port (C) is disconnected from port (D) and
connected to pump discharge port (B).
• As a result, the pressure in port (C) rises and the piston pressure is increased and servo piston (9) stops
moving to the left.

When pump pressure (PA) is high


• The pressing force of piston (10) is increased and spool (6) is a little closer to the left (Fig. 2). At this time,
port (C) is connected to port (B) and the pressure transmitted to the LS valve becomes pump pressure
(PA).
• When port (F) is connected to port (G) of the LS valve, the pressure in port (J) becomes pump pressure
(PA) and servo piston (9) moves to the right.
• Consequently, the pump delivery is decreased.
• As servo piston (9) moves, lever (2) moves to the right and spring (3) is compressed and spring force is
increased. Consequently, spool (6) moves to the right and port (C) is disconnected from port (B) and
connected to drain pressure port (D).
• As a result, the pressure in port (C) lowers and the piston pressure is decreased and servo piston (9)
stops moving to the right.

10-126 WA470-7
10 Structure and function
Steering pump

• Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
thrust caused by pressure (PA) applied to piston (10) is balanced with the spring force of spring (3) acting
through spool (6). (Fig. 3)

When PC mode selector pressure increases or decreases


• PC-EPC changes output pressure (PM) according to the input current from the controller to change the
pressing force of piston (8). As a result, the PC valve moves similarly to when (PA) increases or
decreases.
When load is light
(Fig. 1)

When load is heavy


(Fig. 2)

WA470-7 10-127
10 Structure and function
Steering pump

When servo valve is balanced


(Fig. 3)

10-128 WA470-7
10 Structure and function
Steering valve

Steering valve (WA380-F570-041-K-00-A)

P: From steering pump


Pr: To steering pump port P1L
Pa: From stop valve (left)
Pb: From stop valve (right)
A: To steering cylinder
B: To steering cylinder
T1: Drain
T2: Drain

WA470-7 10-129
10 Structure and function
Steering valve

1. Relief valve
2. Flow control spool
3. Steering relief valve
4. Steering spool
5. Overload relief valve

10-130 WA470-7
10 Structure and function
Steering valve

Operation (WA380-F570-044-K-00-A)
Operation of flow amplifier

When spool is in neutral (When orbit-roll valve is not operating)

• Since ports (Pa) and (Pb) are connected to the drain circuit through the orbit-roll valve, steering spool (1)
is held in the neutral position by right and left return springs (2).

When spool operates (When oil flows in port (Pa))

• The pressure in port (Pa) increases and steering spool (1) compresses left return spring (2) and moves to
the left.
• The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port (Pb).
• Since port (Pb) is connected to the drain circuit through the orbit-roll valve, the oil in port (Pb) is drained.
• Since the pressure generated in port (Pa) is in proportion to the oil flow, steering spool (1) moves to a
position in which the oil pressure reduced by orifice (a) is balanced with the reaction force of return spring
(2).

When spool returns (When steering wheel operation is stopped)

WA470-7 10-131
10 Structure and function
Steering valve

• Since ports (Pa) and (Pb) are connected to the drain circuit through the orbit-roll valve, steering spool (1)
is returned to the neutral position by left return springs (2).

Operation of flow control spool

When steering spool is in neutral

• The oil from the steering pump flows in port (P).


• Since notch (e) is closed, the oil pressure in port (P) increases and flows through orifice (a) to pressure
receiving chamber (X), and moves flow control spool (1) to the left.
• The oil in pressure receiving chamber (Y) is drained through orifice (b), notch (f) and port (T1).
• If the oil pressure in pressure receiving chamber (X) exceeds the set pressure, flow control spool (1)
moves to the left, and notch (c) opens.
• The oil in port (P) flows through notch (c) and port (Pr) to the LS valve of the steering pump. Port (Pr) is
connected to port (T2) through orifice (j).
• The oil pressure in port (Pr) becomes the middle between the pump pressure and the drain pressure of
port (T2) by the passing resistance through notch (c) and orifice (j).
• When the oil pressure in port (Pr) exceeds the set pressure, the swash plate angle of the steering pump is
decreased to reduce the delivery.
• If the oil pressure in port (P) increases further even after the pump delivery becomes the minimum, flow
control spool (1) moves to the left further.
• When the oil pressure in pressure receiving chamber (X) exceeds the set pressure, notch (d) opens and
the oil in port (P) is drained through notch (d) and port (T1).

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10 Structure and function
Steering valve

When steering spool operates

• When steering spool (2) operates, notch (f) closes to disconnect pressure receiving chamber (Y) and port
(T1), and notch (e) opens.
• The oil pressure in pressure receiving chamber (Y) increases, flow control spool (1) moves to the right,
and the open area of notch (d) decreases.
• The oil before passing through notch (e) is led to pressure receiving chamber (X) and the oil after passing
through notch (e) is led to pressure receiving chamber (Y).
• When the oil pressure in pressure receiving chamber (Y) exceeds that in port (A), the oil flowing in through
orifice (h) pushes load check valve (3) open to the left.
• Since the oil from notch (e) flows through port (A) to the steering cylinder, pressure difference is made
before and after notch (e).
• Since flow control spool (1) operates to maintain the differential pressure generated over notch (e) to the
set pressure, oil is delivered to the steering cylinder according to the open area of notch (e).
• The excessive oil from the steering pump is drained through orifice (d) and port (T1).
• The return oil from the steering cylinder is drained through orifice (g) and port (T1).
• Even if flow control spool (1) moves to the right until notch (d) is closed, it moves further to the right if the
pressure before notch (e) is below the set pressure.
• Since the open area of notch (c) is narrowed and the oil flow to port (Pr) is reduced, the oil pressure in port
(Pr) decreases.
• When the oil pressure in port (Pr) decreases, the LS valve of the steering pump increases its delivery to
maintain the oil pressure in port (Pr) at the set pressure.
• Flow control spool (1) is held in a position where the pressure in port (P) is balanced with the pressure in
port (Pr), and the pump delivery is kept constant.

WA470-7 10-133
10 Structure and function
Steering valve

• If the open area of notch (e) changes, the steering pump delivers oil according to the open area of notch
(e) to keep the oil pressure in port (Pr) constant.

Operation of steering valve

When in neutral

• Since the steering wheel is not operated, steering spool (1) does not move.
• The oil from the steering pump flows in port (P).
• When the oil pressure in port (P) increases, flow control spool (2) moves to the left to drain the oil from the
steering pump through notch (a) and port (T1).

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10 Structure and function
Steering valve

When machine turns to left

• When the steering wheel is turned to the left, the output pressure from the orbit-roll valve enters port (Pa)
and steering spool (1) is pushed to the right.
• The oil from the steering pump enters port (P) and flows through flow control spool (2) to steering spool
(1).
• Load check valve (3) is pushed open to the left and the oil flows to the head side of the left steering
cylinder and to the bottom side of the right steering cylinder to turn the machine to the left.
• The return oil from the right and left steering cylinders is drained through load check valve (4) and port
(T1).

WA470-7 10-135
10 Structure and function
Steering valve

When machine turns to right

• When the steering wheel is turned to the right, the output pressure from the orbit-roll valve enters port (Pb)
and steering spool (1) is pushed to the left.
• The oil from the steering pump enters port (P) and flows through flow control spool (2) to steering spool
(1).
• Load check valve (4) is pushed open to the right and the oil flows to the head side of the right steering
cylinder and to the bottom side of the left steering cylinder to turn the machine to the right.
• The return oil from the right and left steering cylinders is drained through load check valve (3) and port
(T1).

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10 Structure and function
Steering valve

Steering relief valve (WA380-F590-041-K-00-A)

1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat

Function (WA380-F590-042-K-00-A)
• The steering relief valve is installed to the steering valve and maintains the oil pressure in the steering
circuit at the set pressure during steering operation.

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10 Structure and function
Steering valve

Operation (WA380-F590-044-K-00-A)

• If the oil pressure in the steering circuit increases to the pressure set with adjustment screw (1) and spring
(2), pilot poppet (3) opens to drain the oil through port (T1).
• Pressure receiving chambers (X) and (Y) are unbalanced in pressure and flow control spool (4) moves to
the left.
• Flow control spool (4) operates to drain the oil from the steering pump and maintain the steering circuit
pressure below the set value.

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10 Structure and function
Steering valve

Overload relief valve (WA380-F5B0-041-K-00-A)

1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring

Function (WA380-F5B0-042-K-00-A)
• The overload relief valve is installed to the steering valve and protects the cylinder circuit from abnormally
high pressure generated by impacts applied to the cylinder for some reason while the steering valve is in
neutral.
• If abnormally high pressure is generated on the cylinder side, this valve works as a safety valve to prevent
breakage of the cylinder and hydraulic piping.
• If negative pressure is generated on the cylinder side, this valve works as a suction valve to prevent a
vacuum in the circuit.

WA470-7 10-139
10 Structure and function
Steering valve

Operation (WA380-F5B0-044-K-00-A)

Operation as relief valve

• Port (A) is connected to the cylinder circuit and port (B) is connected to the drain circuit.
• The oil flows through the hole of poppet (1) to the inside of relief valve poppet (2).
• Check valve poppet (3) and relief valve poppet (2) are securely seated because of the area difference
between diameters (d1) and (d2).

• If the oil pressure in port (A) exceeds the set pressure of the relief valve, pilot poppet (4) is moved open to
the right.
• The oil flows through pilot poppet (4) and drill hole to port (B).

• Since pilot poppet (4) opens, the oil pressure inside poppet (1) lowers.
• Poppet (1) moves to the right to seat pilot poppet (4).

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10 Structure and function
Steering valve

• The oil pressure inside relief valve poppet (2) is lower than the oil pressure in port (A).
• Since the oil pushes open relief valve poppet (2) to the right and flows from port (A) to port (B), the circuit
is protected from abnormally high pressure.

Operation as suction valve

• If negative pressure is generated in port (A), it acts on the area difference between diameters (d3) and
(d4) and pushes check valve poppet (3) to the right.
• The oil flows from port (B) to port (A) to prevent a vacuum.

WA470-7 10-141
10 Structure and function
Steering valve

Relief valve (WA380-F530-041-K-00-A)

1. Plug
2. Spring
3. Valve
4. Valve seat

Function (WA380-F530-042-K-00-A)
• The relief valve is installed to the steering valve and relieves the oil when the oil pressure in port (Pr)
exceeds the set pressure to protect the LS circuit of the steering pump from abnormally high pressure.

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10 Structure and function
Orbit-roll valve

Orbit-roll valve (WA380-F550-041-K-00-A)

P: From charge valve


T: Drain
L: To left stop valve
R: To right stop valve
1. Gerotor
2. Valve body
3. Drive shaft
4. Centering spring
5. Needle bearing
6. Bushing
7. Center pin
8. Sleeve
9. Spool

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10 Structure and function
Orbit-roll valve

10. Spacer
11. End cap

Outline

• The orbit-roll valve is connected directly to the drive shaft of the steering column, and sends the oil from
the steering pump to the right or left steering cylinder to change the travel direction of the machine.
• The orbit-roll valve roughly consists of two sections; One is the section of spool (9) and sleeve (8) which
has rotary-type direction selection function, and the other is gerotor (5) (combination of rotor (5a) and
stator (5b)) which works as a hydraulic motor during the normal steering operation but works as a hand
pump when no oil is supplied because of a steering pump failure or an engine failure (however, it cannot
be operated actually since its operating effort is too high).

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10 Structure and function
Orbit-roll valve

Structure

• Top (A) of spool (9) is connected to the drive shaft of the steering column and further connected to sleeve
(8) by center pin (7) (which does not touch spool (9) when the steering wheel is in "neutral") and centering
spring (2).
• Drive shaft (3) is meshed at top (B) with center pin (7) and forms one unit with sleeve (8). Its bottom is
meshed with the spline of rotor (5a) of gerotor (5).
• Valve body (4) has four ports, which are connected respectively to the pump circuit, tank circuit, left
steering circuit, and right steering circuit. The ports on the pump and tank are connected through the
check valve inside the body. If the pump or the engine is failed, the oil can be sucked in directly from the
tank through this check valve.

WA470-7 10-145
10 Structure and function
Orbit-roll valve

Connection of hand pump and sleeve

• The above figure shows the connections of suction and discharge ports (P) of the gerotor and the sleeve
ports.
• When the steering wheel is turned to the right, ports (a), (c), (e), (g), (i) and (k) are connected by the
vertical grooves in the spool to the pump. At the same time, ports (b), (d), (f), (h), (j) and (l) are connected
to the head side of the right steering cylinder in the same way.
In the condition shown in Fig. 1, ports (1), (2) and (3) are the discharge ports of the gerotor and connected
to ports (l), (b) and (d) to send the oil to the steering cylinder.
Ports (5), (6) and (7) are also connected to each other and the oil flows in from the pump.
Fig. 2 shows the condition after the steering wheel is turned 90° from the above condition. Under this state,
ports (2), (3) and (4) are in the suction condition and connected to ports (k), (a) and (c). Ports (5), (6) and
(7) are in the discharge condition and connected to ports (d), (f) and (h).
• In this way, the ports of the gerotor in the discharge condition are connected to the ports connected to the
steering cylinder. The ports in the suction condition are connected to the pump circuit.
• For every 1/7 turn of the steering wheel, the inner teeth of the gerotor gear advance one position to deliver
oil from the pump by the quantity for this operation.
Accordingly, the quantity of the oil delivered from the pump is directly proportional to the turning angle of
the steering wheel.

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10 Structure and function
Orbit-roll valve

Role of centering spring

• Centering spring (2) is composed of layers of two flat leaf springs and four X-shaped leaf springs and
installed between spool (9) and sleeve (8) as shown in the figure.

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10 Structure and function
Orbit-roll valve

• When the steering wheel is turned, spool (9) compresses the centering spring and angular displacement
(a) is generated between spool (9) and sleeve (8).
As a result, the ports in spool (9) and sleeve (8) are connected and the oil is sent to the steering cylinder.
When the steering wheel is stopped turning, the gerotor also stops turning, and accordingly no more oil is
sent to the steering cylinder and the oil pressure rises.
To prevent this, when the steering wheel is stopped turning, centering spring (2) rotates spool (9) by the
turning angular displacement (a) from sleeve (8) to return the steering wheel to the neutral condition.

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10 Structure and function
Stop valve

Stop valve (WA380-F5U0-041-K-00-A)

A: From orbit-roll valve


B: To steering valve
DR: Drain
1. Boot
2. Wiper
3. Seal
4. Poppet
5. Spring
6. Spool
7. Spring

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10 Structure and function
Emergency steering motor

Emergency steering motor (WA380-F9R0-041-K-00-A)

(if equipped)

1. Terminal E
2. Terminal M
Function (WA380-F9R0-042-K-00-A)

• The emergency steering motor drives the emergency steering pump according to the signals from the
transmission controller when the steering circuit pressure decreases abnormally.
Specification (WA380-F9R0-030-K-00-A)

Name DC motor
Rated voltage (V) 24
Rated output (KW) 0.9

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10 Structure and function
Emergency steering pump

Emergency steering pump (WA380-F940-041-K-00-A)

(if equipped)

Specification (WA380-F940-030-K-00-A)

Model SBL (1) 21


Rotating speed (rpm) 3,500
Delivery pressure (MPa {kg/cm2}) 20.6 {210}
Standard delivery (l/min) 67.6
Allowable delivery (l/min) 62.4

Function (WA380-F940-042-K-00-A)

• The emergency steering pump is installed together with the emergency steering motor to the right side of
the transmission. It supplies oil to the steering circuit if the engine stops or the steering circuit pressure
decreases below the specified value.

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10 Structure and function
Layout of brake parts

Brake system (ALL-G000-001-K-00-A)

Layout of brake parts (WA470-G000-04D-K-00-A)

1. Slack adjuster (front)


2. Cooling fan and brake pump
3. Hydraulic tank
4. Rear brake
5. Slack adjuster (rear)
6. Parking brake
7. Front brake
8. Transmission cut-off oil pressure sensor
9. Brake valve
10. Stop lamp oil pressure switch
11. Brake pedal
12. Brake accumulator (for front)

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10 Structure and function
Layout of brake parts

13. Accumulator charge valve


14. Brake accumulator (for rear)
15. Parking brake emergency release valve
16. Rear brake oil pressure switch
17. Front brake oil pressure switch
18. Parking brake solenoid valve
19. Parking brake oil pressure switch

WA470-7 10-153
10 Structure and function
Charge valve

Charge valve (WA470-G2H0-041-K-00-A)

P: From pump
A: To cooling fan motor
PPC: To Orbitrol valve or work equipment valve or EPC valve of each pump
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain
G: Accumulator charge pressure pickup port

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10 Structure and function
Charge valve

1. Valve body
2. Sequence valve (H1)
3. Relief valve (R2)
4. Shuttle valve (S1)
5. Priority valve
6. PPC relief valve (R3)
7. Main relief valve (R1)
Function (WA380-G2H0-042-K-00-A)

• The charge valve maintains the oil pressure from the pump at the set pressure and saves the pressure in
the accumulator.
• When the pressure is saved in the accumulator, the circuit to the cooling fan motor opens to output the
pressurized oil from the pump to drive the cooling fan motor.
• When the oil pressure rises above the specified pressure, the oil from the pump is led to the drain circuit to
reduce the load on the pump.
• The charge valve reduces the oil from the pump in pressure and outputs the source pressure for the pilot
circuit.
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10 Structure and function
Charge valve

Operation (WA380-G2H0-044-K-00-A)
When oil is not supplied to accumulator (cut-out condition)

• Since the pressure in oil passage (B) is higher than the set pressure of relief valve (1), piston (2) is pushed
forcibly to the right by the pressurized oil from oil passage (B).
• Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
• The pressurized oil from the pump flows through orifices (a) and (b) and oil passage (C) to port (T).
• Since the pressure drops when it passes orifice (a), pressure difference is generated between pressure
receiving chambers (D) and (E).
• When the pressure in pressure receiving chamber (D) exceeds the set pressure of priority valve (5),
priority valve (5) compresses spring (6) and moves to the right.
• The open areas of port (P) and orifice (c) are narrowed and port (P) starts to be interconnected to port (A).
• The pressurized oil from the pump flows through port (P), sequence valve (7), and port (A) to the cooling
fan motor.
When oil is supplied to accumulator (Cut-in condition)

• When the pressure in oil passage (B) decreases below the set pressure of relief valve (1), relief valve (1)
is returned to the left by the reaction forces of springs (3) and (4).

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10 Structure and function
Charge valve

• Relief valve (1) closes, and oil passage (C) and port (T) are disconnected.
• Since oil passage (C) and port (T) are disconnected, the pressure drops less when it passes orifice (a)
and the pressure difference between pressure receiving chambers (D) and (E) decreases.
• Priority valve (5) is moved to the left by the reaction force of spring (6).
• The open areas of port (P) and orifice (c) are increased and port (P) starts to be disconnected from port
(A).
• When the oil pressure from the pump exceeds the pressure of ports (ACC1) and (ACC2), it pushes up
check valve (8) and pressure starts being saved in the accumulator through ports (ACC1) and (ACC2).
• A certain quantity of oil decided by the size (area) of orifice (c) and the pressure difference over orifice (c)
(equivalent to force of spring (6)) is supplied through ports (ACC1) and (ACC2) to the accumulator. The
excess oil flows to ports (A) and (PPC).

When pressure reaches cut-off pressure

• When the pressure in oil passage (C) reaches the set pressure of relief valve (1), relief valve (1) is pushed
to the right by the oil pressure from oil passage (C).
• Relief valve (1) opens, and oil passage (C) and port (T) are interconnected.
• Pressure difference is generated between the right and left sides of piston (2), and then piston (2) moves
to the right to open relief valve (1) forcibly.
• Since pressure receiving chamber (E) of priority valve (5) is also connected to oil passage (C), the
pressure in pressure receiving chamber (E) becomes the drain pressure.
• Since the pressure in pressure receiving chamber (D) decreases to the level for the force of spring (6), oil
supply to oil passage (B) stops.
Main relief valve (R1)

• When the pressure in port (P) (pump pressure) exceeds the set pressure, it compresses spring (1) and
moves ball (2) to the left.

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10 Structure and function
Charge valve

• The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left largely.
• Since ports (P) and (T) are connected to drain the pump pressure, the maximum pressure of the charge
circuit is limited to protect the circuit.
PPC relief valve (R3)

• When the pressure in port (PPC) (pilot pressure) exceeds the set pressure, the pressurized oil from the
pump compresses spring (1) and moves ball (2) to the left.
• The pressurized oil from the pump reduces in pressure when it passes through orifice (a). As a result, the
pressure difference compresses spring (3) and moves valve (4) to the left.
• The open area between ports (PPC) and (P) decreases and causes pressure drop. As a result, the
pressure in port (P) does not decrease to the set pressure of the PPC relief valve but is maintained.
• The pressure in port (PPC) is maintained at a certain value of pressure by adjusting the open area
between ports (PPC) and (P) and supplied as the source pressure of the pilot pressure.
• When the pressure in port (PPC) becomes abnormal, port (PPC) and port (T) are interconnected to
release the abnormal pressure and protect the pilot circuit.
Sequence valve (H1)

• The pressure of port (P) (pump pressure) is applied to the left end of sequence valve (1) and the drain
pressure is applied to the right end.
• When the pump pressure exceeds the set pressure of spring (2), sequence valve (1) moves to the right to
interconnect ports (P) and (A).
• The pressurized oil from the pump flows through priority valve (3) and port (A) to the cooling fan motor to
drive the motor.
• Even when the driving pressure of the cooling fan motor is low, the sequence valve maintains the pump
pressure above the set pressure of spring (2) and prevents the accumulator charge pressure and the
source pressure of the pilot circuit from decreasing.

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10 Structure and function
Charge valve

Shuttle valve (S1)

• When the pressure in port (ACC1) is higher than the pressure in port (ACC2), shuttle valve (1) moves to
the left to disconnect port (ACC1) and oil passage (B).
• The open area between port (ACC2) and oil passage (B) increases and the oil is supplied to the
accumulator on the port (ACC2) side.
• When the pressure in port (ACC2) is higher than port (ACC1), the oil is supplied to the accumulator on the
port (ACC1) side.
• The pressurized oil from the pump is supplied first to the lower pressure circuit of the two systems.

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10 Structure and function
Brake valve

Brake valve (WA380-G2B0-041-K-00-A)

PA: From charge valve ACC1 port


PB: From charge valve ACC2 port
A: To rear brake
B: To front brake
TA: Plug
TB: Drain
SA: Stop lamp oil pressure switch
SB: Plug
1. Piston
2. Spool (for rear)
3. Cylinder (for rear)
4. Spool (for front)
5. Cylinder (for front)
Function (WA380-G2B0-042-K-00-A)

• The brake valve is installed to the front lower part of the operator's seat. When the brake pedal is
depressed, the oil flows to the brake piston to operate the brake.
• The right and left brake pedals are connected mechanically. When either of them is depressed, the other
one is operated, as well.
• If the brake pedal is depressed, the transmission cut-off oil pressure sensor operates and supplies signals
to the transmission controller to set the transmission in neutral electrically.

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10 Structure and function
Brake valve

Operation (WA380-G2B0-044-K-00-A)
When brake pedal is depressed

• When brake pedal (1) is depressed, the depressing force is transmitted to spool (5) through rod (2), piston
(3), and spring (4).
• When spool (5) is pushed to the right, port (TA) is closed and the oil from the pump flows through the
accumulator to port (PA) and further flows through port (A) to the rear brake piston to operate the rear
brake.
• At the same time when spool (5) is moved to the right, spool (6) is also moved to the right to close port
(TB). Then, the oil from the pump flows through the accumulator to port (PB) and further flows through port
(B) to the front brake piston to operate the front brake.

When only either brake operates


(When either brake has trouble)

• Even if the front or rear brake system has trouble such as oil leakage and only either of them operates, the
depressing force of brake pedal (1) moves spools (5) and (6) to the right mechanically.
Accordingly, the oil from the pump flows to the normal brake piston to apply the brake as usual, thus the
machine can be stopped and the safety is kept high.

WA470-7 10-161
10 Structure and function
Brake valve

Balancing operation

• When the oil fills the rear brake piston and the pressure between ports (PA) and (A) increases, the oil
flowing in chamber (E) through orifice (c) of spool (5) pushes spool (5) back to the left against the reaction
force of spring (4) to disconnect port (PA) from port (A).
At this time, port (TA) is kept closed to maintain the oil in the brake piston and leave the brake applied.
• At the same time when spool (5) moves to the left, the oil also fills the front brake piston and the pressure
between ports (PB) and (B) increases, and the oil flowing in chamber (F) through orifice (d) of spool (6)
pushes back spool (6) to the left by the distance of movement of spool (5) to disconnect port (PB) from
port (B).
Port (TB) is kept closed to maintain the oil in the brake piston and leave the brake applied.
• The oil pressure in the rear brake circuit [on port (A) side] is balanced with the depressing force of the
brake pedal, and the oil pressure in the front brake circuit [on port (B) side] is balanced with the oil
pressure in the rear brake circuit [on port (A) side].
When spools (5) and (6) are moved to the right stroke end, the line between port (PA) and (A) and that
between port (PB) and (B) are open fully, and the oil pressures in the rear and front brake circuits are
equal to the oil pressure from the pump.
Accordingly, the braking force can be adjusted by adjusting the depressing force of the brake pedal until
spools (5) and (6) move to the right stroke end.

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10 Structure and function
Brake valve

When brake pedal is released

• If brake pedal (1) is released, the depressing force of the pedal applied to spool (5) is released.
• When spool (5) is pushed back to the left by the back pressure on the rear brake piston and the reaction
force of spring (7), port (PA) is closed and the oil in the rear brake piston flows through port (A) to port (TA),
and then is drained into the hydraulic tank through port (TB), and the rear brake is released.
• At the same time when spool (5) is moved to the left, spool (6) is also pushed back to the left by the back
pressure on the front brake piston and the reaction force of spring (7), and port (PB) is closed and the oil in
the front brake piston flows through port (B) to port (TB), and then is drained into the hydraulic tank, and
the front brake is released.

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10 Structure and function
Slack adjuster

Slack adjuster (WA500-G310-041-K-00-A)

A: Inlet port
B: Outlet port
1. Cylinder
2. Check valve
3. Piston
4. Spring
5. Bleeder
Specifications (WA470-G310-030-K-00-A)

Piston operating pressure (MPa {kg/cm2}) 0.01 to 0.02 {0.1 to 0.2}


Cracking pressure of check valve (MPa {kg/cm2}) 0.93 ± 0.05 {9.5 ± 0.5}
Closing pressure of check valve (MPa {kg/cm2}) 0.60 ± 0.05 {6.0 ± 0.5}

Function (WA470-G310-042-K-00-A)

• The slack adjuster is installed in the brake oil line going to the brake piston from the brake valve, and
keeps the time lag in braking operation at a constant value.

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Slack adjuster

Operation (WA470-G310-044-K-00-A)
1. When brake pedal is depressed

• Before the brake pedal is depressed, pistons (4) are returned by stroke (S) (full stroke). When the brake
pedal is depressed, the oil from the brake valve is divided at slack adjuster port (P) and flows to the right
and left cylinders (2) to move pistons (4) rightward and leftward by stroke (S).

• As a result, brake piston (6) moves by stroke (S). At this time, the clearance between brake piston (6) and
disc becomes zero, but no braking force is generated.

• When the brake pedal is depressed further and the oil pressure from the brake valve exceeds the
specified pressure, check valve (3) opens and pressure is applied to port (C) to generate braking force.
Thus, the time lag when the brake is applied is maintained constant.

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10 Structure and function
Slack adjuster

2. When brake pedal is released

• When the brake pedal is released, piston (4) is returned by return spring (7) of brake piston (6) for the oil
amount equivalent to stroke (S) and the brake is released. That is, return stroke (T) of brake piston (6) is
decided by the oil amount for piston stroke (S) of the slack adjuster and the time lag in braking is kept
constant, regardless of wear of the brake disc.

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Accumulator (for brake)

Accumulator (for brake) (WA380-G2G0-041-K-00-A)

1. Plug
2. Gas valve
3. Top cover
4. Cylinder
5. Free piston
6. End cover
Specifications (WA380-G2G0-030-K-00-A)

Gas to be used Nitrogen gas


Gas capacity (cc) 2,850
Charged pressure 3.43 ± 0.1 {35 ± 1.0}
(MPa {kg/cm2}) (At 20°C)
Max. pressure used
20.6 {210}
(MPa {kg/cm2})

Function (WA380-G2G0-042-K-00-A)

• The accumulator is installed between the charge valve and brake valve. The space between cylinder (4)
and free piston (5) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated
by the hydraulic pump by utilizing its compressibility, and secures the braking force and operability when
the engine is stopped.

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10 Structure and function
Brake

Brake (HM300-G160-001-K-00-A)

Front (WA470-G16H-041-K-00-A)

1. Differential housing
2. Carrier
3. Piston
4. Spring
5. Plate
6. Sun gear shaft
7. Axle housing
8. End plate
9. Disc
Structure
• The front brake is a wet-type multiple-disc brake, which consists of piston (3), plate (5), disc (9), end plate
(8), and spring (4).
• The brake cylinder consists of differential housing (1) and carrier (2), and piston (3) is installed in it.
Plate (5) and end plate (8) are engaged with the spline of differential housing (1).
• Disc (9) has linings stuck to its both sides and is installed between plate (5) and end plate (8), and
engaged with the spline of sun gear shaft (6).

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Brake

Rear (WA470-G16K-041-K-00-A)

1. Differential housing
2. Carrier
3. Piston
4. Spring
5. Plate
6. Sun gear shaft
7. Axle housing
8. End plate
9. Disc
Structure
• The rear brake is a wet-type multiple-disc brake, which consists of piston (3), plate (5), disc (9), end plate
(8), and spring (4).
• The brake cylinder consists of differential housing (1) and carrier (2), and piston (3) is installed in it.
Plate (5) and end plate (8) are engaged with the spline of differential housing (1).
• Disc (9) has linings stuck to its both sides and is installed between plate (5) and end plate (8), and
engaged with the spline of sun gear shaft.

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10 Structure and function
Brake

Operation (WA380-G160-044-K-00-A)
When brake is applied

• When the brake pedal is depressed, pressurized oil (P) supplied from the hydraulic tank through the pump
and brake charge valve flows through the oil passage in the brake cylinder to pushes piston (2) to the left.
Accordingly, discs (4) held between piston (2), plates (3), and end plate (5) are locked and the machine is
braked.
When brake is released

• When the oil pressure is released, piston (2) is returned by the reaction force of spring (8). As a result,
clearance is made between plate (3) and end plate (5), and the brake is released.
The linings stuck to discs (4) are grooved in a check pattern, and oil flows in the grooves to cool the linings
while discs (4) are turning.

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10 Structure and function
Parking brake control

Parking brake control (WA470-GJ00-041-K-00-A)

1. Parking brake switch


2. Parking brake emergency release valve
3. Parking brake solenoid valve
4. Parking brake oil pressure switch
5. Parking brake

Outline
• Parking brake (4) is a wet-type multiple-disc brake built in the transmission, which is installed in the output
shaft bearing area, operated mechanically with the pressing force of the spring, and released hydraulically.
• When parking brake switch (1) installed in the operator's compartment is turned "ON", parking brake
solenoid valve (3) installed to the valve assembly blocks the hydraulic oil, and consequently parking brake
(5) operates.
• When parking brake switch is turned "OFF", the hydraulic pressure of the cylinder releases parking brake
(5).
• While the parking brake is applied (the solenoid valve is in "OFF"), the neutralizer signal blocks the signals
from the transmission controller to the transmission solenoid valve to keep the transmission in neutral.
• Parking brake emergency release valve (2) is installed to move the machine when it stops because of a
trouble in the engine or drive system (the parking brake is applied).

WA470-7 10-171
10 Structure and function
Parking brake

Parking brake (WA470-GJ20-041-K-00-A)

1. Output shaft
2. Spring (outside)
3. Spring (inside)
4. Parking brake oil port
5. Piston
6. Plate
7. Disc
8. Wave spring

Structure
• The parking brake is a wet-type multiple-disc brake, which is operated mechanically by springs (2) and (3)
to brake output shaft (1).
Operation (WA380-GJ20-044-K-00-A)

• When the brake is applied, piston (5) presses plates (6) and discs (7) against each other with the tension
of springs (2) and (3) to lock output shaft (1).
• When the brake is released, the oil pressure from parking brake oil port (4) moves piston (5) to release the
pressing force on discs (7) and plates (6).

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10 Structure and function
Parking brake solenoid valve

Parking brake solenoid valve (WA470-GJD0-041-K-00-A)

1. Transmission control valve assembly (L.H. valve assembly)


2. Coil (ON/OFF type)
3. Push pin
4. Spring
5. Spool
6. Valve block
7. Check valve

WA470-7 10-173
10 Structure and function
Parking brake solenoid valve

Operation (WA380-GJD0-044-K-00-A)
When parking brake is applied (solenoid is de-energized)

• When the parking brake switch is turned "ON", coil (1) is "de-energized" and spool (2) is moved down by
the reaction force of spring (3).
• Pump port (P) and parking brake port (A) are closed and the pressurized oil from the pump does not flow
to the parking brake. At this time, the oil that is operating the parking brake flows through port (A) to port
(T) and is drained.
• Since the oil that is operating the piston is drained, the piston pushed back by the spring presses the
plates and discs to apply the brake.

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10 Structure and function
Parking brake solenoid valve

When parking brake is released (solenoid is energized)

• When the parking brake switch is turned "OFF", coil (1) is "energized" and spool (2) moves up.
• The pressurized oil from the pump enters port (P) and flows around spool (2) and through port (A) to the
parking brake. At the same time, port (T) closes and the oil is not drained.
• Since the oil pressure is applied to the piston, the piston compresses the spring and separates the plates
and discs to release the parking brake.

WA470-7 10-175
10 Structure and function
Parking brake emergency release valve

Parking brake emergency release valve (WA470-GJG0-041-K-00-A)

A: From accumulator
B: To parking brake solenoid valve
1. Grip
2. Valve
Function (WA380-GJG0-042-K-00-A)

• The parking brake emergency relief valve is installed between the accumulator of the brake circuit and
parking brake solenoid. When the oil pressure from the power train pump cannot be supplied because of
an engine trouble etc., the accumulator charge pressure of the brake circuit can be supplied to the parking
brake cylinder by opening this valve manually.

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10 Structure and function
Axle mount and center hinge pin

Undercarriage and frame (ALL-DT00-001-K-00-A)

Axle mount and center hinge pin (WA470-H1K0-041-K-00-A)

1. Front axle
2. Front frame
3. Rear axle
4. Rear frame
Function (WA380-H1K0-042-K-00-A)

• Front frame (2) and rear frame (4) are connected by the center hinge pin with the bearing between them.
The right and left steering cylinders connecting front frame (2) and rear frame (4) adjust the articulate
angle of the frames, or the turning radius, by extending and retracting their piston rods.

WA470-7 10-177
10 Structure and function
Tire

Tire (WA470-DW60-041-K-00-A)

This machine has the following features by employing radial tires.


• High grip
• High operator comfort
• Low puncture rate
• Less uneven wear
• Less fuel consumption
• Long life
• Less damage on machine
• Less heat generation

Comparison of structures and characteristics of tires

Radial tire

Structure
• The cords composing carcass (1) are arranged at right angles (radially) to the center line of tread (T).
• Tread (T) is stabilized and protected by several strong belts (2).
• Side wall (W) and tread (T) are independent structurally from each other.

Gripping characteristics
• Even when the tire is deflected by the load, it makes little unnecessary movement and grips the ground
stably and securely.

Deflection characteristics
• When the tire is loaded, only its side wall (W) is deflected and tread (T) composed of strong belts (2)
maintains independent stability.

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10 Structure and function
Tire

Bias tire

Structure
• The cords composing carcass (1) are arranged diagonally (bias) to the center line of tread (T).
• Side wall (W) and tread (T) are made integrally.

Gripping characteristics
• When the tire is deflected by the load, its ground contact face is deflected and it makes unnecessary
movement. Accordingly, the ground contact face becomes unstable.

Deflection characteristics
• When the tire is loaded, side wall (W) and tread (T) move as one piece.

WA470-7 10-179
10 Structure and function
Hydraulic component layout

Hydraulic system (D65-PM10-001-K-00-A)

Hydraulic component layout (WA470-PM10-04D-K-00-A)

1. Lift cylinder (R.H.)

10-180 WA470-7
10 Structure and function
Hydraulic component layout

2. Bucket cylinder
3. Control valve
4. Work equipment lock solenoid valve
5. Steering valve
6. Orbitrol valve
7. Stop valve (R.H.)
8. Brake valve
9. Cooling fan and brake pump
10. Work equipment pump
11. Hydraulic tank
12. Power train oil cooler
13. Hydraulic oil cooler
14. Cooling fan motor
15. Slack adjuster (rear)
16. Steering pump
17. Double type gear pump (power train charge pump and power train lubrication pump)
18. Emergency steering motor (if equipped)
19. Emergency steering pump (if equipped)
20. Stop valve (L.H.)
21. ECSS accumulator
22. Steering cylinder (L.H.)
23. Steering cylinder (R.H.)
24. Lift cylinder (L.H.)
25. Slack adjuster (front)
26. Brake accumulator (for front)
27. Accumulator charge valve
28. PPC accumulator
29. Brake accumulator (for rear)
30. Brake emergency release valve
31. Breather
Outline
• The hydraulic system consists of the work equipment circuit and steering circuit. The work equipment
circuit controls the operation of the bucket and attachment.
• The oil in hydraulic tank (11) is sent to control valve (3) by work equipment pump (10). While the spools of
control valve (3) for the bucket and boom are in the hold position, the oil flows through the drain circuit of
control valve (3) and is filtrated by the filter in hydraulic tank (11) and returned to the tank.
• When the work equipment control lever is operated, the work equipment controller sends a command
current to EPC valve.
• EPC valve operates each spool of control valve (3) hydraulically in accordance with the command current.
• The oil flows from control valve (3) to lift cylinders (1) and (24) or bucket cylinder (2) to move the boom or
bucket.
• The maximum pressure in the hydraulic circuit is controlled with the relief valve in control valve (3). The
bucket cylinder circuit is equipped with a safety valve (with suction valve) to protect itself.
• Hydraulic tank (11) is of pressurized and sealed type, and equipped with an oil filler cap/breather having a
relief valve, which pressurizes the tank, prevents generation of negative pressure in the tank, and
prevents cavitation in the pump. Air is taken in through the breather (31).
• When the machine cannot be steered normally during travel because of an engine stall, steering pump
trouble, oil leakage from the piping, etc., electric emergency steering motor (18) is operated to drive
emergency steering pump (19) and enables steering (if equipped).
• Fan motor (14) installed to the radiator is driven with variable hydraulic pressure by cooling fan/ brake
pump (9).

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10 Structure and function
Work equipment control

Work equipment control (WA380-PK00-001-K-00-A)

3-lever type (WA380-PK3A-041-K-00-A)

a The figure shows the machine with the auxiliary control lever.

1. Work equipment lock switch


2. Boom control lever
3. Bucket control lever
4. Auxiliary control lever (if equipped)
5. Armrest
6. Armrest height and angle adjustment grip
7. R.H. console fore-and-aft lever
8. Electric service lever (if equipped)
9. Electric bucket lever
10. Electric boom lever

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10 Structure and function
Hydraulic tank

Hydraulic tank (WA470-PM30-041-K-00-A)

Oil filler cap with relief valve


2. Breather (for air intake)
3. Hydraulic tank

WA470-7 10-183
10 Structure and function
Hydraulic tank

4. Drain plug
5. Strainer
6. Filter element
7. Bypass valve
8. Suction strainer
9. Sight gauge
Specifications (WA470-PM30-030-K-00-A)

Hydraulic tank capacity (l) 255


Hydraulic oil in tank (l) 173
Bypass valve set pressure (MPa {kg/cm2}) 0.15 ± 0.03 {1.53 ± 0.31}

Oil filler cap with relief valve (WA470-PM37-041-K-00-A)

1. Bottom plate
2. Gasket
Prevention of pressure rise in tank
• While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and
the temperature in the hydraulic tank rise according to the operation of the hydraulic cylinders.
If the pressure in the tank exceeds the set pressure, bottom plate (1) is pushed up to release the pressure
in the tank and prevent pressure rise.
(Set pressure of air bleeding valve: 75 ± 15 kPa {0.76 ± 0.15 kg/cm 2})

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10 Structure and function
Hydraulic tank

Breather (WA500-PM38-041-K-00-A)

1. Body
2. Filter element
3. Poppet
4. Sleeve

Function (WA470-PM38-042-K-00-A)
• Prevention of negative pressure in tank
Since the tank is pressurized and sealed, the oil level in it decreases and negative pressure is generated
in it. At this time, poppet (3) is opened by the differential pressure from the ambient pressure. As a result,
the ambient pressure is let into the tank and generation of negative pressure is prevented.
(Set pressure of air bleeding valve: 0 – 2.9 kPa {0 – 0.03 kg/cm2})
• Prevention of pressure rise in tank
If the circuit pressure increases above the specified pressure because of the oil level change caused by
the hydraulic cylinder and temperature rise during operation, sleeve (4) operates to release the pressure
in the hydraulic tank.
(Set pressure of air bleeding valve: 137 ± 20 kPa {1.4 ± 0.2 kg/cm2})

WA470-7 10-185
10 Structure and function
Double type gear pump

Double type gear pump (WA470-RA1S-041-K-00-A)


Power train charge pump and power train lubrication pump

1. Power train charge pump (SAL (3) 80)


2. Power train lubrication pump (SAL (1) 32)
Specifications (WA470-RA1S-030-K-00-A)

Model SAL (3) 80 SAL (1) 32


Rotating speed (rpm) 2,500 2,500
Discharge pressure (MPa {kg/cm2}) 2.9 {30} 2.9 {30}
Standard discharge (l/min) 192 78
Allowable discharge (l/min) 176 70
Function (WA380-RA1S-042-K-00-A)

• The double type gear pump consists of the power train charge pump and the power train lubrication pump.
• It is installed to the PTO shaft of the torque converter and driven by the PTO shaft to supply oil pressure to
the torque converter and transmission circuits.

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10 Structure and function
Work equipment pump

Work equipment pump (WA470-C200-041-K-00-A)

IM: PC mode selector current


PA: Pump discharge port
PB: Pump pressure inlet port

WA470-7 10-187
10 Structure and function
Work equipment pump

PC: Cooling port


PD1: Case drain port
PD2: Air bleeder
PEN: Control pressure pickup port
PEPC: EPC source pressure port
PEPCC: EPC source pressure pickup port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve

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10 Structure and function
Work equipment pump

1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve

Structure
• Cylinder block (7) is supported to shaft (1) by spline (12).
• Shaft (1) is supported by each bearing (13) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and crimped together with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to the case. High-pressure oil is supplied
between them to form a static pressure bearing.
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).

WA470-7 10-189
10 Structure and function
Work equipment pump

• Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
• The oil pressure is balanced properly on the sealing surface of cylinder block (7) and valve plate (8).
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Specifications (WA470-C200-030-K-00-A)

Model HPV140
Type Variable displacement swash plate type piston pump
Theoretical delivery (cm3/rev) 120 ± 1
Rated delivery pressure: (MPa {kg/
34.3 {350}
cm2})
Rated speed (rpm) (*1) 2,282
*1: It shows the value when engine speed is at rated speed of 2,000 rpm.
Function (WA500-C200-042-K-00-A)

• This pump converts the rotation and torque of the engine transmitted to its shaft into hydraulic pressure
and discharges pressurized oil according to the load.
• It is possible to change the discharge by changing the swash plate angle.
Operation (WA470-C200-044-K-00-A)
Operation of pump

• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.

• While angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7), plane
(A) works as a cam for shoe (5).
• Piston (6) slides inside cylinder block (7) and a difference is made between volumes (E) and (F) in cylinder
block (7).
• Oil in amount of (F) minus (E) is sucked in and discharged from each piston (6).

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10 Structure and function
Work equipment pump

• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• Oil is sucked in when the volume of chamber (F) increases.

• When center line (X) of rocker cam (4) matches the axis of cylinder block (7) (the swash plate angle is
zero), the difference between volumes (E) and (F) inside cylinder block (7) is zero.
• Pressurized oil is not sucked or discharged, namely pumping action is not performed. (Actually, however,
the swash plate angle does not become 0 deg.)
• The pump discharge is in proportion to swash plate angle (a).

Control of discharge

WA470-7 10-191
10 Structure and function
Work equipment pump

• When the swash plate angle (a) increases, the difference between volumes (E) and (F) increases and also
pump discharge (Q) increases.
• Swash plate angle (a) is changed by servo piston (10).
• Servo piston (10) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• The linear reciprocating movement of servo piston (10) is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• The area of servo piston (10) for receiving the pressure are not identical on the left side and right side.
Main pump discharge pressure (self pressure) (PP) is always brought to the pressure chamber of the
small diameter piston side.
• Output pressure (PEN) of LS valve is supplied to the chamber receiving the pressure at the large diameter
piston end.
• The movement of servo piston (10) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter side (PEN) and by the ratio of the area receiving the pressure
between small diameter piston and large diameter piston.
LS valve (WA470-C2J0-041-K-00-A)

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10 Structure and function
Work equipment pump

PA: Pump port


PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: Drain port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut

Function (WA470-C2J0-042-K-00-A)
• The LS (load sensing) valve detects the load of the actuator and controls the pump discharge.
• The LS valve controls pump discharge (Q) according to differential pressure (dPLS) [ = (PP - PLS)] (called
LS differential pressure) between pump discharge pressure (PP) and control valve outlet port pressure
(PLS).
• The LS valve receives main pump pressure (PP) and pressure (PLS) (called the LS pressure) coming
from the control valve output.

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10 Structure and function
Work equipment pump

Operation (WA500-C2J0-044-K-00-A)

When control valve is in neutral

• The LS valve is a 3-way selector valve, and LS pressure (PLS) on the inlet of the control valve is
transmitted to spring chamber (B), and pump discharge pressure (PP) is transmitted to port (H) of sleeve
(8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump discharge
pressure (PP) determine the position of spool (6).
• Before the engine is started, servo piston (12) is pushed to the left. (See the figure below)
• When the control lever is in the NEUTRAL position when the engine is started, LS pressure (PLS) is set to
0 MPa {0 kg/cm2}. (It is connected to the drain circuit through the control valve spool)
• Spool (6) is pushed to the right, and port (C) and port (D) are connected.
• Shuttle valve output pressure (PPH) is transmitted to the large end of the piston through port (K).
• Pump pressure (PP) is transmitted to port (J) on small end side.
• According to the area difference of servo piston (12), the servo piston is moved in the direction which
makes the swash plate angle minimum.

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10 Structure and function
Work equipment pump

Operation in direction to increase pump discharge

• When the difference between pump discharge pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) becomes smaller [for example, when the area of opening of the control valve
becomes larger and pump discharge pressure (PP) drops], spool (6) is pushed to the left by the combined
force of LS pressure (PLS) and the force of spring (4).
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve is connected to the drain port, the pressure between circuits (D) and (K) becomes
drain pressure (PT). (The operation of the PC valve is described later.)

WA470-7 10-195
10 Structure and function
Work equipment pump

• The pressure at the large end of servo piston (12) becomes drain pressure (PT) and pump pressure (PP)
is constantly transmitted to port (J) at the small end. Accordingly, servo piston (12) is pushed to the left
and moves the swash plate in the direction to increase the discharge.

Operation in direction to increase pump discharge

• When LS differential pressure (dPLS) becomes larger (for example, when the area of opening of the
control valve becomes smaller and pump pressure (PP) rises), pump pressure (PP) pushes spool (6) to
the right.
• When spool (6) moves, shuttle valve output pressure (PPH) is transmitted to port (D) through port (C), and
then to the large end of the piston through port (K).
• Main pump pressure (PP) is transmitted to port (J) of the small end of the piston, but servo piston (12) is
pushed to the right because of the difference in area between the large and the small ends of servo piston
(12). As a result, the swash plate angle is decreased.

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10 Structure and function
Work equipment pump

When servo piston is balanced

• The symbols (A1), (A0) and (PEN) respectively represent the area receiving the pressure at the large end
of the piston, the area receiving the pressure at the small end and the pressure transmitted to the large
diameter end of the piston.
• When main pump pressure (PP) of the LS valve is balanced with the combined force of LS pressure (PLS)
and spring (4) and (A0) x (PP) = (A1) x (PEN), servo piston (12) stops at the current position.
• The pump swash plate is held at an intermediate position. [The swash plate stops at a position where the
opening between ports (D) and (E) of spool (6) and that between ports (C) and (D) are approximately
equal]
• The relation between the area receiving the pressure at both ends of servo piston (12) is (A0):(A1) = 3:5,
so the pressure applied to both ends of the piston when it is balanced becomes (PP):(PEN) C 5 : 3.
• The position where spool (6) is balanced and stopped is the standard center, and the force of spring (4) is
adjusted so that it is determined when (PP) - (PLS) = 1.4 MPa {14 kg/cm 2}.

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10 Structure and function
Work equipment pump

PC valve (WA470-C2K0-041-K-00-A)

PA: Pump port


PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring

Function (WA470-C2K0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depends on the discharge pressure) even if the stroke of
the control valve is increased extremely when pump discharge pressure (PP) is high.
• If the pump discharge pressure increases due to increased load during operation, this valve decreases the
pump discharge.
• If the pump discharge pressure decreases, this valve increases the pump discharge.
• The relation between the pump discharge pressure (PP) and pump discharge (Q) is as shown in the
following figure, as a parameter for each current (X) value applied to the PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• During low speed, command current (X) flows from the controller to PC-EPC valve solenoid according to
the engine speed to reduce the pump discharge.

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10 Structure and function
Work equipment pump

Operation (WA470-C2K0-044-K-00-A)

When actuator load is small and pump discharge pressure (PP) is low

Action of PC-EPC valve solenoid (1)


• Command current (X) from the work equipment controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
• Spool (3) stops at a position where the combined force exerted by spring (4) is equalized to the force
exerted by pump pressure (PP) acting on spool (3).

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10 Structure and function
Work equipment pump

• Depending on the position where spool stops, the pressure output from the PC valve [port (C) pressure]
varies.
• The amperage of the command current (X) depends on the type of work (lever operation), working mode
selection, engine speed setting, and the actual engine speed.

Action of spring
• The spring force of spring (4) in the PC valve depends on the position of the swash plate.
• When servo piston (9) compresses or decompresses spring (4), the spring force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring force of spring (4) is also varied by the PC-EPC valve solenoid command current (X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Pump pressure (PP) is transmitted to the small diameter end of servo piston (9), port (A), and port (B).
• When pressures (PP) is low, spool (3) is at the left.
• Port (C) and port (D) are connected, and the pressure entering the LS valve will be drain pressure (PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter side of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump discharge goes to increase.
• The movement of servo piston (9) lets spring (4) to expand, and the spring force decreases.
• When the spring force decreases, spool (3) moves to the right. Ports (C) and (D) are blocked, while pump
discharge pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.

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10 Structure and function
Work equipment pump

• Stop position of servo piston (9) (= pump discharge) is determined by a position where the press force
generated by pressure (PP) on spool (3) and the thrust by PC-EPC valve solenoid and the force of spring
(4) are balanced.

When actuator load is large and pump discharge pressure is high

• When the load is large and the pump discharge pressure (PP) is high, the thrust moving spool (3) to the
right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP), because a
part of the pressure from port (B) is transmitted to port (D) through the LS valve and port (C), as shown
above.
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP) increases more and spool (3) moves further to the right, pump pressure (PP)
flows to port (C) to minimize the pump discharge.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and push back spool (3).
• When spool (3) moves to the left, the openings of ports (C) and (D) widen.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
• At this time, servo piston (9) stops at a position further to the right than the position when pump pressure
(PP) is low.
• The relationship between pump pressure (PP) and pump average discharge (Q) becomes as shown in the
following figure.

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10 Structure and function
Work equipment pump

• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
pump pressure (PP) and pump discharge (Q) is shifted parallel in proportion to the thrust of PC-EPC valve
solenoid.
• The thrust of PC-EPC valve solenoid (1) is added to the rightward thrust caused by the pump pressure
applied to spool (3), so the relationship between pump pressure (PP) and pump discharge (Q) moves from
(A) to (B) as the command current (X) is increased.

10-202 WA470-7
10 Structure and function
Work equipment pump

PC-EPC valve (WA500-C2N0-041-K-00-A)

C: To PC valve
P: From pilot lamp
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger

Function (WA500-C2N0-042-K-00-A)
• The EPC valve consists of the proportional solenoid and the hydraulic valve.

WA470-7 10-203
10 Structure and function
Work equipment pump

• When signal current (i) from the controller is received, an EPC output pressure proportional to the
amperage of current is generated and output to the PC valve.

Operation (WA500-C2N0-044-K-00-A)

When signal current is zero (coil de-energized)


• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the pilot pump does not flow to the PC valve.
• The pressurized oil from the PC valve is drained to the tank through port (C) and port (T).

10-204 WA470-7
10 Structure and function
Work equipment pump

WA470-7 10-205
10 Structure and function
Work equipment pump

When signal current is minute (coil is energized)


• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
force of spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and ports (P) and (C) are blocked.
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the pressure at
port (C) and the force of spring (4).
• The circuit pressure between the EPC valve and the PC valve is controlled in proportion to the amperage
of the signal current.

10-206 WA470-7
10 Structure and function
Work equipment pump

When signal current is maximum (coil is energized)


• Coil (2) is energized when signal current is supplied to coil (2).
• As the amperage of energized signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and PC valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.

WA470-7 10-207
10 Structure and function
Control valve

Control valve (WA470-R404-041-K-00-A)

a In this section, the 4-spool valve (with ECSS control valve) is described.

A1: To bucket cylinder bottom


A2: To lift cylinder bottom

10-208 WA470-7
10 Structure and function
Control valve

A3: To attachment port


ACC: To accumulator for ECSS
B1: To bucket cylinder head
B2: To lift cylinder head
B3: To attachment port
CAC: Accumulator pressure pickup port
CLS: LS pressure pickup port
CP1: Pump discharge pressure pickup port
CP2: Pressure sensor mounting port
CR: Accumulator charge pressure pickup port
P1: From work equipment hydraulic pump
PA1: From bucket tilt controller
PA2: From boom raise controller
PA3: From attachment control
PACC: From ECSS controller
PB1: From bucket dump controller
PB2: From boom lower controller
PB3: From attachment control
PLS: To work equipment hydraulic pump LS port
PP: From pilot pump
PPS: To work equipment hydraulic pump
T: To tank
TS: To tank
1. Bucket valve
2. Boom valve
3. ECSS valve
4. Attachment valve
5. Cover (A)
6. Cover (B)
7. Boom suction valve
8. Accumulator charge valve

WA470-7 10-209
10 Structure and function
Control valve

1. Load check valve (bucket bottom)


2. Load check valve (boom bottom)
3. Pressure compensation valve (boom head)
4. Pressure compensation valve (bucket head)
5. Pressure compensation valve (attachment)
6. Pressure compensation valve (attachment)

10-210 WA470-7
10 Structure and function
Control valve

1. Spool (ECSS control)


2. Spool (boom)
3. Spool (bucket)
4. Spool (attachment)

WA470-7 10-211
10 Structure and function
Control valve

1. Suction safety valve (bucket bottom)


2. Suction safety valve (bucket head)
3. Suction safety valve (boom bottom)
4. Suction safety valve (boom head)
5. Suction safety valve (attachment)
6. Suction safety valve (attachment)

10-212 WA470-7
10 Structure and function
Control valve

1. Unload valve
Bucket valve
2. EPC valve (dump)
3. Load check valve (tilt)
4. Pressure compensation valve (dump)
5. EPC valve (tilt)
6. Suction safety valve (dump)
7. Bucket spool
8. Suction safety valve (tilt)

WA470-7 10-213
10 Structure and function
Control valve

Boom valve
1. EPC valve (lower and float)
2. Load check valve (raise)
3. LS shuttle valve
4. Pressure compensation valve (lower)
5. EPC valve (raise)
6. Suction safety valve (lower and float)
7. Suction safety valve (lower and float)
8. Boom spool

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10 Structure and function
Control valve

9. Suction safety valve (raise)

ECSS valve
10. ECSS spool
11. EPC valve (ECSS ON - OFF)
12. Accumulator charge valve

Attachment valve
1. EPC valve
2. Load check valve
3. LS shuttle valve

WA470-7 10-215
10 Structure and function
Control valve

4. Load check valve


5. EPC valve
6. Suction safety valve
7. Attachment spool
8. Suction safety valve

9. Unload valve
10. Main relief valve
11. LS bypass valve

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10 Structure and function
CLSS

CLSS (ALL-PNJ1-001-K-00-A)

CLSS: Abbreviation for Closed center Load Sensing System


Structure of CLSS (WA470-PNJ1-041-K-00-A)

Features
CLSS is an abbreviation for Closed center Load Sensing System, which has the following features.
• Fine control not influenced by load
• Control performance that allows digging even under fine control operation condition
• Ease of combined operation ensured by the flow dividing performance that is determined by the opening
areas of spools during combined operations
• Energy saving by variable discharge pump control

Configuration
• CLSS consists of variable capacity piston pump, control valves, and respective actuators.
• The variable capacity piston pump consists of a pump body, LS valve, and PC valve.

Basic principle

Pump swash plate angle control


• The pump swash plate angle (pump discharge) is so controlled that LS differential pressure (dPLS), which
is the differential pressure between pump discharge pressure (PP) and control valve outlet LS pressure
(PLS) (actuator load pressure), is kept constant.
• [LS differential pressure (dPLS) = Pump discharge pressure (PP) - LS pressure (PLS)]

WA470-7 10-217
10 Structure and function
CLSS

• The pump swash plate shifts toward the maximum angle position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve.
• The pump swash plate shifts toward the minimum angle position if LS differential pressure is higher than
the set pressure.

10-218 WA470-7
10 Structure and function
CLSS

LS differential pressure (d
d PLS) and pump swash plate angle

a For details of the operation, see "Work equipment pump".

Pressure compensation control

WA470-7 10-219
10 Structure and function
CLSS

• A valve to balance the load (pressure compensation valve) is installed on the lift cylinder head outlet side
of the control valve.
• When actuators are operated in combined operations, the pressure difference (dP) between the upstream
(inlet port) and downstream (outlet port) of the spool of each valve is kept the same among them,
regardless the level of the load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
• If the pressurized oil flows into the lift cylinder head too much because of the hydraulic drift of the boom
and combined operation of the bucket, the bucket does not move. This is prevented by the above control.

10-220 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves

Hydraulic circuit diagram and names of valves (WA470-PM10-054-K-00-A)

1. Bucket valve
2. Boom valve
3. ECSS valve
4. Attachment valve
5. Bucket spool
6. Boom spool
7. ECSS spool
8. Attachment spool

WA470-7 10-221
10 Structure and function
Hydraulic circuit diagram and names of valves

9. Pressure compensation valve


10. Suction valve
11. Load check valve
12. Accumulator charge valve
13. Main relief valve
Relief pressure: 34.3 MPa {350 kg/cm2}
14. Unload valve
Cracking pressure: 1.9 MPa {19.5 kg/cm2}
15. Suction safety valve
Cracking pressure: 32.4 MPa {330 kg/cm2}
16. Safety valve
Cracking pressure: 38.2 MPa {390 kg/cm2}
17. Safety valve
Cracking pressure: 45.1 MPa {460 kg/cm2}
18. Safety valve
Cracking pressure: 22.6 MPa {230 kg/cm2}
Unload valve (WA470-PQD0-040-K-00-A)
When the unload valve is actuating

a: Orifice
b: Port
c: Port
P: Pump circuit
PLS: LS circuit
T: Tank circuit
1. Spring

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10 Structure and function
Hydraulic circuit diagram and names of valves

2. Valve
Function
• Drains an oil discharge for the portion of the minimum pump swash plate angle while all control valves are
in the holding.
• The pump pressure will correspond to a set load of spring (5) inside the valve (this pressure will be P1).
• Since LS pressure is drained from the LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}

Operation

• Pressure of pump circuit (P) is received by the end of valve (2).


• Since the control valve is in neutral position, pressure of LS circuit (PLS) is 0 MPa {0 kg/cm2}.
• Pressurized oil of pump circuit (P) stops at valve (2), and the pressure rises as no relief is available.
• When this pressure becomes larger than the force of spring (1), valve (2) moves to the right.
• Ports (b) and (c) are interconnected and the pump pressure flows to tank circuit (T).
• Since the pump discharge pressure - LS circuit pressure during unloading is larger than the pump LS
control pressure, the signal is output to minimize the pump swash plate angle.
• During operation (a work within a scope of discharge by a minimum swash plate angle), the discharge
pressure for the portion of minimum pump swash plate angle is set to LS pressure + P1 pressure.
• LS control differential pressure (dPLS) of discharge for the portion of minimum swash plate angle will be
equal to P1 pressure.

Operation of relief valve


• When cylinder reaches its stroke end, main relief valve opens.
• Pump delivery (Q) is relieved to the tank.
• Since the pump delivery pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor
downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa
{0 kg/cm2}.
• As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to
make the pump swash plate angle maximum.
• Mechanically, operation of PC valve has priority over that of LS valve.
• The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.

WA470-7 10-223
10 Structure and function
Hydraulic circuit diagram and names of valves

Pressure compensation valve (WA470-C790-040-P-00-A)

(installed to cylinder head side of boom valve)

When high load is applied to the boom.

1. Main pump
Pressure compensation valve
2. Load check valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• High load pressure is generated during independent operation of the boom and combined operation with
the bucket.
• When the load pressure of the boom is higher than the pump pressure, this valve functions as a load
check valve to prevent reverse oil flow in the circuit.

Operation
• Actuator circuit pressure (B) increases higher than pump discharge pressure (PPS) and LS pressure
(PLS).
• Shuttle valve (3) of the pressure compensation valve moves to the right.

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10 Structure and function
Hydraulic circuit diagram and names of valves

• Actuator circuit pressure (B) is interconnected with spring chamber (C).


• Piston (4) is pushed to the left by spring (5).
• Valve (2) is also pushed to the left by piston (4) to close pump outlet circuit (A) and prevent reverse flow
from actuator circuit (B) to pump outlet circuit (A).

During combined operation (lowering boom and tilting bucket)

Function
• When the flow rate of the boom starts to increase because the load pressure of the boom becomes lower
than that of the bucket during combined operation, this valve compensates the pressure on the boom side.
• On the bucket side, the load pressure is higher and the flow rate starts to decrease.

Operation
• When the load pressure on the boom side increases during combined operation, the flow to the actuator
circuit (B) starts to increase.
• Since the LS pressure (PLS) on the bucket side increases, it pushes shuttle valve (3) of the pressure
compensation valve on the boom side to the left.
• The pressurized oil flows through the internal passage of piston (4) to spring chamber (C).
• Piston (4) and valve (2) are pushed to the left to close the outlet side of pump circuit (PPS).
• Outlet pressure (A) (spool meter-in downstream pressure) becomes equal to the output pressure of the
bucket.
• Pump pressure (PPS) (spool meter-in upstream pressure) becomes the same in all the actuators.
• Pump pressure (PPS) and outlet pressure (A) become the same in all the operated spools.
• The pump discharge flow is divided in proportion to the opening area of each spool.

WA470-7 10-225
10 Structure and function
Hydraulic circuit diagram and names of valves

Shuttle valve in pressure compensation valve (WA470-C7C0-041-P-00-A)

When holding pressure in port (B) > LS pressure in spring chamber (C)

1. Hydraulic pump
2. Load check valve
3. Shuttle valve
4. Piston

Function (WA500-C7C0-042-P-00-A)
• Shuttle valve (3) is pushed to the right by the port (B) pressure to disconnect the port (B) from port (D).
• The holding pressure of port (B) is transmitted to spring chamber (C) to push piston (4) to the left so that
piston (4) and load check valve (2) do not separate from each other.

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10 Structure and function
Hydraulic circuit diagram and names of valves

Surface area ratio of pressure compensation valve (WA470-C790-042-P-00-A)

• The flow division ratio varies with the surface area ratio of portions (A1) and (A2) of the pressure
compensation valve. Surface area ratio = (A2)/(A1)
• When the surface area ratio is 1: The spool meter-in downstream pressure is equal to the maximum load
pressure and oil flows in accordance with the opening area ratio of spool meter-in.
• When the surface area ratio is 1 or more: The spool meter-in downstream pressure is more than the
maximum load pressure and oil flows less than the opening area ratio of spool meter-in into the lower
pressure side.
• When the surface area ratio is 1 or less: The spool meter-in downstream pressure is less than the
maximum load pressure and oil flows more than the opening area ratio of spool meter-in into the lower
pressure side.

WA470-7 10-227
10 Structure and function
Hydraulic circuit diagram and names of valves

Introduction of LS pressure (ALL-C2A4-001-K-01-A)

LS shuttle valve (WA470-L1P0-041-K-00-A)

1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. Load check valve
5. Check valve
6. LS circuit
7. LS shuttle valve

Function (WA500-L1P0-042-K-00-A)
• LS pressure (PLS) is the actuator load pressure on the outlet side of the control valve.
• The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted through main spool (2) to LS shuttle valve (7).
• The LS pressure is connected through valve (5) to port (B) of the actuator, and then it ≒ the actuator load
pressure.
• Inlet hole (a) in main spool (2) is small in diameter and has a throttling function.

Operation (WA500-L1P0-044-K-00-A)
• When main spool (2) is operated, the discharged oil from pump flows into actuator circuit (B).
• Pump discharge pressure (PPS) is transmitted through inlet hole (a) of main spool (2) to LS circuit (PLS).
• Pump discharge pressure (PPS) increases to the necessary pressure for actuator circuit (B).

10-228 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves

• Check valve (5) in main spool (2) opens and the high pressure oil of LS circuit (PLS) flows into actuator
circuit (B).
• The pressure in LS circuit (PLS) becomes almost the same as that in actuator circuit (B).
LS bypass plug (WA470-PNSH-041-K-00-A)

1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function (WA500-PQH2-042-K-00-A)

• This valve releases the remaining pressure in LS pressure circuit (6) through orifices (a) and (b).
• This valve decreases the rising speed of the LS pressure to prevent a sudden change of the oil pressure.
• Since the oil flows through LS valve (5), pressure loss is made by the circuit resistance between throttle
(c) of main spool (2) and LS shuttle valve (4).
• The effective LS differential pressure decreases to improve the dynamic stability of the actuator.

WA470-7 10-229
10 Structure and function
Hydraulic circuit diagram and names of valves

ECSS control valve (WA500-L320-041-K-00-A)

1. Spool
2. Solenoid valve
3. Plug
4. Nut
5. Check valve
Function (WA500-L320-042-K-00-A)

• The controller automatically turns ON/OFF the accumulator charged with the high-pressure gas according
to the travel condition of the machine.
• This valve gives elasticity to the vertical movement of the work equipment to restrict the machine body
from rocking, improve the operator comfort, and prevent the load from spilling during high-speed travel.
Operation (WA500-L320-044-K-00-A)

• When the travel speed exceeds 5 km/h, the signal enters solenoid valve (2) and the pressure is
transmitted to (a).
• Spool (1) moves to the left.
• When spool (1) moves, the passage of (PR) → accumulator (ACC) closes and the passage of (A2) →
accumulator (ACC), (B2) → (T) opens, and ECSS is turned ON.
• When the travel speed is 4 km/h or below, no signal enters solenoid valve (2) and spool (1) is kept in
neutral position. At this time, the passage of (PR) → accumulator (ACC) opens and accumulator (ACC) is
charged.

10-230 WA470-7
10 Structure and function
Hydraulic circuit diagram and names of valves

• When accumulator (ACC) is charged up to the set pressure, check valve (5) closes and the pressure in
the accumulator (ACC) does not increase any more.

Pressure release valve of accumulator


• To release the pressure in accumulator (ACC), loosen nut (4) and plug (3) to open the circuits of (PR) and
(TS).

WA470-7 10-231
10 Structure and function
Accumulator charge valve

Accumulator charge valve (WA500-G2H0-040-K-00-A)

CR: Accumulator charge pressure pickup port


P: From main pump
PR: To accumulator via ECSS spool
TS1: To tank
TS2: To tank
TS3: To tank
1. Screw
2. Poppet (relief valve)
3. Spring (relief valve)
4. Spring (main pressure reducing valve)
5. Pressure reducing valve spool
6. Check valve
7. Spring (check valve)

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10 Structure and function
Accumulator charge valve

WA470-7 10-233
10 Structure and function
Accumulator charge valve

When in neutral and (P) is low

Function
• The discharge pressure (P) of the hydraulic pump is reduced and the pressurized oil is supplied to the
accumulator for ECSS.
Operation
• Spring (3) presses poppet (2) against the seat and the line between ports (P1) and (T) is closed.
• Check valve (6) is pushed to the left and the line between ports (P1) and (PR) is closed.
• Check valve (6) is moved to the right by the pressure of (P1) and the line between (P1) and (PR) is
opened. When (P1) < (PR), spring (7) pushes check valve (6) to the left and the line between ports (P1)
and (PR) is closed.

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10 Structure and function
Accumulator charge valve

When load pressure (P) is high

Operation
• When the pressure increases to the set pressure or above, poppet (3) opens and the pressurized oil flows
from port (P1) through hole (a) in spool (5) and the opening of poppet (2) to tank port (T). As a result,
pressure P2 is kept constant.
• When pressure P1 is larger than pressure P2, spool (5) moves to the left and closes the opening of the P
o (P1) part. When pressure P1 becomes smaller than pressure P2, the opening of the P o (P1) part
opens. The pressure (P) is reduced to equalize pressure P2 and pressure P1 when this movement is
repeated.

WA470-7 10-235
10 Structure and function
Work equipment lock solenoid valve

Work equipment lock solenoid valve (WA380-PK1K-041-K-00-A)

P: From charge valve


A: To work equipment EPC valve port P
T: Drain
Function (WA380-PK1K-042-K-00-A)

• This valve is installed between the charge valve and work equipment EPC valve. Upon receiving the
operation signal from the work equipment controller, the solenoid is "energized" to block the oil to the work
equipment EPC valve and disables the operation of the work equipment.

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10 Structure and function
Accumulator (for PPC circuit)

Accumulator (for PPC circuit) (WA380-PL40-041-K-00-A)

1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Specification (WA380-PL40-030-K-00-A)

Gas to be used Nitrogen gas


Gas capacity (cc) 500
Charged pressure (MPa {kg/cm2
1.18 {12} (at 80°C)
})
Max. allowable working pressure
3.92 {40}
(MPa {kg/cm2 })

Function (WA380-PL40-042-K-00-A)

• This accumulator is installed between the charge valve and work equipment PPC valve. Even if the
engine is stopped while the work equipment is raised, pilot oil pressure can be supplied to the work
equipment control valve with the pressure of the compressed nitrogen gas in the accumulator to lower the
work equipment by its own weight.

WA470-7 10-237
10 Structure and function
Accumulator (for ECSS)

Accumulator (for ECSS) (WA470-L370-041-K-00-A)

1. Valve
2. Top cover
3. Cylinder
4. Free piston
Specifications (WA470-L370-030-K-00-A)

Gas to be used Nitrogen gas


Gas capacity (cc) 4,000
Charged pressure (MPa {kg/cm2
2.94 {30} (at 20°C)
})
Max. operating pressure (MPa
40 {408}
{kg/cm2 })

Function (WA380-L370-042-K-00-A)

• This accumulator is installed in the lift cylinder bottom circuit. The space between cylinder (3) and free
piston (4) is filled with nitrogen gas. The nitrogen gas absorbs the hydraulic pulsation generated on the lift
cylinder bottom side to improve the travel performance and workability during travel by utilizing its
compressibility.

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10 Structure and function
Work equipment linkage

Work equipment (ALL-L000-001-K-00-A)

Work equipment linkage (WA470-LB31-041-K-00-A)

1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Boom
6. Bucket link

WA470-7 10-239
10 Structure and function
Bucket

Bucket (WA470-LB00-041-K-00-A)

1. Bucket
2. Wear plate
3. Bolt-on cutting edge
4. Bucket tooth (if equipped)

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10 Structure and function
Bucket positioner and boom positioner

Bucket positioner and boom positioner (WA470-LEE0-041-K-00-A)

1. Bell crank
2. Boom
3. Bucket potentiometer
4. Bucket potentiometer lever
5. Boom potentiometer
6. Front frame
7. Boom potentiometer lever

WA470-7 10-241
10 Structure and function
ROPS cab

Cab and its attachments (ALL-K000-001-K-00-A)

ROPS cab (WA380-K211-041-K-00-A)

The appearance differs corresponding to the destination.


1. Front working lamp
2. Radio antenna
3. Door (left)
4. Air conditioner fresh air filter
5. Front glass
6. Front wiper
7. KOMTRAX communication antenna
8. KOMTRAX GPS antenna
9. Emergency escape door
10. Rear wiper

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10 Structure and function
Engine control system

Electrical system (ALL-RA1D-001-K-00-A)

Engine control system (WA470-AK60-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Slow-blow fuse
5. Fuse box 1
6. Fuse box 2
7. Engine shutdown secondary switch
8. Starting switch
9. KOMTRAX terminal
10. Monitor controller
11. Engine controller
12. Transmission controller
13. Work equipment controller
14. Service connector
15. Machine monitor
16. Rear view monitor
17. Neutral holding relay

WA470-7 10-243
10 Structure and function
Engine control system

18. Neutral safety relay


19. Personal code relay
20. Cooling fan pump relay
21. Alternator
22. Starting motor
23. Accelerator pedal

Function
• The neutral safety circuit is employed to secure safety when the engine is started.
• The engine does not start while the directional lever is not in the "N" position.
• When you cannot stop the engine due to stuck starting switch, engine shutdown secondary switch is
usable for stopping the engine.

Operation

When starting switch is in "ON" position


• When the starting switch is turned to the "ON" position, starting switch terminals B and BR are closed and
a current flows from the battery to the ground through the starting switch and battery relay, and the battery
relay contacts are closed. As a result, power is supplied to each circuit of the machine. At this time, the
ACC signal flows from starting switch terminal ACC to the engine controller, and the engine is ready to
start.
Neutral safety circuit
• When the directional lever is set to the "N (Neutral)" position, a current flows from contact N of the
directional lever to the neutral safety relay coil.

When starting switch is in "START" position


• When the starting switch is turned to the "START" position, a current flows from starting switch terminal C
to the starting motor safety relay through the neutral safety relay and personal code relay, and then the
engine starts.
• When the directional lever is not in the "N (Neutral)" position, the neutral safety relay does not operate and
the engine does not start.

When starting switch is in "OFF" position


• When the starting switch is turned to the "OFF" position, the ACC signal from starting switch terminal ACC
to the engine controller is cut off.
• When the ACC signal is cut off, the engine decreases its speed and stops. At the same time, the alternator
stops generating power and the voltage from alternator terminal R is cut off. The current from starting
switch terminal BR is also cut off and the battery relay contacts open to cut off the power supplied to each
circuit of the machine.
Stopping engine with engine shutdown secondary switch
• If the engine shutdown secondary switch is turned to the "Stop Engine" position, the current from starting
switch terminal ACC to the engine controller is forcibly cut off.
• The above induces the same condition as when starting switch is turned to "OFF" position and the engine
stops.

10-244 WA470-7
10 Structure and function
Preheating system

Preheating system (WA500-AM40-051-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Slow-blow fuse
5. Starting switch
6. Engine controller
7. Machine monitor
8. Fuse box 2
9. Electric heater
10. Preheater relay
11. Electric heater relay
Automatic preheating system (WA470-AM40-042-K-00-A)
Function
• The automatic preheating system is installed to improve the engine startability in a cold district.
• When the starting switch is turned to the "ON" position, the automatic preheating system shortens the
preheating time and sets the preheating time automatically according to the intake air temperature.
• When the starting switch is turned to the "ON" position, the preheater pilot lamp on the machine monitor
lights up and the electric heater preheats the intake air
• The engine controller sets the preheating time according to the engine coolant temperature sensed.
• Keep the starting switch in the "ON" position while the pilot lamp is lit since the engine is being preheated
during this period. In this period, if the starting switch is turned to the "START" position, preheating is
canceled.

Operation (WA470-AM40-044-K-00-A)
• When the starting switch is turned to the "ON" position, the engine controller starts.
• When the intake air temperature is -5°C or below, the engine controller drives the preheater relay just after
the starting switch is turned to the "ON" position, and then the electric heater relay operates and the
electric heater start preheating the engine.
• The operating time of the preheater is shown below.

WA470-7 10-245
10 Structure and function
Preheating system

Manual preheating system (WA380-AM40-042-K-01-A)


Function
• When the engine is started in the cold season, the preheating time can be lengthened more than the time
with the auto preheating by turning the starting switch to the "Manual preheat" position.
• If the starting switch is turned to the "Manual preheat" position, the preheater pilot lamp on the machine
monitor lights up and the electric heater preheats the intake air.
• When the starting switch is turned to the "OFF" position, the pilot lamp goes off and the manual preheating
function is canceled.

Operation (WA380-AM40-044-K-01-A)
• If the starting switch is turned to the "Manual preheating" position, the electric heater relay operates and
the electric heater starts preheating.

10-246 WA470-7
10 Structure and function
Engine power mode selector circuit

Engine power mode selector circuit (WA380-AP11-051-K-00-A)

1. Power mode selector switch


2. Transmission controller
3. Machine monitor
4. Engine controller
5. Work equipment controller
Function (WA380-AP11-042-K-00-A)

• The engine output can be maximized by turning the power mode selector switch to the "P mode" position.
The fuel consumption during work can be reduced by setting the power mode selector switch to the "E
mode".
• The switch signal is input to the work equipment controller. The work equipment controller sends the
signal to the transmission controller, which selects a proper gear speed and travel speed matched to the
power mode in the auto-shift mode.
Operation (WA380-AP11-044-K-00-A)

• When the power mode selector switch is turned to the "P mode" position, the switch signal is input to the
work equipment controller and the CAN signal is sent to the transmission controller.
• The transmission controller determines the final engine mode and sends the CAN signal to the engine
controller, and the engine torque performance curve changes to the "P-mode".
• When the engine mode is set to the "P mode" with the one-touch power maximizing function, the
transmission controller also sends the CAN signal to the engine controller, and the engine torque
performance curve changes to the "P-mode".
• The transmission controller sends the engine output mode pilot lamp lighting signal to the machine
monitor with the CAN signal .

WA470-7 10-247
10 Structure and function
Engine output limit function

Engine output limit function (WA380-AP12-042-K-00-A)

• If the engine controller recognizes a failure, it limits the engine torque or engine speed to protect the
engine.
• The engine torque performance when the torque is limited is shown in the following figure.

A: 30% cut of maximum torque point


B: Approximately 50% of rated output point
• The engine torque performance when the engine speed is limited is shown in the following figure.

A: Cut up to about engine speed at maximum torque point

10-248 WA470-7
10 Structure and function
Automatic warm-up function

Automatic warm-up function (WA470-AP13-042-K-00-A)

• When the engine is started in a cold district, the low idle speed of the engine is increased automatically to
warm up the engine.
• If the coolant temperature is 30°C or below when the engine is started, the low idle speed increases to
1,020 rpm. The condition for the low idle speed to increase is determined according to the coolant
temperature as shown in the following figure.
• If the coolant temperature reaches 60°C or higher or the accelerator pedal position is kept at 70% or
above for 3 seconds or longer during the warm-up operation, the automatic warm-up function is canceled
and the engine speed returns to 800 rpm.

WA470-7 10-249
10 Structure and function
Parking brake control system

Parking brake control system (WA380-GP10-051-K-00-A)

1. Parking brake relay


2. Parking brake switch
3. Parking brake solenoid valve
4. Transmission controller
5. Auto idle stop parking brake relay
Operation (WA470-GP10-044-K-00-A)
When starting switch is in "OFF" position
• When the starting switch is turned to the "OFF" position, the contacts of parking brake relay (1) open, thus
no current flows in the parking brake circuit and the parking brake is applied.
• While starting switch is in the "OFF" position, no current flows in parking brake solenoid valve (3) and the
parking brake keeps applied, regardless of the operating condition of parking brake switch (2).

When starting switch is in "ON" position


When parking brake switch is turned "ON" (operating) before starting switch is turned "ON"

• When parking brake switch (2) is turned "ON" (operating), the current from the battery relay flows through
parking brake switch (2) to the coil of parking brake relay (1) and the contacts close.
• If the contacts of parking brake relay (1) are closed, the current from the battery relay continues to flow
into the coil, and the relay contacts are held until the current from the battery relay is cut out.
• No current flows in parking brake solenoid valve (3), and the parking brake keeps applied.
• Transmission controller (4) recognizes the operation signal of parking brake switch (2) and keeps the
transmission in neutral while the parking brake is in operation to prevent dragging of the parking brake.
• If parking brake switch (2) is turned "OFF" (release), the current from the battery relay flows through
parking brake relay (1), parking brake switch (2), and auto idle stop parking brake relay (5) to parking
brake solenoid valve (3), and then release the parking brake.
When parking brake switch is turned "OFF" (releasing) before starting switch is turned "ON"

10-250 WA470-7
10 Structure and function
Parking brake control system

• When parking brake switch (2) is turned "OFF" (release), no current flows in parking brake relay (1) and
the relay contacts are open.
• Even if starting switch is turned "ON", no current flows to parking brake solenoid valve (3). Accordingly, the
parking brake is not released automatically.

When auto-idle stop operates

• If parking brake switch (2) is turned "OFF" (release) while the starting switch is turned "ON", the current
from the battery relay flows through parking brake relay (1), parking brake switch (2), and auto idle stop
parking brake relay (5) to parking brake solenoid valve (3), thus the parking brake is kept released.

• When the auto idle stop operates, transmission controller (4) outputs a current to auto idle stop parking
brake relay (5).
• The current flows in the coil of auto idle stop parking brake relay (5) and the contacts open.
• No current flows in parking brake solenoid valve (3), and the parking brake is applied.
• When the auto-idle stop operates, the parking brake also operates automatically and keeps operating
during restarting operation.

WA470-7 10-251
10 Structure and function
System operating lamp function

System operating lamp function (WA380-AW1Q-051-K-00-A)

1. Battery disconnect switch


2. Battery
3. Fusible link
4. Fuse box
5. System operating lamp
6. Monitor controller
7. Engine controller
8. Transmission controller
9. Work equipment controller
10. KOMTRAX terminal
Function
• The operating condition of each controller can be checked with the system operating lamp to prevent the
abnormal end of the disconnection of the battery power supply circuit while the controllers are in
operation.
a Before cutting off the battery power supply circuit, turn the starting switch to the "OFF" position, and check
that the system operating lamp goes out, then turn the battery disconnect switch to the "OFF" position.
a If you turn the battery disconnect switch to the "OFF" position (battery power supply circuit is cut off) while
the system operating lamp lights up, Controller Data Lost Error can occur. Do not operate the battery
disconnect switch as long as the system operating lamp lights up.
a The system operating lamp goes out in two minutes longest after the starting switch is turned to the "OFF"
position.
a Even if the starting switch is in the OFF position, the system operating lamp may light up since the
KOMTRAX terminal may perform communication.

Lighting up and going off of system operating lamp


• Voltage of 24 V is always applied to the one end of the system operating lamp (LED).
• When any controller is in operation, the output from the controller to the system operating lamp becomes
Low (0 V). This allows electric current to flow through the diode, lighting up the system operating lamp.
• When all controllers are resting, the output from each controller to the system operating lamp becomes Hi
(24 V). The electric current does not flow through the diode, and the system operating lamp goes out.
a The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the
minute leakage of current and not an abnormal phenomenon.
• The KOMTRAX terminal performs communication periodically even if the starting switch is kept in the OFF
position, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication status and machine stop time. So the lamp can light up as long as approximately an hour.

10-252 WA470-7
10 Structure and function
System operating lamp function

a When you want to cut off the battery circuit for maintenance but the system operating lamp keeps on
lighting up, turn the starting switch to the "ON" position once, then turn it to the "OFF" position. The lamp
will go out in two minutes maximum.
After the system operating lamp goes out, turn the battery disconnect switch to the OFF position
immediately.

WA470-7 10-253
10 Structure and function
Battery disconnect switch function

Battery disconnect switch function (WA470-AW1P-041-K-00-A)

1. System operating lamp


2. Battery disconnect switch

O: OFF
I: ON
Function (WA380-AW1P-042-K-00-A)

• Usually, the battery disconnect switch is used instead of disconnecting the cable from the negative
terminal of the battery in the following cases.
1. When storing the machine for a long period (more than one month)
2. When servicing or repairing the electrical system
3. When performing electric welding
• When the battery disconnect switch is turned OFF (the contact is opened), all the continuous power
supplies for the components, including the starting switch B terminal and controllers, are all cut out, and
the condition is the same as the condition when the battery is not connected. Accordingly, all the electric
system of the machine is disabled.

Precautions for using battery disconnect switch


• The system operating lamp lights up when the controller is turned ON. Even if the starting switch is in the
OFF position, the lamp lights up while the KOMTRAX is performing communication.
• Do not turn OFF the battery disconnect switch while the system operating lamp is lighting up.
• If the battery disconnect switch is turned OFF while the lamp is lighting up, the data in the controller may
be lost and the controller may be damaged seriously.
• Do not turn OFF the battery disconnect switch while the engine is running or immediately after the engine
is stopped.

10-254 WA470-7
10 Structure and function
Battery disconnect switch function

• If the battery disconnect switch is turned OFF while the alternator is generating power, the generated
current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may
cause serious damage to the electrical system, including the electric devices and controllers.
• If the battery disconnect switch is turned OFF for a long period, the machine monitor and the clock of the
radio may be initialized. In this case, re-setting is required.

WA470-7 10-255
10 Structure and function
Transmission controller system

Transmission controller system (WA380-CN20-001-K-00-A)

a The display of the travel speed explained in this section is for the tires of size 26.5-25, unless otherwise
specified.
Transmission controller system diagram (WA470-CN20-051-K-00-A)

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10 Structure and function
Transmission controller system

WA470-7 10-257
10 Structure and function
Transmission controller system

Transmission gear shift control function (WA380-CN11-042-K-00-A)

Electronic modulation function (WA380-CN12-042-K-00-A)

1. Engine
2. Torque converter
3. Transmission
4. Axle
5. Transmission controller
6. Combination switch
7. Accelerator pedal
8. Transmission ECMV
9. Engine speed sensor
10. Transmission input speed sensor
11. Transmission output speed sensor

10-258 WA470-7
10 Structure and function
Transmission controller system

Input/output signal
a. Directional signals
b. Shift range signal
c. Accelerator signal
d. Transmission output speed signal
e. ECMV operation signal
f. Fill switch signal
g. Transmission input speed signal
h. Engine speed signal
• The modulation control system controls the clutch pressure so that the transmission is shifted properly to
all the gear speeds (including the lockup clutch) and less shocks are generated at gear shifting
(engagement of the clutch) according to the engine speed, transmission oil temperature, transmission
input and output speeds, and gear shift pattern.
• The clutch pressure is so controlled that the difference between the input and output speeds will follow the
target value corresponding to the engine speed and accelerator pedal position to prevent sharp
engagement.
• After the clutch is disengaged, the disengagement pressure is kept low to prevent loss of torque until
engagement of the clutch starts.
• If abnormal gear shift time lag occurs, the learning function corrects the modulation automatically.

Gear shift display function (WA380-CN13-042-K-00-A)


• The transmission controller sends the input signal condition related to gear shift via the network to the
machine monitor to display it.
1. Travel direction indicator
The shift lever position pilot lamps of the machine monitor indicate the directional lever condition input
from the transmission controller.
If the directional lever is in neutral and no signal is input to the transmission controller, all the shift lever
position pilot lamps of the machine monitor go off.
If two signals are input to the transmission controller because of a failure, two shift lever position pilot
lamps of the machine monitor may light up simultaneously.
While the directional lever is in the "R (Reverse)" position, the controller operates the backup lamp relay to
turn on the backup lamp and backup alarm buzzer.
2. Gear speed indicator
The shift lever position pilot lamps of the machine monitor indicate the gear shift lever condition input from
the transmission controller.
If the gear shift lever is in neutral and no signal is input to the transmission controller, all the shift lever
position pilot lamps of the machine monitor go off.
If two signals are input to the transmission controller because of a failure, a shift lever position pilot lamp
which is different from the gear shift lever position may light up since the higher gear speed is given priority.
3. Display of actual gear speed
The shift indicator of the machine monitor indicates the travel direction and gear speed output by the
transmission controller.
If the directional lever is in the "N (Neutral)" position, "N" is displayed. If the directional lever is in the "F
(Forward)" or "R (Reverse)" position, "F" or "R" and the gear speed are displayed simultaneously.
While the parking brake is in operation, "N" is always displayed since no gear speed signal is output.
While the transmission cut-off function is in operation and the transmission is in neutral, "N" is always
displayed as well.

Automatic gear shift function (WA380-CN14-042-K-00-A)


• The transmission gear is shifted in the automatic shift mode where the gear speed is selected
automatically according to the travel speed or is shifted in the manual shift mode where the gear speed is
selected with the gear shift lever.
• The shift mode is changed with the transmission shift mode selector switch. If the auto-shift is selected,
the auto shift pilot lamp on the machine monitor lights up.
• In the auto-shift mode, upshift/downshift operations and ON/OFF of the lockup clutch are controlled
according to the condition of the power mode.

WA470-7 10-259
10 Structure and function
Transmission controller system

• There are two modes of "H" and "L" in the auto-shift mode, which are selected as shown in the following
table according to the condition of the transmission mode selector switch and power mode selector switch.
Power mode Transmission shift mode selector switch
selector switch H L MANUAL
P mode Auto-shift H mode Auto-shift L mode Manual shift mode
E mode Auto-shift L mode Auto-shift L mode Manual shift mode
• In the auto-shift mode, the upshift/downshift operations are controlled, corresponding to the directional
lever, gear shift lever, travel speed, accelerator pedal position, and engine speed.

a1: Upshift (Other than hunting prevention)


a2: Upshift (Hunting prevention)
b: Upshift
c: Downshift
d: Downshift
1. When gear shift lever is in either position of "1st" to "4th"
The maximum gear speed of auto-shift operation (gear shift range) is limited.
Since the machine is usually started in the 2nd gear in the auto-shift mode, the gear is upshifted/
downshifted between the 2nd and 4th. If the kickdown function is used, the gear can be downshifted to the
1st under a certain condition.
2. When directional lever is in “N (Neutral)“ position
When the directional lever is in the "N (Neutral)" position, the actual transmission gear speed is fixed to
the gear speed before the directional lever is set in the "N (Neutral)" position.
Even if the gear shift lever is operated while the directional lever is in the "N (Neutral)" position, the gear
speed before the operation is held. The gear speed changes when the directional lever is operated to the
"F (Forward)" or "R (Reverse)" position.

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10 Structure and function
Transmission controller system

Shift hold function (WA380-CP11-042-K-00-A)


• If the auto-shift is selected and the hold switch is pushed, the shift hold function maintains the current gear
speed and does not upshift the gear even when the travel speed increases. When the travel speed
decreases, this function does not downshift the gear.
• The shift hold pilot lamp on the machine monitor keeps lighting while the shift hold function is in operation.
The shift hold function is canceled and the pilot lamp is turned OFF by pressing the hold switch again.
• When the directional lever, gear shift lever, or kickdown switch is operated, the shift hold function is
canceled automatically. The operating condition of the torque converter lockup is not maintained.

Kickdown function (WA470-CP12-042-K-00-A)


1. In manual shift mode
While the directional lever is not in "N (Neutral)" and the gear shift lever is in the "2nd", if the kickdown
switch is pressed, the gear is shifted to the "1st".
While the directional lever is not in "N (Neutral)" or the gear shift lever is not in the 2nd, the operation of the
kickdown switch is ignored.
If the directional lever is operated or the gear shift lever is operated to a position other than the "2nd" after
the actual gear speed is changed to the "1st", the kickdown function is canceled. After the kickdown
function is canceled, the gear speed is changed to the gear speed selected with the gear shift lever.
2. In auto-shift mode
The kickdown function works when the directional lever is not in "N (Neutral)" and the gear shift lever is not
in the "1st".
The gear speed is changed as shown in the following table by the operation of the kickdown switch.
When the directional lever is operated or the disapproved time for shift for preventing shift hunting passes,
the kickdown function is canceled. After it is canceled, the gear shifting becomes normal as an automatic
gearshift.
Transmission output speed when kickdown switch is pressed
Gear speed before [rpm] Gear speed after
kickdown kickdown
(Reference: Actual travel speed [km/h])
2nd T/C Whole range 1st T/C
Below 775 (10.5) 1st T/C
3rd T/C
775 (10.5) or above 2nd T/C
Below 775 (10.5) 1st T/C
4th T/C
775 (10.5) or above 3rd T/C
2nd L/U Whole range 1st T/C
Below 775 (10.5) 1st T/C
3rd L/U
775 (10.5) or above 3rd T/C (*1)
Below 775 (10.5) 1st T/C
4th L/U
775 (10.5) or above 4th T/C (*1)
T/C: Indicates travel through torque converter
L/U: Indicates travel through direct drive (lockup operation)
*1: When the lockup function is canceled by pressing the kickdown switch, it is not turned on again until
the following conditions are met.
• After the torque converter lockup switch is returned to the "OFF" position, it is turned to the "ON"
position again.
• The travel speed becomes the faster speed at which the lockup operates.
3. In forward 1st
If the kickdown switch is pressed while the power mode is in "E mode" and the transmission is in the
forward 1st, the power mode changes to "P mode" temporarily. (One-push power max. function)
The change of the power mode occurs only when the transmission is in the forward 1st, regardless of the
auto-shift / manual shift, and canceled when the actual gear speed is changed to another position from the
1st or the directional lever is changed to another position from the forward.

Auto-kickdown function (WA380-CP13-042-K-00-A)


• When the machine is set in the digging condition in the auto-shift mode, if the travel speed reaches the
specified speed, the gear speed is changed to the 1st gear automatically.
• The digging condition means the condition in which the travel speed decreases, the boom is near the
ground, the bucket is not tilted, and the brake pedal is not depressed.

WA470-7 10-261
10 Structure and function
Transmission controller system

Torque converter lockup function (WA500-CDR8-042-K-00-A)


• The torque converter lockup function automatically controls the lockup operation while the torque
converter lockup switch is turned "ON", regardless of the shift mode.
• The torque converter lockup pilot lamp on the machine monitor keeps lighting while the lockup is in
operation.
• The lockup operates in the gear speeds shown in the following table.
Transmission shift Gear speed for lockup operation (Lockup operates: Q)
mode selector
switch F1 F2 F3 F4 R1 R2 R3 R4
H Q Q Q Q Q Q
L Q Q Q Q Q Q
MANUAL Q Q Q Q Q Q
1. Travel speed for lock up operation
The travel speed at which the lockup operates is determined by the directional lever, the gear shift lever,
the travel speed, and the accelerator pedal position. When the manual shift is selected, the lockup
operates at the same travel speed as in the auto-shift H mode.
2. Lockup protection function
The lockup operates only when the machine travel direction matches to the directional lever position.
3. Condition for disabling lockup
The lockup does not operate in the following cases.
• Machine is digging (lockup protection)
• Boom is being raised (boom raise operation priority)
• When the accelerator is operated and the engine speed is low.

Hunting prevention function (WA500-CN15-042-K-00-A)


• The transmission controller detects and prevents hunting that occurs when the gear speed is shifted from
the 2nd to the 3rd and from the 3rd to the 2nd in the auto-shift mode.
• If the gear is shifted continuously in the order of the 2nd o 3rd o 2nd o 3rd (3rd o 2nd o 3rd o 2nd), the
transmission controller judges that hunting occurs and changes the upshift point temporarily.
• The hunting prevention function is canceled at the next gear shift operation (including the directional
change operation and kickdown operation). After the hunting prevention function is canceled, the normal
auto-shift point is applied.
• When the 2nd lockup is turned ON/OFF continuously, the lockup is canceled. (This is also applied to the
3rd lockup.) Then the travel speed at which the lockup operates is changed temporarily.
• The hunting prevention function related to the lockup operates when the controller recognizes hunting
even in the manual shift mode.

Adjustment of transmission initial learning and ECMV current (WA380-CN16-042-K-00-A)


• Dispersion of the transmission itself and ECMV can be corrected by adjusting the items of "ECMV
automatic correction" and "T/M initial learning" with the adjustment function of the machine monitor.
• If the above items are not adjusted, gear shift shocks or time lag may occur.
a For the adjustment procedure, see Testing and adjusting, "Special functions of machine monitor".

Change of shift point (WA380-CN17-042-K-00-A)


• The transmission controller has the function to adjust gear shift point of forward travel in the auto-shift "L
mode".
• Hunting occurs under a certain condition of jobsite, the travel speed at which the gear speed is
downshifted/upshifted can be adjusted by adjusting the items of "T/M gear shift point" with the adjustment
function of the machine monitor.
a For the adjustment procedure, see Testing and adjusting, "Special functions of machine monitor".

4th gear speed limit function (WA380-CN18-042-K-00-A)


• Operation in the 4th gear can be limited by setting "4th Gear Prohibition" to "ADD" with the "Option Select
function" of the machine monitor.
a For the setting procedure, see Testing and adjusting, "Special functions of machine monitor".

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10 Structure and function
Transmission controller system

Transmission protection function (WA380-CV31-001-K-00-A)

Protection function when travel direction is changed (WA470-CV32-042-K-00-A)


• When the directional lever is operated during high-speed (3rd/4th gear) travel, gear shifting is limited to
protect the transmission.
1. In manual shift mode
Range X: Travel direction is changed. (Normal range)
Range Y: Travel direction is changed and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds. The gear speed is shifted to the 3rd or 4th
gear, depending on the travel speed. Then, the gear speed is downshifted to the current speed position as
the travel speed decreases.
2. In auto-shift mode
Range X: Travel direction is changed and transmission is shifted to the 2nd. (Normal range)
Range Y: Travel direction is changed and transmission is shifted to the 2nd and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds. The gear speed is shifted to the 3rd or 4th
gear, in accordance with the travel speed. Then, the gear speed is downshifted to the 2nd if the travel
speed decreases further.
a The upshift/downshift and kickdown operations are not accepted for 2 seconds just after the travel
direction changing operation. If the upshift/downshift operation is performed with the gear shift lever, the
gear speed is shifted after 2 seconds.
In the auto shift mode, the gear is not upshifted until it is downshifted to the 2nd.

Transmission output shaft speed [rpm]


(Reference: Actual travel speed [km/h]) Engine speed [rpm]
A 960 {13} D 1,700

B 1,034 {14} E 1,900

C 1,181 {16}

Downshift protection function (WA470-CV33-042-K-00-A)


• If the travel speed is above the set speed in downshift operation, downshift is not accepted for protection
of the engine and pump.
• The alarm buzzer sounds while the downshift protection function is in operation.
• The alarm buzzer keeps sounding until the gear speed position of the gear shift lever matches with the
actual gear speed. Accordingly, the alarm buzzer stops sounding if the gear is upshifted even if the travel
speed does not decrease.
• The downshift protection is effective even in the kickdown operation. If the kickdown switch is pressed
when the travel speed is higher than the protection condition, it is not accepted but the alarm buzzer
sounds for 3 seconds.
• The downshift protection is effective even when the auto kickdown is applied, but the alarm buzzer does
not sound in this case.
• The downshift protection operates under the following condition.

WA470-7 10-263
10 Structure and function
Transmission controller system

Downshift Transmission output shaft speed [rpm]


target gear (Reference: Actual travel speed [km/h])
speed Protection condition Protection cancelation condition
To 3rd speed Min. 2,227 (30.2) Below 2,005 (27.2)
To 2nd speed Min. 1,470 (19.9) Below 1,322 (17.9)
To 1st speed Min. 1,061 (14.4) Below 951 (12.9)

Engine overrun prevention function (WA380-CV34-042-K-00-A)


• If the engine speed rises above 2,425 rpm, the alarm buzzer sounds for notice of operation of engine
overrun prevention function. The alarm buzzer stops when the engine speed lowers below 2,325 rpm.
• If the engine speed rises above 2,500 rpm, the lockup is cancelled automatically to prevent overrun of the
engine.
• The alarm buzzer sounds while the engine overrun prevention function is in operation.
• Once the lockup is cancelled, the lockup condition is maintained for 5 seconds. When the transmission
output shaft speed decreases to a level corresponding to below 2,350 rpm of the engine speed after 5 or
more seconds, the lockup is applied again.
• While the lockup is not in operation, the buzzer sounds for notice or warning at the above engine speeds,
but no special remedy is performed.

Speed limiting function (WA470-CV35-042-K-00-A)


• If the travel speed exceeds the specified maximum travel speed, the alarm buzzer sounds.
Unit: km/h
Model WA470-7
Alarm activation specified value (actual travel speed) 40.0
Alarm cancellation specified value (actual travel speed) 39.5
• If the travel speed exceeds the threshold value in the 4th lockup mode, the upper limit of the accelerator
pedal position is restricted to limit the maximum travel speed.
Unit: km/h
Model WA470-7
Shift range F4 R4
Actual travel speed (B) 37.0
Actual travel speed (C) 38.0

Neutralizer function (WA380-CV36-042-K-00-A)


• While the parking brake switch is turned "ON", the transmission is kept in neutral to prevent dragging of
the parking brake, regardless of the positions of the directional lever and gear shift lever.
• Since the parking brake circuit employs the safety mechanism, the parking brake is kept applied even if
the starting switch is turned from the "OFF" position to the "ON" position. Accordingly, when the starting
switch is turned to the "ON" position, the transmission is always set in neutral, regardless of the positions
of the directional lever and gear shift lever.

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Engine control function (WA380-CN19-001-K-00-A)

Power mode selection control (WA380-CN1A-042-K-00-A)


• When the power mode selector switch is set to the "P mode" position, the torque curve information in the P
mode is sent to the engine controller. At the same time, the information of the power mode is sent to the
machine monitor to change the output mode pilot lamp.
• The output mode pilot lamp also changes when the "P mode" is selected with the one-touch power
maximizing function.

Engine stop prevention function (WA500-CN1B-042-K-00-A)


• When the travel direction is changed during high-speed travel, if the engine speed is low, the engine
receives counter-torque from the tires and may stall.
• To prevent the engine from stalling, the throttle (accelerator pedal) position lower limit value is sent to the
engine controller when the travel direction is changed.

Overheat prevention function of transmission controller (WA500-CV3C-042-K-00-A)


• When the torque converter oil temperature exceeds 120°C, the accelerator pedal position is controlled to
prevent overheat.
• When the coolant temperature exceeds 100°C, the engine output torque is limited to prevent overheat.

Brake load reduction control (WA500-CV3D-042-K-00-A)


• When the 2nd gear is selected in P mode, the upper limit of the accelerator pedal position is restricted to
limit the rim pull and reduce the load when the brake is dragged, according to the transmission output
shaft speed and the brake oil pressure.
a The larger one between the accelerator pedal position judged by the transmission output speed and that
judged by the brake oil pressure is selected.
Judgment by transmission output speed

A: Upper limit of accelerator pedal position


Judgment by brake oil pressure

B: Upper limit of accelerator pedal position

WA470-7 10-265
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Driving force cut control (WA470-CV3E-042-K-00-A)


• In the digging work, the upper limit of the accelerator pedal position is restricted to reduce the driving force
and priority is given to the "raising" operation of the boom, according to the load on the work equipment.
• When conditions 1 to 4 are satisfied, the rim pull is judged too large and the upper limit of the accelerator
pedal position matched to the target rim pull is sent to the engine controller.
• This function becomes effective when “Lift up mode“ in “Option select function“ of the machine monitor is
set to ADD.
a For the setting procedure of the “Lift up mode“, see Testing and adjusting, “Special functions of machine
monitor“.
Operating condition
Condition 1 Machine is digging
Condition 2 Machine is not scraping up
Condition 3 The traction force is high comparing to the lifting force. Or, boom stalls in boom RAISE
operation.
Condition 4 "Lift up mode" is set to ADD in Option Select

Engine torque control function (WA380-CV3H-042-K-00-A)


Engine torque control by phase of work
The engine output torque is controlled so that it is sufficient for each phase of the work by judging each phase
from the engine speed, travel speed, pump discharge pressure, travel direction, work equipment condition,
etc.
Cooling fan control function (WA470-B711-042-K-00-A)

• The hydraulic cooling fan is employed and the swash plate angle of the hydraulic pump is controlled to
reduce the horsepower loss and noise at low temperature.
• The transmission controller receives the engine speed and coolant temperature received by the engine
controller via the network. The transmission controller also directly receives the information on the
hydraulic oil temperature and torque converter oil temperature.
• The transmission controller sends the signal current to the swash plate angle control EPC valve of the
cooling fan pump on the basis of the received information and sets the fan speed corresponding to each
temperature and engine speed by controlling the swash plate angle.

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Transmission controller system

1. Radiator
2. Cooling fan motor
2a. Cooling fan reverse rotation solenoid valve
3. Cooling fan pump
3a. Swash plate angle control EPC valve
4. Cooling fan speed sensor
5. Accelerator pedal
6. Engine
7. Coolant temperature sensor
8. Engine speed sensor
9. Engine controller
10. Transmission controller
11. Hydraulic oil temperature sensor
12. Hydraulic tank
13. Torque converter oil temperature sensor
14. Torque converter
15. Monitor controller
16. Front brake accumulator pressure drop sensor switch
17. Rear brake accumulator pressure drop sensor switch

Input/output signal
a. Accelerator position signal
b. Coolant temperature signal
c. Engine speed signal
d. CAN signal
e. Cooling fan speed signal

WA470-7 10-267
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Transmission controller system

f. Hydraulic oil temperature signal


g. Torque converter oil temperature signal
h. Cooling fan reverse signal
j. Cooling fan pump swash plate angle control signal
k. Cooling fan reverse pilot lamp signal
l. Front brake accumulator pressure drop signal
m. Rear brake accumulator pressure drop signal

Fan speed and temperature

*1: The target fan speed is decided by the highest temperature information among the coolant temperature,
hydraulic oil temperature, and torque converter oil temperature. However, when the coolant temperature is
low, the torque converter oil temperature is not used.
*2: In this range, the fan speed corresponds to the coolant temperature, hydraulic oil temperature, and torque
converter oil temperature.
*3: When the air conditioner is in operation, the minimum speed becomes 600 rpm.

Control function when engine is started (WA470-B714-042-K-00-A)


• When the engine is started, control different from the ordinary control by temperature is performed.

Range A: Engine speed Z 500 rpm (Engine "stopped" to "being cranked")


• The target fan speed is set to 0 rpm to reduce the torque required to start the engine and for higher engine
startability. After the engine speed reaches 500 rpm, the target fan speed is kept at 100 rpm for 2 seconds.
Range B: Basic control (500 rpm < Engine speed)

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Transmission controller system

• The ordinary fan control based on "Fan speed set by temperature" is performed.

Control function when brake accumulator is charged (WA380-B71B-042-K-00-A)


• The fan pump is used for charging the brake accumulator as well.
• While the brake accumulator is being charged, the charge time is shortened and the control is performed
differently from the normal control by temperature to prevent the fan from stopping during the charge.
• For 10 seconds after the brake accumulator pressure drop signal is turned OFF, the minimum fan speed is
set to 750 rpm.
• If the brake accumulator pressure is turned OFF, the minimum fan speed is 750 rpm for 10 seconds after
the control at the start of the engine is finished.

Fan reverse function (WA470-B715-042-K-00-A)


• When the manual fan reverse mode is operated through the machine monitor to clean the radiator core,
the cooling fan reverse rotation solenoid valve of the cooling fan motor operates to reverse the fan
rotation.
Fan rotation auto reverse function
1. Fan rotation manual reverse function
• The operator can change the fan rotation direction freely by setting the manual fan reverse mode to the
“Reverse“ or “Default“ position.
• While the fan rotation direction is being changed, the pilot lamp indicating the change is displayed on
the standard screen to notify the operator of the operating condition. If the changing condition is not
satisfied because of high temperature of the coolant or oil, changeover condition waiting pilot lamp
lights up.
• On the standard screen, the cooling fan reverse pilot lamp indicates the fan reverse rotation condition.
When all the conditions are satisfied, the fan rotation direction is changed from “Default“ to “Reverse“.
Condition 1 The manual fan reverse rotation mode is set to "Reverse".
The coolant temperature is below 102°C.
Condition 2
[for prevention of overheat]
The hydraulic oil temperature is below 97°C.
Condition 3
[for prevention of overheat]
The torque converter oil temperature is below 120°C.
Condition 4
[for prevention of overheat]
At least 10 seconds elapse after the brake accumulator pressure drop signal is turned OFF.
Even if the accumulator pressure drop signal turns OFF, at least 10 seconds elapse after the
Condition 5 engine is started.
[For securing oil quantity to be added to the brake accumulator]
Condition 6 There is no error in the fan speed sensor or engine speed sensor.
When any of the conditions is satisfied, the fan rotation direction is changed from “Reverse“ to “Default“.
The manual fan reverse rotation mode is set to the "Default" position while the fan is rotating in
Condition 1
reverse.
Condition 2 10 minutes elapse with the fan rotating in reverse.
Condition 3 An error is detected in the fan reverse solenoid or fan pump EPC solenoid.
Condition 4 The engine stops.
2. Fan rotation auto reverse function
• The fan rotation reverse cycle and fan reverse rotation duration can be set at a certain interval by
setting the auto-fan rotation reverse mode through the machine monitor.
• While the fan rotation direction is being changed, the pilot lamp indicating the change is displayed on
the standard screen to notify the operator of the operating condition. If the changing condition is not
satisfied because of high temperature of the coolant or oil, changeover condition waiting pilot lamp
lights up.
• On the standard screen, the cooling fan reverse pilot lamp indicates the fan reverse rotation condition.
When all the conditions are satisfied, the fan rotation direction is changed from “Default“ to “Reverse“.

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Transmission controller system

The fan reverse rotation switch is set to “AUTO“.


Condition 1
The auto-fan reverse rotation mode is set to any position of A to D.
The coolant temperature is below 102°C.
Condition 2
[for prevention of overheat]
The hydraulic oil temperature is below 97°C.
Condition 3
[for prevention of overheat]
The torque converter oil temperature is below 120°C.
Condition 4
[for prevention of overheat]
At least 10 seconds elapse after the brake accumulator pressure drop signal is turned OFF.
Even if the accumulator pressure drop signal turns OFF, at least 10 seconds elapse after the
Condition 5 engine is started.
[For securing oil quantity to be added to the brake accumulator]
Condition 6 The fan rotation direction change cycle has passed.
Condition 7 There is no error in the fan speed sensor or engine speed sensor.
When any of the conditions is satisfied, the fan rotation direction is changed from “Reverse“ to “Default“.
The auto-fan reverse rotation mode is turned OFF while the fan is rotating in reverse.
Condition 1 Or, it is set to a mode of fan reverse rotation time which is shorter than the fan reverse rotation
elapsed time.
Condition 2 The fan reverse rotation time has passed.
Condition 3 An error is detected in the fan reverse solenoid or fan pump EPC solenoid.
Condition 4 The engine stops.
3. Adjustment of fan reverse rotation changing cycle and duration
Three defaults, A to C, for fan reverse rotation cycle and duration are prepared. The fan reverse rotation
cycle and duration can be adjusted freely by adjusting the "Fan reverse rotation cycle" and "Fan reverse
rotation duration" with the adjustment function of the machine monitor. The set value is displayed as mode
D.
a For the adjustment procedure, see Testing and Adjusting, "Special functions of machine monitor".
4. Overheat prevention function
When the coolant, hydraulic oil, or torque converter oil overheats (the thermometer caution lamp on the
machine monitor lights up) while the fan is rotating in reverse, the reverse rotation is stopped and changed
to the forward rotation forcibly to increase the air flow to the radiator.
5. Fan speed in reverse rotation mode
The fan speed in the reverse rotation mode depends on the engine speed.
Engine speed [rpm] 850 1,750 2,050
Fan target speed [rpm] 900 1,300 1,300

Fan 100% setting function (WA380-B71D-042-K-00-A)


• The cooling fan speed can be set to 100% forcibly, independent from the hydraulic oil temperature or
coolant temperature.
• The cooling fan speed can be set to 100% by setting the "Fan 100% adjustment" with the adjustment
function of the machine monitor.
• The fan speed becomes the lower one of 1) or 2) below.
1) Max. target fan speed
2) Target fan speed decided by engine speed
a For the setting procedure, see Testing and Adjusting, "Special functions of machine monitor".

Protection function (WA470-B713-042-K-00-A)


• If the engine speed increases to 2,300 rpm or above, the swash plate angle of the cooling fan pump is
minimized to prevent overrun of the cooling fan motor.
• If the transmission controller cannot recognize the engine speed or each temperature data because of a
network communication trouble etc., it sets those items as follows.
1) Engine speed: Assumes as 2,170 rpm.

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Transmission controller system

2) Engine coolant temperature: Ignored. The value obtained from the remaining normal sensors are used.
However, if neither of the hydraulic oil temperature and torque converter oil temperature is recognized, the
engine coolant temperature is assumed to be 90 °C.
3) Hydraulic oil temperature: Ignored. The value obtained from the remaining normal sensors are used.
4) Torque converter oil temperature: Ignored. The value obtained from the remaining normal sensors are
used.
Transmission cut-off function (WA380-CP30-042-K-00-A)

• The transmission cut-off oil pressure sensor detects the brake pilot pressure when the right and left brake
pedals are depressed and the transmission is set in neutral.
• The transmission can be cut off at any position by saving the brake pilot pressure at the brake pedal
position where the transmission comes in neutral.
1. Contents of control
• If the transmission cut-off operating condition is met, the transmission is set in
neutral.
Outline • If the transmission cut-off cancellation condition is met, the cut-off is canceled
and the transmission gear is shifted by modulation.
<Operating condition in 1st or 2nd gear>
• The transmission cut-off pilot lamp is turned "ON" and the brake pilot pressure
Transmis- exceeds the cut-off-IN pressure.
sion cut- Operating <Operating condition in 3rd or 4th gear>
off control condition • The transmission cut-off pilot lamp is turned "ON" and the accelerator pedal
depression is larger than 30% and the brake pilot pressure exceeds the IN
pressure of the cut-off circuit.
Condition The cut-off is canceled when any of the following conditions is met.
for
cancella- • The transmission cut-off pilot lamp is turned "OFF".
tion • The brake pilot pressure is below the OUT pressure of the cut-off circuit.
Condition
possible to • The transmission cut-off pilot lamp is turned "ON".
be set
1) The brake pedal is depressed to a set position. (Setting is possible even if the
brake pedal is not depressed)
2) The transmission cut-off set switch is pressed.
3) The brake pilot pressure when the switch is pressed is recognized.
<In case of within settable range>
The brake pilot pressure when the switch is pressed is saved temporarily.
Setting <In case of out of settable range>
method The upper or lower limit of the brake pilot pressure in the settable range is saved
Setting of temporarily.
transmis- The setting completion buzzer (pip, pip) sounds.
sion cut-
off point 4) The transmission cut-off switch built-in pilot lamp flashes for 2.5 seconds.
5) The set value is saved. (Setting mode is finished)
a The set condition is maintained even after the starting switch is turned to the
"OFF" position.
1) Under the condition of setting method Step 4) (the pilot lamp built in the
transmission cut-off switch flashes for 2.5 seconds), press the transmission cut-off
set switch again.
Resetting 2) The pilot lamp stops flashing and the cut-off point is set to the brake pilot pressure
method in default. The setting cancel buzzer (peep) sounds.
3) The set (default) value is saved. (Setting mode is finished)
a The set condition is maintained even after the starting switch is turned to the
"OFF" position.
2. Outputting condition

WA470-7 10-271
10 Structure and function
Transmission controller system

Buzzer
Pilot lamp built-in command
Outputting condition transmission cut-off Cut-off point
(Communication
switch
output)
Controlled by
Transmission cut-off pilot lamp is turned "ON". Lights up None previously saved
value
Transmission cut-off pilot lamp is turned "ON" When set switch
and transmission cut-off set switch is turned is pressed,
"ON". Flashes Brake pilot pressure
setting
(For 2.5 seconds or when set switch is
For 2.5 seconds or until resetting (sensor is completion
until resetting) pressed is saved.
normal) buzzer sounds
Setting method Steps 2) to 5) (pip, pip).
None
Transmission cut-off pilot lamp lamp is turned (Error is Control is not made.
"ON" and transmission cut-off pressure sensor Keeps turned OFF displayed on Saved value is not
is abnormal. machine changed.
monitor)
None Controlled by
(Error is position where error
Transmission cut-off pilot lamp is turned "ON" Lights up occurred. Saved
displayed on
and transmission cut-off set switch is abnormal value is not
machine
monitor) changed.
When set switch
Transmission cut-off pilot lamp is turned "ON" is pressed,
and transmission cut-off set switch is turned Default value for
setting
"ON". Lights up brake pilot oil
cancelltion
pressure is saved.
Reset during 2.5 seconds buzzer sounds
(peep).
Transmission cut-off pilot lamp is turned "OFF" Goes out None Control is not made.

a While the transmission is cut off, "N" is displayed on the shift indicator of the machine monitor. (Travel
direction output signal "N")
a If the transmission is cut off after the kickdown switch is pressed to set the gear speed to the 1st, it is
reset to the 1st, regardless of the shift mode.
a When the lockup is in operation, the cut-off operates after the lockup is released.
3. Settable range of transmission cut-off point
Settable range
0.49 to 4.41 MPa {5 to 45 kg/cm2}
Note 1: When the cut-off point is set 0.49 MPa {5 kg/cm2} or less, it is actually set to 0.49 MPa {5 kg/cm2}.
Note 2: When the cut-off point is set 4.41 MPa {45 kg/cm2} or more, it is actually set to 4.41 MPa {45 kg/
cm2}. The default value is 1.47 MPa {15 kg/cm2}.
• Set a hysteresis of 0.20 MPa {2 kg/cm2} between cut-off-IN (neutralizing) pressure and cut-off-OUT
(restoration) pressure.
Example) When pressure sensor is set to a position of 0.98 MPa {10 kg/cm2}
Cut-off-IN pressure = 0.98 MPa {10 kg/cm2}
Cut-off-OUT pressure = 0.78 MPa {8 kg/cm2}

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E.C.S.S. function (WA500-L3B0-051-K-00-A)

E.C.S.S.: Electronically Controlled Suspension System

1. Transmission controller
2. Gear shift lever
3. Speed sensor
4. E.C.S.S. switch
5. 1st clutch ECMV
6. 2nd clutch ECMV
7. 3rd clutch ECMV
8. 4th clutch ECMV
9. E.C.S.S. solenoid valve
Input/output signal
a. Gear shift lever "1st" signal
b. Gear shift lever "2nd" signal
c. Gear shift lever "3rd" signal
d. Gear shift lever "4th" signal
e. Travel speed signal
f. Pulse GND
g. E.C.S.S. switch "ON" signal
h. 1st clutch ECMV operation signal
i. 2nd clutch ECMV operation signal
j. 3rd clutch ECMV operation signal
k. 4th clutch ECMV operation signal
l. ECMV GND
m. ECMV GND
n. E.C.S.S. operation signal

Function (WA380-L3B0-042-K-00-A)
• The ECSS gives elasticity to the vertical movement of the work equipment to restrict rocking of the
machine body, improve the operator comfort, prevents the load from spilling, and improves the working
efficiency during high-speed travel by using the buffering effect of the accumulator charged with high-
pressure gas and automatically controlling the relief pressure of the lift cylinder for the traveling condition.

Setting method
• The ECSS does not function unless “ECSS Operating Speed“ is set to "ADD" with the "Option selection
function" of the machine monitor.
a For the setting procedure, see Testing and adjusting, "Special functions of machine monitor".

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10 Structure and function
Transmission controller system

Operation (WA500-L3B0-044-K-00-A)
• The operating condition of the ECSS is as per the following table.
Boom lever E.C.S.S. operation
ECSS switch Gear speed Travel speed [km/h]
condition (*1) signal
OFF All gear speeds 0 to Max. ON/OFF OFF
All gear speeds 0 to Max. OFF OFF
1st 0 to Max. ON/OFF OFF
ON
(*3) Max. 4 ON/OFF OFF
2nd to 4th
(*2) Min. 5 ON ON
*1. Boom lever condition ON: Boom lever stroke > -80%

E.C.S.S. selection point A B


(*3) (*2)
Travel speed [km/h]
4 5
*2: ECSS selection point (A) is the value obtained by subtracting 1 km/h from ECSS selection point (B) (4 to
15 km/h).
*3: The travel speed of ECSS selection point (B) can be set freely in the range from 5 to 15 km/h by adjusting
“ECSS Operating Speed“ in the adjustment function of the machine monitor.
a For the adjustment procedure, see Testing and Adjusting, "Special functions of machine monitor".
Directional switch control function (WA380-CV3F-042-K-00-A)

• The switch to select the travel direction is installed on the side of the work equipment control lever
independently from the standard directional lever so that the operator can select the travel direction with
his/her right hand.
1. Selection of directional selector switch
• When only the directional lever is used, the directional lever input signal leads to recognition of
travel direction. Since the switch to select the travel direction is added, a selector switch is installed
to select the additional switch or the directional lever.
a The operation with the directional selector switch is selected only when the directional selector
switch actuation switch is turned ON. However, the directional lever (standard directional lever) is
given the priority for the operation.
• The condition for operating with the directional selector switch is that the standard directional lever
is in N (Neutral), the directional selector switch is in N (Neutral), and the directional selector switch
actuation switch is turned ON.
a When travel direction can be changed with the directional selector switch, the directional selector
pilot lamp of the machine monitor lights up in green.
a If the directional selector switch actuation switch is turned ON/OFF while either is not in N (Neutral),
the directional selector pilot lamp of the machine monitor lights up in yellow and the caution lamp
lights up.
• Even if the directional selector switch is effective, if the standard directional lever is set in a position
other than N (F or R), the travel direction is set according to the operation of the directional lever.

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Transmission controller system

Since the directional operation is not selected normally, the directional selector pilot lamp of the
machine monitor lights up in yellow and the caution lamp lights up.
a If the alarm operates and the directional selector pilot lamp lights up in yellow, the alarm is not
turned OFF and the directional selector switch does not work until both of the standard directional
lever and the directional selector switch are set in N (Neutral).
• The above description is shown in the table below.
Right Monitoring
FNR operation
Mode Condition FNR recognition
enabled/ (Reference)
disabled
Directional lever: [F or N or R]
OFF Pilot lamp
Directional lever Directional selector switch: [N] Subject to directional
(dis- Goes out
(normal) Directional selector switch lever
abled) Buzzer stops
actuation switch: [OFF]
Directional lever: [N]
Directional selector Pilot lamp
Directional selector switch: [F ON
switch enable switch Subject to directional Lights up in
or N or R] (en-
(normal [directional selector switch green
Directional selector switch abled)
selector switch]) Buzzer stops
actuation switch: [ON]
Directional lever: [F or R]
Pilot lamp
OFF
Directional lever priority Directional selector switch: [F Subject to directional Lights up in
or N or R] (dis-
(emergency operation) lever yellow
Directional selector switch abled)
Buzzer stops
actuation switch: [ON]
Directional lever: [F or N or R]
Subject to directional Pilot lamp
Directional lever, Directional selector switch: [F OFF
lever Lights up in
directional switch error or R] (dis-
(Directional selector yellow
(wrong operation) Directional selector switch abled)
switch is ignored) Buzzer stops
actuation switch: [OFF]
Directional lever: [other than
N] Pilot lamp
OFF
<e> Selection error Directional selector switch: Subject to directional Lights up in
[other than N] (dis- yellow
(wrong operation) lever
abled)
Directional selector switch Buzzer stops
actuation switch: [OFFio
2. Interlock when engine is started (Prohibition of starting of engine)
When the directional selector switch actuation switch is in the ON position and the directional selector
switch is not in the N (Neutral) position, the transmission controller operates the neutral safety function
to cut the starting motor C terminal signal to prevent the machine from moving just after the engine is
started.
3. Setting of directional selector switch
The directional selector switch does not perform control, unless the option setting of the directional
selector switch is set effective by the option setting of the machine monitor. This switch cannot be
installed together with joystick steering.
a For the method of setting the option, see Testing and Adjusting, "Special functions of machine
monitor".
Auto idle stop function (WA380-AF87-042-K-00-A)

• When the operating condition is satisfied, the engine is stopped after a set period.
• After the engine is stopped, if the parking brake switch is in OFF position, the parking brake is applied.
• After the engine is stopped, if the work equipment lever lock is released, the work equipment lever lock is
operated.
• This function works when conditions 1 to 4 are satisfied at the same time.
a For the adjustment procedure of the set time, see Testing and Adjusting, "Special functions of machine
monitor".

WA470-7 10-275
10 Structure and function
Transmission controller system

Operating condition
Condition 1 Accelerator pedal is released
Condition 2 Directional lever is in neutral
Condition 3 Machine is stopped
Condition 4 KDPF is not in regeneration
Action for restarting engine
To restart the engine, turn the starting switch from the ON position to the START position.
Real-time monitoring function of transmission controller (WA380-CV3G-042-K-00-A)

The conditions of the input and output signals of the controller can be checked with the monitoring function of
the machine monitor.
a For the monitoring procedure, see Testing and adjusting, "Special functions of machine monitor".
Transmission controller self-diagnosis function (WA380-CN1G-042-K-00-A)

• The transmission controller constantly monitors the input and output conditions and performs self-
diagnosis of the system.
• If any failure is detected by the self-diagnosis, its information is sent to the machine monitor through the
network.
• If any failure occurs, it can be checked with the machine monitor / KOMTRAX.

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Work equipment control system

Work equipment control system (WA380-PK01-001-K-00-A)

Work equipment control system diagram (WA470-PK01-051-K-00-A)

WA470-7 10-277
10 Structure and function
Work equipment control system

10-278 WA470-7
10 Structure and function
Work equipment control system

Work equipment control function (WA380-PK01-042-K-00-A)


Neutral position and work equipment speed (WA500-PK11-042-K-00-A)

Function
• The work equipment control lever has a play of 5% of the lever travel in the neutral position. The work
equipment starts moving when the lever moves over the play.
• The work equipment speed for the lever travel can be changed by the setting of the controller.
• The boom has five changeable tables and the bucket has three.
a For the adjustment method and the features of each table, see Testing and adjusting "Changing boom
lever pattern" and "Changing bucket lever pattern".
Boom lever stroke vs. speed table

Bucket lever stroke vs. speed table

WA470-7 10-279
10 Structure and function
Work equipment control system

Work equipment neutral lock function (WA380-PTLD-051-K-00-A)

1. Transmission controller
2. Work equipment lock switch
3. Work equipment controller
4. Monitor controller
5. Machine monitor
6. Work equipment neutral lock valve

Function (WA380-PTLD-042-K-00-A)
• When the work equipment lock switch is operated, the controller turns OFF the output of the work
equipment EPC to stop the operation of the work equipment.
• When the ECSS switch is turned OFF, the work equipment neutral lock valve is turned ON. Then, the EPC
pilot source pressure is cut and the operation of the work equipment is stopped.
• When the lever is operated while the work equipment is locked even if the operator tries to unlock the work
equipment, the work equipment is not unlocked but kept locked for safety.
Work Operation Controller output Movement
Controller
equip- of ECSS of machine
ment Work equipment
control lock
lever indicator
condi- Work
Operator's ECSS equip-
tion switch
intention in Work ment
when signal
operation of work equip- EPC,
work Recogni- (Transmis- ment lock Hydraulic
equipment lock work
equip- zes sion
switch solenoid equip-
ment controller Switch Monitor
valve ment
lock input)
switch detent
is
oper-
ated
Cut (Work
ECSS ON equipment
switch = ON ON
In locking (no OFF
(24 V) OFF (No and ECSS
— In locking (Lights (Lights stop)
switch operation) output)
up) up)
ECSS SW OFF Only ECSS
= ON (OPEN) operates

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10 Structure and function
Work equipment control system

Work Cut (Work


equip- ECSS ON equipment
Lock o Unlock ment switch = ON ON and ECSS
(24 V) OFF (No
(Switch control In locking OFF (Lights (Lights stop)
output)
operation) lever is up) up)
ECSS SW OFF Only ECSS
not in
= ON (OPEN) operates
neutral
Work
equip- Outputs
Lock o Unlock ment OFF OFF OFF
In according
(Switch control — (Lights (Lights Operates
unlocked (OPEN) to lever
operation) lever is out) out)
operation
in
neutral
Outputs
OFF OFF OFF
In unlocking (no In according
— — (Lights (Lights Operates
switch operation) unlocked (OPEN) to lever
out) out)
operation
Cut (Work
ECSS ON ON
equipment
Unlock o Lock switch = ON (Lights
OFF
(24 V) up) OFF (No and ECSS
(Switch — In locking (Lights stop)
output)
operation) up) +
ECSS SW OFF Only ECSS
= ON * Popup operates
(OPEN)
* If the work equipment is locked with the switch operation by the operator, popup display appears on the
machine monitor.

Operation of work equipment control lever (WA500-PK11-042-K-01-A)

Function
• The work equipment controller detects the quantity of RAISE/LOWER and TILT/DUMP operations through
the signals of the work equipment control lever potentiometers, controls the operation of each EPC valve
with current, and operates the main spool with the EPC pressure to operate the work equipment.

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• The work equipment control lever has detent notches and the system is adjusted so that the work
equipment operates at the maximum speed just before each detent.
• The range beyond the LOWER detent is the "Boom float" position, where the boom is moved by external
forces.

Bucket priority control (WA500-PTL3-042-K-00-A)

Function
• Since this machine employs the CLSS, it can operate the bucket and boom simultaneously. However, it
can prevent the boom from rising to improve the digging work efficiency when the bucket operation
frequency is large.
• This is realized by limiting the maximum boom rising speed for the bucket speed (Table below).

Boom stop modulation (WA500-PTL4-042-K-00-A)

Function
• When the operator performs boom stop operation faster than a certain speed, the work equipment
controller operates the modulation to reduce the stopping shocks of the boom raise/lower operation.
• The operation of this stop modulation function can be changed by the setting of the controller.

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a For the changing method and precautions, see Testing and adjusting, "Boom stop modulation".

Case A: Modulation 0
When lever command flow > modulation command flow
• Output matched to lever command flow
Case B: Modulation 20
When lever command flow < modulation command flow
• Output matched to modulation command flow
a: Modulation 10 (when shipped)
b: Modulation starting position

Adjustment of lever detent position and work equipment starting current (WA380-PLT5-042-K-00-A)

Function
• The work equipment controller has the adjustment function of correcting dispersion.
• The controller saves the lever potentiometer voltage in the detent position and adjusts the detent position
to perform the control before and after the detent securely. If the adjustment is not performed, "the
positioner may not operate normally before and after the detent" or "the lever position for floating the boom
may be abnormal".
• If the work equipment starting current is not adjusted, "the dead zone of neutral may be wide" or "the work
equipment may generate large shocks when it starts/stops".
a For the adjustment procedure, see Testing and adjusting, "Boom raise adjustment", "Bucket tilt
adjustment", or "Bucket dump adjustment".
Swash plate control function of work equipment pump and steering
pump (WA470-PLT6-042-K-00-A)
• The control function of the swash plate of the work equipment pump and steering pump includes "Pickup
assistance control when engine speed is low" and "Overheat prevention control". The smaller pump
discharge (the command current to the swash plate angle control EPC valve is large) among the
calculation results of each control is selected.
Oil pressure - Flow characteristics when command current to swash plate angle control EPC valve of work
equipment pump is controlled

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Work equipment control system

A: Small electric current


B: Large electric current
Oil pressure - Flow characteristics when command current to swash plate angle control EPC valve of steering
pump is controlled

A: Small electric current


B: Large electric current

Pickup assistance control function when engine speed is low (WA500-PTL7-042-K-00-A)


• When the work equipment and steering are operated simultaneously while the engine speed is low, the
pump absorption torque is larger for the torque generated by the engine and the engine does not pick up
well.
• To help the engine picking up, when the accelerator pedal is depressed while the engine speed is low, a
command current matched to the work equipment pump pressure or travel speed is sent to the swash
plate angle control EPC valves of the work equipment pump to control the pump swash plate angles and
reduce the load is reduced.

Overheat prevention function of work equipment controller (WA470-PLT8-042-K-00-A)


• The work equipment controller controls the work equipment pump discharge in accordance with the
hydraulic oil temperature to prevent overheat.
• It sends a command current to the swash plate angle control EPC valve of the work equipment pump to
control the pump swash plate angle.

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Remote positioner function (WA380-PTL9-001-K-00-A)


Remote bucket positioner (WA470-PTL9-042-K-01-A)

Function
• When the bucket is at the flat position or below, if the tilt lever is set in the detent position, the bucket stops
slowly at a set position.
1. Setting stop position
• The bucket stop position when the positioner is operated is changed with the bucket positioner
position set switch.
Condition for
Bucket lever is in Neutral and bucket is within ±5.5 degrees of setting angle.
enabling
Set the bucket to a desired position and push the bucket positioner switch. (less than
(1)
1 second)
Setting method The current bucket cylinder length is saved for the saved set position, and the setting
(2) completion buzzer sounds and the value is displayed on the monitor for 3 seconds.
(The set position is maintained even after the key is turned to the OFF position.)
To cancel the saved position (returned it to the default), hold down the bucket
(1)
positioner switch for 1 second or more.
Cancellation If within the set range, the position is set temporarily. However, the setting
method (2)
cancellation buzzer sounds 1 second after and the stop position is set to the default.
(3) The monitor displays the saved value (default: 0) for 3 seconds.

a The value displayed on the monitor is indication of a level and does not match to the actual bucket
angle.
a The bucket-equivalent angle means a calculated bucket angle. It does not always match to the
actual angle because of the shape of the bucket.
2. Cancellation of tilt detent
• When the bucket lever is in the tilt detent position, if the cylinder reaches the detent cancellation
position, the detent is canceled and the bucket stops slowly.
3. Stopping tilting (slowly)
• Tilting (slow) stop function decreases the speed of tilting within the range of 100 to 7 mm before the
target stop position by feeding back the cylinder length, corresponding to the stopping angle.
• After the tilt detent is canceled, if the bucket lever is held in the tilt detent position, tilting is not
stopped (slowly) but accelerated from the time when the lever is judged to be held, in the return
modulation at the target flow set with the lever.

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• Accordingly, if the detent is held with the bucket positioner operated and the bucket is operated
over the stop position, the bucket tilting is decelerated temporarily and then accelerated.
4. Detent operation while engine is stopped
• While the engine is stopped, the detent is kept OFF, thus the lever is not held in the detent position
while the engine is stopped.
5. Adjustment of bucket angle
• The work equipment controller has a function to correct the cylinder length when the bucket is in
the flat position.
• As for the flat position of the bucket, one of the three positions A, B, and C can be saved according
to the attachment.
a For details of adjustment procedure, see "Bucket flat level adjustment" of "Explanation of components",
"Operation" in the Operation and maintenance manual.

Remote boom positioner (WA500-PTL9-042-K-01-A)

Function
Raising kick-out (When pilot lamp lights up to indicate that only raising is effective or both raising and lowering
are effective)
• If the boom lever is set in the "Raising detent" position, the boom starts deceleration before the set
position, cancels the raising detent, and controls stopping (slowly).
• When the boom is not in the "Raising detent" position, it is raised by the operator's operation.
• If raising is not selected, only the raising detent operates.
• If the detent is turned ON, the remote positioner does not operated and only the kick-out function operates
(the boom stops at the top).
Stopping boom lowering (When pilot lamp lights up to indicate that only lowering is effective or both raising
and lowering are effective)
• If the boom lever is set in the "Floating detent" position, the boom starts deceleration before the set
position, cancels the floating detent, and controls stopping (slowly).
• If the boom lever is kept as it is, the boom starts lowering again.
• If lowering is not selected, only the floating detent operates.
• If the detent is turned ON when the boom angle is flat or below, the remote positioner does not operate
and only the floating detent function operates (the boom does not stop automatically).
a If the detent is turned ON when the boom is flat or below, the lowering remote positioner does not function
as the positioner and does not stop the boom, for distinction from the floating operation in the grading
work.

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a The floating detent does not operate at around the setting stop position. However, the floating detent
operates when the boom angle is below -37 degrees for the grading work.
1. Setting stop position
• The boom stop position when the positioner is operated is changed with the boom positioner switch.

Setting and cancelation of raising stop position


Condition for
Boom lever travel: Neutral and boom position is flat or above
enabling
(1) Raise the boom to a position to set.
(2) Press the remote positioner raising position set switch (less than 1 second).
(3) If the position in which the switch is pressed is within the set range, the boom angle
is saved, the setting completion buzzer (pip, pip) sounds, and the pilot lamp on the
monitor lights up.
Method of setting (4) If the position is out of the range (boom angle is below 0 degrees) or the sensor has
raising stop an error, setting is not performed again.
(The buzzer does not sound and set position is not changed)
(5) If the setting switch is operated less than 1 second, the set position is always
changed.
(The set position is maintained even after the key is turned to the OFF position.)
(1) Press the remote positioner raising position set switch for 1 second or more.
(2) If the position is within the set range when the switch is pressed, it is set temporarily.
If the switch is held down for 1 second or more in (3) above, the setting cancel buzzer
Method of sounds (peep) when 1 second elapses and the raising selection is canceled and the
canceling setting of pilot lamp of the monitor goes off.
raising stop a The setting can be canceled when the boom is in the range above the flat position.
(3) Leave the remote positioner raising stop control unexecuted. Perform only the boom
kick-out control.
(4) In this operation, the lowering stop setting is not canceled.

Setting and cancelation of lowering stop position


Condition for
Boom lever stroke: Neutral and boom position is flat or below
enabling
(1) Lower the boom to a position to set.
(2) Press the remote positioner lowering position set switch. (less than 1 second)
(3) If the position in which the switch is pressed is within the set range, the boom angle
is saved, the setting completion buzzer (pip, pip) sounds, and the pilot lamp on the
monitor lights up.
Method of setting (4) If the position is out of the range (boom angle is out of the range between -37
lowering stop degrees and 0 degrees ) or the sensor has an error, setting is not performed again.
(The buzzer does not sound and set position is not changed)
(5) If the setting switch is operated less than 1 second, the set position is always
changed.
(The set position is maintained even after the key is turned to the OFF position.)
(1) Press the remote positioner lowering position set switch for 1 second or more.
(2) If the position is within the set range when the switch is pressed, it is set temporarily.
If the switch is held down for 1 second or more in (3) above, the setting cancel buzzer
sounds (peep) when 1 second elapses and the lowering selection is canceled and the
Method of
pilot lamp of the monitor goes off.
canceling setting of
lowering stop a The setting can be canceled when the boom is in the range below the flat position.
(3) Leave the remote positioner lowering stop control unexecuted.
Perform only the float detent control.
(4) In this operation, the lowering stop setting is not canceled.

Remote positioner stop position settable range


[Raising/Lowering stop position settable range]

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Work equipment control system

Stop position "Raising" "Lowering"


Range Min. 0 degrees 0 to -37 degrees
0 degrees: Boom horizontal position
2. Cancelation of boom raising detent
• When the remote positioner is operated, the detent is turned OFF if the boom reaches the detent
cancelation position.
• Once the boom raising detent is turned OFF automatically by the operation of the stop (slow) function, the
boom raising/lowering detent is kept OFF for 1 second.
3. Raising stop (slow)
• Boom raising (slow) stop function decreases boom speed according to the stopping angle by feeding back
the boom angle.
• After the boom raising detent is canceled, if the boom lever is held in the raising detent position, boom
raising (slow) stop function does not work and the boom raising is accelerated again.
• Accordingly, if the detent is held with the boom raising remote positioner operated and the boom is
operated over the target stop angle, the boom raising is decelerated temporarily o accelerated.
4. Boom kick-out function
• When the stop position of the remote positioner is not set or the boom raising detent is turned ON above
the stop position, the boom performs the kick-out operation and stops slowly before the travel end to
reduce the stopping shocks at the travel end.
5. Cancelation of boom lowering detent
• When the remote positioner is operated, the detent is turned OFF if the boom reaches the detent
cancelation position.
• Once the boom lowering detent is turned OFF automatically by the operation of the stop (slow) function,
the boom raising/lowering detent is kept OFF for 1 second.
6. Boom lowering stop (slow)
• Boom lowering (slow) stop function decreases boom speed according to the stopping angle by feeding
back the boom angle.
• After the boom lowering detent is canceled, the system checks for 0.05 seconds if the boom is held in the
raising detent. If the boom is held in the detent, the system does not perform the stopping (slow) operation
but accelerates the boom lowering again.
• Accordingly, if the detent is held with the boom lowering remote positioner operated and the boom is
operated over the target stop angle, the boom lowering is decelerated temporarily o accelerated.
• When the boom angle reaches -37 degrees, the system stops acceleration and performs the floating
operation even if during acceleration.
7. Detent operation while engine is stopped
• While the engine is stopped, the detent is kept OFF, thus the lever is not held in the detent position while
the engine is stopped.
8. Adjustment of boom angle
• The work equipment controller has function to correct the installation error of the boom potentiometer.
• The controller saves the boom potentiometer voltage at the boom top and operates the remote boom
positioner function.
• If the adjustment is not performed, the kick-out position may be "too much near this side" or "the boom
may not kick out and shocks may be generated at travel end".
Semi auto-digging function (WA380-PTLA-042-K-00-A)

• The semi auto-digging function uses only the kickdown switch and boom raising operation for the ease of
digging work. With this function, even an unskilled operator can improve the working efficiency. This
function has two modes of LOOSE and ROCK, either of which is selected according to the properties of
the objective material.

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• A bucket automatic operation pattern matched to the working cycle and load is selected.

Mode selection
No. Objective material Mode
1 Gravel/Sand LOOSE mode
2 Quarry/Blasted rocks ROCK mode

1. Condition for starting semi auto-digging


The semi auto-digging is ready when following (1) to (4) are satisfied.
(1) Semi auto-digging is set in "ROCK" or "LOOSE" mode.
(2) Machine is traveling forward (There is F signal)
Condition 1 (3) Boom angle is less than -30 ° (almost on ground)
(4) Kickdown switch is operated
a Even during work in 1st gear speed, semi auto-digging does not start if kickdown
switch is not operated.
Semi auto-digging (auto tilt) starts when following (1) and (2) are satisfied.
Condition 2
(1) Boom is raised after condition 1 is satisfied.

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Work equipment control system

(2) Low speed travel (km/h) < 3.5 x ENG rpm/1,800


2. Condition for finishing semi auto-digging
Semi auto-tilt finishes when one of the following conditions is satisfied.
(1) Forward travel is finished (There is F signal o There is no F signal.)
(2) Boom angle is above flat.
Condition
(3) Tilt end is detected (Full tilt condition)
(4) Boom is lowered.
(5) Bucket is dumped.
3. Tilt operation in digging mode
1) Operation in "LOOSE" mode

2) Operation in "ROCK" mode

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Electric emergency steering function (WA470-F910-042-K-00-A)

1. Emergency steering switch


2. Transmission controller
3. Work equipment controller
4. Fuse box
5. Slow-blow fuse
6. Battery relay
7. Battery
8. Battery disconnect switch
9. Emergency steering switch relay
10. Emergency steering relay
11. Emergency steering pump oil pressure sensor
12. Steering pump
13. Steering pump oil pressure sensor
14. Steering valve
15. Emergency steering pump
16. Emergency steering motor

Input/output signal
a. CAN signal
b. Emergency steering manual operation signal
c. Steering pump oil pressure signal
d. Emergency steering relay signal
e. Emergency steering pump oil pressure signal
f. Sensor power supply

Function
• The condition of the oil pressure sensors in the steering circuit is constantly monitored. When the steering
oil pressure decreases and the transmission output shaft speed (travel speed) increases above the
emergency steering "ON" value in the following figure, the emergency steering operation signal is output
to the emergency steering switch relay to operate the emergency steering.
• The emergency steering motor can be operated by operating the emergency steering switch, regardless
of the steering oil pressure or transmission output shaft speed (travel speed).

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a The continuous operation time with the emergency steering switch must be limited within 60 seconds.
a The travel speed must be kept 5 km/h or below while the emergency steering is operated.

Emergency steering selection point A B


Travel speed [km/h] 1.9 2.0
• The emergency steering does not function if "Emergency steering" is not set to "ADD" with the "Option
select function" of the machine monitor.
a For the setting procedure, see Testing and Adjusting, "Special functions of machine monitor".

Self-check function for emergency steering


• The emergency steering performs the self-check of its operation automatically 3 seconds after the starting
switch is turned to the "ON" position (after the self-check of the machine monitor is finished).
However, the self-check is not performed in the following cases.
1. The starting motor is started by turning the starting switch to the "START" position
2. The engine is running already.
(Engine speed of 500 rpm or higher is detected)
3. Steering pressure is detected
4. The automatic preheating function operates
5. An error related to the emergency steering is detected by the self-check of the machine monitor
6. The engine is not started for 10 seconds or more after the previous self-check
(Engine speed of 500 rpm is not detected for 10 seconds or more)
• During the self-check of the emergency steering, the emergency steering operation signal is output for up
to 3 seconds.
• When the machine monitor detects the emergency steering operating pressure within 3 seconds, the
emergency steering system receives the emergency steering operation sensing signal through the
network from the machine monitor and finishes its self-check.
• If the machine monitor does not detect the emergency steering operating pressure in 3 seconds, the
emergency steering system does not receive the emergency steering operation signal from the machine
monitor, thus it gives an error alarm.
Real-time monitoring function of work equipment controller (WA380-PTLB-042-K-00-A)

The conditions of the input and output signals of the controller can be checked with the monitoring function of
the machine monitor.
a For the monitoring procedure, see Testing and adjusting, “Special functions of machine monitor“.
Self-diagnosis function of work equipment controller (WA380-PTLC-042-K-00-A)

• The work equipment controller constantly monitors the input and output conditions and performs self-
diagnosis of the system.
• If any failure is detected by the self-diagnosis, its information is sent to the machine monitor via the
network.
• If any failure occurs, it can be checked with the machine monitor / KOMTRAX.

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Machine monitor system (WA470-Q170-041-K-00-A)

Function (WA380-Q170-042-K-00-A)

• The machine monitor system mainly consists of the machine monitor, monitor controller, and switch panel.
1. Machine monitor

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Machine monitor system

Displays the machine condition to the operator.


a The machine monitor has two display modes; One is the operator mode and the other is the service
mode.
2. Monitor controller
Obtains the condition data of various sections of the machine monitored with sensors and switches and
processes them. Communicates the network information with each controller.
a For details, see "Monitor controller".
3. Switch panel
Accepts operations of the operator.
a For details, see "Switch panel".
Details of monitor controller network signals (WA470-Q180-03C-K-00-A)

Data sent
Updated every 10 msec (RTCDB/r)
No. Item
1 Fan reverse set condition (reverse time)
2 Fan reverse set condition (interval time)
3 Fan manual selection (forward/reverse) enabled/disabled
4 Air conditioner Compressor Status
5 Attachment flow mode
6 Attachment flow level
7 Attachment set switch information
Updated every 100 msec (RTCDB/r)
No. Item
1 Service meter reading
2 Semi-auto digging mode setting
3 Auto-deceleration enabled/disabled setting
4 Parking brake operation
5 Adjustment ID
6 Adjustment switch information
7 Data for adjustment
8 Auto-kickdown enabled/disabled
9 Machine model data
10 Option data
11 Brake oil pressure (front)
12 Brake oil pressure (rear)
13 Idle stop set time
14 In-idle stop service mode flag
15 Idle stop set entry signal
16 Preheat condition
17 Engine speed fixing control command
18 Bucket flat level adjustment selection information
19 Bucket flat level adjustment initialization command
20 Recirculation air temperature
21 Set temperature
22 Air conditioner setting
Data received
Updated every 10 msec (RTCDB/r)
No. Item
1 Engine speed
2 Final injection rate

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No. Item
3 1st throttle position (accelerator pedal)
4 Engine condition
5 Key switch ACC terminal (engine controller)
6 Throttle correction value
7 Throttle upper limit value
8 Throttle lower limit value
9 Dynamic torque request
10 Torque curve selection
11 Droop type selection
12 Droop switch selection
13 ABS droop trim
14 Automatic warm-up cancel flag
15 Machine safety state 1
16 Machine safety state 2
17 Engine speed control flag
18 Travel speed (tire diameter and correction counted in)
19 Actual gear speed display (F)
20 Actual gear speed display (N)
21 Actual gear speed display (R)
22 Actual gear speed display (1st)
23 Actual gear speed display (2nd)
24 Actual gear speed display (3rd)
25 Actual gear speed display (4th)
26 Directional lever display (F)
27 Directional lever display (N)
28 Directional lever display (R)
29 Shift range display (1st)
30 Shift range display (2nd)
31 Shift range display (3rd)
32 Shift range display (4th)
33 Transmission controller recognition lever direction
34 Working situation discrimination status
35 ECSS switch condition
36 Rim pull
37 Engine output mode
38 Engine output mode (Engine output mode condition in transmission controller)
39 Engine output mode selection
40 Throttle lock (RPM set) lower limit command value
41 Engine start permission flag
42 Boom lever condition
43 Bucket lever condition
44 Working condition check
45 Target rim pull
46 Scrape-up flag
47 Digging flag
48 Loader pump neutral flag
49 Steering pump neutral flag
50 Boom angle
51 Boom bottom pressure
52 Boom head pressure
53 Bell crank angle
54 Key SIG condition (ACC)

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No. Item
55 Auto-kickdown work equipment posture sensing information
56 Depressing right brake pedal
Updated every 100 msec (RTCDB/r)
No. Item
1 Engine coolant temperature
2 Overrun condition
3 Grid heater control condition
4 Instantaneous fuel consumption
5 Soot accumulation level
6 KDPF regeneration mode
7 Manual regeneration permission condition
8 Thermal management auxiliary request
9 HC desorb flag
10 Hydraulic oil temperature
11 Torque converter oil temperature
12 AJSS indicator or FNR switch
13 Auto shift condition
14 Shift hold condition
15 Lockup operation condition
16 Fan reverse pilot lamp
17 Kickdown switch condition
18 Kickdown information
19 Transmission cut-off point setting buzzer operation
20 Lockup function switch
21 Left brake pressure
22 Idle stop remaining time
23 Idle stop condition
24 Cut-off switch built-in indicator condition
25 Semi-auto digging condition
26 Multicoulper operation condition
27 Throttle lock (RPM set) operation condition
28 Boom positioner operation condition
29 Positioner setting buzzer operation
30 Emergency steering motor operation condition
31 All work equipment lever neutral flag
32 Work equipment pump relief flag
33 AJSS warning
34 ATT (PCS) detent condition
35 ATT (PCS) mode (flow mode) condition
36 ATT (PCS) flow rate level
37 Bucket selection information
38 Work equipment lock indicator

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Machine monitor (HM300-Q180-042-K-00-A)

Precautions on the machine monitor display


• If there is trouble in the machine monitor, monitor controller, another controller, or network wiring, the
machine monitor does not display normally.
• One of the features of the liquid crystal unit is that there may be black spots (spots that do not light up) or
white spots (spots that stay lighting up) on the screen.
When there are fewer than 10 black or white spots, this is not a failure or a defect.
• When the emergency steering self check is performed or the engine is started, the battery voltage may
drop suddenly, depending on the ambient temperature and the condition of the battery.
In this case, the machine monitor may go out for a moment or may be restarted. However, this
phenomenon is not a trouble.

Input and output signals of machine monitor (WA380-Q180-03C-K-01-A)


JAE-8P [ CN-MDM1] (for LC unit)
Input/Output
Pin No. Signal name
Signal
1 LC unit LVDS + Input
2 LC unit LVDS - Input
3 LC unit power supply return GND ―
4 LC unit backlight adjustment Input
5 LC unit power supply Input
6 LC unit ON/OFF control Input

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Machine monitor system

Input/Output
Pin No. Signal name
Signal
7 LC unit backlight ON/OFF control Input
8 LC unit temperature sensor Input
AMP-6P [ CN-MDM2] (for LED unit)
Input/Output
Pin No. Signal name
Signal
1 LED unit power supply (+12 V) Input
2 LED unit power supply return GND ―
3 LIN Input/Output
4 LED unit power supply (+5 V) Input
5 (*1)
6 GND
AMP-8P [ CN-MDM3] (for meter unit)
Input/Output
Pin No. Signal name
Signal
1 Meter unit power supply (battery direct 24 V) Input
2 Key switch ACC terminal Input
3 CAN (+) Input/Output
4 Meter unit power supply return GND ―
5 Monitor brightness selector switch (night mode signal) Input
6 (*1)
7 CAN2 terminating resistor Input
8 CAN (-) Input/Output
*1: Never connect these pins. Malfunctions or failures may occur.

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Display (WA470-Q1LA-042-K-00-A)

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Machine monitor system

A: Standard screen
B: ECO guidance screen
C: Maintenance time warning screen
D: Warning screen
E. Bucket positioner pop-up screen
F: User menu screen
1. Speedometer
2. Engine tachometer
3. Centralized warning lamp

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4. Parking brake pilot lamp


5. Turn signal pilot lamp (left)
6. Headlamp (high beam) pilot lamp
7. Turn signal pilot lamp (right)
8. Brake oil pressure caution lamp
9. Clearance lamp pilot lamp
10. Engine coolant temperature gauge
11. Engine coolant temperature caution lamp
12. Torque converter oil temperature gauge
13. Torque converter oil temperature gauge caution lamp
14. Hydraulic oil level gauge
15. Hydraulic oil temperature caution lamp
16. Fuel level gauge
17. Fuel level caution lamp
18. ECO gauge
19. Air conditioner display area
20. Clock
21. L.H. meter display area (select service meter, odometer, or clock)
22. R.H. meter display area (select service meter, odometer, clock, or average fuel consumption gauge)
23. Shift indicator
24. Shift lever position pilot lamp
25. Message pilot lamp
26. Semi-auto digging/ Multi-coupler lock release pilot lamp (if equipped)
27. Directional selector pilot lamp (if equipped)
28. ECSS (Electronically Controlled Suspension System) pilot lamp
29. Double low idle pilot lamp
30. Remote positioner/ work equipment lock pilot lamp
31. KDPF regeneration pilot lamp
32. Emergency steering pilot lamp (if equipped)
33. Power mode pilot lamp
34. Shift hold pilot lamp
35. Lockup pilot lamp
36. Auto shift pilot lamp
37. Fan reverse rotation pilot lamp
38. Engine preheater/ transmission cut-off pilot lamp
39. ECO guidance
40. Maintenance time caution lamp
41. Guidance icon
42. Seatbelt caution lamp
43. Caution display area
44. Action level
45. Bucket positioner pilot lamp

WA470-7 10-301
10 Structure and function
Machine monitor system

Meters and gauges (WA470-Q1LB-043-K-00-A)

Monitor Item Display


display displayed Contents Remarks
color
• If communication error
occurs between monitor
controller and transmission
Charac- controller, "0" is displayed.
Speedom- Display range: 0 to 99 km/h
ters: • If communication error
eter
black occurs between monitor
controller and meter unit,
"00" is displayed.
• If engine speed increases
Charac- above specified level,
ters: engine overrun caution
Engine white Display range: 0 to 3,500 rpm (red lights up. (For details, see
tachom- Gradua- zone: 2,500 rpm and above) engine overrun caution.)
eter tions: • If communication error
white, red occurs, gauge pointer reads
0.
Coolant
Gradua- Point tempera- • If temperature exceeds 102
tions: ture (°C) °C, engine coolant overheat
Engine Display range: A1 135 caution lights up. (For
white,
coolant 50 to 135 °C A2 102 details, see engine overrun
green, (red zone: 102 caution.)
tempera-
red °C and above) A3 88 • If communication error
ture gauge
Pointer: A4 74 occurs, gauge pointer
red A5 59 disappears.
A6 50
Oil
Gradua- Point tempera-
• If temperature exceeds 120
Torque tions: ture (°C)
Display range: °C, torque converter oil
converter green, B1 135
50 to 135 °C overheat caution lights up.
oil
red (red zone: 120 B2 120 • If communication error
tempera-
Pointer: °C and above) B3 97 occurs, gauge pointer
ture gauge
red B4 73 disappears.
B5 50
Oil
Gradua- Point tempera-
• If temperature exceeds 100
Hydraulic tions: Display range: ture (°C)
°C, hydraulic oil caution
oil green, 50 to 125 °C C1 125 lights up.
tempera- red (red zone: 100 C2 100 • If communication error
ture gauge Pointer: °C and above) C3 83 occurs, gauge pointer
red C4 67 disappears.
C5 50
Fuel
Point level (l)
Gradua-
Display range:
tions: D1 226 • 42 l or below, fuel level
EMPTY to
Fuel level green, D2 190 caution lights up.
FULL (red
gauge red • If sensor is abnormal, gauge
zone: 42l or D3 114
Pointer: pointer disappears.
less) D4 42
red
D5 41

10-302 WA470-7
10 Structure and function
Machine monitor system

Monitor Item Display


display displayed Contents Remarks
color
• Indicates instantaneous fuel
consumption (average of
fuel consumption per 3
seconds) in 10 steps.
• Display/Non display of ECO
gauge can be set by using
user menu as follows; "ECO
Guidance" o "Display
ECO Green, Display range: 0 to 48.75 l/h Setting" o "ECO Gauge
gauge orange (Orange zone: 39 l/h or above) Display".
• Display/Non display of ECO
gauge can be set by using
user menu as follows; "ECO
Guidance" o "Display
Setting" o "ECO Gauge
Display".
• If communication error
occurs, gauge reads 0.
Air
Charac- • Set temperature
conditioner • For details, see Operation &
ters: • Air blow rate
display Maintenance Manual.
white • Vent
area
• Displays time.
• 12-hour/24-hour system
Charac- • 12-hour system display (AM/PM) display can be switched by
Clock ters: • 24-hour system display using user menu as follows;
white "Monitor Setting" o "Clock
Adjustment".
• Indicates accumulated
engine operating hours.
Service Charac-
Display range: 0 to 999999.9 h • When engine operating
meter (*1) ters: hours exceeds 999999.9 h,
white
meter reading stops at
999999.9 h.
• Indicates accumulated travel
distance.
Travel Charac- • When travel distance
odometer ters: Display range: 0 to 3999999.9 km
exceeds 3,999,999.9 km,
(*1) white meter reading stops at
3,999,999.9 km.
• Displays time.
• 12-hour/24-hour system
Charac- • 12-hour system display (AM/PM) display can be switched by
Clock (*1) ters:
• 24-hour system display using user menu as follows;
white "Monitor Setting" o "Clock
Adjustment".
• Indicates average fuel
consumption.
Fuel • 1 Day/Split can be switched
consump- Charac- • 1 Day display by using user menu as
tion gauge ters: • Split display follows; "ECO Guidance" o
(*1) white "Display Setting" o "Fuel
Consumption Gauge
Display".
*1: These items indicated to R.H. and L. H. meter display can be selected with user menu "Monitor Setting" o
"Select Meter Display" as follows.
L.H. meter display: Service meter, odometer, clock
R.H. meter display: Service meter, odometer, clock, fuel consumption gauge

WA470-7 10-303
10 Structure and function
Machine monitor system

Alarm monitor (WA470-Q1LA-043-K-00-A)


Centra-
Monitor Item Display Action lized Alarm
display displayed warning Remarks
color level buzzer
lamp
Q
L04 Q (continu-
ous)
Q
(intermit- • Appears when trouble is
Red L03 Q
Action tent) detected in machine.
level Q
L02 Q (intermit-
tent)
• Lights up for 2 seconds, then
Yellow L01 ― ―
goes out.
• Lights up when failure of
Centra-
Q action level L02 or higher
lized Red See
Q (intermit- occurs or alarm to warn
warning (LED) remarks. tent) operator is made. Buzzer
lamp
sounds, as well.
Q • Appears when brake oil
L03 Q (intermit- pressure drops while engine
tent) is running.
Brake oil Q • Appears if brake oil pressure
Red
pressure ― Q (intermit- does not increase after
(LED)
caution tent) engine is started.
• Lights up if brake oil pressure
― ― ― drops while engine is
stopped.
Q • Appears when engine coolant
Engine L02 Q (intermit- temperature is 105°C or
coolant tent) above.
Red
tempera- • Lights up when engine
ture ― ― ― coolant temperature is 102°C
or above.
Q • Appears when torque
Torque (intermit-
L02 Q converter oil temperature is
converter tent) 130°C or above.
oil Red
tempera- • Appears when torque
― ― ― converter oil temperature is
ture
120°C or above.
Hydraulic Q • Appears when hydraulic oil
oil (intermit-
Red L02 Q temperature is 100°C or
tempera- tent) above.
ture

― ― ― • Lights up when fuel level is


Fuel level Red
42 l or below.

• Lights up for 30 seconds after


starting switch is turned to the
Red ― ― ―
ON position if maintenance
Mainte- due time of any item is over.
nance time • Lights up for 30 seconds after
warning starting switch is turned to the
Yellow ― ― ― ON position if maintenance
reminder due time of any item
is over.

10-304 WA470-7
10 Structure and function
Machine monitor system

Centra-
Monitor Item Display Action lized Alarm
display displayed warning Remarks
color level buzzer
lamp
• Notice time can be changed
in service menu
"Mmaintenance Mode
Setting" o "Maintenance
ModeChange" o
"Maintenance Notice Time
Setting".

― ― ― • Lights up when seat belt is


Seat belt Red
not fastened.

Q
L04 Q (continu-
Engine ous)
Red Q • Appears when error is
system detected in engine system.
error L03 Q (intermit-
tent)
Yellow L01 ― ―
Q
L04 Q (continu-
Defective ous)
Red Q • Appears when error is
KDPF
(intermit- detected in KDPF system.
system L03 Q
tent)
Yellow L01 ― ―
KDPF soot Q • Appears when much soot is
accumula- Red L03 Q (intermit- accumulated in KDPF or
tion tent) system error including
caution lowered purification function
Yellow L01 ― ―
icon is detected.
Q
• Appears when engine speed
L02 Q (intermit-
is 2,525 rpm or above.
Engine tent)
Red Q
overrun
• Appears when engine speed
― Q (intermit-
is 2,425 rpm or above.
tent)

Q • Appears when engine oil


Engine oil
Red L03 Q (intermit- pressure is below specified
pressure
tent) value
Q
L04 Q (continu-
Transmis- ous) • Appears when error is
sion Red
Q detected in transmission
system (intermit- system.
L03 Q
error tent)
Yellow L01 ― ―
Fan Q
Red L03 Q (intermit- • Appears when error is
control detected in fan control
system tent)
system.
error Yellow L01 ― ―

Radiator
― ― • Lights up when radiator
coolant Yellow L01
coolant level is low.
level

WA470-7 10-305
10 Structure and function
Machine monitor system

Centra-
Monitor Item Display Action lized Alarm
display displayed warning Remarks
color level buzzer
lamp

Engine oil ― ― • Lights up when engine oil


Yellow L01
level level is low.

Air cleaner • Lights up when air cleaner is


Yellow L01 ― ―
clogging clogged.

Steering
system • Appears when error is
error Yellow L01 ― ―
detected in steering system.
caution
icon
Emergen- Q
cy steering Red L03 Q (intermit-
system tent) • Appears when error is
error detected in emergency
caution steering system.
icon (if Yellow L01 ― ―
equipped)

Q • Lights up when directional


Directional ― (intermit- switch or directional lever is
Red Q
switch tent) operated wrongly.

• Lights up when brake oil


Brake oil temperature is kept at 140°C
tempera- Yellow ― ― ― or above for 900 seconds, or
ture at 150°C or above for 20
seconds.
Q
Work Red L03 Q (continu- • Appears when trouble is
equipment ous) detected in work equipment
system system.
Yellow L01 ― ―
Q • Appears when steering oil
L03 Q (intermit- pressure drops while engine
Steering tent) is running.
oil Red
pressure Q • Lights up when steering oil
― Q (intermit- pressure does not increase
tent) after engine is started.
Q • Appears when emergency
Emergen- L02 Q (intermit- steering motor is used for 60
cy steering tent) seconds or more.
motor (if Red
• Lights up while emergency
equipped) ― ― ― steering motor is functioning
normally.
Q • Appears when error related to
System (intermit-
Red L03 Q machine monitor or rear view
error tent) monitor or error in
caution
communication between
icon Yellow L01 ― ―
controllers is detected.
Air
conditioner • Appears when error is
system ― ― detected in air conditioner
Yellow L01
error system.
caution
icon

10-306 WA470-7
10 Structure and function
Machine monitor system

a If three or more cautions are occurring, the icons displayed are changed two by two every 2 seconds.

WA470-7 10-307
10 Structure and function
Machine monitor system

Pilot lamp (WA470-C7K6-043-K-00-A)

Monitor Item Display


display displayed Contents Remarks
color

Parking Red Lights up when parking brake is


brake (LED) applied.

Turn signal Green Lights up when left turn signal is


(left) (LED) turned on.

Headlamp
Blue Lights up when headlamp (high
(high
(LED) beam) is turned on.
beam)

Turn signal Green Lights up when right turn signal is


(right) (LED) turned on.

Clearance Green Lights up when clearance lamp is


lamp (LED) turned on.

Charac- Indicates actual gear speed (F1, F2,


Shift
ters: F3, F4, N, R1, R2, R3, or R4).
indicator
White

• When starting switch is


turned to the ON position
while shift lever is not in N,
character of current shift
Charac- lever position flashes,
ters: centralized warning lamp
Highligh- lights up and alarm buzzer
Shift lever Current shift lever position (1, 2, 3,
ted in sounds. (Neutral safety
position 4, N, R, N, or F) is highlighted.
white alarm)
(other • When all signals from shift
than N) lever are OFF, character of
current shift lever position
flashes , centralized warning
lamp lights up and alarm
buzzer sounds.

Message Back- Lights up when there is unread


(Unread) ground: message.
Green

Message
Back- Lights up when there is message • Goes out when answer is
(read but
ground: read but not returned yet. sent or validity of message
unre-
Black expires.
turned)

Semi-auto Lights up while machine is digging in


Digging Green
semi-auto mode.

10-308 WA470-7
10 Structure and function
Machine monitor system

Monitor Item Display


display displayed Contents Remarks
color
Multi-
coupler
lock Lights up when multi-coupler lock is
Red
release (if released.
equipped)
Lights up when directional switch is
Green
Directional effective.
selection Lights up when wrong operation is
Yellow
made.

E.C.S.S. Green Lights up when ECSS is effective.

2-stage
low idle (if Lights up when 2-stage low idle is
Green
equipped) effective.

Lights up when raise stop is set.

Remote
Green Lights up when lower stop is set.
positioner

Lights up when raise and lower


stops are set.

Work
Lights up when work equipment is
equipment Red
locked.
lock

Auto-shift Green Lights up when auto-shift operates.

• Lights up when transmission cut-


Transmis- off operates.
Green • Flashes when resetting is
sion cut-off
acceptable.
• Pops up for only 3 seconds when
Bucket bucket positioner switch is
positioner Green turned ON.
• Displays set angle in range of ±5
levels.

Lights up during KDPF regeneration.


KDPF
regenera- Yellow
tion • KDPF soot accumulation
Lights up when KDPF regeneration caution icon lights up when
is stopped. manual stationary
regeneration is required.

WA470-7 10-309
10 Structure and function
Machine monitor system

Monitor Item Display


display displayed Contents Remarks
color
Emergen-
cy steering Lights up when emergency steering
(if Green operates.
equipped)

Lights up when P mode is selected


P mode with power mode selector switch.

Green
Lights up when E mode is selected
E mode with power mode selector switch.

Shift hold Green Lights up when shift hold operates.

Lockup Green Lights up when lockup is engaged.

• Lights up when fan rotates in


reverse.
Yellow • Flashes while rotation direction
Fan is being changed.
reverse
rotation Lights up while rotation direction
Red change condition is being waited to
meet.

Lights up when engine electric


Preheating Yellow preheater operates.

• Guidance on excessive engine


idling
• Guidance on deterrence of
hydraulic relief
Back- • Guidance on deterrence of brake
ground: dragging
ECO Green • Guidance on deterrence of
guidance Charac- accelerator pedal depressing
ters: • Guidance on recommendation of
White 4th gear
• Guidance on recommend of
lockup
• Guidance on deterrence of long-
period digging

10-310 WA470-7
10 Structure and function
Machine monitor system

Guidance icon (WA380-Q1L3-043-K-00-A)


Monitor Function (Action that starts when
Item Display location
display corresponding switch is pressed)
<When KDPF soot accumulation
caution lights up> • Standard screen (when KDPF
Moves to user menu "KDPF soot accumulation caution lights
User menu regeneration" up)
selection • Standard screen (when
<When maintenance caution lights
up> maintenance caution lights up)
Moves to user menu "Maintenance"

Display of • Standard screen (when failure


Displays occurred error list
occurred error list occurs)

<In user menu or service menu>


Move between Moves to upper item • Overall user menu
items (upper) <When value is input> • Overall service menu
Increases value
<In user menu or service menu>
Move between Moves to upper item • Overall user menu
items (lower) <When value is input> • Overall service menu
Decreases value
<In user menu or service menu>
Returns to previous screen or
standard screen • Overall user menu
Return
• Overall service menu
<When Yes/No is selected>
Selects "No"
<In user menu or service menu>
Moves to upper item • Overall user menu
Enter
<When Yes/No is selected> • Overall service menu
Selects "Yes"
Moves to right tab
Move between • User menu
<In service menu>
tabs (right) • Service menu "Monitoring"
Selects monitoring item tab
• Occurred error list
• User menu "ECO guidance" →
"Operation record", "ECO
Moves to upper page guidance record"
Move between
(Moves to bottom page from top • Service menu "Monitoring / Pre-
pages (upper)
page) defined"
• Service menu "Abnormality
record" → "Mechanical system
abnormality record"
• Occurred error list
• User menu "ECO guidance" →
"Operation record", "ECO
Moves to lower item guidance record"
Move between
(Moves to top page from bottom • Service menu "Monitoring / Pre-
pages (lower)
page) defined"
• Service menu "Abnormality
record" → "Mechanical system
abnormality record"

Start split fuel • User menu "ECO guidance" →


Starts measurement of split fuel
consumption "Operation record", "ECO
consumption
measurement guidance record"

WA470-7 10-311
10 Structure and function
Machine monitor system

Monitor Function (Action that starts when


Item Display location
display corresponding switch is pressed)
a Displayed when setting of
"Average fuel consumption
display" is split
• User menu "ECO guidance" →
"Operation record", "ECO
Stop split fuel Stops measurement of split fuel guidance record"
consumption consumption
measurement a Displayed when setting of
"Average fuel consumption
display" is split

Clear average fuel Clears average fuel consumption • User menu "ECO guidance" →
consumption logs logs "Average fuel consumption logs"

Select average
Selects 1-hour/1-day average fuel • User menu "ECO guidance" →
fuel consumption
consumption log "Average fuel consumption logs"
log

Initialize screen Returns to monitor screen brightness • User menu "Monitor setting" →
brightness to initial level "Screen adjustment"

Store monitoring Stores monitoring item • Service menu "Monitoring"


item

Clear saved
Clears monitoring item • Service menu "Monitoring"
monitoring item

• Service menu "Monitoring / Pre-


defined"
Hold monitoring • Service menu "Monitoring"
Holds value of monitoring item
value • Service menu "Testing" →
"Cylinder cut-out operation"
• Service menu "Adjusting"
• Service menu "Monitoring / Pre-
defined"
Cancel held Cancels held value of monitoring • Service menu "Monitoring"
monitoring value item • Service menu "Testing" →
"Cylinder cut-out operation"
• Service menu "Adjusting"
<Electrical system abnormality • Service menu "Abnormality
record> record" → "Electrical system
Clears electrical system abnormality abnormality record"
record a For method of clearing
Clear <Phone number entry> abnormality record, see
Clears phone number “Testing and adjusting“
• Service menu "Phone number
<Adjusting> entry"
Clears input value • Service menu "Adjusting"
• Service menu "Phone number
entry"
Move between
Moves to right item • Service menu "Testing" →
items (right)
"Cylinder cut-out operation"
Other items (Adjusting screen)

10-312 WA470-7
10 Structure and function
Machine monitor system

Monitor Function (Action that starts when


Item Display location
display corresponding switch is pressed)
• Service menu "Phone number
entry"
Move between
Moves to left item • Service menu "Testing" →
items (left)
"Cylinder cut-out operation"
Other items (Adjusting screen)

Change between
Changes plus or minus of input value • Service menu "Adjusting"
plus and minus

Input decimal point Inputs decimal point • Service menu "Adjusting"

WA470-7 10-313
10 Structure and function
Machine monitor system

Operator mode functions (WA470-Q193-042-K-00-A)


• The functions which the operator can display or set by operating switches in normally displayed screen.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Category
(*1) Item
Display of KOMATSU logo
Password input screen
A Display of standard screen
Display of end screen
Display of the operation screen for engine shutdown secondary switch
Operation of air conditioner
Displaying and setting user menu
• “ECO Guidance“
B • “Machine Setting / Information“
• “KDPF Regeneration“
• “Maintenance“
• “Monitor Setting“
• “User Message“ (including KOMTRAX messages for user)
Display of ECO guidance
Display of warning (caution and action level)
C
Display of maintenance due time over
Display of KDPF regeneration
Checking function by LCD (Liquid Crystal Display)
D Function of checking service meter and odometer
Function of setting usage limitation/ changing password
*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to “ON“ position until the standard screen appears, and
the displays that appear after starting switch is turned to “OFF“ position.
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied.
D: Displays that require special switch operations.
a For how to operate the operator mode functions, see the Operation and Maintenance Manual or "Operator
mode (Outline)" section in Testing and adjusting.
a For the operating method of the engine start lock function, see "Password setting and canceling manual".
a For how to operate the function of changing the ID key registration, see the Operation and Maintenance
Manual.

10-314 WA470-7
10 Structure and function
Machine monitor system

Service mode functions (WA470-Q194-042-K-00-A)


• These functions are not displayed normally. A technician can display and set them by performing special
operations.
This mode is used for special setting, testing, adjusting, or troubleshooting.
• The main service mode functions are as follows.
Monitoring/Pre-defined
Monitoring/Custom
Mechanical Systems
Abnormality Record
Electrical Systems
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Machine Model Select
Option Select
Default
Unit
Auto Idle Stop Time Fixing
Cylinder Cut-out
Diagnostic Tests Regeneration for Service
KDPF Memory Reset
ECMV Automatic Compensation
T/M Initial Learning
T/M Initial Learning Reset
T/M Shift Point
T/M Shift Point Data Clear
Boom Angle Sensor for EPC (Raise)
Boom Angle Sensor for EPC (Lower)
Boom Raise Adjustment
Boom Lower Adjustment
Bucket Tilt Adjustment
Bucket Dump Adjustment
3rd Ext Adjustment
Adjustment 3rd Ret Adjustment
PCS Adjustment (Push)
PCS Adjustment (Pull)
Change of Boom Lever Pattern
Change of Bucket Lever Pattern
Boom Stop Modulation
2-Stage Low Idle Throttle Position
Loader Pump Displacement
Steering Pump Displacement
Fan Reverse Cycle
Fan Reverse Duration
ECSS Operating Speed
Fan 100% Mode
No Injection
Terminal Status
KOMTRAX Settings GPS & Communication Status
Modem Status
Service Message

a For operating method of the service mode functions, see "Service mode" section in Testing and adjusting.

WA470-7 10-315
10 Structure and function
Machine monitor system

Switch panel (HM300-Q1C0-042-K-00-A)

Input/output signals of switch panel (WA380-Q1A1-03C-K-00-A)


AMP-6P [ CN-MOM1]
Pin No. Signal name Input/output signal
1 Switch panel power supply (+12 V) Input
2 GND (Switch panel power supply) ―
3 LIN Input/Output
4 Switch panel continuous power supply (+5.6 V) Input
5 External starting signal (for switch panel) Output
6 Switch panel built-in buzzer Input

10-316 WA470-7
10 Structure and function
Rear view monitor system

Rear view monitor system (HM300-Q162-041-K-00-A)

Function (HM300-Q162-042-K-00-A)

• The rear view monitor system mainly consists of the rear view monitor, rear view camera, and monitor
controller.
1. Rearview monitor
Displays the rear view camera image to the operator according to the setting of the rear view monitor
controller (guide lines, display of reverse-interlock, luminance, etc.)
2. Rear view camera
Transmits the taken images to the rear view monitor.
3. Monitor controller
Sends the contents of change of the rear view monitor setting to the monitor.

WA470-7 10-317
10 Structure and function
Rear view monitor system

Rear view monitor (HM300-Q16D-042-K-00-A)

Precautions for using rear view monitor


• The reference lines must be re-adjusted in the following cases.
1. When the machine dimensions are changed because of replacement of tires, installation of optional
attachment, etc.
2. When the rear view camera is removed or its direction is changed because of damage etc.

Rear view monitor input/output signals (WA380-Q16D-03C-K-00-A)


AMP-12P [ CN-RVM1]
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 GND (continuous power supply) ―
3 Service connector external start signal Input
4 (*1) ―
5 Rear view monitor brightness adjustment switch + Input
6 Rear view monitor brightness adjustment switch - Input
7 Shift lever R signal Input
Monitor brightness selector switch
8 Input
(Night mode signal)
9 LIN Input/Output
10 (*1) ―
11 (*1) ―
12 Key switch ACC signal Input
*1: Never connect these pins. Malfunctions or failures may occur.
AMP-8P [ CN-RVM2]
Pin No. Signal name Input/output signal
1 Rear view camera power supply output Output

10-318 WA470-7
10 Structure and function
Rear view monitor system

2 Rear view camera NTSC signal Input


3 (*1) ―
4 (*1) ―
5 GND (rear view camera power supply) ―
6 (*1) ―
7 (*1) ―
8 GND (rear view camera shield) ―
*1: Never connect these pins. Malfunctions or failures may occur.
Rear view camera (HM300-Q162-042-K-01-A)

Rear view camera input/output signals (WA380-Q162-03C-K-00-A)


DT-T-8P [ CN-RVC_1]
Pin No. Signal name Input/output signal
1 Rear view camera power supply Input
2 Rear view camera NTSC signal output Output
3 (*1) ―
4 GND (rear view camera power supply) ―
*1: Never connect these pins. Malfunctions or failures may occur.

WA470-7 10-319
10 Structure and function
KOMTRAX system

KOMTRAX system (HM300-Q210-042-K-00-A)

• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna, and GPS antenna.
• This system transmits various machine information by use of the radio communication. KOMTRAX
operator can refer this information and provide various services to the customers.
• Following information can be transmitted from the KOMTRAX system.
1. Position information
2. Operation information (service meter, odometer, etc.)
3. Alarm and failure information
4. Fuel consumption information
5. Maintenance information
6. Machine working condition information
a To provide the services, you need to establish radio station for KOMTRAX separately.
KOMTRAX terminal (HM300-Q220-042-K-00-A)
Model: TC330

1. LED lamp display


2. GPS antenna connection port

10-320 WA470-7
10 Structure and function
KOMTRAX system

3. Machine wiring harness connection port (CN1A)


4. Machine wiring harness connection port (CN1B)
5. Communication antenna connection port

Input and output signals of KOMTRAX terminal (HM300-Q220-03C-K-00-A)

CN1A[CN-KOM1]
Input/output
Pin No. Signal name
signal
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 CAN2_H Input/Output
11 CAN2_L Input/Output
12 (*1) —
13 (*1) —
14 External starting signal Input/Output
15 System operating lamp Output
16 (*1) —
17 (*1) —
18 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

CN1B[CN-KOM2]
Input/output
Pin No. Signal name
signal
1 GND (continuous power supply) —
2 GND (continuous power supply) —
3 Starting switch ACC signal Input
4 Alternator R signal Input
5 (*1) —
6 Continuous power supply (24 V) Input
7 Continuous power supply (24 V) Input
8 (*1) —
9 (*1) —
10 (*1) —
11 Starting switch C signal Input
12 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

Function (D65-Q220-042-K-01-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of “KOMTRAX setting“ in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.

WA470-7 10-321
10 Structure and function
KOMTRAX system

• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.

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10 Structure and function
System component parts

System component parts (ALL-RA1C-001-K-00-A)

Engine controller (PC220-AP70-041-K-00-A)

Engine controller input and output signals (PC400-AP70-03C-K-00-A)


• The following is the list of the symbols used for signal classification in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
Pin No. Signal name Signal category
1 (*1) –
2 Engine oil pressure sensor B
3 Crankcase pressure sensor B
4 (*1) –
5 Charge temperature sensor B
6 Intake temperature MAF sensor B
7 CAN_C(+) E
8 CAN_B(+)(KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) –
11 (*1) –
12 (*1) –
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
16 Ambient pressure sensor B

WA470-7 10-323
10 Structure and function
System component parts

Pin No. Signal name Signal category


17 CAN_C(-) E
18 CAN_B(-)(KOMNET/r) E
19 (*1) –
20 (*1) –
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow sensor B
24 (*1) –
25 (*1) –
26 Ne (crankshaft) speed sensor (+) B
27 (*1) –
28 (*1) –
29 (*1) –
30 (*1) –
31 (*1) –
32 (*1) –
33 (*1) –
34 (*1) –
35 (*1) –
36 Sensor power supply (5 V) A
37 NE (crankshaft) speed sensor (-) C
38 (*1) –
39 (*1) –
40 (*1) –
41 (*1) –
42 (*1) –
43 Injector #4 (+) D
44 Injector #5 (+) D
45 Injector #6 (+) D
46 Injector #3 (+) D
47 Injector #2 (+) D
48 Injector #1 (+) D
49 (*1) –
50 (*1) –
51 (*1) –
52 (*1) –
53 Injector #4 (–) C
54 Injector #5 (–) C
55 Injector #6 (–) C
56 Injector #3 (–) C
57 Injector #2 (–) C
58 Injector #1 (–) C
59 GND C
60 Sensor power supply (5 V) A
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
Pin No. Signal name Input/output
1 Supply pump #2 (–) C
2 Supply pump #2 (+) D
3 (*1) –
4 Supply pump #1 (–) C

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10 Structure and function
System component parts

Pin No. Signal name Input/output


5 Supply pump #1 (+) D
6 EGR actuator (+) D
7 (*1) –
8 Fuel dozer solenoid valve #2 (+) D
9 Fuel dozer solenoid valve #1 (+) D
10 KVGT actuator (+) D
11 (*1) –
12 (*1) –
13 (*1) –
14 (*1) –
15 (*1) –
16 EGR actuator (-) C
17 (*1) –
18 GND C
19 (*1) –
20 KVGT actuator (-) C
21 GND C
22 (*1) –
23 (*1) –
24 CAN_B(+) E
25 CAN_B(-) E
26 (*1) –
27 (*1) –
28 (*1) –
29 (*1) –
30 Power supply of dosing fuel pressure sensor (5 V) A
31 Power supply of common rail pressure sensor (5 V) A
32 KVGT speed sensor (+) B
33 KVGT speed sensor (-) C
34 (*1) –
35 (*1) –
36 Dosing fuel pressure sensor B
37 (*1) –
38 KVGT position sensor B
39 (*1) –
40 (*1) –
41 (*1) –
42 (*1) –
43 (*1) –
44 (*1) –
45 (*1) –
46 (*1) –
47 GND C
48 (*1) –
49 (*1) –
50 HC dozing solenoid (+) D
51 (*1) –
52 (*1) –
53 (*1) –
54 (*1) –
55 Common rail pressure sensor B
56 (*1) –

WA470-7 10-325
10 Structure and function
System component parts

Pin No. Signal name Input/output


57 (*1) –
58 (*1) –
59 EGR valve lift sensor B
60 HC dozing solenoid (-) C
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(3)[CN-CE03]
Pin No. Signal name Input/output
1 Electric power supply (24 V) A
2 Electric power supply (24 V) A
3 Starting switch ACC signal B
4 Electrical intake air heater relay (+) D
5 (*1) –
6 (*1) –
7 (*1) –
8 (*1) –
9 System operating lamp (in-use signal) D
10 (*1) –
11 Unswitched power supply (24 V) A
12 Unswitched power supply (24 V) A
13 (*1) –
14 Dozing pump relay drive D
15 (*1) –
16 (*1) –
17 CAN_A(+)(KOMNET/c) E
18 CAN_A(-)(KOMNET/c) E
19 Sensor GND C
20 (*1) –
21 GND (return from power supply) C
22 GND (return from power supply) C
23 (*1) –
24 (*1) –
25 (*1) –
26 (*1) –
27 (*1) –
28 (*1) –
29 (*1) –
30 (*1) –
31 GND (return from power supply) C
32 GND (return from power supply) C
33 (*1) –
34 (*1) –
35 (*1) –
36 (*1) –
37 (*1) –
38 (*1) –
39 (*1) –
40 (*1) –
41 Fuel control dial GND C
42 Fuel control dial power supply (5 V) A
43 KDPF pressure sensor GND C
44 (*1) –

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System component parts

Pin No. Signal name Input/output


45 KDOC inlet temperature sensor B
46 (*1) –
47 (*1) –
48 KDOC outlet temperature sensor B
49 (*1) –
50 (*1) –
51 Fuel control dial B
52 KDPF pressure sensor power supply (5 V) A
53 (*1) –
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 (*1) –
57 (*1) –
58 KDPF outlet pressure sensor B
59 (*1) –
60 (*1) –
*1: Never connect these pins. Malfunctions or failures may occur.
Work equipment controller (WA380-PT10-041-K-00-A)

Input and output signals of work equipment controller (WA380-PT10-03C-K-00-A)


DEUTSCH-24P [CN-L71]
Pin No. Signal name Input/output signal
1 Joystick lever position B Input
2 Boom lever B Input
3 Steering pump oil pressure sensor Input
4 Signal GND ―
5 (*1) ―

WA470-7 10-327
10 Structure and function
System component parts

Pin No. Signal name Input/output signal


6 (*1) ―
7 Joystick lever potentiometer A Input
8 Boom lever A Input
9 Oil pressure sensor of work equipment pump Input
10 (*1) ―
11 (*1) ―
12 Emergency steering pump oil pressure sensor Input
13 (*1) -
14 Bucket lever B Input
15 (*1) ―
16 (*1) ―
17 (*1) ―
18 (*1) ―
19 (*1) ―
20 Bucket lever A Input
21 (*1) ―
22 Potentiometer power supply (5 V) Output
23 (*1) ―
24 2-stage low idle switch Input
*1: Never connect these pins. Malfunctions or failures may occur.
DEUTSCH-40P (1) [CN-L72]
Pin No. Signal name Input/output signal
1 Potentiometer power supply (5 V) Output
2 (*1) ―
3 Remote positioner switch (boom) Input
4 (*1) ―
5 4th lever B Input
6 Lift cylinder bottom oil pressure sensor Input
7 (*1) ―
8 Emergency steering relay Output
9 Bucket tilt detent Output
10 (*1) ―
11 (*1) ―
12 Remote positioner switch (bucket) Input
13 (*1) ―
14 (*1) ―
15 4th lever A Input
16 Lift cylinder head oil pressure sensor Input
17 (*1) ―
18 Boom raise detent Output
19 Work equipment lock solenoid Output
20 (*1) ―
21 (*1) ―
22 CAN-L (KOMNET/c) Input/Output
23 CAN-L (KOMNET/r) Input/Output
24 External starting signal Input
25 3rd lever B Input
26 Boom potentiometer Input
27 Joystick steering HI/LO selector switch Input
28 Work equipment lock pilot monitor Output
29 (*1) ―

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10 Structure and function
System component parts

Pin No. Signal name Input/output signal


30 (*1) ―
31 (*1) ―
32 CAN-H (KOMNET/c) Input/Output
33 CAN-H (KOMNET/r) Input/Output
34 (*1) ―
35 3rd lever A Input
36 Bucket potentiometer Input
37 Power mode selector switch (E) Input
38 (*1) ―
39 (*1) ―
40 (*1) ―
*1: Never connect these pins. Malfunctions or failures may occur.

WA470-7 10-329
10 Structure and function
System component parts

DEUTSCH-40P (2) [CN-L73]


Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 Power supply (24 V) Input
3 GND (solenoid) ―
4 (*1) ―
5 4th valve retraction EPC Output
6 Boom RAISE EPC Output
7 Joystick lever left EPC Output
8 (*1) ―
9 Multicoulper release Input
10 Starting switch C signal Input
11 Continuous power supply (24 V) Input
12 Power supply (24 V) Input
13 GND (solenoid) ―
14 Starting switch ACC signal Input
15 4th valve extension EPC Output
16 Boom LOWER EPC Output
17 Joystick lever right EPC Output
18 (*1) ―
19 Battery relay Input
20 Work equipment lock switch Input
21 GND (controller) ―
22 Power supply (24 V) Input
23 GND (solenoid) ―
24 Starting switch ACC signal Input
25 Steering pump EPC Output
26 3rd valve retraction EPC Output
27 Bucket DUMP EPC Output
28 Joystick EPC cut relay Output
29 (*1) ―
30 Emergency steering switch Input
31 GND (controller) ―
32 GND (controller) ―
33 GND (controller) ―
34 System operating lamp Input
35 Work equipment pump EPC Output
36 3rd valve extension EPC Output
37 Bucket TILT EPC Output
38 (*1) ―
39 (*1) ―
40 Multicoupler release switch failure Input
*1: Never connect these pins. Malfunctions or failures may occur.

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10 Structure and function
System component parts

Transmission controller (WA380-CV10-041-K-00-A)

Transmission controller input and output signals (WA380-CV10-03C-K-00-A)


DEUTSCH-24P [CN-L61]
Pin No. Signal name Input/output signal
1 Torque converter outlet pressure sensor Input
2 (*1) ―
3 Torque converter oil temperature sensor Input
4 Signal GND ―
5 Gear speed switch 4th Input
6 Joystick downshift switch Input
7 Torque converter inlet pressure sensor Input
8 Directional lever position (analogue) Input
9 Transmission oil temperature sensor Input
10 (*1) ―
11 Gear speed switch 3rd Input
12 Joystick upshift switch Input
13 Transmission cut-off oil pressure sensor Input
14 (*1) ―
15 (*1) ―
16 Sensor power supply (24 V) Output
17 Gear speed switch 2nd Input
18 Shift mode manual Input
19 (*1) ―
20 Hydraulic oil temperature sensor Input
21 Analog GND ―
22 Directional lever power supply (5 V) Output

WA470-7 10-331
10 Structure and function
System component parts

Pin No. Signal name Input/output signal


23 Gear speed switch 1st Input
24 Shift mode H Input
*1: Never connect these pins. Malfunctions or failures may occur.
DEUTSCH-40P (1) [CN-L62]
Pin No. Signal name Input/output signal
1 (*1) ―
2 ECMV fill switch R Input
3 ECMV fill switch 4th Input
4 (*1) ―
5 Directional selector switch (F) Input
6 Parking brake switch Input
7 ECMV fill switch 2nd Input
8 (*1) ―
9 (*1) ―
10 (*1) ―
11 (*1) ―
12 ECMV fill switch F Input
13 ECMV fill switch 3rd Input
14 (*1) ―
15 Directional lever (R) Input
16 Starting switch C signal Input
17 ECMV fill switch 1st Input
18 (*1) ―
19 Backup lamp relay Output
20 Transmission output shaft speed sensor Input
21 (*1) ―
22 CAN-L (KOMNET/c) Input/Output
23 CAN-L (KOMNET/r) Input/Output
24 External starting signal Input
25 Directional lever (N) Input
26 Directional selector switch (R) Input
27 Directional selector switch enable switch Input
28 Transmission cut-off switch built-in indicator Input
29 Pulse GND ―
30 Cooling fan speed sensor Input
31 (*1) ―
32 CAN-H (KOMNET/c) Input/Output
33 CAN-H (KOMNET/r) Input/Output
34 (*1) ―
35 Directional lever (F) Input
36 Directional selector switch (N) Input
37 E.C.S.S. switch Input
38 Torque converter lockup switch Input
39 Pulse GND ―
40 Transmission input speed sensor Input
*1: Never connect these pins. Malfunctions or failures may occur.

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10 Structure and function
System component parts

DEUTSCH-40P (2) [CN-L63]


Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 Power supply (24 V) Input
3 GND (solenoid) ―
4 Battery relay Output
5 ECMV R Output
6 ECMV 3rd Output
7 (*1) ―
8 Neutral safety relay Output
9 Kickdown switch Input
10 (*1) ―
11 Continuous power supply (24 V) Input
12 Power supply (24 V) Input
13 GND (solenoid) ―
14 Starting switch ACC signal Input
15 E.C.S.S. solenoid Output
16 ECMV 4th Output
17 (*1) ―
18 Parking brake relay Output
19 Shift hold switch Input
20 Transmission cut-off switch Input
21 GND (controller) ―
22 Power supply (24 V) Input
23 GND (solenoid) ―
24 Starting switch ACC signal Input
25 Cooling fan EPC Output
26 ECMV F Output
27 ECMV 1st Output
28 (*1) ―
29 (*1) ―
30 Transmission cut-off set switch Input
31 GND (controller) ―
32 GND (controller) ―
33 GND (controller) ―
34 System operating lamp Input
35 Cooling fan reverse rotation solenoid Output
36 ECMV L/U Output
37 ECMV 2nd Output
38 (*1) ―
39 (*1) ―
40 (*1) ―
*1: Never connect these pins. Malfunctions or failures may occur.

WA470-7 10-333
10 Structure and function
System component parts

Monitor controller (HM300-Q180-041-K-00-A)

Monitor controller input and output signals (WA380-Q180-03C-K-02-A)


AMP-81P [CN-MCM1 A]
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 GND (controller) ―
3 GND (controller) ―
4 Continuous power supply (24 V) Input
5 (*1) ―
6 Alternator R signal Input
7 (*1) ―
8 Fuel level sensor Input
9 Signal GND ―
10 Auto grease A Input
11 Starting switch C signal Input
12 Preheating Input
13 Signal GND ―
14 Right headlamp Input
15 Left turn signal lamp Input
16 Right turn signal lamp Input
17 Signal GND ―
18 Engine speed signal (pulse) Output
19 Personal lock relay Output
20 Alarm buzzer Output
21 (*1) ―
22 (*1) ―
23 (*1) ―

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10 Structure and function
System component parts

Pin No. Signal name Input/output signal


24 Starting switch ACC signal Input
25 (*1) ―
26 (*1) ―
27 Brake oil temperature sensor Output
28 (*1) ―
29 Seat belt Input
30 Unit selection Input
31 Engine shutdown secondary switch Input
32 (*1) ―
33 Monitor brightness selector switch Input
34 Clearance lamp switch Input
35 Auto grease B Input
36 Signal GND ―
37 (*1) ―
38 (*1) ―
39 (*1) ―
40 (*1) ―
41 (*1) ―
42 (*1) ―
43 Starting switch ACC signal Input
44 (*1) ―
45 (*1) ―
46 Battery electrolyte level sensor Input
47 (*1) ―
48 Coolant level sensor Input
49 Headlamp high beam Input
50 (*1) ―
51 (*1) ―
52 (*1) ―
53 Air cleaner clogging sensor Input
54 (*1) ―
55 (*1) ―
56 Travel speed signal (pulse) Output
57 System operating lamp Output
58 Tachograph power supply Output
59 (*1) ―
60 (*1) ―
61 (*1) ―
62 External starting signal Input
63 (*1) ―
64 (*1) ―
65 (*1) ―
66 (*1) ―
67 Load meter subtotal switch Input
68 Load meter sub cancel switch Input
69 Engine oil level sensor Input
70 (*1) ―
71 Parking brake oil pressure switch Input
72 Rear brake oil pressure switch Input
73 Front brake oil pressure switch Input
74 (*1) ―
75 (*1) ―

WA470-7 10-335
10 Structure and function
System component parts

Pin No. Signal name Input/output signal


76 (*1) ―
77 (*1) ―
78 (*1) ―
79 (*1) ―
80 (*1) ―
81 (*1) ―

*1: Never connect these pins. Malfunctions or failures may occur.


AMP-40P [CN-MCM1 B]
Pin No. Signal name Input/output signal
82 Switch panel built-in buzzer Output
83 (*1) ―
84 (*1) ―
85 (*1) ―
86 Load meter printer BUSY Input
87 (*1) ―
88 (*1) ―
89 CAN-L (KOMNET/c) Input/Output
90 (*1) ―
91 Caution LED power supply Output
92 (*1) ―
93 (*1) ―
94 Load meter printer GND ―
95 (*1) ―
96 (*1) ―
97 CAN-H (KOMNET/c) Input/Output
98 Continuous power supply (5.6 V) Output
99 GND ―
100 (*1) ―
101 (*1) ―
102 Load meter printer TX Output
103 (*1) ―
104 (*1) ―
105 CAN-L (KOMNET/r) Input/Output
106 External starting signal Input
107 Power supply (12 V) Output
108 LIN Input/Output
109 (*1) ―
110 (*1) ―
111 (*1) ―
112 CAN-H (KOMNET/r) Input/Output
113 CAN-H (KOMNET/r) Input/Output
114 (*1) ―
115 (*1) ―
116 (*1) ―
117 (*1) ―
118 (*1) ―
119 (*1) ―
120 (*1) ―
121 (*1) ―
*1: Never connect these pins. Malfunctions or failures may occur.
JAE-8P [CN-MCM2]

10-336 WA470-7
10 Structure and function
System component parts

Pin No. Signal name Input/output signal


1 LC unit LVDS (+) Output
2 LC unit LVDS (-) Output
3 LC unit GND (power supply return) ―
4 LC unit backlight adjustment Output
5 LC unit power supply Output
6 LC unit ON/OFF control Output
7 LC unit backlight ON/OFF control Output
8 LC unit temperature sensor Output
*1: Never connect these pins. Malfunctions or failures may occur.
Work equipment electric lever (WA380-PK11-041-K-00-A)

a Do not disassemble this lever since it needs to be adjusted for maintaining the performance after
reassembly.

1. Boot
2. Sensor

WA470-7 10-337
10 Structure and function
System component parts

3. Detent solenoid
4. Connector

Function (WA380-PK11-042-K-02-A)

10-338 WA470-7
10 Structure and function
System component parts

Operating effort characteristics

"Boom LOWER", "Boom RAISE", and "Bucket TILT" operations

• The control lever is held at the three operation stroke ends of "Boom LOWER", "Boom RAISE", and
"Bucket TILT". (Electric detent)

"Bucket DUMP" operation

• Free return
Output voltage characteristics
• The operating angle (stroke) of the control lever is detected with the sensor and signal voltages are output
to the controller.
• Each sensor outputs two signal voltages which are opposite to each other as shown in the figure.

WA470-7 10-339
10 Structure and function
System component parts

10-340 WA470-7
10 Structure and function
System component parts

Throttle position sensor (WA380-AG22-041-K-00-A)

1. Pedal
2. Connector
3. Sensor

Function (WA470-AG22-042-K-00-A)
• This sensor, installed to the floor top, outputs accelerator signals and idle validation signals according to
the depressing angle of the accelerator pedal.

Accelerator signal
• The potentiometer in the sensor detects displacement of the accelerator pedal and outputs the variable
voltage through pin No. 2.

Idle validation signal


• The switch in the sensor detects the operating condition of the accelerator pedal. It outputs the signal input
to pin No. 5 from pin No. 4 while the accelerator pedal is released, and outputs the signal input to pin No. 6
from pin No. 4 while the accelerator pedal is depressed.

WA470-7 10-341
10 Structure and function
System component parts

Output characteristics

10-342 WA470-7
10 Structure and function
System component parts

Combination switch (WA380-CX10-041-K-00-A)

Structure
• The directional lever has three positions and the gear speed switch has four positions. The switch itself
does not have a detent mechanism, which is in the combination switch. Each switch is positioned with
pins at two places and fixed to the body with three screws. When each lever is operated to a desired
position, the switch connected with the shaft moves to supply the current to only its circuit.

Function (WA380-CX10-042-K-00-A)

No. Name Operation


1 Gear speed switch Selects gear speed.
2 Directional lever Selects forward or reverse travels and neutral.
Returns turn signal lever to neutral position automatically when steering wheel
3 Self-cancel is returned after turning to right or left.
4 Turn signal lever Operates turn signal lamps.
5 Dimmer switch Selects high or low beams of headlamp.
6 Lamp switch Lights up headlamp, clearance lamp, tail lamp, and instrument panel lamp.

WA470-7 10-343
10 Structure and function
System component parts

Operation (WA380-CX10-044-K-00-A)

• When directional lever (1) of the combination switch is operated, body (2) rotates.
• Slider (4) moves on control switch (5) via arm (3) of body (2). Slider (4) has magnet (6) in it.
• Control switch (5) has Hall elements (7), which are arranged on the circuit board and matched to each
position of forward and reverse travels.
• If the combination switch senses that magnet (6) comes just above Hall element (7) at each position, it
outputs the "F (Forward)", "N (Neutral)", or "R (Reverse)" signal according to the operation of directional
lever (1).
• At the same time, slider (9) moves on control switch (5) via arm (8) of body (2). Slider (9) has magnet (10)
in it.
• Hall elements (11) built in control switch (5) are arranged respectively on the circuit boards at each
position of forward and reverse travels and at the intermediate position between them.
• Hall elements (11) are in the voltage signal output circuit. When it is sensed that magnet (10) comes just
above each Hall element (11), the output signal voltage changes.
• The combination switch changes the output voltage of the analogue backup signal according to the
position of directional lever (1).
• If gear speed switch (13) is rotated around shaft (12) of the combination switch, slider (16) moves on
control switch (5) via shaft (14) and arm (15) connected to gear speed switch (13). Slider (16) has magnet
(17) in it.
• Control switch (5) has Hall elements (18), which are arranged on the circuit board and matched to each
position of the gear speeds.
• If the combination switch senses that magnet (17) comes just above Hall element (18) at each position, it
outputs the "1st", "2nd", "3rd", or "4th" signal according to the operation of gear speed switch (13).

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System component parts

Kickdown switch (WA380-CP22-001-K-00-A)


2-lever type (WA380-CP22-041-K-00-A)

1. Switch A (white harness)


2. Switch B (yellow harness)
3. Spring
4. Harness

Function (WA380-CP22-042-K-00-A)
• Switch A (1) installed to the boom control lever knob operates as a kickdown switch to downshift the gear.
• Switch A (1) is a momentary type switch, namely, its contacts are closed only while it is pressed.
Hold switch (WA380-CP25-001-K-00-A)
2-lever type (WA380-CP25-041-K-00-A)

1. Switch A (white harness)


2. Switch B (yellow harness)
3. Spring
4. Harness

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10 Structure and function
System component parts

Function (WA380-CP25-042-K-00-A)
• Switch B (2) installed to the boom control lever knob operates as a hold switch to hold the gear speed in
the auto-shift mode.
• Switch B (2) is a momentary type switch, namely, its contacts are closed only while it is pressed.

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System component parts

CAN terminating resistor (PC220-Q2V1-041-K-00-A)

CAN: Abbreviation for Controller Area Network

1. Connector (with built-in resistor)

Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z

Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
Front brake oil pressure switch (WA380-G41C-041-K-00-A)

1. Switch
2. Connector

Specification (WA380-G41C-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 5.39 ± 0.49 MPa {55 ± 5 kg/cm2}
Resetting (OFF) pressure: 4.41 ± 0.49 MPa {45 ± 5 kg/cm2}

Function (WA380-G41C-042-K-00-A)
• This sensor, installed to the inlet port of the front brake accumulator, senses the charge pressure in the
front brake circuit and turns the switch "ON" when the pressure exceeds the specified level.

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10 Structure and function
System component parts

Rear brake oil pressure switch (WA380-G41E-041-K-00-A)

1. Switch
2. Connector

Specification (WA380-G41E-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 5.39 ± 0.49 MPa {55 ± 5 kg/cm2}
Resetting (OFF) pressure: 4.41 ± 0.49 MPa {45 ± 5 kg/cm2}

Function (WA380-G41E-042-K-00-A)
• This sensor, installed to the inlet port of the rear brake accumulator, senses the charge pressure in the
rear brake circuit and turns the switch "ON" when the pressure exceeds the specified level.
Stop lamp oil pressure switch (WA380-G7B4-041-K-00-A)

1. Switch
2. Connector

Specification (WA380-G7B4-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 0.59 ± 0.098 MPa {6 ± 1.0kg/cm 2}
Resetting (OFF) pressure: 0.39 ± 0.049 MPa {4 ± 0.5 kg/cm2}

Function (WA380-G7B4-042-K-00-A)
• This sensor, installed to the brake valve, senses the actuating pressure in the brake circuit and turns the
switch "ON" when the pressure exceeds the specified level.

10-348 WA470-7
10 Structure and function
System component parts

Parking brake oil pressure switch (WA380-GP2F-041-K-00-A)

1. Switch
2. Connector

Specification (WA380-GP2F-030-K-00-A)
Contact type: Normally open
Operating (ON) pressure: 0.59 ± 0.049 MPa {6 ± 0.5 kg/cm 2}
Resetting (OFF) pressure: 0.39 ± 0.049 MPa {4 ± 0.5 kg/cm2}

Function (WA380-GP2F-042-K-00-A)
• This sensor, installed to the parking solenoid valve of the transmission control valve, senses the actuating
pressure in the parking brake circuit and turns the switch "ON" when the pressure exceeds the specified
level.

WA470-7 10-349
10 Structure and function
Sensor

Sensor (ALL-E700-001-P-00-A)

Ambient pressure sensor (ENG-AAP2-041-K-00-A)

1. Connector
2. Sensor

Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.

Output characteristics

10-350 WA470-7
10 Structure and function
Sensor

Engine oil pressure sensor (PC400-ABK5-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (PC400-ABK5-042-K-00-A)
• This oil pressure sensor, installed in the cylinder block, It detects engine oil pressure to output variable
voltage.
Charge (Boost) pressure sensor (PC400-AAM3-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (PC400-AAM3-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine boost pressure to output
signals as a variable voltage.
a a "Chargepressure" is the turbocharged pressure of a turbocharged engine. It is also referred to as a
"boost pressure".

WA470-7 10-351
10 Structure and function
Sensor

Charge (Boost) temperature sensor (D155-AAM4-041-K-00-A)

Function (D155-AAM4-042-K-00-A)
• The charge (boost) temperature sensor detects the intake air temperature (boost temperature) and sends
it to the engine controller.
• The sensor unit is a thermistor the resistance of which changes according to the temperature. The engine
controller applies voltage to the thermistor and detects the temperature by the voltage divided by the
resistance in the computer and the resistance of the thermistor.
Coolant temperature sensor (ENG-BA87-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (WA470-BA87-042-K-00-A)
• This sensor, installed on the cylinder block of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.

10-352 WA470-7
10 Structure and function
Sensor

Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (WA470-AG42-042-K-00-A)
• This sensor, installed to the flywheel housing, outputs the pulse voltage according to the rotation of the
gear.

WA470-7 10-353
10 Structure and function
Sensor

Bkup (camshaft) speed sensor (ENG125-AG62-041-K-00-A)

Function (ENG125-AG62-042-K-00-A)
• Like the NE speed sensor, it utilizes 0 to 5 V pulses that result from the change in the magnetic lines
passing through the sensor.
• The disc gear installed to the central part of the camshaft of the high-pressure pump has teeth (cut parts)
around it at intervals of 120 deg.
• In addition to the above teeth, one more tooth is installed. Accordingly, seven pulses are generated every
two revolutions of the engine.
• The standard pulse of No. 1 cylinder is recognized by the combination of the NE speed sensor pulse and
Bkup speed sensor pulse.
Common rail pressure sensor (ENG-AE28-041-K-00-A)

1. Connector
2. Sensor

10-354 WA470-7
10 Structure and function
Sensor

Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
EGR valve lift sensor (ENG125-A9S2-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector

Function (ENG125-A9S2-042-K-00-A)
• The sensor, installed to EGR valve on the engine, detects the EGR valve opening to output the
corresponding variable voltage.

Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.

WA470-7 10-355
10 Structure and function
Sensor

KVGT speed sensor (ENG125-AAQ4-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. Sensor
2. O-ring
3. Connector

Function (ENG125-AAQ4-042-K-00-A)
• This sensor, installed to KVGT in the engine, outputs the pulse voltage by means of the rotation of KVGT
turbine.

10-356 WA470-7
10 Structure and function
Sensor

KVGT position sensor (ENG-AAQ3-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector

Function (ENG-AAQ3-042-K-00-A)
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.

Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.

WA470-7 10-357
10 Structure and function
Sensor

Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)

1. Connector
2. O-ring
3. Sensor

Function (ENG-A96H-042-K-00-A)
• This sensor is installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.

10-358 WA470-7
10 Structure and function
Sensor

KDPF differential pressure and outlet pressure sensor (ENG-A9HL-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor

Function (ENG-A9HL-042-K-00-A)
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
corresponding variable voltage.
• The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).

WA470-7 10-359
10 Structure and function
Sensor

KDOC inlet temperature sensor (ENG-A9HG-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor
2. Connector

Function (ENG-A9HG-042-K-00-A)
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDOC outlet temperature sensor (ENG-A9HH-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor
2. Connector

Function (ENG-A9HH-042-K-00-A)
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.

10-360 WA470-7
10 Structure and function
Sensor

KDPF outlet temperature sensor (ENG-A9HJ-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Sensor
2. Connector

Function (ENG-A9HJ-042-K-00-A)
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
Crankcase pressure sensor (ENG-A18C-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.

WA470-7 10-361
10 Structure and function
Sensor

Engine oil level sensor (ENG-AB45-041-K-00-A)

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

Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns “OFF“ by the lowered float, if the oil level
becomes lower than specified.
Dosing fuel pressure sensor (PC400-A9JC-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (PC400-A9JC-042-K-00-A)
• This sensor, which is installed to the dosing fuel solenoid valve assembly, detects the pressure of the fuel
supplied to output the corresponding variable voltage.

10-362 WA470-7
10 Structure and function
Sensor

Transmission input speed sensor (WA470-CNB1-041-K-00-A)

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

Function (WA470-CNB1-042-K-00-A)
• This sensor, installed to the left side of the transmission rear case, outputs the pulse voltage according to
the rotation of the gear.

WA470-7 10-363
10 Structure and function
Sensor

Transmission output shaft speed sensor (WA380-CNA1-041-K-00-A)

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

Function (WA470-CNA1-042-K-00-A)
• This sensor, installed to the right side of the transmission front case, outputs the pulse voltage according
to the rotation of the gear.
Cooling fan speed sensor (D65-B750-041-K-00-A)

1. Sensor
2. Connector

Function (D65-B750-042-K-00-A)
• This sensor is installed to the cooling fan motor.
• This sensor detects the gear speed and outputs corresponding pulse signals.

10-364 WA470-7
10 Structure and function
Sensor

Torque converter oil temperature sensor (WA380-CDK4-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function (WA380-CDK4-042-K-00-A)
• This sensor is installed to the block on the right side of the transmission rear case. It outputs a resistance
change signal of the thermistor for the temperature change.
Transmission oil temperature sensor (WA380-CH18-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function (WA470-CH18-042-K-00-A)
• This sensor, installed to the transmission rear case, outputs a resistance change signal of the thermistor
for the temperature change.

WA470-7 10-365
10 Structure and function
Sensor

Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function (WA380-PMT1-042-K-00-A)
• This sensor is installed to the block of the hydraulic tank return line. It outputs a resistance change signal
of the thermistor for the temperature change.
Brake oil temperature sensor (WA380-GGD1-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function (WA380-GGD1-042-K-00-A)
• This sensor is installed to the rear axle. It outputs a resistance change signal of the thermistor for the
temperature change.

10-366 WA470-7
10 Structure and function
Sensor

Torque converter inlet pressure sensor (WA470-CDL5-041-K-00-A)

1. Sensor
2. Lead wire
3. Connector

Function (WA470-CDL5-042-K-00-A)
• This sensor, installed to the block on the left side of the transmission rear case, detects the torque
converter in let pressure and outputs it as a variable voltage.

Output characteristics

WA470-7 10-367
10 Structure and function
Sensor

Torque converter outlet pressure sensor (WA470-CDL6-041-K-00-A)

1. Sensor
2. Lead wire
3. Connector

Function (WA470-CDL6-042-K-00-A)
• This sensor, installed to the block on the right side of the transmission rear case, detects the torque
converter outlet pressure and outputs it as a variable voltage.

Output characteristics

10-368 WA470-7
10 Structure and function
Sensor

Oil pressure sensor of work equipment pump (WA380-PPD1-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function (WA380-PPD1-042-K-00-A)
• This sensor is installed to the work equipment control valve. It senses the pump delivery pressure and
outputs a variable voltage for it.

Output characteristics

WA470-7 10-369
10 Structure and function
Sensor

Steering pump oil pressure sensor (WA380-F7C1-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function (WA380-F7C1-042-K-00-A)
• This sensor is installed to the block of the steering pump delivery line. It senses the pump delivery
pressure and outputs a variable voltage for it.

Output characteristics

10-370 WA470-7
10 Structure and function
Sensor

Emergency steering pump pressure sensor (WA380-F9SA-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function (WA380-F9SA-042-K-00-A)
• This sensor, installed to the block of the emergency steering pump discharge port, detects the pump
discharge pressure and outputs a variable voltage for it.

Output characteristics

WA470-7 10-371
10 Structure and function
Sensor

Lift cylinder bottom oil pressure sensor (WA380-L261-041-K-00-A)

1. Plug
2. Sensor
3. Connector

Function (WA380-L261-042-K-00-A)
• This sensor is installed to the line piping of the lift cylinder bottom. It senses the oil pressure in the cylinder
bottom and outputs a variable voltage for it.

Output characteristics

10-372 WA470-7
10 Structure and function
Sensor

Transmission cut-off oil pressure sensor (WA380-CP61-041-K-00-A)

1. Sensor
2. Lead wire
3. Connector

Function (WA380-CP61-042-K-00-A)
• This sensor is installed to the front brake circuit tube under the floor. It senses the brake actuating
pressure and outputs a variable voltage.

Output characteristics

WA470-7 10-373
10 Structure and function
Sensor

Coolant level sensor (WA380-B252-041-K-00-A)

1. Reservoir tank
2. Float
3. Sensor
4. Connector

Function (WA380-B252-042-K-00-A)
• This sensor is installed to the ladder on the right side of the machine. When the coolant level lowers below
the specified level, the float of this sensor lowers and turns the switch "OFF".

10-374 WA470-7
10 Structure and function
Sensor

Fuel level sensor (WA380-AD41-041-K-00-A)

1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer

Function (WA380-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level. The movement of the float moves the variable resistor through the arm and the resistance
change is converted into the change of the power supply voltage, which is output as a signal voltage.

WA470-7 10-375
10 Structure and function
Sensor

Air cleaner clogging sensor (WA380-A968-041-K-00-A)

1. Boss
2. Switch
3. Conduit
4. Wire
5. Connector

Function (PC-A968-042-K-00-A)
• This sensor is installed on the air cleaner outlet side. The switch is turned to “ON“ position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).

10-376 WA470-7
10 Structure and function
Sensor

Boom potentiometer (WA380-L6W6-041-K-00-A)

1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector

Function (WA380-L6W6-042-K-00-A)
• This potentiometer is installed to the front frame. The movement of the boom moves the variable resistor
through the link installed to the boom and the resistance change is converted into the change of the power
supply voltage, which is output as a signal voltage.

Output characteristics

WA470-7 10-377
10 Structure and function
Sensor

Bucket potentiometer sensor (WA380-LENB-041-K-00-A)

1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector

Function (WA380-LENB-042-K-00-A)
• This potentiometer is installed to the pin connecting bell crank and boom. The movement of the bucket
moves the variable resistor through the link installed to the bell crank and the resistance change is
converted into the change of the power supply voltage, which is output as a signal voltage.

Output characteristics

10-378 WA470-7
SHOP MANUAL

WHEEL LOADER
WA470-7
Model Serial Number

WA470-7 10001 and up

20 Standard value tables


4 20 Standard value tables

WA470-7 20-1
20 Standard value tables
Table of contents

Table of contents (ALL-0310-002-A-00-A)


20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-18

20-2 WA470-7
20 Standard value tables
Standard value table for engine

Standard service value table (ALL-A000-001-K-00-A)

Standard value table for engine (WA470_7-A000-033-K-00-A)

Machine model WA470-7


Engine SAA6D125E-6
Classification

Standard value
Item Measurement condition Unit for new Repair limit
machine

• Coolant temperature: 60 to High idle rpm 2,170 ± 50 ―


Engine speed 102°C Low idle rpm 800 (+ 50/-0) ―
• Power mode Rated speed rpm 2,000 ―
• Coolant temperature: 60 to 102°C
Boost • Torque converter oil temperature: 60 to 80° kPa Min. 153 127
pressure C {mmHg} {Min. 1,150} {950}
• Torque converter stall
• Coolant Engine At high idle Bosch ―
Max. 1.0
temperature: outlet index
60 to 102°C (between
• After kept for turbochar- Torque Bosch
5 seconds at ger and Max. 1.5 ―
Exhaust gas converter stall index
normal KDPF inlet)
color
condition
Bosch
• Torque KDPF outlet At high idle Max. 0.5 ―
index
converter oil (exhaust
temperature: pipe outlet) Torque Bosch
Max. 0.5 ―
60 to 80°C converter stall index
Valve Intake valve mm 0.33 ―
• At cold
clearance Exhaust valve mm 0.71 ―
• Engine oil temperature: 40
Compression to 60°C Compression MPa Min. 2.9 2.0
Engine

pressure • Engine speed: 200 to 280 pressure {kg/cm2} {Min. 30} {20}
rpm
• Coolant temperature: 60 to 102°C
• Torque converter oil temperature: 60 to 80° kPa
Blowby Max. 1.96 3.92
pressure C {mmH2-
• With torque converter stalled {Max. 200} {400}
O}
• KCCV circuit disconnected
• Coolant temperature: Min. MPa 0.29 to 0.69 0.18
60°C High idle
{kg/cm2} {3.0 to 7.0} {1.8}
Engine oil • EOS5W30-LA
pressure • EOS5W40-LA MPa Min. 0.08 0.05
• EO10W30-LA Low idle
{kg/cm2} {Min. 0.8} {0.5}
• EO15W40-LA
EGR valve oil MPa Min. 1.43 1.43
High idle
pressure and • Coolant temperature: 60 to {kg/cm2} {Min. 14.6} {14.6}
KVGT oil 102°C MPa Min. 1.18 1.18
pressure Low idle
{kg/cm2} {Min. 12.0} {12.0}
Oil
Whole speed range (inside oil pan) °C 90 to 110 120
temperature
• Between crankshaft pulley and alternator
Alternator belt pulley
mm 13 to 16 13 to 16
tension • Deflection when pressed with finger at 59
N {6 kg}

WA470-7 20-3
20 Standard value tables
Standard value table for engine

Machine model WA470-7


Engine SAA6D125E-6
Classification

Standard value
Item Measurement condition Unit for new Repair limit
machine

Air • Between compressor pulley and fan pulley


conditioner • Deflection when pressed with finger at 98 mm 25 to 26 25 to 26
compressor N {10 kg}
belt tension
Others
Machine model WA470-7
Engine SAA6D125E-6
Classification

Standard value
Item Measurement condition Unit for new Repair limit
machine

compression • Coolant temperature: 60 to 102°C MPa 0.15 to 0.3 0.15 to 0.3


pressure • Engine at high idle {kg/cm2} {1.5 to 3.0} {1.5 to 3.0}
Engine speed:
― Max. 960
1,600 rpm
Engine speed:
― Max. 1,020
1,700 rpm
Fuel return
• Coolant temperature: 60 to Engine speed:
Engine

rate from cc/min ― Max. 1,080


102°C 1,800 rpm
injector
Engine speed:
― Max. 1,140
1,900 rpm
Engine speed:
― Max. 1,200
2,000 rpm
• Coolant temperature: 60 to 102°C
Leakage from • Torque converter oil temperature: 60 to 80°
pressure cc/min ― Max. 10
C
limitter • Torque converter stall

20-4 WA470-7
20 Standard value tables
Standard value table for machine

Standard value table for machine (WA470_7-0000-033-K-00-A)


Directional lever
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
NEUTRAL o • Engine stopped 9.0 ± 1.0 9.0 ± 1.7
Operating N {kg}
FORWARD/ • Measure at center of lever
effort {0.92 ± 0.1} {0.92 ± 0.17}
REVERSE knob stem.
• Measure at 10 mm from lever
NEUTRAL o top.
Stroke FORWARD/ • Tilt angle of steering column: mm 39 ± 6 39 ± 12
REVERSE Deepest position (monitor
side)

Gear speed switch


Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
0.39 ± 0.03 0.36 ± 0.12
1st o 2nd
{4 ± 0.3} {3.7 ± 1.2}
Operating 0.39 ± 0.03 0.36 ± 0.12
2nd o 3rd • Engine stopped N {kg}
effort {4 ± 0.3} {3.7 ± 1.2}
0.39 ± 0.03 0.36 ± 0.12
3rd o 4th
{4 ± 0.3} {3.7 ± 1.2}
1st io 2nd 20 ± 2 20 ± 4
Rotation
2nd io 3rd deg 20 ± 2 20 ± 4
angle
3rd io 4th 20 ± 2 20 ± 4

WA470-7 20-5
20 Standard value tables
Standard value table for machine

Work equipment control lever


Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
HOLD o 6.5 to 11.4
Max. 17.1 {1.74}
RAISE (*1) {0.66 to 1.16}
RAISE (*2) o 9.8 to 20.6 4.9 to 30.5
HOLD {1.0 to 2.10} {0.5 to 3.11}
HOLD o 6.5 to 11.4
Max. 17.1 {1.74}
LOWER (*1) {0.66 to 1.16}
Boom
LOWER o
Operating effort

- -
HOLD
LOWER o 11.4 to 20.2
• Engine speed: Low idle N {kg} Max. 30.3 {3.09}
FLOAT {1.16 to 2.06}
FLOAT (*2) o 9.8 to 20.6 4.9 to 30.5
HOLD {1.0 to 2.0} {0.5 to 3.11}
HOLD o 7.5 to 17.7
Max. 26.6 {2.7}
DUMP {0.76 to 1.80}
HOLD o TILT 6.5 to 11.4
Bucket Max. 17.1 {1.74}
(*1) {0.66 to 1.16}
TILT (*2) o 9.8 to 20.6 4.9 to 30.5
HOLD {1.0 to 2.10} {0.5 to 3.11}
HOLD io
RAISE (*2) 44.5 ± 2.2 44.5 ± 4.4
HOLD io
Boom 31.2 to 37.9 Min. 31.2
LOWER (*1)
Stroke

HOLD io • Engine speed: Low idle mm 44.5 ± 2.2 44.5 ± 4.4


FLOAT
HOLD o
44.5 ± 2.2 44.5 ± 4.4
DUMP
Bucket HOLD o TILT
(*2) 44.5 ± 2.2 44.5 ± 4.4

*1: Position before detent


*2: Position of detent
Steering wheel
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Engine stopped
Play • Machine facing straight to mm Max. 20 Max. 40
front
• Flat, level, straight, and dry
paved road 9.4 to 15.6 9.4 to 15.6
Operating effort N {kg}
• Engine speed: Low idle {0.96 to 1.6} {0.96 to 1.6}
(bucket empty)
No. of turns (not including • Engine speed: High idle
play) • Left lock to right lock times 3.5 ± 0.4 3.5 ± 0.4
Low idle • Start engine. 4.1 ± 0.4 4.1 ± 0.4
Operating • Hydraulic oil temperature: 45
sec.
time High idle to 55°C 3.5 ± 0.4 3.5 ± 0.4
• Left lock to right lock

20-6 WA470-7
20 Standard value tables
Standard value table for machine

Accelerator pedal
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Start engine. 45.5 to 58.8
Depressing effort • Measure at 150 mm away N {kg} -
from pedal fulcrum {4.64 to 6.00}
NEUTRAL
Depressing a For details, see Fig. A at end 45 ± 2 -
(a1) deg.
angle of this section
Max. (a2) • Start engine. 17 ± 2 -

Brake pedal
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
323 ± 30 Min. 264
Depressing effort N {kg}
a For details, see Fig. B at the {32.9 ± 3.0} {Min. 26.9}
NEUTRAL end of this section
Depressing 53 -
(a1) • Engine speed: Low idle
angle • Hydraulic oil temperature: 45 deg.
Max. (a2) 15 (+1 / 0) -
Play to 55°C -
5±1

Tire
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
A Max. 2.5 -
Fitting of wheel lock ring a For details, see Fig. C at end
B of this section. Max. 4.0 -
mm
Clearance of wheel lock
ring C • Tire inflation pressure: 2 to 10 -
Specified pressure

Engine speed
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil E mode 1,710 ± 50 1,710 ± 100
Torque converter stall temperature: 60 to P mode 1,785 ± 50 1,785 ± 100
Hydraulic stall 102°C E mode 1,825 ± 100 1,825 ± 200
• Torque converter
Bucket CURL relief oil temperature: 60 P mode rpm 2,110 ± 100 2,110 ± 200
to 80°C E mode 1,555 ± 100 1,555 ± 200
Torque converter stall and
hydraulic relief speed • Hydraulic oil
temperature: 45 to P mode 1,645 ± 100 1,645 ± 200
Bucket CURL relief
55°C

WA470-7 20-7
20 Standard value tables
Standard value table for machine

Transmission and torque converter


Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
2.32 ± 0.2 2.32 ± 0.2
Low idle
{23.5 ± 2.0} {23.5 ± 2.0}
Main relief oil pressure Engine 2.55 ± 0.2 2.55 ± 0.2
speed:
2,000 rpm {26.0 ± 2.0} {26.0 ± 2.0}
• Torque Engine 0.1 to 0.88 0.1 to 0.88
Torque converter relief (inlet) converter oil speed:
pressure temperature: 60 {1.0 to 9.0} {1.0 to 9.0}
2,000 rpm
to 80°C Engine
Torque converter outlet 0.06 to 0.71 0.06 to 0.71
speed:
pressure {0.6 to 7.1} {0.6 to 7.1}
2,000 rpm MPa
Engine {kg/ 0.175 ± 0.075 0.175 ± 0.075
Lubricating oil pressure speed: cm2}
2,000 rpm {1.75 ± 0.75} {1.75 ± 0.75}
2.35 ± 0.15 2.35 ± 0.15
1st, 2nd
{24 ± 1.5} {24 ± 1.5}
2.30 ± 0.15 2.30 ± 0.15
ECMV output 3rd, 4th • Torque converter oil
temperature: 60 to 80°C {23.5 ± 1.5} {23.5 ± 1.5}
(clutch)
Forward, • Engine speed: 2,000 rpm 2.06 ± 0.15 2.06 ± 0.15
Oil pressure • Manual switch: ON
Reverse {21.0 ± 1.5} {21.0 ± 1.5}
1.66 ± 0.15 1.66 ± 0.15
Lockup
{17.0 ± 1.5} {17.0 ± 1.5}

Steering
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
24.5 (+1.23 /
• Hydraulic oil temperature: 45 24.5 ± 1.23 -2.45)
Steering relief pressure to 55°C
• Engine speed: High idle MPa {250 ± 12.5} {250 (+12.5 /
-25)}
{kg/
• Hydraulic oil temperature: 45 cm2}
to 55°C 1.25 to 1.45 1.15 to 1.55
Steering control pressure
• Engine speed: Low idle {12.7 to 14.8} {11.7 to 15.3}
• Steering wheel: Free

20-8 WA470-7
20 Standard value tables
Standard value table for machine

Accumulator
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Checking to
be
performed
when the 5.9 (+0.98 /
• Engine 5.9 (+0.5 / 0)
Charge cut-in pressure brake oil -0.5)
speed: Low pressure {60 (+5 / 0)}
{60 (+10 / -5)}
idle warning MPa
• Hydraulic lamp goes {kg/
oil off cm2}
tempera- • Measure
ture: 45 to when brake
55°C oil pressure 9.8 (+0.98 / 0) 9.8 (+1.5 / -0.5)
Charge cut-out pressure
starts {100 (+10 / 0)} {100 (+15 / -5)}
lowering
after rising.

WA470-7 20-9
20 Standard value tables
Standard value table for machine

Power train
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
1st speed 7.6 ± 0.4 7.6 ± 0.5
2nd
speed 13.1 ± 0.7 13.1 ± 0.9
P mode
3rd
speed 22.9 ± 1.1 22.9 ± 1.6
4th speed 36.2 ± 1.8 36.2 ± 2.5
Forward
1st speed 6.6 ± 0.3 6.6 ± 0.5
2nd
speed 11.4 ± 0.6 11.4 ± 0.8
E mode
3rd
speed 19.6 ± 1.0 19.6 ± 1.4
Travel speed
4th speed 30.8 ± 1.5 30.8 ± 2.2
(bucket empty) km/h
1st speed 7.9 ± 0.4 7.9 ± 0.6
(Lockup clutch: OFF)
2nd
speed 13.5 ± 0.7 13.5 ± 0.9
P mode
3rd
speed 23.6 ± 1.2 23.6 ± 1.7
4th speed 37.3 ± 1.9 37.3 ± 2.6
Reverse
1st speed 6.8 ± 0.3 6.8 ± 0.5
2nd
speed 11.7 ± 0.6 11.7 ± 0.8
E mode
3rd
speed 20.2 ± 1.0 20.2 ± 1.4
4th speed 31.7 ± 1.6 31.7 ± 2.2
1st speed 7.6 ± 0.4 7.6 ± 0.5
2nd
speed 13.2 ± 0.7 13.2 ± 0.9
P mode
3rd
speed 23.6 ± 1.2 23.6 ± 1.7
4th speed 38.3 ± 1.9 38.3 ± 2.7
Forward
1st speed 6.6 ± 0.3 6.6 ± 0.5
2nd
speed 11.5 ± 0.6 11.5 ± 0.9
E mode
3rd
speed 20.4 ± 1.0 20.4 ± 1.5
Travel speed
4th speed 33.1 ± 1.7 33.1 ± 2.4
(bucket empty) km/h
1st speed 7.9 ± 0.4 7.9 ± 0.6
(Lockup clutch: ON)
2nd
speed 13.7 ± 0.7 13.7 ± 0.9
P mode
3rd
speed 24.3 ± 1.2 24.3 ± 1.7
4th speed 39.0 ± 2.0 39.0 ± 2.8
Reverse
1st speed 6.8 ± 0.3 6.8 ± 0.5
2nd
speed 11.8 ± 0.6 11.8 ± 0.9
E mode
3rd
speed 21.1 ± 1.1 21.1 ± 1.6
4th speed 34.2 ± 1.7 34.2 ± 2.4

20-10 WA470-7
20 Standard value tables
Standard value table for machine

Wheel brake
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil temperature: 45 4.8 ± 0.4 Min. 4.2
Brake oil pressure
to 55°C {48.9 ± 4.1} {Min. 42.7}
• Engine stopped MPa
• Measure lowering of oil {kg/
Max. 0.49 Max. 0.49
Drop of brake oil pressure pressure after depressing cm2}
brake pedal for 5 min with 4.9 Max. {5.0} Max. {5.0}
MPa {50 kg/cm2}
• Tire inflation pressure:
Specified pressure
• Flat, level, straight, and dry
paved road
• Travel speed at beginning of
brake application 20 km/h:
Performance Delay in applying brakes m Max. 5 Max. 5
Max. 0.1sec.
• Brake pedal depressing
force:
Specified depressing effort
323 ± 30 N {32.9 ± 3 kg}
• Measure braking distance.
Shaft protrusion
• Oil pressure: 4.9 MPa {50 kg/ Protrusion of reaches wear
Wear of disc cm2} mm shaft limit position
• Pedal depressed completely 0 [Max. 2.4 mm]

Parking brake
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Torque converter oil Min. 2.32 Min. 2.32
Parking brake oil pressure MPa
temperature: 60 to 80°C {Min. 23.5} {Min. 23.5}
• Engine speed: Low idle {kg/
Parking brake solenoid valve Min. 2.32 Min. 2.32
• Parking brake: OFF cm2}
basic pressure {Min. 23.5} {Min. 23.5}
• Tire inflation pressure:
Specified pressure
• Flat paved road with a slope
of 1/5 (11 degrees 20') and
dry surface
Performance • Set machine in operating - Stopped Stopped
condition.
a For measuring posture, see
Figs. D and E at the end of
this section
Disc thickness mm 3.2 ± 0.08 2.97

WA470-7 20-11
20 Standard value tables
Standard value table for machine

Work equipment EPC


Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil temperature: 45 3.72 (+0.2 /
Work equipment EPC valve 3.72 (+0.2 / 0)
to 55°C -0.2)
source pressure {38 (+2 / 0)}
• Engine speed: High idle {38 (+2 / -2)}
2.94 ± 0.16 2.94 ± 0.16
Boom RAISE
{30.0 ± 1.6} {30.0 ± 1.6}
MPa 3.37 ± 0.17 3.37 ± 0.17
Work Boom FLOAT • Hydraulic oil temperature: 45 {kg/ {34.4 ± 1.7} {34.4 ± 1.7}
equipment to 55°C cm2} 1.99 ± 0.14 1.99 ± 0.14
EPC valve Boom LOWER • Engine speed: High idle
output • Work equipment control lever {20.3 ± 1.4} {20.3 ± 1.4}
pressure full operation 2.75 ± 0.14 2.75 ± 0.14
Bucket DUMP
{28.0 ± 1.4} {28.0 ± 1.4}
3.1 ± 0.17 3.1 ± 0.17
Bucket TILT
{31.5 ± 1.7} {31.5 ± 1.7}

20-12 WA470-7
20 Standard value tables
Standard value table for machine

Work equipment
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Hydraulic oil temperature: 45 34.3 (+1.8 /
Work equipment relief 34.3 ± 1.77
to 55°C -4.4)
pressure {350 ± 18}
• Engine speed: High idle {350 (+18 / -45)}
• Hydraulic oil temperature: 45
to 55°C 1.72 to 3.43 1.72 to 3.43
Unload pressure • Engine speed: High idle MPa
• Work equipment control {kg/ {17.5 to 35} {17.5 to 35}
lever: NEUTRAL cm2}
• Hydraulic oil temperature: 45
to 55°C 1.37 ± 0.1 1.37 ± 0.2
LS differential pressure • Engine speed: High idle
• Boom control lever: In {14 ± 1} {14 ± 2}
halfway
• Hydraulic oil E mode 6.3 ± 0.5 Max. 8.4
Boom RAISE temperature: 45 to P mode 5.9 ± 0.5 Max. 7.7
55°C E mode 3.1 ± 0.5 Max. 4.4
• Engine speed:
High idle
• Apply no load
Work equipment speed

Boom LOWER
a For measuring P mode 3.1 ± 0.5 Max. 4.0
posture, see Figs.
F and G at end of
this section sec.
• Hydraulic oil E mode 1.8 ± 0.3 Max. 2.4
Dump temperature: 45 to
Bucket full P mode 1.6 ± 0.3 Max. 2.1
stroke 55°C E mode 2.6 ± 0.3 Max. 3.5
Tilt back • Engine speed:
High idle P mode 2.4 ± 0.3 Max. 3.2
• Apply no load E mode 1.6 ± 0.3 Max. 2.1
Bucket from a For measuring
level position Tilt back posture, see Figs. P mode 1.5 ± 0.3 Max. 2.0
H and J at the end
of this section
Retraction of lift cylinder • Hydraulic oil temperature: 45
Max. 30 Max. 36
rod to 55°C
• Stop the engine and leave it
Hydraulic drift

for 5 minutes, then take


measurement for 15 minutes.
• Apply no load to bucket and mm
Retraction of bucket set boom and bucket in level
cylinder rod Max. 20 Max. 24
position.
a For measuring posture, see
Fig. K at the end of this
section

WA470-7 20-13
20 Standard value tables
Standard value table for machine

Hydraulic fan
Machine model WA470-7
Standard value Repair limit
Item Measurement condition Unit
for new machine
• Engine high idle
• Coolant temperature: Min.
95°C
Cooling fan maximum speed • Hydraulic oil temperature: 1,300 ± 100 1,300 ± 200
Min. 95°C
• Torque converter oil
temperature: Min. 105°C
• Engine low idle rpm
• Coolant temperature: Max. Air conditioner: Air conditioner:
70°C OFF OFF
• Hydraulic oil temperature: 175 ± 50 175 ± 100
Cooling fan minimum speed
Max. 70°C Air conditioner: Air conditioner:
• Torque converter oil ON ON
temperature: Max. 80°C 727 ± 50 727 ± 100
• Air conditioner: OFF
• Engine high idle
• Fan 100% mode (*) 14.3 ± 1.4 14.3 ± 2.1
Cooling fan drive pressure
• Hydraulic oil temperature: MPa {146 ± 15} {146 ± 22}
50°C
{kg/
• When cooling fan is reversed
Cooling fan reverse solenoid cm2} 2.51 ± 0.35 2.51 ± 0.53
• Engine high idle
output pressure • Hydraulic oil temperature: {25.6 ± 3.6} {25.6 ± 5.4}
50°C
*: Fan speed becomes 100% when it is set to reverse mode.

20-14 WA470-7
20 Standard value tables
Standard value table for machine

Machine posture and procedure for measuring performance (WA380_7-0000-321-K-00-A)

a Fig. A

a Fig. B

a Fig. C

WA470-7 20-15
20 Standard value tables
Standard value table for machine

a Fig. D

a Fig. E

a Fig. F

a Fig. G

20-16 WA470-7
20 Standard value tables
Standard value table for machine

a Fig. H

a Fig. J

a Fig. K

WA470-7 20-17
20 Standard value tables
Standard value table for electrical system

Standard value table for electrical system (D155-E000-001-P-00-A)

Controller (WA470-RA1E-033-K-00-A)
Equipment name Procedure, measuring location, criteria and remarks
1. Turn starting switch to the OFF position, and set battery disconnect switch to
the OFF position.
2. Insert T-adapter into EC3.
Continuous 3. Set battery disconnect switch to ON position.
Engine power 4. Measure voltage with starting switch at OFF position and when starting
controller supply engine.
voltage Between EC3 (1) and (21) 20 to 30 V
Between EC3 (2) and (22) 20 to 30 V
Voltage
Between EC3 (11) and (31) 20 to 30 V
Between EC3 (12) and (32) 20 to 30 V
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Continuous 3. Insert T-adapter into connector L73.
power 4. Turn battery disconnect switch to ON position.
supply 5. Turn starting switch to ON position.
voltage Between L73 (1) and each of (21), (31), (32),
Voltage and (33), and between L73 (11) and each of 20 to 30 V
Work (21), (31), (32), and (33)
equipment 1. Turn starting switch to OFF position.
controller 2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L73.
Solenoid 4. Turn battery disconnect switch to ON position.
power 5. Turn starting switch to ON position.
supply
Between L73 (2) and (21) 20 to 30 V
voltage
Between L73 (12) and (31) 20 to 30 V
Voltage
Between L73 (22) and (32), and between L73
(22) and (33) 20 to 30 V

1. Turn starting switch to OFF position.


2. Turn the battery disconnect switch to OFF position.
Continuous 3. Insert T-adapter into connector L63.
power 4. Turn battery disconnect switch to ON position.
supply 5. Turn starting switch to ON position.
voltage Between L63 (1) and each of (21), (31), (32),
Voltage and (33), and between L63 (11) and each of 20 to 30 V
Transmis- (21), (31), (32), and (33)
sion 1. Turn starting switch to OFF position.
controller 2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L63.
Solenoid 4. Turn battery disconnect switch to ON position.
power 5. Turn starting switch to ON position.
supply
Between L63 (2) and (21) 20 to 30 V
voltage
Between L63 (12) and (31) 20 to 30 V
Voltage
Between L63 (22) and (33), and between L63
(32) and (33) 20 to 30 V

1. Turn starting switch to OFF position.


2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector MCM1 A, and connect T-adapter to female side.
Continuous 4. Turn battery disconnect switch to ON position.
Monitor power 5. Turn starting switch to ON position.
controller supply Between MCM1 A (female) (1) and (2) 20 to 30 V
voltage Voltage
Between MCM1 A (female) (4) and (3) 20 to 30 V
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.

20-18 WA470-7
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


2. Turn starting switch to OFF position.
3. Disconnect connector MCM1 A, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a Check that engine shutdown secondary switch is at lower (OFF) position.
Between MCM1 A (female) (43) and (2) 20 to 30 V
Voltage Between MCM1 A (female) (31) and (2) 20 to 30 V
Between MCM1 A (female) (24) and (3) 20 to 30 V

WA470-7 20-19
20 Standard value tables
Standard value table for electrical system

Engine control (WA470-AG10-033-K-00-A)

Equipment name Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male side.
Resistance Between EGR-SOL (male) (1) and (2) 5 to 10 z
1. Turn starting switch to OFF position.
KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapter to male side.
Resistance Between VGT-SOL (male) (1) and (2) 5 to 10 z
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700 z to 37
kz when coolant temperature is min. 0°C.
0°C 30 to 37 kz
Coolant temperature Between TWTR (male) (A) and
(B) 25°C 9.3 to 10.7 kz
sensor 50°C 3.2 to 3.8 kz
a Coolant temperature- 80°C 1.0 to 1.3 kz
Resistance Resistance characteristics
95°C 700 to 800 z
Whole coolant
Between TWTR (male) (B) and
temperature Min. 1 Mz
ground
range
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a Regard charge temperature sensor as normal if its resistance is 280 z to
382 kz.
-40°C 291 to 382 kz
Charge temperature
sensor -20°C 85 to 109 kz
Between TIM (male) (A) and (B) 0°C 29 to 36 kz
Resistance a Charge temperature- 30°C 7.3 to 8.8 kz
Resistance characteristics 60°C 2.3 to 2.7 kz
90°C 860 to 970 z
130°C 280 to 320 z
1. Turn starting switch to OFF position.
2. Disconnect connector E27 and connect T-adapter to male side.
-30°C 25 to 28 kz
Between E27 (male) (3) and (4) 0°C 5.5 to 6.1 kz
Intake air temperature
sensor a Intake air temperature- 25°C 1.9 to 2.1 kz
Resistance Resistance characteristics 40°C 1.1 to 1.2 kz
100°C 180 to 185 z
Between E27 (male) (3) and
Whole range Min. 1 Mz
ground (sensor body)
1. Turn starting switch to OFF position.
2. Disconnect connectors TEMP1 and connect T-adapter to female side.
-10°C 33 to 65 kz
Between TEMP1 (female) (1) 0°C 25 to 47 kz
KDOC inlet temperature and (2) 50°C 7.8 to 12.2 kz
sensor
Resistance a Temperature-Resistance 100°C 3.2 to 4.5 kz
characteristics 400°C 200 to 240 z
700°C 64 to 69 z
Between TEMP1 (female) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
KDOC outlet temperature 2. Disconnect connectors TEMP2 and connect T-adapter to female side.
sensor Between TEMP2 (female) (1) -10°C 33 to 65 kz
Resistance and (2)
0°C 25 to 47 kz

20-20 WA470-7
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


50°C 7.8 to 12.2 kz
a Temperature-Resistance 100°C 3.2 to 4.5 kz
characteristics 400°C 200 to 240 z
700°C 64 to 69 z
Between TEMP2 (female) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors E38 and connect T-adapter to female side.
-10°C 33 to 65 kz
KDPF outlet temperature Between E38 (female) (1) and 0°C 25 to 47 kz
sensor (2) 50°C 7.8 to 12.2 kz
Resistance
a Temperature-Resistance 100°C 3.2 to 4.5 kz
characteristics 400°C 200 to 240 z
700°C 64 to 69 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1 or PIM.
Charge (Boost) pressure 3. Turn starting switch to ON position.
sensor
Between J1 (15) and (59), or
Voltage Sensor output 0.3 to 4.7 V
between PIM (3) and (2)
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1 or POIL.
Engine oil pressure 3. Turn starting switch to ON position.
sensor
Between J1 (2) and (59) or
Voltage Sensor output 0.3 to 4.7 V
between POIL (3) and (2)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1 or PAMB.
Ambient pressure sensor 3. Turn starting switch to ON position.
Between J1 (16) and (59) or
Voltage Sensor output 0.3 to 4.7 V
between PAMB (3) and (2)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PFUEL or J2.
Common rail pressure 3. Turn starting switch to ON position.
sensor
Between PFUEL (2) and (3) or
Voltage Sensor output 0.2 to 4.6 V
J2 (55) and (21)
1. Turn starting switch to OFF position.
Crankcase pressure 2. Insert T-adapter into connector PCCV.
sensor 3. Turn starting switch to ON position.
Voltage Between PCCV (3) and (2) Sensor output 0.3 to 4.7 V
1. Turn starting switch to OFF position.
KDPF differential 2. Insert T-adapter into connector E25.
pressure sensor 3. Turn starting switch to ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
1. Turn starting switch to OFF position.
Dosing fuel pressure 2. Insert T-adapter into connector PDOSER.
sensor 3. Turn starting switch to ON position.
Voltage Between PDOSER (3) and (2) 0.5 to 4.5 V
1. Turn starting switch to OFF position.
KDPF outlet pressure 2. Insert T-adapter into connector E25.
sensor 3. Turn starting switch to ON position.
Voltage Between E25 (3) and (1) 0.5 to 4.5 V
1. Turn starting switch to OFF position.
Turbocharger speed 2. Disconnect connector VGT REV, and connect T-adapter to female side of
sensor connector.
Resistance Between VGT REV (female) (1) and (2) 600 to 1600 z

WA470-7 20-21
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Accelerator pedal (throttle 2. Insert T-adapter into connector PD.
sensor) 3. Turn starting switch to ON position.
Voltage Between PD (2) and (1) 3.7 to 4.0 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J2 or SEGR.
EGR valve lift sensor 3. Turn starting switch to ON position.
Between J2 (59) and (47), or between SEGR (3)
Voltage 1.0 to 4.0 V
and (2)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J2 or SVGT.
KVGT position sensor 3. Turn starting switch to ON position.
Between J2 (38) and (47), or between SVGT (C)
Voltage 1.0 to 4.0 V
and (B)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R37.
3. Start engine.
4. Turn emergency steering ON and operate steering.
Continuous 0.50 to 4.5 V
When
Emergency steering pump emergency
steering is 0.50 to 0.90 V
pressure sensor
stopped
Voltage Between R37 (2) and (1) When
emergency
steering is
turned ON and 0.50 to 3.05 V
steering is
operated

20-22 WA470-7
20 Standard value tables
Standard value table for electrical system

Machine control (WA470-E000-033-P-00-A)


Equipment name Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector F20 and connect T-adapter to male side.
E.C.S.S. solenoid Between F20 (male) (1) and (2) 35 to 45 z
Resistance Between ground and each of F20 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector F23, and connect T-adapter to male side.
Boom RAISE EPC
Between F23 (male) (1) and (2) 5 to 15 z
solenoid
Resistance Between ground and each of F23 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector F24 and connect T-adapter to male side.
Boom LOWER EPC
Between F24 (male) (1) and (2) 5 to 15 z
solenoid
Resistance Between ground and each of F24 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector F21 and connect T-adapter to male side.
Bucket TILT EPC solenoid Between F21 (male) (1) and (2) 5 to 15 z
Resistance Between ground and each of F21 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector F22, and connect T-adapter to male side.
Bucket DUMP EPC
Between F22 (male) (1) and (2) 5 to 15 z
solenoid
Resistance Between ground and each of F22 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector R59 and connect T-adapter to male side.
Radiator fan reverse
Between R59 (male) (1) and (2) 5 to 15 z
solenoid
Resistance Between ground and each of R59 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector F31, and connect T-adapter to male side.
Neutral lock solenoid Between F31 (male) (1) and (2) 35 to 45 z
Resistance Between ground and each of F31 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector L28B, and connect T-adapter to male side.
Boom detent solenoid
Between L28B (male) (1) and (2) 100 to 123 z
Resistance
Between L28B (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector L29B, and connect T-adapter to male side.
Bucket detent solenoid
Between L29B (male) (1) and (2) 100 to 123 z
Resistance
Between L29B (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector R29, and connect T-adapter to male side.
Fan pump EPC solenoid Between R29 (male) (1) and (2) 5 to 10 z
Resistance Between chassis ground and each of R29
(male) (1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Loader pump EPC 2. Disconnect connector R71, and connect T-adapter to male side.
solenoid
Resistance Between R71 (male) (1) and (2) 5 to 15 z

WA470-7 20-23
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


Between ground and each of R71 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


Lockup clutch ECMV 2. Disconnect connector LC.PS, and connect T-adapter to male side.
solenoid Between LC.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and LC.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector 1.PS, and connect T-adapter to male side.
1st clutch ECMV solenoid
Between 1.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 1.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2nd clutch ECMV 2. Disconnect connector 2.PS, and connect T-adapter to male side.
solenoid Between 2.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 2.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector 3.PS, and connect T-adapter to male side.
3rd clutch ECMV solenoid
Between 3.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 3.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector R.PS and connect T-adapter to male side.
R clutch ECMV solenoid
Between R.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and R.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector F.PS, and connect T-adapter to male side.
F clutch ECMV solenoid
Between F.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and F.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector 4.PS, and connect T-adapter to male side.
4th clutch ECMV solenoid
Between 4.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 4.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector F25, and connect T-adapter to male side.
3rd valve (attachment)
Between F25 (male) (1) and (2) 5 to 15 z
EXTEND EPC solenoid
Resistance Between ground and each of F25 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector F26, and connect T-adapter to male side.
3rd valve (attachment)
Between F26 (male) (1) and (2) 5 to 15 z
RETRACT EPC solenoid
Resistance Between ground and each of F26 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector TM.T and connect T-adapter to male side.
Transmission oil
temperature sensor Oil temperature: 25°C
Between TM.T (normal temperature) 35 to 50 kz
Resistance (male) (1) and (2)
Oil temperature: 100°C 3.1 to 4.5 kz
1. Turn starting switch to OFF position.
2. Disconnect connector R47 and connect T-adapter to male side.
Hydraulic oil temperature
sensor Oil temperature: 25°C
Between R47 (male) (normal temperature) 35 to 50 kz
Resistance (1) and (2)
Oil temperature: 100°C 3.1 to 4.5 kz
Brake oil temperature 1. Turn starting switch to OFF position.
sensor (rear) 2. Disconnect connector R60, and connect T-adapter to male side.

20-24 WA470-7
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


Rear brake oil
temperature: 25°C 42.7 kz
Rear brake oil
temperature: 30°C 35.13 kz
Between R60 (male) Rear brake oil
Resistance (1) and (2) temperature: 80°C 6.556 kz
Rear brake oil
temperature: 90°C 4.925 kz
Rear brake oil
temperature: 100°C 3.75 kz

1. Turn starting switch to OFF position.


2. Disconnect connector TC.T and connect T-adapter to male side.
Torque converter oil Torque converter oil
temperature sensor temperature: 25°C 35 to 50 kz
Between TC.T (normal temperature)
Resistance (male) (1) and (2)
Torque converter oil
temperature: 100°C 3.1 to 4.5 kz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector F10.
3. Start engine.
Loader pump pressure Loader pump pressure:
0.50 to 4.4 V
sensor Continuous
Between F10 (C) Loader pump pressure: At
Voltage 0.50 to 0.90 V
and (A) NEUTRAL
Loader pump pressure: At
2.97 to 3.39 V
bucket tilt relief
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F12.
3. Start engine, and move lever to boom RAISE to perform troubleshooting.
Boom cylinder bottom
pressure sensor Always 0.50 to 4.4 V
Between F12 (C) Boom: At NEUTRAL 0.50 to 0.90 V
Voltage
and (A) Boom cylinder bottom:
Hydraulic relief 2.97 to 3.39 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector F13.
3. Start engine, and troubleshoot by lowering boom.
Boom cylinder head
pressure sensor Always 0.50 to 4.4 V
Between F13 (C) Boom: At NEUTRAL 0.50 to 0.90 V
Voltage
and (A) Boom cylinder head:
Hydraulic relief 2.97 to 3.39 V

1. Turn starting switch to OFF position.


Pilot pressure sensor of 2. Disconnect connector FLOW.P, and connect T-adapter to female side.
main flow selector 3. Turn starting switch to ON position.
solenoid
Voltage Between FLOW.P (female) (2) and (1) 0.3 to 4.7 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R73.
3. Start engine.
4. Turn transmission cut-off switch ON.
Transmission cut-off
When brake is released 0.9 to 1.1 V
pressure sensor
When brake pedal is
Between R73 (C)
Voltage depressed (both right and 1.1 to 5.1 V
and (A)
left)
Always 0.9 to 5.1 V
Torque converter input 1. Turn starting switch to OFF position.
pressure sensor 2. Insert T-adapter into connector TCIN.P.
3. Turn starting switch to ON position.

WA470-7 20-25
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


Sensor output
Between TCIN.P (C) and (A) 0.9 to 5.1 V
voltage
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R91.
Torque converter outlet oil
3. Turn starting switch to ON position.
pressure sensor
Sensor output
Between R91 (C) and (A) 0.9 to 5.1 V
voltage
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R86.
Steering pump pressure 3. Start engine and operate steering.
sensor Always 0.50 to 4.5 V
Between R86 (2)
Voltage Steering: At NEUTRAL 0.50 to 0.90 V
and (1)
Steering: At Relief 3.02 to 3.42 V
1. Turn starting switch to OFF position.
2. Disconnect connector REV IN, and connect T-adapter to male side.
Transmission input shaft
speed sensor Between REV IN (male) (1) and (2) 500 to 1,000 z
Resistance Between ground and each of REV IN (male) (1)
and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector R89 and connect T-adapter to male side.
Radiator fan speed 1,000 to 4,000
Between R89 (male) (1) and (2)
sensor z
Resistance Between ground and each of R89 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector REV OUT, and connect T-adapter to male side.
Transmission output shaft
speed sensor Between REV OUT (male) (1) and (2) 500 to 1,000 z
Resistance Between ground and each of REV OUT (male)
(1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L02.
3. Turn starting switch to ON position.
4. Move FNR lever to perform troubleshooting.
Analog signal system of FNR (directional) lever: F
(FORWARD) 1.2 to 1.8 V
FNR lever
Between L02 (11) FNR (directional) lever: N
Voltage 1.7 to 3.3 V
and (12) (NEUTRAL)
FNR (directional) lever: R
(REVERSE) 3.2 to 3.8 V

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L28A.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate boom lever to perform troubleshooting.
Boom lever: NEUTRAL 2.38 to 2.62 V
Boom lever potentiometer Boom lever: RAISE (to
short of detent position) 3.38 to 4.04 V
Between L28A (3) Boom lever: RAISE (at
Voltage 3.90 to 4.40 V
and (2) detent position)
Boom lever: RAISE (at
detent position) 0.96 to 1.62 V
Boom lever: FLOAT 0.60 to 1.10 V
Bucket lever 1. Turn starting switch to OFF position.
potentiometer 2. Insert T-adapter into connector L29A.
3. Turn work equipment lock switch to LOCK position.

20-26 WA470-7
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


4. Turn starting switch to ON position.
5. Operate bucket lever to perform troubleshooting.
Bucket lever: NEUTRAL 2.38 to 2.62 V
Bucket lever: TILT (to
short of detent position) 3.38 to 4.04 V
Between L29A (3)
Voltage
and (2) Bucket lever: TILT (at
detent position) 3.90 to 4.40 V
Bucket lever: Full DUMP 0.60 to 1.10 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L30.
3. Turn work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever 3rd (attachment) lever:
2.38 to 2.62 V
potentiometer NEUTRAL
3rd (attachment) lever:
Between L30 (3) and Operated to extend 3.90 to 4.40 V
Voltage cylinder fully
(2)
3rd (attachment) lever:
Operated to retract 0.60 to 1.10 V
cylinder fully
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F11.
3. Turn starting switch to ON position.
Boom angle sensor 4. Operate boom lever to perform troubleshooting.
Always 1.13 to 4.02 V
Between F11 (B)
Voltage RAISE stroke end 3.52 to 4.02 V
and (A)
LOWER stroke end 1.13 to 1.63 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F32.
3. Turn starting switch to ON position.
Bucket angle sensor 4. Operate bucket lever to perform troubleshooting.
Always 2.15 to 4.45 V
Between F32 (B)
Voltage Full TILT 3.95 to 4.45 V
and (A)
Full DUMP 2.15 to 2.65 V
1. Turn starting switch to OFF position.
2. Disconnect connector E45 and connect T-adapters to male side.
3. Turn starting switch to ON position.
Air cleaner clogging
sensor When air cleaner is
Max. 1 z
Between E45 (male) normal
Resistance (1) and (2) When air cleaner is
clogged Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector R33, and connect T-adapters to male side.
Fuel level sensor
Between R33 (male) Fuel level: Full Max. 12 z
Resistance (1) and (2)
Fuel level: Empty 80 to 100 z
1. Turn starting switch to OFF position.
2. Disconnect connector S40 and connect T-adapter to male side.
3. Troubleshoot by turning starting switch to ON, OFF, START, and HEAT
positions.
Starting switch Starting switch: START Max. 1 z
Between S40 (male)
(1) and (3) Starting switch: OFF and
Resistance Min. 1 Mz
ON
Between terminal B Starting switch: HEAT
Max. 1 z
and terminal R1
Transmission cut-off
1. Turn starting switch to OFF position.
switch

WA470-7 20-27
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


2. Disconnect connector S_RH1 and connect T-adapter to male side.
Engine power mode
Between S_RH1 Max. 1 z
selection switch: ON
(male) (5) and (6) Engine power mode
Min. 1 Mz
Resistance selection switch: OFF
Between ground and
each of S_RH1 Always Min. 1 Mz
(male) (5) and (6)
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH6, and connect T-adapters to male side.
Remote positioner set
Max. 1 z
Remote positioner set Between S_RH6 switch: Boom set ON
switch (boom) (male) (5) and (6) Remote positioner set
Resistance switch: Other than boom Min. 1 Mz
set ON
Between ground and each of S_RH6 (male) (5)
and (6) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector S_RH7, and connect T-adapter to male side.
Throttle lock set/ Throttle lock set/
acceleration switch Between S_RH7 acceleration switch: Other Min. 1 Mz
Resistance (male) (5) and (6) than ON
Throttle lock set/
Max. 1 z
acceleration switch: ON
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH7, and connect T-adapter to male side
Defective throttle lock Throttle Lock Resume/
resume/deceleration Deceleration Switch: Min. 1 Mz
switch Between S_RH7
Resistance (male) (4) and (5) Other than ON
Throttle Lock Resume/
Max. 1 z
Deceleration Switch: ON
1. Turn starting switch to OFF position.
2. Disconnect connector S_FS and connect T-adapter to male side.
Between S_FS
(male) (3) and (2) Min. 1 Mz
Engine shutdown
Engine shutdown Between S_FS secondary switch: ON
secondary switch (male) (6) and (5) Min. 1 Mz
Resistance
Between S_FS
(male) (1) and (2) Max. 1 z
Engine shutdown
Between S_FS secondary switch: OFF
(male) (4) and (5) Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connector PB.SW, and connect T-adapter to male side.
Parking brake pressure:
When parking brake is
Parking brake indicator released, Min. 0.61 MPa Max. 1 z
switch Between PB.SW {Min. 6.2 kg/cm }
2
Resistance (male) (1) and (2)
Parking brake pressure:
When parking brake is
applied, Max. 0.34 MPa Min. 1 Mz
{Min. 3.5 kg/cm2}
1. Turn starting switch to OFF position.
Remote positioner set 2. Disconnect connector S_RH6, and connect T-adapters to male side.
switch (bucket) Between S_RH6 Remote positioner set
Resistance (male) (5) and (6) switch: Bucket angle set Max. 1 z
ON

20-28 WA470-7
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


Remote positioner set
switch: Other than bucket Min. 1 Mz
angle set ON
Between ground and each of S_RH6 (male) (5)
and (6) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector S_RHB, and connect T-adapter to male side.
Right FNR (directional)
Between S_RHB switch: F (FORWARD) Max. 1 z
(male) (1) and (2) Right FNR (directional)
Min. 1 Mz
switch: Other than F
Right FNR (directional)
Between S_RHB switch: N (NEUTRAL) Max. 1 z
Right FNR (directional)
(male) (1) and (3) Right FNR (directional)
switch Min. 1 Mz
Resistance switch: Other than N
Right FNR (directional)
Between S_RHB switch: R (REVERSE) Max. 1 z
(male) (1) and (4) Right FNR (directional)
Min. 1 Mz
switch: Other than R
Between S_RHB (1)
or (2),(3),(4) and Always Min. 1 Mz
ground
1. Turn starting switch to OFF position.
2. Disconnect connector S_RHC, and connect T-adapter to male side.
Work equipment lock Work equipment lock
switch Between S_RHC Min. 1 Mz
switch: OFF
Resistance (male) (5) and (6)
Work equipment lock
Max. 1 z
switch: ON
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH3 and connect T-adapter to male side.
Shift mode: Manual shift Max. 1 z
Transmission auto/ Between S_RH3
Shift mode: Auto shift (L) Min. 1 Mz
manual shift mode (male) (4) and (5)
Shift mode: Auto shift (H) Min. 1 Mz
selector switch Resistance
Shift mode: Manual shift Min. 1 Mz
Between S_RH3
Shift mode: Auto shift (L) Min. 1 Mz
(male) (5) and (6)
Shift mode: Auto shift (H) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1, and connect T-adapters to male side.
Transmission cut-off set
Between S_RH1 Max. 1 z
Transmission cut-off switch: ON
(male) (5) and (6) Transmission cut-off set
switch Min. 1 Mz
Resistance switch: OFF
Between ground and
each of S_RH1 Always Min. 1 Mz
(male) (5) and (6)
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Between L14 (male) Kickdown switch: ON Max. 1 z
Kickdown switch (1) and (2) Kickdown switch: OFF Min. 1 Mz
Resistance Between ground and
each of L14 (male) Always Min. 1 Mz
(1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Hold switch
Between L14 (male) Kickdown switch: ON Max. 1 z
Resistance (3) and (4)
Kickdown switch: OFF Min. 1 Mz

WA470-7 20-29
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


Between ground and
each of L14 (male) Always Min. 1 Mz
(3) and (4)

20-30 WA470-7
20 Standard value tables
Standard value table for electrical system

Machine monitor (WA470-Q170-033-K-00-A)


Equipment name Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MCM2, and connect harness checker to female side.
Continuous 4. Turn battery disconnect switch to ON position.
LCD unit of power 5. Turn starting switch to ON position.
machine supply
monitor Between harness checker (1) and (3) Min. 0.3 V
voltage
Between harness checker (2) and (3) Min. 0.3 V
Voltage Between harness checker (4) and (3) Min. 0.3 V
Between harness checker (5) and (3) 6.2 to 9.1 V
Between harness checker (7) and (3) 6.2 to 9.1 V
a When using T-adapters for connector MDM3 (070-8)
1. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MDM3, and connect T-adapters to female side.
Continuous 4. Turn battery disconnect switch to ON position.
Meter unit of power 5. Turn starting switch to ON position.
machine supply 6. Lighting up of clearance lamp
monitor voltage Between MDM3 (female) (1) and (4) 20 to 30 V
Between MDM3 (female) (2) and (4) 20 to 30 V
Voltage Between MDM3 Night lighting switch:
(female) (5) and (4) Max. 0.2 V
OFF
Between MDM3 Night lighting switch:
(female) (5) and (4) 20 to 30 V
ON
a When using T-adapter for connector MDM2 (070-6)
1. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Continuous 3. Disconnect connector MDM2, and connect T-adapters to female side.
LED unit of power
machine 4. Turn battery disconnect switch to ON position.
supply 5. Turn starting switch to ON position.
monitor voltage Between MDM2 (female) (1) and (2)
9.3 to 14.1 V
a 12 V power supply
Voltage
Between MDM2 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
a When using T-adapter for connector MOM1 (070-6)
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Switch Continuous 3. Disconnect connector MOM1, and connect T-adapters to female side.
panel of power 4. Turn battery disconnect switch to ON position.
machine supply 5. Turn starting switch to ON position.
monitor voltage Between MOM1 (female) (1) and (2)
9.3 to 14.1 V
a 12 V power supply
Voltage
Between MOM1 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply

WA470-7 20-31
20 Standard value tables
Standard value table for electrical system

20-32 WA470-7
SHOP MANUAL

WHEEL LOADER
WA470-7
Model Serial Number

WA470-7 10001 and up

30 Testing and adjusting


5 30 Testing and adjusting

WA470-7 30-1
30 Testing and adjusting
Table of contents

Table of contents (ALL-0310-002-A-00-A)


30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-4
Tools for testing and adjusting ............................................................................................... 30-4
Sketch of tools for testing and adjusting ................................................................................. 30-8
Engine and cooling system ........................................................................................................ 30-10
Testing engine speed ......................................................................................................... 30-10
Testing boost pressure ....................................................................................................... 30-12
Testing exhaust gas color ................................................................................................... 30-14
Testing and adjusting valve clearance .................................................................................. 30-16
Testing compression pressure............................................................................................. 30-18
Testing blowby pressure ..................................................................................................... 30-22
Testing engine oil pressure ................................................................................................. 30-24
Testing EGR valve and KVGT oil pressures .......................................................................... 30-25
Testing fuel pressure .......................................................................................................... 30-26
Testing fuel return rate and leakage ..................................................................................... 30-27
Bleeding air from fuel system .............................................................................................. 30-31
Testing fuel circuit for leakage ............................................................................................. 30-33
Handling cylinder cutout mode operation.............................................................................. 30-34
Handling no injection cranking operation .............................................................................. 30-35
Testing of KDPF and muffler stack for looseness and damage ............................................... 30-36
Testing of installed condition of cylinder head and manifolds .................................................. 30-37
Testing engine piping for damage and looseness .................................................................. 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Testing and adjusting alternator belt tension ......................................................................... 30-41
Procedures for cleaning fuel doser....................................................................................... 30-43
Writing compensation values at replacement of injector and engine controller ......................... 30-46
Power train............................................................................................................................... 30-50
Adjusting transmission output speed sensor ......................................................................... 30-50
Adjusting transmission input speed sensor ........................................................................... 30-51
Flushing procedure for torque converter and transmission hydraulic circuit.............................. 30-52
Retrieval of disabled machine due to transmission valve failure.............................................. 30-54
Testing oil leakage from axle final drive ................................................................................ 30-56
Testing drive shaft for looseness, backlash, and damage....................................................... 30-57
Testing and adjusting power train oil pressure....................................................................... 30-58
Steering system........................................................................................................................ 30-73
Testing directional lever ...................................................................................................... 30-73
Testing steering wheel ........................................................................................................ 30-74
Testing work equipment control lever ................................................................................... 30-76
Testing and adjusting steering circuit oil pressure.................................................................. 30-78
Bleeding air from steering cylinder circuit.............................................................................. 30-81
Testing and adjusting steering stopper valve......................................................................... 30-82
Brake system ........................................................................................................................... 30-83
Testing brake pedal ............................................................................................................ 30-83
Testing and adjusting brake pedal linkage ............................................................................ 30-84
Testing braking performance ............................................................................................... 30-85
Testing and adjusting of accumulator charge pressure........................................................... 30-86
Testing of brake accumulator nitrogen gas pressure and procedure for charging brake
accumulator with nitrogen gas................................................................................ 30-88
Testing wheel brake oil pressure.......................................................................................... 30-92
Testing lowering of wheel brake pressure ............................................................................. 30-94
Testing wear of wheel brake disc ......................................................................................... 30-96
Bleeding air from wheel brake circuit.................................................................................... 30-97
Releasing remaining pressure in brake accumulator circuit .................................................... 30-99
Testing parking brake performance .................................................................................... 30-100
Testing parking brake oil pressure ..................................................................................... 30-101
Testing wear of parking brake disc ..................................................................................... 30-102

30-2 WA470-7
30 Testing and adjusting
Table of contents

Method of releasing parking brake manually ....................................................................... 30-103


Hydraulic system .................................................................................................................... 30-105
Testing fan speed............................................................................................................. 30-105
Testing fan pump circuit oil pressure .................................................................................. 30-106
Bleeding air from hydraulic fan circuit ................................................................................. 30-108
Testing and adjusting work equipment EPC oil pressure ...................................................... 30-110
Testing and adjusting work equipment oil pressure.............................................................. 30-113
Bleeding air from work equipment circuit ............................................................................ 30-117
Releasing remaining pressure from work equipment circuit .................................................. 30-118
Testing of ECSS accumulator nitrogen gas pressure and procedure for charging accumulator
with nitrogen gas ................................................................................................ 30-119
Work equipment ..................................................................................................................... 30-123
Testing and adjusting bucket position detection lever........................................................... 30-123
Testing and adjusting boom position detection lever ............................................................ 30-124
Electrical system .................................................................................................................... 30-125
Adjusting replaced, reassembled or added sensor, controller, etc. with machine
monitor .............................................................................................................. 30-125
Special functions of machine monitor ................................................................................. 30-127
Adjusting rearview camera angle ....................................................................................... 30-216
Handling voltage circuit of engine controller........................................................................ 30-217
Handling battery disconnect switch .................................................................................... 30-218
Testing diodes ................................................................................................................. 30-219
Pm clinic ................................................................................................................................ 30-220
Pm Clinic service ............................................................................................................. 30-220
Check sheet .................................................................................................................... 30-221

WA470-7 30-3
30 Testing and adjusting
General information on testing and adjusting

General information on testing and adjusting (ALL-3831-001-A-00-A)

Tools for testing and adjusting (WA470-5320-304-A-00-A)

Testing and Sym-

Q'ty
adjusting item Part No. Part name Remarks
bol
Testing boost -101 to 200 kPa {-760 to 1,500
A 799-201-2202 Boost gauge kit 1 mmHg}
pressure
1 799-201-9002 Handy smoke checker 1
Testing exhaust gas
C Commercially Bosch index: 0 to 9
color 2 Smoke meter 1
available
Testing and
Commercially Feeler gauge
adjusting valve D 1 1
available
clearance
1 795-502-1590 Gauge assembly 1
795-471-1420 Adapter 1
Testing compression 2
pressure E 6217-71-6112 Gasket 1
Commercially Inner diameter 14 mm, length
3 Hose 1 approx. 2 m
available
1 799-201-1504 Blowby checker 1 0 to 10 kPa {0 to 1,000 mmH2O}
Testing blowby
F 2 799T-201-3210 Plug 1 Hose inside diameter: 24 mm
pressure
3 799T-201-3220 Cap 2 Pipe outside diameter: 25.4 mm
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Testing engine oil
pressure G Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Pressure gauge: 1.0 MPa {10
3 799-401-2320 Gauge 1 kg/cm2}
795T-401-1310 Plug 1
1
02896-21018 O-ring 1
Testing EGR valve Pressure gauge: 2.5, 6.0, 40, 60
and KVGT oil H 2 799-101-5002 Hydraulic tester 1 MPa
pressure {25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
3 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
Testing fuel 2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
pressure J
795-790-5120 Screw 1 M14 x 1.5 o Rc1/8
3 07005-01412 Gasket 1
790-301-1530 Elbow 1 Rc1/8 x Rc1/8
4 799-401-2320 Gauge 1 1 MPa
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercially
3 Hose 1 Inside diameter: approx. 6 mm
Testing fuel available
discharge, return K Commercially
4 Hose 1 Inside diameter: approx. 16 mm
and leakage available
Commercially Measuring cylinder
5 1
available
Commercially Stopwatch
6 1
available

30-4 WA470-7
30 Testing and adjusting
General information on testing and adjusting

Testing and Sym-

Q'ty
adjusting item Part No. Part name Remarks
bol
Developer for dye
Testing fuel circuit Commercially
L penetrant (color 1
for leakage available checker)
Testing directional
M 79A-264-0021 Push-pull scale 1
lever
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Testing and Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1
adjusting power N kg/cm2}
train oil pressure Pressure gauge: 1.0 MPa {10
3 799-401-2320 Gauge 1 kg/cm2}
799-101-5220 Nipple 1 10 x 1.25 mm
4
07002-11023 O-ring 1
Retrieval of disabled
machine due to Plug
O 794-423-1190 1
transmission valve
failure
Testing steering
P 79A-264-0021 Push-pull scale 1
wheel
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
Testing and {25, 60, 400, 600 kg/cm2}
adjusting steering oil Q Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
pressure
799-101-5220 Nipple 1 10 x 1.25 mm
3
07002-11023 O-ring 1
Pressure gauge: 2.5, 6.0, 40, 60
Testing oil pressure 1 799-101-5002 Hydraulic tester 1 MPa
in cooling fan pump R {25, 60, 400, 600 kg/cm2}
circuit Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
Bleeding air from {25, 60, 400, 600 kg/cm2}
hydraulic fan circuit S
Pressure gauge: 40 MPa {400
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
3 790-261-1130 Coupling 1
Pressure gauge: 2.5, 6.0, 40, 60
Testing and
1 799-101-5002 Hydraulic tester 1 MPa
adjusting of
T {25, 60, 400, 600 kg/cm2}
accumulator charge
pressure Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
Testing lowering of 3 790-101-1102 Pump 1
wheel brake U 4 790-301-1720 Adapter 1 10 x 1.25 mm o R1/8
pressure 5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Testing wear of Commercially Vernier calipers
V 1
wheel brake disc available

WA470-7 30-5
30 Testing and adjusting
General information on testing and adjusting

Testing and Sym-

Q'ty
adjusting item Part No. Part name Remarks
bol
Pressure gauge: 2.5, 6.0, 40, 60
799-101-5002 Hydraulic tester 1 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing parking
brake oil pressure W Pressure gauge: 60 MPa {600
790-261-1204 Digital hydraulic tester 1 kg/cm2}
793T-615-1820 Adapter 1 10 x 1.25 mm
2
07002-11023 O-ring 1
Testing wear of Commercially
X Vernier calipers 1
parking brake disc available
Testing work 1 79A-264-0021 Push-pull scale 1
equipment control Y Commercially
lever 2 Ruler 1
available
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
Testing and {25, 60, 400, 600 kg/cm2}
adjusting work
equipment EPC oil Z Pressure gauge: 60 MPa {600
2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
pressure
799-101-5220 Nipple 1 10 x 1.25 mm
3
07002-11023 O-ring 1
Pressure gauge: 2.5, 6.0, 40, 60
1 799-101-5002 Hydraulic tester 1 MPa
{25, 60, 400, 600 kg/cm2}
Testing and Pressure gauge: 60 MPa {600
adjusting work 2 790-261-1204 Digital hydraulic tester 1 kg/cm2}
equipment oil ZA
pressure 799-101-5220 Nipple 1 10 x 1.25 mm
3
07002-11023 O-ring 1
Differential pressure
4 799-401-2701 gauge
1 401-799-2930 Adapter 1
Pressure gauge: 2.5, 6.0, 40, 60
Testing wheel brake 2 799-101-5002 Hydraulic tester 1 MPa
oil pressure ZB
{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
3 790-261-1204 Digital hydraulic tester 1 kg/cm2}
Commercially Lap top type personal Windows XP SP2/VISTA/
1 computer 1
available Windows 7
2 Cu3886388 INSITE ver. 7.4 1
Writing
compensation 3 795-799-5730 INLINE 5 Kit 1
values at Commercially
ZC available
replacement of • Cable (USB)
injector and engine 4 • Cable (RS232) 1
or
controller 795-799-5740
5 795-799-5720 Cable (9P) 1
6 799-601-4510 Cable (12P) 1
Testing ECSS Commercially Gas charge tool
1 1
accumulator available
nitrogen gas Commercially Pressure reducing valve
2 1
pressure and available
procedure for ZD
charging Commercially
3 Charging hose 1
accumulator with available
nitrogen gas.

30-6 WA470-7
30 Testing and adjusting
General information on testing and adjusting

Testing and Sym-

Q'ty
adjusting item Part No. Part name Remarks
bol
1 792-610-1702 Gas charge tool 1
Nipple
792-610-1310 1 GOST
(for Russia)
Testing brake Nipple
accumulator 792-610-1320 1 CGA No. 351
nitrogen gas (for US)
pressure and Nipple
procedure for ZE 792-610-1330 1 ASA B-571-1965
2 (for US)
charging DIN 477-7963
accumulator with Nipple
nitrogen gas. 792-610-1350 1 NEN 3268-1966
(for German)
SIS-SMS 2235/2238
Nipple BS 341
792-610-1360 1
(for UK) Part1-1962
Removal and
installation of — 795T-981-1010 Socket 1
coolant temperature
sensor

WA470-7 30-7
30 Testing and adjusting
General information on testing and adjusting

Sketch of tools for testing and adjusting (WA470-3531-061-A-00-A)

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
H1: Plug

-:Socket

30-8 WA470-7
30 Testing and adjusting
General information on testing and adjusting

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
W: Adapter

WA470-7 30-9
30 Testing and adjusting
Engine and cooling system

Engine and cooling system (ALL-R401-001-K-00-A)

Testing engine speed (WA470-A000-360-K-01-A)

k Place the machine on a level ground and a Bucket does not move even when the bucket
lower the work equipment to the ground. lever is operated, since work equipment lock
switch is in ON (LOCK) position.
a Measure the engine speed under the following
conditions. Measuring torque converter stall speed
• Coolant temperature: 60 to 102°C 1. Start the engine.
• Hydraulic oil temperature: 45 to 55°C 2. Set transmission cut-off switch to "OFF" position
• Torque converter oil temperature: 60 to 80°C and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
Testing (WA470-A000-388-K-00-A) equipped) to OFF position.
a Check the engine speed with “Monitoring/Pre- 4. Set transmission shift mode selector switch to
defined“ or “Monitoring/Custom“ function of the the MANUAL position.
machine monitor. 5. While keeping the directional lever or directional
selector switch in N (neutral) position, set the
Preparation
gearshift lever to the 4th speed.
Operate machine monitor to display “Fan 100% 6. Release parking brake.
Mode“. 7. While depressing brake pedal, set directional
a For the machine monitor operating method, see lever or directional selector switch to "F
the section of "Adjustment (Fan 100% Mode)". (forward)" or "R (reverse)" position.

k Keep brake pedal firmly depressed.


8. Depress the accelerator pedal gradually to run
the engine at full speed and stall the torque
converter to measure the engine speed.
a Measure the stall speed 2 to 3 times.
a Do not keep stalling torque converter for
more than 20 seconds. Take care that torque
converter oil temperature does not exceed
120°C.
a Measure the torque converter stall speed
respectively when the power mode and
Measuring engine speed (low idle) economy mode are selected.
Start the engine, set it in the measuring condition,
Measuring hydraulic stall speed
and measure the engine speed.
1. Start the engine and run it at high idle.
Measuring engine speed (high idle) 2. Set the work equipment lock switch to OFF
1. Start the engine. (released) position.
2. Set the work equipment mode to P, and work 3. Set boom at the lowest position. (Boom angle:
equipment lock switch to OFF (released) Max. -35.5 degrees)
position. 4. Relieve the bucket cylinder on the extension
3. Set boom at the lowest position. (Boom angle: side (bucket digging relief), and measure the
Max. -35.5 degrees) engine speed.

a Bottom of the bucket is approx. 100 mm off a Measure the hydraulic stall speed
the ground while the bucket is level, and the respectively when the power mode and
boom angle is Max. -35.5 degrees. economy mode are selected.
4. Set work equipment lock switch to ON (LOCK)
Measuring engine speed at torque converter
position. stall and hydraulic stall (full stall)
5. Depress the accelerator pedal gradually while 1. Start the engine.
operating bucket lever tilting. Measure the 2. Set transmission cut-off switch to "OFF" position
engine speed at high idle. and depress left brake pedal securely.
3. Set the torque converter lockup switch (if
equipped) to OFF position.

30-10 WA470-7
30 Testing and adjusting
Engine and cooling system

4. Set transmission shift mode selector switch to


the MANUAL position.
5. While keeping the directional lever in N (neutral)
position, set the gear speed switch to the 4th
speed.
6. Release parking brake.
7. While depressing the brake pedal, set the
directional lever to the "F (forward)" or "R
(reverse)" position.

k Keep brake pedal firmly depressed.


8. Run the engine at high idle with the torque
converter stalled, and relieve the bucket cylinder
on the extension side (bucket digging relief), and
measure the engine speed at this time.
a Do not keep stalling torque converter for
more than 20 seconds. Take care that torque
converter oil temperature does not exceed
120°C.
a Measure the full stall speed when the power
mode is selected.

WA470-7 30-11
30 Testing and adjusting
Engine and cooling system

Testing boost pressure (WA470-A900-360-K-01-A)

a Testing tools
Sym-
Part No. Part name
bol
A 799-201-2202 Boost gauge kit

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k When installing and removing testing tools,


be careful not to touch a hot part of the
2. Install nipple [1] of boost gauge kit A, and
engine.
connect it to gauge [2].
a Testing of the boost pressure is to be performed 3 Nipple [1]:
under the following conditions. 15 ± 2 Nm {1.53 ± 0.2 kgm}
• Coolant temperature: 60 to 102°C
• Torque converter oil temperature: 60 to 80°C
• With torque converter stalled
Testing with machine monitor (WA380-
A900-362-K-00-A)

Check the boost pressure with “Monitoring/Pre-


defined“ or “Monitoring/Custom“ of the machine
monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".
a Monitoring code: 36500 “Charge Pressure-A“ 3. Start the engine and increase the coolant
temperature to the operating range.
4. Run the engine at medium or higher speed to
drain the oil in the hose.
a Repeat opening the self-sealing portion on
the hose by inserting approximately half of
the connection part of the gauge into the
hose to drain oil.
a When Pm kit (A) is available, you can use air
bleeding coupling (790-261-1130) in the kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
5. Set the transmission cut-off switch to OFF
Testing by use of testing tools (WA470- position and depress the left brake pedal
A900-362-K-00-A) securely.
1. Open side cover on the right of engine, and 6. Set the torque converter lockup switch to OFF
remove boost pressure pickup port plug (1). position.
7. Set transmission shift mode selector switch to
the MANUAL position.
8. While keeping the directional lever or directional
selector switch in N (neutral) position, set the
gearshift switch to the 4th speed.
9. Release parking brake.

30-12 WA470-7
30 Testing and adjusting
Engine and cooling system

10.While depressing the brake pedal, set the


directional lever to the "F (forward)" or "R
(reverse)" position.

k Keep brake pedal firmly depressed.


11.Depress the accelerator pedal gradually to run
the engine at high idle and stall the torque
converter, then measure the boost pressure.
a Do not keep stalling torque converter for
more than 20 seconds. Be careful that torque
converter oil temperature does not exceed
120°C.
3 Pickup port plug (1):
15 ± 2 Nm {1.53 ± 0.2 kgm}
Boost pressure Min. 93 kPa {min. 700 mmHg}

12.After finishing test, remove the testing tools and


restore the machine.

WA470-7 30-13
30 Testing and adjusting
Engine and cooling system

Testing exhaust gas color (WA470-A900-360-K-00-A)

a Testing tools 3 Plug:


Sym- 42.1 to 70.6 Nm {4.3 to 7.2 kgm}
Part No. Part name
bol
2 Plug:
1 799-201-9002 Handy smoke checker
C Commercially Seizure prevention compound (LC-G)
2 Smoke meter
available

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Be careful not to touch any hot part when


installing or removing the testing tools.

k When KDPF regeneration is started, the


high-temperature exhaust gas spurts from
the inspection port, that may cause burn 3. Measuring by using handy smoke checker C1
injury. Therefore, you must stop KDPF
1) Fit a sheet of filter paper to handy smoke
regeneration through the machine monitor
checker C1.
before starting the inspection.
2) Insert the exhaust gas intake pipe into plug
(For the stopping procedure for KDPF hole (6).
regeneration, see the Operation and
Maintenance Manual.) a Set the probe end so that it is in parallel
with the direction of the pipe at its center.
a Measure the exhaust gas color under the 3) Start the engine, and operate the handle of
following conditions. handy smoke checker C1 under the torque
• Coolant temperature: 60 to 102°C converter stalled condition so that the filter
• Torque converter oil temperature: 60 to 80°C paper will absorb the exhaust gas.
• With torque converter stalled a Suction time: 1.4 ± 0.2 second
• Hold in stationary state for 5 seconds, then
collect the exhaust gas.
a If an air source and a electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, etc.,
use smoke meter C2.
Testing (WA470-A900-385-K-00-A)

1. Open the engine left side cover and remove


cover (4).

4) Remove the filter paper and compare it with


the attached scale for judgment.
5) After finishing the test, remove the testing
tools and restore the machine.
4. Testing with smoke meter C2
1) Connect the probe hose, accelerator switch
outlet and air hose to smoke meter C2.
a The supplied air pressure must be 1.5
MPa {15 kg/cm2} or below.
2) Connect the power cable to an AC 100 V
2. Remove plug (5). receptacle.

30-14 WA470-7
30 Testing and adjusting
Engine and cooling system

a Before connecting the power cable, make


sure that the power switch of the smoke
meter is turned OFF.
3) Insert probe [1] of the smoke meter C2 into
port (6) for the removed plug.
a Set the probe end so that it is in parallel
with the direction of the pipe at its center.

4) Loosen the cap nut of the suction pump and


place the filter paper.
a Place the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of smoke meter C2
ON.

6) Start the engine, put the torque converter in


the stalled condition, and then depress the
accelerator pedal of smoke meter C2 to
collect the exhaust gas impurities on the filter
paper.
7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
8) After finishing the test, remove the testing
tools and restore the machine.

WA470-7 30-15
30 Testing and adjusting
Engine and cooling system

Testing and adjusting valve clearance (WA470-A700-360-K-00-A)

a Testing tools a The rocker arm of No.1 cylinder with the


Sym- piston at the compression top dead center
Part No. Part name can be moved by hand by the distance
bol
Commercially Feeler gauge equivalent to the valve clearance. If the
D rocker arm cannot be moved, the No.1
available
cylinder is not at its compression top dead
k Place the machine on a level ground, lower center. In that case, rotate the crankshaft one
the work equipment to the ground, set the more turn.
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Turn the battery disconnect switch to OFF


position, and remove the key.

a Test and adjust the valve clearance under the


following conditions.
• When engine is cold
Testing (WA470-A700-361-K-00-A)

1. Remove cylinder head cover (1). For details, see


Disassembly and assembly, removal and
installation of cylinder head assembly.

2. Remove rubber cover (2) on the front side of


damper

4. While No.1 cylinder is at the compression top


dead center, check the valve clearance of the
valves marked with q in the following figure.
5. Rotate the crankshaft in the normal direction by
3. Rotate the crankshaft in the normal direction to one turn and check the valve clearance of the
set No.1 cylinder to the compression top dead remaining valves marked with Q.
center by matching "1.6 TOP" stamping mark (a)
of the damper to pointer (4).
a Stamp marks are "1.6 TOP", "2.5 TOP" and
"3.4 TOP".

30-16 WA470-7
30 Testing and adjusting
Engine and cooling system

4. After finishing the adjustment, remove the


adjusting tools and restore the machine.
a You may check the valve clearance of No.1
cylinder while No.1 cylinder is at the 3 Cylinder head cover (1) mounting
compression top dead center and then turn bolt:
the crankshaft in the normal direction by 120 9.8 ± 1 Nm {1.0 ± 0.1 kgm}
degrees and check the valve clearance of
each cylinder in the firing order.
a Firing order: 1-5-3-6-2-4
a The valve clearance is normal if it is within
the range of the standard value. For standard
values, see "Standard value table",
"Standard value table related to engine".
6. After finishing the test, remove the testing tools
and restore the machine.
Adjusting (WA470-A700-27D-K-00-A)

After testing, adjust the valve clearance according


to the following procedure if necessary.
a After setting the No.1 cylinder at the
compression top dead center, adjust valve
clearance of No.1 cylinder.
1. While fixing adjustment screw (6), loosen lock
nut (7).
2. Insert feeler gauge D into the clearance between
rocker arm (8) and crosshead (9), and adjust the
valve clearance with adjustment screw (6).
a With feeler gauge D inserted, turn the
adjustment screw (6) until the feeler gauge D
can move lightly.
a For standard values, see "Standard value
table", "Standard value table related to
engine".
3. With adjustment screw (6) fixed, tighten lock nut
(7).
3 Lock nut (7):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a After tightening lock nut (7), check the valve
clearance again.
a The following figure shows adjustment of air
intake side of No.4 cylinder.

WA470-7 30-17
30 Testing and adjusting
Engine and cooling system

Testing compression pressure (WA470-A000-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
1 795-502-1590 Gauge assembly
795-471-1420 Adapter
2
E 6217-71-6112 Gasket
Hose (inside diameter 14
Commercially mm, length approximately
3
available 2 m)

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Turn the battery disconnect switch to OFF


position and remove the key.

k When testing the compression pressure, be


careful not to burn yourself by touching the
exhaust manifold or KDPF, or get caught in a
rotating part.

a Measure the compression pressure under the


following conditions.
• Engine oil temperature: 40 to 60°C 3. Remove spill tube (8).
Testing (WA470-A000-36B-K-00-A) a This helps the sleep nut to be removed
1. Remove engine hood, air cleaner assembly, and easily.
KDPF assembly according to "Removal and
installation of cylinder head assembly" in
"Disassembly and assembly".
2. Remove tubes (1) and (2) of KCCB, and
harness (3).
a Remove all connectors and clamps of supply
pump (4), EGR Valve (5), air conditioner
compressor (6), and dosing valve (7) for
wiring harness (3) to be released.

4. Remove the cylinder head cover (9), and set the


cylinder to be tested to the compression top
dead center. For details, see "Testing and
adjusting valve clearance".

30-18 WA470-7
30 Testing and adjusting
Engine and cooling system

8. Pull high-pressure tube (12), and remove the


a Check that both the intake rocker arm and
injector (16).
exhaust rocker arm at the compression top
dead center are movable by hand by the
distance equivalent to the valve clearance.
5. Replace the filter cartridge (10).

9. Install adapter E2 to the injector mounting hole.


a Be sure to install the gasket to the top of the
adapter E2.
6. Remove cover (11) of the common rail, then
a Fix the adapter E2 with the injector holder
remove high-pressure fuel tube (12) to be
(17).
checked.
3 Holder mounting bolt (18):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
10.Install rocker arm assembly (13).
3 Rocker arm assembly mounting bolt
(19):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
11.Adjust the valve clearance.
See "Testing and adjusting valve clearance".

7. Remove rocker arm assembly (13), and


disconnect injector wiring harness (14).
a Disconnect the injector wiring harness (14)
from the terminals on the injector side, and
pull it to the outside of the rocker housing.
(Loosen 2 pieces of terminal nuts
alternately).
a QR code tab (15) is attached to the top of the
injector. Do not remove or damage it. 12.Install spill tube, filter cartridge, wiring harness,
and air cleaner assembly.
13.Connect compression gauge E1 to adapter E2.

WA470-7 30-19
30 Testing and adjusting
Engine and cooling system

a Apply a small amount of engine oil to the


connecting portion of the adapter E2 and
compression gauge to prevent air leakage.

16.Rotate the crankshaft by the starting motor and


measure the compression pressure.
17.After finishing the test, remove the testing tools
14.Install a fuel drain hose (E3) at where the tube is and restore the machine to its original condition.
disconnected of the common rail, and let a Install the injector, injector wiring harness
injected fuel drain to a container.
and high-pressure fuel tube according to the
following procedure.
1) Install 2 O-rings (20) and (21) and gasket
(22) to injector (16).
a Do not fit O-ring (20) into spill groove in
the center, but fit it into O-ring groove.
Insert injector into cylinder head after
applying engine oil to O-ring.
2) Assemble holder (17) and injector (16), then
install them to the cylinder head temporarily.
3) Set spherical washer (23) to mounting bolt
(18) and tighten the bolts to the cylinder
head.
15.Select the "No-Injection cranking" operation by
operating the machine monitor. 2 Spherical part of spherical washer
(23):
a Turn the battery disconnect switch to ON Engine oil (SAE30DH)
position, then turn the starting switch to ON
position. 3 Mounting bolt (18):
a For the "No-Injection cranking" setup 58.8 to 73.5 Nm {6.0 to 7.5 kgm}
procedure, see the section of "Special 4) Tighten 2 nuts at the tip of wiring harness
functions of machine monitor". (14) alternately to injector (16).
3 Nut:
k If the engine is not set to the "No-Injection
2.0 to 2.4 Nm {0.2 to 0.24 kgm}
cranking", it may start during 5) Tighten tube (12) to injector (16).
measurement and cause personal injury.
Accordingly, be sure to set the engine in 3 Sleeve nut:
this mode. 39.2 to 44.1 Nm {4 to 4.5 kgm}
6) Tighten the clamp bolt for the fuel piping.

30-20 WA470-7
30 Testing and adjusting
Engine and cooling system

3 Clamp bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

3 Rocker arm assembly mounting


bolt (19):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a Adjust the valve clearance. For details of
the procedure, see "Adjusting valve
clearance".
3 Cylinder head cover mounting
bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}

WA470-7 30-21
30 Testing and adjusting
Engine and cooling system

Testing blowby pressure (WA470-A000-360-K-02-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-201-1504 Blowby checker
Plug (hose inside
2 799T-201-3210 diameter: 24 mm)
F
Cap (pipe outside
3 799T-201-3220 diameter: 25.4 mm)

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the 4. Start the engine to increase temperature of the
engine, and chock the wheels. engine coolant to the operating range.
5. Set the transmission cut-off selector switch to
a Measure the blowby pressure under the
OFF position, and depress the left brake pedal
following conditions.
securely.
• Coolant temperature: 60 to 102°C 6. Set the torque converter lockup switch to OFF
• Torque converter oil temperature: 60 to 80°C position.
• Perform when the regeneration is stopped. 7. Set transmission shift mode selector switch to
Testing (WA470-A000-36C-K-00-A) MANUAL position.
8. While keeping the directional lever or directional
1. Open the side cover on the right side of engine. selector switch in N (neutral) position, set the
2. Disconnect KCCV gas outlet side hose (1) and gearshift lever to 4th speed.
KCCV gas inlet side hose (2). 9. Release parking brake.
10.While depressing brake pedal, set directional
lever or directional selector switch to "F
(forward)" or "R (reverse)" position.

k Keep brake pedal firmly depressed.


11.Depress the accelerator pedal gradually to run
the engine at full speed and stall the torque
converter to measure the blowby pressure.
a Do not keep stalling the torque converter for
more than 20 seconds. Be careful that the
torque converter oil temperature will not
exceed 120°C.
3 Clamp:
a Normally, the blowby pressure should be
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm} measured while the engine is operated at the
3. Plug pipe (3) on KCCV gas outlet side with plug rated output. In the field, however, an
F2, and install cap F3 to KCCV gas inlet pipe (4) approximate value can be obtained by
and outlet pipe (5). Install tool and adapter [1] of stalling the torque converter.
blowby checker F1 to KCCV gas inlet hose (6),
and connect gauge [3]. a Precaution for measuring blowby pressure
The blowby pressure may vary largely with
the engine condition. If the measured value
is judged unusual, make a check for increase
of oil consumption, bad exhaust gas color,
early deterioration or contamination of oil, etc.
which are related to the unusual blowby
pressure.

30-22 WA470-7
30 Testing and adjusting
Engine and cooling system

12.After finishing test, remove the testing tools and


restore the machine.

WA470-7 30-23
30 Testing and adjusting
Engine and cooling system

Testing engine oil pressure (WA470-AB00-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
G 2 790-261-1204 Digital hydraulic tester
3 799-401-2320 Gauge

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.
3. Start the engine to increase the cooling
a Measure the engine oil pressure under the temperature to the operating range.
following condition. 4. Measure the oil pressure with the engine at low
• Coolant temperature: 60 to 102°C idle and high idle.
Testing (WA470-AB00-362-K-00-A) a The engine oil pressure is normal if it is within
a Check the engine oil pressure with “Monitoring/ the range of the following standard values.
Pre-defined“ or “Monitoring/Custom“ of the At high idle See standard value table
machine monitor. At low idle See standard value table
a Monitoring code: 37200 “Engine Oil Pressure“
1. Open side cover on the left of engine, and
remove oil pressure pickup port plug (1) from the
engine oil filter.

5. After finishing the test, remove the testing tools


and restore the machine.
3 Oil pressure pickup plug:
2. Install nipple [1] and hose [2] of hydraulic tester 20 ± 2 Nm {2.04 to 0.2 kgm}
G1 and connect them to gauge G3.
3 Nipple:
20 ± 2 Nm {2.04 to 0.2 kgm}
a The nipple and hose for digital hydraulic
tester G2 can also be used.

30-24 WA470-7
30 Testing and adjusting
Engine and cooling system

Testing EGR valve and KVGT oil pressures (WA470-A9K1-360-K-00-A)

a Testing tools a The nipple and hose of digital hydraulic tester


Sym- H3 can also be used.
Part No. Part name
bol 3 Plug H1:
795T-401-1310 Plug
1 34.3 to 44.1 Nm {3.5 to 4.5 kgm}
02896-21015 O-ring
H
2 799-101-5002 Hydraulic tester
3 790-261-1204 Digital hydraulic tester

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

• Coolant temperature: 60 to 102°C


a The standard values for the EGR valve drive oil
pressure and the KVGT drive oil pressure are
the same, because they share the same circuit. 5. Start the engine and measure the oil pressure at
low idle and high idle.
Testing (WA470-A9K1-362-K-00-A)

1. Open side cover (1) on the left of engine a When the EGR valve and KVGT driving oil
pressure is in the following standard range, it
is normal.
At low idle See standard value table
At high idle See standard value table

2. Remove clamp (2), and lower dosing fuel hose


(4).
3. Remove plug (3) (driving oil pressure).

6. After finishing the test, remove the testing tools


and restore the machine.
3 When installing plug (3), install new O-
rings H1(2 pieces).
3 Joint plug (3):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}

4. Install plug H1, and install nipple and hose of


hydraulic tester H2, and then connect them to
gauge [3].
a Be sure to fit the O-ring to plug H1.
a Use gauge [3] of 2.5 MPa {25 kg/cm2}.

WA470-7 30-25
30 Testing and adjusting
Engine and cooling system

Testing fuel pressure (WA470-AE20-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
795-790-5120 Screw
J
3 07005-01412 Gasket
790-301-1530 Elbow
4 799-401-2320 Gauge

k When removing or installing testing tools for


the fuel system, stop the engine and wait for
at least 30 seconds until the remaining 5. Start the engine and measure the fuel pressure
pressure is released from the fuel circuit. (Do at engine high idle.
not start the work immediately after the
a The fuel pressure is normal when it is within
engine is stopped since remaining pressure
the following standard value range.
is still in the circuit.)
Engine speed Fuel pressure
k Place the machine on a level ground, lower High idle See standard value table
the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Since the pressure in the high-pressure


circuit from the supply pump through the
common rail to the injector is very high and
dangerous, do not measure it.

Testing (WA470-AE20-362-K-00-A)

1. Open the side cover on the right side of engine.


2. Remove fuel tube mounting bolt (3) on the upper
side of fuel filter. 6. After finishing the test, remove the testing tools
and restore the machine.
3 Fuel pressure pickup plug (3):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}

3. Install screw and elbow J3.


a Be sure to fit the gasket.
4. Install nipple and hose [2] of hydraulic tester J1
to screw and elbow J3, and then connect them
to gauge J4.
a The nipple and hose of digital hydraulic tester
J2 can also be used.

30-26 WA470-7
30 Testing and adjusting
Engine and cooling system

Testing fuel return rate and leakage (WA500-AE20-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially Hose (inside diameter:
3 approximately 6 mm)
available
K Commercially Hose (inside diameter:
4 approximately 16 mm)
available
Commercially Measuring cylinder
5
available
Commercially Stopwatch
6
available

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a Since some fuel flows out during test, prepare a


container of approximately 20 l.
k When removing or installing testing tools for
the fuel system, stop the engine and wait for
at least 30 seconds until the remaining
pressure is released from the fuel circuit. (Do
not start the work immediately after the
engine is stopped since remaining pressure
is still in the circuit.)

WA470-7 30-27
30 Testing and adjusting
Engine and cooling system

A: Measuring position of leakage from pressure limiter


B: Measuring position of return rate from injector

30-28 WA470-7
30 Testing and adjusting
Engine and cooling system

Testing (WA470-AE20-363-K-00-A)

Testing leakage from pressure limiter a Be sure to install the gasket to the both ends
1. Open engine right side cover (1) and (2). of the joint.
5. Connect test hose K3 to the end of joint K2.
a Bind the connected part of the test hose with
a wire, etc. to prevent it from coming off.
a Arrange the route of the test hose so that it
does not sag, and put its end in a container.

2. Remove tube (5) between pressure limiter (3)


and return block (4).

6. Start the engine, and stall the torque converter.


a For the torque converter stalling procedure,
see "Testing engine speed".
7. After the engine speed is stabilized, measure
the leakage for 1 minute by using measuring
cylinder K5.
a Measuring duration can be 20 seconds if the
leaked amount is multiplied by 3 after the
3. Insert spacer K1 into the return block (4) side, measurement.
and tighten the removed joint bolt again. a Leakage from the pressure limiter is normal
3 Joint bolt: when it is within the following standard value
range.
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
Leakage
a Be sure to install the gasket to the both ends Measurement condition
(cc/min)
of the spacer.
With torque converter
See standard value table
stalled

4. Insert joint K2 into the common rail (6) side and


tighten the removed joint bolt again.
8. Stop the engine after the measurement is over.
3 Joint bolt: Testing fuel return rate from injector
17.7 to 22.6 Nm {1.8 to 2.3 kgm}

WA470-7 30-29
30 Testing and adjusting
Engine and cooling system

a While measuring the fuel return rate from the a Return (spill) rate from the injector is normal
injector, keep the hose on the pressure limiter if it is within the following standard value
side connected and insert the hose end in the range.
container. Engine speed Limit return (spill) rate
1. Disconnect fuel return hose (7) of return block (rpm) (cc/min)
(4).
1,600 See standard value table
a Plug the fuel hose by using a plug.
1,700 See standard value table
Plug part number: 07376-70315 1,800 See standard value table
1,900 See standard value table
2,000 See standard value table

2. Connect test hose K4 to the return block (4)


side.
a Bind the connected part of the test hose with 5. After finishing the test, stop the engine, remove
a wire, etc. to prevent it from coming off. the testing tools and restore the machine.
a Arrange the route of the test hose so that it 3 Joint bolt on block side:
does not sag, and put its end in a container. 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolt on common rail side:
17.7 to 22.6 Nm {1.8 to 2.3 kgm}

3. Start the engine, and stall the torque converter.


a For the torque converter stalling procedure,
see "Testing engine speed".
4. After the engine speed is stabilized, measure
the return rate for 1 minute by using measuring
cylinder K5.
a Measuring duration can be 20 seconds if the
leaked amount is multiplied by 3 after the
measurement.
a If the error of no-pressure feed occurs on the
supply pump, there is a case that the engine
speed does not increase. In such case,
record the engine speed during testing, as
well.

30-30 WA470-7
30 Testing and adjusting
Engine and cooling system

Bleeding air from fuel system (PC400-AD00-001-K-00-A)

Low-pressure fuel circuit

1. Fuel tank a In the following cases, bleed air according to this


2. Fuel connector procedure.
3. Pre-filter • When a fuel filter is replaced
• When run out of fuel occurs
4. Fuel feed pump
• When starting the engine for the first time
5. Doser after replacing fuel piping or supply pump
6. Supply pump
k Place the machine on a level ground, and
7. Feed pump lower the work equipment to the ground.
8. Cooling plate
9. Main fuel filter k While the fuel feed pump is in operation,
pressure is applied to the fuel circuit. Do not
10. Common rail pressure
loosen the air bleeding plug at this time,
11. Injector since the fuel may spout out.
12. Pressure limiter valve

WA470-7 30-31
30 Testing and adjusting
Engine and cooling system

Bleeding air (WA470-AD00-231-K-00-A)

1. Supply fuel to the fuel tank.


a Continue the supply of fuel until the fuel
gauge monitor turns to blue.
(Check the fuel level with monitor after
turning the starting switch to ON position.)
2. Open side cover (1) on the right of engine.

4. After the specified time (approximately 6


minutes and 30 seconds), lamp (3) automatically
goes off and the fuel feed pump stops.
a When only the fuel filter is replaced, air
bleeding work is completed at this point.
5. When fuel in the fuel circuit is lost in the cases
3. Tilt switch (2) for the fuel feed pump in the as fuel is run out or the fuel piping or supply
engine room to ON position. pump is replaced, set switch (2) to ON position
again immediately after the fuel feed pump stops
a The fuel feed pump operates and lamp (3) automatically.
flashes. 6. Air bleeding is complete when lamp (3) goes off.
7. Start the engine.

k Make sure that no person is found around


the engine before starting the engine.
a Do not turn the starting motor continuously
for more than 20 seconds.
a The air in the high-pressure circuit is bled
automatically by cranking the engine.
a After the engine is started, run it at low idle
for approximately 5 minutes to bleed air
completely from the fuel circuit.
a The timer built in this switch automatically
starts up and stops the fuel feed pump (see
the figure).
a Operation of the fuel feed pump stops while
the lamp is flashing. It is, however, not a
failure.
a If you set the switch to OFF position while the
lamp is lighted, the lamp goes out and the
fuel feed pump stops.

30-32 WA470-7
30 Testing and adjusting
Engine and cooling system

Testing fuel circuit for leakage (WA380-AD00-001-K-01-A)

a Testing tools a To apply a load to the engine installed on the


Symbol machine, perform the torque converter stall
Part No. Part name
operation or hydraulic relief of the hydraulic
Developer
pump.
Commercially for dye penetrant
L 9. Check the fuel piping and devices for fuel
available check (color
leakage.
checker)
a Check the high-pressure circuit for fuel
k Very high pressure is generated in the high- leakage focusing on the area to which color
pressure circuit of the fuel system. If fuel checker L is sprayed.
leaks while the engine is running, it presents
a serious danger that could result in a fire. a If any fuel leakage is detected, repair it and
perform the checks from Step 1 again.
After testing the fuel system and removing or
installing the tools for the test, test it for fuel a If no fuel leakage is detected, check is
leakage according to the following procedure. completed.

k Park the machine on a level ground and


lower the work equipment to the ground.

a Clean and degrease the engine and the parts


around it in advance so that you can check it
easily for fuel leakage.
Testing (WA380-AD00-364-K-00-A)

1. Spray color checker (developer) L to the fuel


supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 1 again.
4. Start the engine and keep it running at low idle.
5. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 1 again.
6. Start the engine and keep it running at high idle.
7. Check the fuel piping and devices for fuel
leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform the checks from Step 2 again.
8. Start the engine and keep it running at high idle,
then apply a load to the engine.

WA470-7 30-33
30 Testing and adjusting
Engine and cooling system

Handling cylinder cutout mode operation (PC-AD00-34F-K-00-A)

a The cylinder cut-out test mode operation means


to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cut-
out Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston or piston ring
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.

30-34 WA470-7
30 Testing and adjusting
Engine and cooling system

Handling no injection cranking operation (PC-A000-25L-K-00-A)

a No-injection cranking means to crank the engine


by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.

WA470-7 30-35
30 Testing and adjusting
Engine and cooling system

Testing of KDPF and muffler stack for looseness and damage (WA380-A9H0-280-K-
00-A)

1. Visually check KDPF and muffler stack for


cracking and damage. If any part is damaged,
replace it.
2. Check the mounting bolts of the KDPF and
muffler stack for looseness. If any part is
loosened, retighten it.

30-36 WA470-7
30 Testing and adjusting
Engine and cooling system

Testing of installed condition of cylinder head and manifolds (WA380-A100-280-K-00-


A)

Check the cylinder head and intake and exhaust


manifold mountings for looseness. If any part is
loosened, retighten it.
a For the tightening torques, see the "Disassembly
and assembly".

WA470-7 30-37
30 Testing and adjusting
Engine and cooling system

Testing engine piping for damage and looseness (WA380-A000-280-K-00-A)

Air intake and exhaust systems: Check the piping


for damage, the mounting bolts and nuts for
looseness, and the joints for air suction and exhaust
gas leakage. If any part is loosened or damaged,
retighten or repair it.
Cooling system: Check the piping for damage, the
mounting bolts and nuts for looseness, and the
joints for water leakage. If any part is loosened or
damaged, retighten or repair it.
Fuel system: Check the piping for damage, the
mounting bolts and nuts for looseness, and the
joints for fuel leakage. If any part is loosened or
damaged, retighten or repair it.

30-38 WA470-7
30 Testing and adjusting
Engine and cooling system

Testing and adjusting air conditioner compressor belt tension (WA380-K5A0-001-K-


00-A)

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing (WA470-K5A0-285-K-00-A)

1. Open the side cover on the right side of engine.


2. Before checking, insert the starting switch key
into lock (1) to release it, and open cover (2).

2. Loosen bolts (4) and (5).


3. Tighten bolt (9) after loosening nut (8) installed
to bracket (7), compressor (6) shifts in direction
A, and the compressor belt can be stretched.

3. Press the intermediate point of the belt between


air conditioner compressor pulley and crankshaft
pulley with a finger and measure deflection (a).
• Belt pressing force: Approx. 98 N {Approx.
10 kg}
• Deflection (a): 25 to 26 mm

4. After measurement, close cover (2), and lock it


with the starting switch key. 4. After adjusting the belt tension properly, tighten
nut (8) until it touches boss (10) and tighten it
Adjusting (WA470-K5A0-27C-K-00-A) further in direction B so that it is not loosened.
a If the belt deflection is abnormal, adjust it 3 Tightening torque:
according to the following procedure.
157 to 196 Nm {16 to 20 kgm}
1. Before adjusting, insert the starting switch key 5. Tighten bolts (4) and (5) to fix bracket (7).
into lock (1) to release it, and open covers (2)
and (3). 3 Tightening torque
Bolt (4): 157 to 196 Nm {16 to 20 kgm}
Bolt (5): 98 to 123 Nm {10 to 12.5 kgm}

WA470-7 30-39
30 Testing and adjusting
Engine and cooling system

6. After adjusting, close covers (2) and (3), and


lock it with the starting switch key.
a Check each pulley for damage, wear of the V-
groove, and the wear of the V-belt. In particular,
be sure to check that the V-belt does not touch
the bottom of the V-groove.
a Replace the belt with a new one if the belt is
stretched and has no allowance for adjustment,
or has slipping sound or squeak because of cuts
or cracks of the belt.
a If the V-belt is replaced, adjust its tension again
after one hour of operation.

30-40 WA470-7
30 Testing and adjusting
Engine and cooling system

Testing and adjusting alternator belt tension (WA470-AKM4-360-K-00-A)

Testing (WA470-AKM4-923-K-00-A) 2. After loosening bolts (5) and (6), loosen locknut
1. Open side cover on the left of engine. (7).
2. Insert the starting switch key into lock (1) to 3. Alternator (8) moves to the direction (A) by
release it, and open cover (2). rotating adjustment nut (9), and tension can be
applied to alternator drive belt.
4. When the belt tension becomes appropriate,
tighten locknut (7) until it comes to contact with
boss (10).
5. Tighten bolts (5) and (6) to fix alternator (8).
Bolt (5): 28.4 to 38.2 Nm {2.9 to 3.9 kgm}
Bolt (6): 107.8 to 147 Nm {11 to 15 kgm}
6. After adjusting, install cover (3) and handrail (4),
close cover (2), and lock it with the starting
switch key.
a Check each pulley for damage, wear of the V-
groove, and the wear of the V-belt. In particular,
be sure to check that the V-belt does not touch
3. Press the belt at the intermediate point between the bottom of the V-groove.
the alternator pulley and crank pulley with your a Replace the belt with a new one if the belt is
finger and measure deflection (a). stretched and has no allowance for adjustment,
• Depressing force: Approximately 59 N {6 kg} or has slipping sound or squeaks because of
• Deflection (a): Approximately 13 to 16 mm cuts or cracks of the belt.
a If the V-belt is replaced, adjust its tension again
after one hour of operation.

4. After measurement, close cover (2), and lock it


with the starting switch key.
Adjusting (WA470-AKM4-285-K-01-A)

1. Insert the starting switch key into lock (1) to


release it, open cover (2), then remove cover (3)
and handrail (4).

WA470-7 30-41
30 Testing and adjusting
Engine and cooling system

30-42 WA470-7
30 Testing and adjusting
Engine and cooling system

Procedures for cleaning fuel doser (WA500-A9H6-360-K-00-A)

a The procedure given below is applicable when


you perform the engine troubleshooting "S-22
Active regeneration is operated for long" due to
malfunctioning of KDPF device or clean the fuel
doser in 4,500-hour periodic maintenance.
k Place the machine on a level ground, lower
the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Install and remove the fuel doser after


making sure that the temperature of the Cleaning (HM300-A9H6-255-K-00-A)
exhaust manifold and exhaust piping has
lowered. 1. Eliminate soot (14) adhered to fuel doser (8).

Removal (WA470-A9H6-520-K-00-A)

1. Open full-length fender (1), and side cover (2).

2. Soak cloth (15) with sufficient volume of diesel


fuel, and press it against the accumulated soot
in the tip of the fuel doser injection port for the
2. Disconnect connector DOSER (3). diesel oil to permeate into the soot.
3. Remove clamps (4) (3 pieces).
4. Disconnect fuel hose (5). [*1]
5. Disconnect coolant hose (6). [*2]
6. Remove bolts (7) (2 pieces) (8 mm of width
across flats), and remove fuel doser assembly
(8).

3. After the diesel fuel permeates into the


accumulated soot, clean it with cloth (15).

WA470-7 30-43
30 Testing and adjusting
Engine and cooling system

4. Eliminate soot in the injection port by scrubbing


the tip of the port by using nylon brush (16).
• Eliminate soot completely from the injection
port by using nylon brush (16) and cloth (15).
a Use a nylon brush for the cleaning since a
wire brush can damage the injection port.
a Use diesel fuel for the cleaning agent without
using other solvents.

Installation (HM300-A9H6-720-K-00-A)

1. Install heat insulator (10) to fuel doser (8).


2. Insert bolt (11) into fuel doser (8), install gasket
(9) to the fuel doser, then install them to the
exhaust connector.
3 Bolt (11) (width across flats 8 mm):
8.5 to 9.5 Nm {0.87 to 0.97 kgm}
a Bolt (11), gasket (9) and heat insulator (10) to
be used must be new ones.

a Tip of injection port after cleaning


Cleaning complete (A: Tip of injection port is a Install gasket (9) so that its stepped portion
free from remaining soot) becomes convex against the exhaust
Cleaning incomplete (B: Tip of injection port connector.
has remaining soot)

30-44 WA470-7
30 Testing and adjusting
Engine and cooling system

a When installing gasket (9) and heat insulator


(10), be careful for them not to fall.
3. Install the bracket, fuel hose clamp and wiring
harness clamp in the reverse order of removal.
4. After installing the fuel doser, run the engine at
low idle for approximately three minutes. Then
stop the engine and check the fuel doser for
water and fuel circuits for leakage.

WA470-7 30-45
30 Testing and adjusting
Engine and cooling system

Writing compensation values at replacement of injector and engine


controller (WA500-AP70-360-K-00-A)
a Equipment for writing compensation values a Service connector (1) (CN-SV) is installed to
Sym- rear left of the operator's seat.
Part No. Part name
bol
Notebook computer:
Commercially
1 Windows XP SP2/VISTA/
available
Windows 7
2 Cu3886388 INSITE ver 7.4
3 795-799-5730 INLINE 5 Kit
ZC Commercially
available • Cable (USB)
4 • Cable (RS232)
or
795-799-5740
5 795-799-5720 Cable (9P)
6 799-601-4510 Cable (12P)

a To install INSITE to a PC, insert DVD-ROM


software and operate the PC according to the Start INSITE
displayed menus. 1. Boot the PC.
2. Turn the starting switch to the ON position and
a Use INSITE ver 7.4 Feature Pack 1 or later supply power from the battery to the engine
version for the writing. controller.
a Since a failure (shutdown or disconnection) on a 3. Double-click the icon on the PC shown below.
PC or cable can induce a serious error to the
engine controller, sufficient care must be taken
for the cable connection.
a When connecting INSITE to the engine
controller, make sure not to stop supply of power
from the battery to the engine controller.
Stopping the power supply loses the connection
with INSITE.
Adjusting (WA500-AP70-270-K-00-A)
Connecting PC
1. Check that the starting switch is turned to the
OFF position.
4. Establish communication with the engine
controller.
k The starting switch must be turned to the
1) Select "Connect to ECM".
OFF position when a PC is connected or
disconnected. • Section A: Make sure that "INLINE 5 USB
(J1939) Connection" is indicated.
2. Install personal computer ZC1, data link adapter
ZC3, and cables ZC4, ZC5, and ZC6, and then
connect them to service connector (1) (CN-SV).

2) Select "Connect".
• Section B: Confirm that "None" is
displayed.

30-46 WA470-7
30 Testing and adjusting
Engine and cooling system

3) Input the new data to "New Barcode"


a C: Connection-in-process screen
column.
D: Screen after the connection is
completed (illustration does not move) a Replacement of the injector and engine
controller is performed.
E: Communication status is displayed
(illustration moves during communication) 1] Replace injector.
• When the injector is replaced, write
the injector compensation value
written on the new injector in the
engine controller.
• If the compensation value is not
correctly written, an engine trouble
can result.
• The character string on the injector
top face is read from left to right.

5. Execute the injector trim function and data


writing.
1) Select "Advanced ECM Data".
• Section F: Make sure that "Advanced
ECM Data" is indicated.

2) Select "High Pressure Common Rail Injector


Setup".
• Section G: Make sure that "High
Pressure Common Rail Injector Setup" is
indicated. 2] Replacing engine controller
• When the engine controller is
replaced, write the injector
compensation value written on the old

WA470-7 30-47
30 Testing and adjusting
Engine and cooling system

engine controller to the new engine • Section K: Select "OK."


controller.
• If the compensation value is not
correctly written, an engine trouble
can result.
• Compensation value information
provided on the back of engine
controller
a: String of characters
b: QR code

• Screen while data processing is


continued (wait for 30 seconds)

• Section H: "New Barcode" column

6) After data processing is over, turn the


starting switch to the ON position and select
"OK".
• Section L: Select "OK."

4) Execute writing to the engine controller.


After entering the injector data, select "Apply".
• I: Entry of data of the target injector.
Examples)
Enter data of No.1 cylinder injector
corresponding to "Cylinder1".
• Section J: Select "Apply."

7) Screen that indicates data writing is over.


Select "OK".
• Section M: Select "OK."

5) After writing data, turn the starting switch to


the OFF position and select "OK".

30-48 WA470-7
30 Testing and adjusting
Engine and cooling system

8) Screen that appears when data writing ends 7. Turn the starting switch to the OFF position, then
successfully. "Success" is displayed on the boot the PC again (turn the starting switch to the
screen. ON position) to make sure that an error is not
• Section N: Make sure that "success" is present on the monitor.
indicated. a Failure code:
CA2765: Inj Trim Data Error
8. When replacing the injector, clear the values on
the compensation values sheet on the back of
the engine controller.
a Clear the data of the replaced injector on the
compensation values sheet that is provided
on the back of the engine controller.
a Record the data of the replaced injector in
the maintenance register.
9. When the engine controller is replaced,
inconsistency may result between the data
recorded on the sheet on the back of the engine
a Screen that appears for faulty data writing controller and that recorded in the register when
• Section P: Indicates that writing is replacement of an injector or engine controller
faulty. was done before. In such case, you must use
• If the following screen appears in the compensation character strings contained in
stead of the screen of item 8) after the the maintenance record information or import
operation of Step 7), it is suspected the compensation value information described
that the entered new data is on the top face of every injector installed on the
inappropriate. cylinders, in the same way as you did in the
(Check the data again and repeat its above when you replaced the injector.
entry.)

6. Disconnect and end the communication with the


engine controller.
• Section Q: Select "Disconnect from ECM."

WA470-7 30-49
30 Testing and adjusting
Power train

Power train (ALL-C100-001-K-00-A)

Adjusting transmission output speed sensor (WA380-CNA1-001-K-00-A)

Adjusting (WA470-CNA1-270-K-00-A)

1. Remove cover on the right side of the rear


frame.
2. Disconnect connector REV OUT (1).

3. Loosen locknut (3), and screw in until tip of


sensor (4) touches a tooth tip of gear (5).
a Check that the sensor tip is free from iron
dust and flaws before installing.
a Apply the liquid gasket between the case and
threaded part of the sensor.
2 Thread portion: Liquid gasket (LG-5)

4. Unscrew sensor (4) from the current position by


a half to one turn.
a Adjust clearance (a) between the sensor tip
and gear (5) tooth tip to 0.75 to 1.5 mm.
5. Secure sensor (4) with lock nut (3).
3 Nut: 49.0 to 68.6 Nm (5.0 to 7.0 kgm)

30-50 WA470-7
30 Testing and adjusting
Power train

Adjusting transmission input speed sensor (WA380-CNB1-001-K-00-A)

Adjusting (WA470-CNB1-270-K-00-A)

1. Remove cover (1) on the left side of the rear


frame.

2. Disconnect connector REV IN (2).


3. Loosen locknut (3), and screw in sensor (4) until
its tip hits a tooth tip of gear(5) lightly.
a Check that the sensor tip is free from iron
dust and flaws before installing.
a Apply the liquid gasket between the case and
threaded part of the sensor.
2 Thread portion: Liquid gasket (LG-5)

4. Secure sensor (4) with lock nut (3).


3 Nut: 24.5 to 34.3 Nm (2.5 to 3.5 kgm)

WA470-7 30-51
30 Testing and adjusting
Power train

Flushing procedure for torque converter and transmission hydraulic


circuit (WA380-C151-001-K-00-A)
a Dust such as metal powder in the hydraulic
circuits of the torque converter and transmission
shortens the life of the torque converter and
transmission and causes internal breakage. To
remove dust in the hydraulic circuit, perform
flushing in the following cases.
1. When metal powder flows into the circuit
because of damage to the torque converter,
transmission and hydraulic components.
2. When the torque converter and transmission
are overhauled or modified.
Flushing procedures (WA470-C151-256-K-00-A)
2. Supply oil to the transmission case.
1. Install a new filter cartridge.
• Add oil through oil filler (4) to the specified
1) Remove inspection cover (1) on the left side
level. Run the engine to circulate the oil
of the rear frame.
through the system. Then, check the oil level
again.

5 Transmission case:
65 l (refill capacity)

2) Loosen drain plug (2) and drain the oil in the


filter piping.

3. Flush the hydraulic circuit according to the


following procedure.
1) Start the engine and run it at low idle without
operating the gear shift lever and directional
lever for approximately 20 minutes.
a Increase the engine speed to
approximately 1,500 rpm sometimes.
a If the engine coolant temperature gauge
does not rise to the operating range
3) Remove transmission oil filter cartridge (3) because of low ambient temperature,
and install cartridge (714-07-28713). continue the warm-up operation further.
2) Operate or travel for at least 20 minutes.
a Use all the gear speeds (Forward,
reverse, and 1st to 4th).
3) Run the engine at low idle for approximately
20 minutes in the similar procedure to the
one described in 3-1).
4. Replace the filter cartridge.
1) Replace cartridge (1) used for flushing with a
new cartridge (714-07-28713) following the

30-52 WA470-7
30 Testing and adjusting
Power train

same procedure as the one described in the


step 1.

k Be sure to replace the cartridge with a


new one because the cartridge used
for flushing for long hours causes
premature clogging.
a When installing the filter cartridge, tighten
it by 2/5 turns after the O-ring came in
touch with the filter head.
2) Add oil and check the oil level again.

WA470-7 30-53
30 Testing and adjusting
Power train

Retrieval of disabled machine due to transmission valve failure (WA470-CJA0-360-


K-00-A)

a Locations of ECMV units

Testing tools k Place the machine on a level ground, and


Sym- lower the work equipment to the ground.
Part No. Part name
bol
O 794-423-1190 Plug k Apply the parking brake, and chock the
wheels.
a If the machine cannot move due to failure of any
part of transmission valves (electrical system, k When working while the oil temperature is
solenoid valve, spool, etc.), install plugs O. Then still high, be careful not to get burn injury.
the machine can move.
k If the machine cannot move in any gear
speed due to transmission control valve
failure, install the plugs L to ECMV. Then the
machine can move from a dangerous work
site to a safe place where repair can be
performed. Do not use this method for any
situations other than failure.

k When moving the machine by this method,


observe the procedure and be careful for
safety.

30-54 WA470-7
30 Testing and adjusting
Power train

How to move (WA470-CJA0-14A-K-00-A)

1. Remove side covers on the right and left of rear


frame.
2. Remove mud and dirt from around the ECMV.
3. Disconnect all connectors (1) from each ECMV.
(13 places)

5. Depress the brake pedal securely.


6. Start the engine, release the parking brake, and
then release the brake pedal gradually to start
and move the machine.

4. Remove 2nd ECMV and F or R ECMV solenoids a If the parking brake cannot be released
(2) (2 pieces), and then install plugs O as because of a failure in the electrical system,
referring to preceding position of each ECMV release the parking brake referring to
installed. "Method of releasing parking brake
• Forward travel: F solenoid and 2nd solenoid manually".
• Reverse travel: R solenoid and 2nd solenoid
k Remove the chocks.
a If a wrong solenoid is removed, the
transmission may be broken. Care must be k If the engine is started, the transmission
taken. is engaged and the machine starts
a Install the plug with its projection facing the immediately. Accordingly, when starting
ECMV. Check that the O-ring is fitted to the the engine, check the moving direction of
mating face. the machine and secure safety around the
machine thoroughly and keep depressing
a Be careful that mud or dirt will not enter the the brake pedal.
removed solenoids and valves.
k Stop the engine after moving the machine,
apply the parking brake, and chock the
wheels.
7. After finishing work, remove the testing tools and
restore the machine.

WA470-7 30-55
30 Testing and adjusting
Power train

Testing oil leakage from axle final drive (WA470-DF10-280-K-00-A)

Check axle final drive (1) for oil leakage.


If oil leakage is found, the seal or the bearing may
be damaged. Check and repair as necessary.
a See "Disassembly and assembly".

30-56 WA470-7
30 Testing and adjusting
Power train

Testing drive shaft for looseness, backlash, and damage (WA380-D510-280-K-00-A)

Check the drive shaft for damage, abnormal


backlash, and loosening of connecting bolts and
nuts. If any part is loosened or damaged, retighten
or repair it.
Move the cross member at the universal joint up
and down, right and left, and rotate in both
directions to check.
Push the sliding part of the front drive shaft upward
for several times, and rotate it both directions to
check.
a For the tightening torques, see the "Disassembly
and assembly".

WA470-7 30-57
30 Testing and adjusting
Power train

Testing and adjusting power train oil pressure (WA470-C100-360-K-00-A)

• Pressure pickup plug for P1 (main relief pressure) and P2 (torque converter inlet pressure) is pressure
pickup port for torque converter valve itself. However, this machine is equipped with pressure pickup
nipple (No. 1 and 2) separately.

30-58 WA470-7
30 Testing and adjusting
Power train

WA470-7 30-59
30 Testing and adjusting
Power train

a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
N 3 799-401-2320 Gauge
799-101-5220 Nipple
4
07002-11023 O-ring
Oil pressure measuring point and measuring gauge
Measuring
gauge
No. Oil pressure to be measured
MPa {kg/
cm2}
1 Main relief pressure 6 {60}
2 Torque converter relief pressure 2.5 {25}
Torque converter outlet
3 pressure 1 {10}
4 Lockup clutch pressure 6 {60}
5 Transmission F clutch pressure 6 {60}
6 Transmission R clutch pressure 6 {60}
Transmission 1st clutch
7 pressure 6 {60}
Transmission 2nd clutch
8 pressure 6 {60}
Transmission 3rd clutch
9 pressure 6 {60}
Transmission 4th clutch
10 pressure 6 {60}
11 Lubricating pressure 1 {10}

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k If the transmission gear speed must be


shifted while the tires are off ground or the
drive shaft is removed, be sure to lower the
engine speed 1,500 rpm or below, and then
operate the gear shift lever.
Also, be sure to shift only one speed at a
time and wait at least 5 seconds before
making the next shift. Never make multiple
shifts in short intervals or shift more than
one speed at once.

a Test the power train oil pressure under the


following conditions.
• Torque converter oil temperature: 60 to 80°C
• Set the transmission cut-off switch to OFF
position, and use the left brake.
1. Remove side covers on the right and left side of
the transmission.

30-60 WA470-7
30 Testing and adjusting
Power train

3. While running the engine at low idle and at 2,000


Testing (WA470-C100-362-K-00-A)
rpm, measure the transmission main relief
Testing transmission main relief pressure pressure.
a Transmission main relief pressure pickup port
(1)

4. After finishing test, remove the testing tools and


restore the machine.
Testing torque converter relief pressure (inlet
pressure)
a Torque converter relief pressure (inlet pressure)
pickup port (nipple) (2)

1. Install hose [1] of hydraulic tester N1 to


transmission main relief pressure pickup nipple
(1). Connect gauge [2] to the hose.
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

Testing by use of testing tools


1. Install hose [1] of the hydraulic tester N1 to
torque converter relief pressure (inlet pressure)
2. Start the engine with power mode, and keep the pickup nipple (2). Connect gauge [2] to the hose.
directional lever or directional selector switch in
N (NEUTRAL). a The hose of digital hydraulic tester N2 can
also be used.

WA470-7 30-61
30 Testing and adjusting
Power train

a Use an oil pressure gauge of 2.5 MPa {25 kg/ a “Monitoring/Pre-defined“ (9/16) screen
cm2}.

2. Start the engine with power mode, and keep the 1. Start the engine with power mode, and keep the
directional lever or directional selector switch in directional lever or directional selector switch in
N (NEUTRAL). N (NEUTRAL).
3. While running the engine at 2,000 rpm, measure 2. While running the engine at 2,000 rpm, measure
the torque converter relief pressure (inlet the torque converter relief pressure (inlet
pressure). pressure).
a When measuring torque converter inlet pressure
accurately for troubleshooting, etc, refer "testing
with testing tools".

Testing torque converter outlet pressure


a Torque converter outlet pressure pickup port (3)

4. After finishing test, remove the testing tools and


restore the machine.
Testing with machine monitor
Torque converter relief pressure (inlet pressure) can
be checked with “Monitering/Pre-difined“ (9/16) or
“Monitering“ (monitoring code: 32601) of the
machine monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".

Testing by use of testing tools


1. Remove torque converter outlet pressure pickup
port plug (3). Install nipple N4 and hose [1] of

30-62 WA470-7
30 Testing and adjusting
Power train

hydraulic tester N1 to it, and connect gauge N3 a “Monitoring/Pre-defined“ (9/16) screen


to the hose.
3 Joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The elbow, nipple, and hose of digital
hydraulic tester N2 can also be used.
a Use an oil pressure gauge of 1 MPa {10 kg/
cm2}.

1. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).
2. While running the engine at 2,000 rpm, measure
torque converter outlet pressure.
a When measuring torque converter outlet
pressure accurately for troubleshooting, etc,
refer "testing with testing tools".
2. Start the engine with power mode, and keep the
directional lever or directional selector switch in
N (NEUTRAL).
3. While running the engine at 2,000 rpm, measure
torque converter outlet pressure.

4. After finishing test, remove the testing tools and


restore the machine.
3 Torque converter outlet pressure
pickup port plug (5):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

Testing with machine monitor


Torque converter outlet pressure can be measured
with “Monitering/Pre-difined“ or “Monitering“
(monitoring code: 32603) of the machine monitor.
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".

WA470-7 30-63
30 Testing and adjusting
Power train

Testing lockup clutch pressure 3. Set the transmission shift mode selector switch
to AUTO.
k This measurement is done in the traveling 4. Set working mode to the power mode, start the
condition. Therefore, care must be taken to engine, and set the parking brake switch to OFF
safety of surrounding area. position.
5. Move the gear speed switch to the 3rd position.
a Lockup clutch pressure pickup port (4)
6. Set the directional lever or directional selector
switch to the F (FORWARD) or R (REVERSE),
and then start traveling.
7. While traveling with the engine speed at 2,000
rpm, measure the lockup clutch oil pressure
when the lockup pilot lamp lights up.

8. After finishing test, remove the testing tools and


restore the machine.
3 Lockup clutch pressure pickup port
plug (3):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

1. Remove lockup clutch pressure pickup port plug


(4). Install nipple N4 and hose [1] of hydraulic
tester N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Set the torque converter lockup switch to ON.

30-64 WA470-7
30 Testing and adjusting
Power train

Testing F (forward) clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a F (forward) clutch pressure pickup port (5)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) position while depressing the
brake pedal.

k Keep brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.
7. While running the engine at 2,000 rpm, measure
the F (forward) clutch oil pressure.

1. Remove F (forward) clutch pressure pickup port 8. After finishing test, remove the testing tools and
plug (4). Install nipple N4 and hose [1] of restore the machine.
hydraulic tester N1, and connect gauge [2] to the
hose. 3 F clutch pressure pickup port plug (4):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

WA470-7 30-65
30 Testing and adjusting
Power train

Testing R (reverse) clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a R (reverse) clutch pressure pickup port (6)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the R (REVERSE) position while depressing the
brake pedal.

k Keep brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.
7. While running the engine at 2,000 rpm, measure
the R (REVERSE) clutch oil pressure.

1. Remove R (reverse) clutch pressure pickup port 8. After finishing test, remove the testing tools and
plug (5). Install nipple N4 and hose [1] of restore the machine.
hydraulic tester N1, and connect gauge [2] to the
hose. 3 R clutch pressure pickup port plug
(5):
3 Nipple: 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can
also be used.
a Use an oil pressure gauge of 6 MPa {60 kg/
cm2}.

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

30-66 WA470-7
30 Testing and adjusting
Power train

Testing 1st clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 1st clutch pressure pickup port (7)
position.
5. While keeping the directional lever or right
directional selector switch in N (NEUTRAL), set
the gear speed switch to 1st (1st speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.

k Keep brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.
a When the directional lever or directional
selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 1st clutch oil pressure.

1. Remove 1st clutch pressure pickup port plug (7).


Install nipple N4 and hose [1] of hydraulic tester
N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can 8. After finishing test, remove the testing tools and
also be used. restore the machine.
a Use an oil pressure gauge of 6 MPa {60 kg/ 3 1st clutch pressure pickup port plug
cm2}. (9):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

WA470-7 30-67
30 Testing and adjusting
Power train

Testing 2nd clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 2nd clutch pressure pickup port (8)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 2nd (2nd speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.

k Keep brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.
a When the directional lever or directional
selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 2nd clutch oil pressure.

1. Remove 2nd clutch pressure pickup port plug (8).


Install nipple N4 and hose [1] of hydraulic tester
N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can 8. After finishing test, remove the testing tools and
also be used. restore the machine.
a Use an oil pressure gauge of 6 MPa {60 kg/ 3 2nd clutch pressure pickup port plug
cm2}. (8):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

30-68 WA470-7
30 Testing and adjusting
Power train

Testing 3rd clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 3rd clutch pressure pickup port (9)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 3rd (3rd speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.

k Keep brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.
a When the directional lever or directional
selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 3rd clutch oil pressure.

1. Remove 3rd clutch pressure pickup port plug (9).


Install nipple N4, elbow (male: 10 x 1.25 and
female: PT1/8) of hydraulic tester N1, and nipple
hose [1], and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 8. After finishing test, remove the testing tools and
a The hose of digital hydraulic tester N2 can restore the machine.
also be used. 3 3rd clutch pressure pickup port plug
a Use an oil pressure gauge of 6 MPa {60 kg/ (9):
cm2}. 9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

WA470-7 30-69
30 Testing and adjusting
Power train

Testing 4th clutch pressure 4. Set working mode to the power mode, start the
engine, and set the parking brake switch to OFF
a 4th clutch pressure pickup port (10)
position.
5. While keeping the directional lever or directional
selector switch in N (NEUTRAL), set the gear
speed switch to 4th (4th speed).
6. Run the engine at low idle, and set the
directional lever or directional selector switch to
the F (FORWARD) or R (REVERSE) position
once while depressing the brake pedal, then
return it to the N (NEUTRAL) position.

k Keep brake pedal firmly depressed. Take


extreme care for safety around the
machine since the machine may move.
a When the directional lever or directional
selector switch is in N (NEUTRAL), the gear
speed is not changed even if the gear speed
switch is moved. To avoid this, perform the
above operation.
7. While running the engine at 2,000 rpm, measure
the 4th clutch oil pressure.

1. Remove 4th clutch pressure pickup port plug


(10). Install nipple N4 and hose [1] of hydraulic
tester N1, and connect gauge [2] to the hose.
3 Nipple:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester N2 can 8. After finishing test, remove the testing tools and
also be used. restore the machine.
a Use an oil pressure gauge of 6 MPa {60 kg/ 3 4th clutch pressure pickup port plug
cm2}. (10):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

2. Set the transmission shift mode selector switch


to MANUAL.
3. Depress the brake pedal.

30-70 WA470-7
30 Testing and adjusting
Power train

Testing lubrication pressure 3. While running the engine at 2,000 rpm, measure
the lubricating oil pressure.
a Lubrication pressure pickup port (11)

4. After finishing test, remove the testing tools and


restore the machine.
3 Lubrication pressure pickup port plug
(13):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}

1. Remove lubrication pressure pickup port plug


(11). Install nipple N4, install elbow [1], and hose
[1] of hydraulic tester N1, and connect gauge N3
to the hose.
3 Joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
a The elbow, nipple, and hose of digital
hydraulic tester N2 can also be used.
a Use an oil pressure gauge of 1 MPa {10 kg/
cm2}.

2. Start the engine with power mode, and keep the


directional lever or directional selector switch in
N (NEUTRAL).

WA470-7 30-71
30 Testing and adjusting
Power train

Adjusting (WA470-C100-270-K-00-A)
Adjusting transmission main relief valve
k Stop the engine before starting adjustment
of the transmission main relief valve.

a If the transmission main relief pressure is out of


the standard value, adjust it according to the
following procedure.
1. Remove plug (13) from transmission and torque
converter relief valve (12).

2. Remove outer spring (16) and inner spring (17).


3. Adjust by adding or removing shims (18).
a Standard shim thickness: 3.5 mm (0.5 x 7
pcs.)
a Amount of adjustment per shim:
0.04 MPa {0.4 kg/cm2}

30-72 WA470-7
30 Testing and adjusting
Steering system

Steering system (ALL-F000-001-K-00-A)

Testing directional lever (WA380-CX31-001-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
M 79A-264-0021 Push-pull scale

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing (WA470-CX31-384-K-00-A)

Operating effort of directional lever


• Set push-pull scale M or a spring scale at the
point 12 mm from the tip of the directional lever
(1). Pull the push-pull scale M or the spring scale
in the operative direction of the lever to measure
the operating effort.

Travel of directional lever


• Put a mark (a) at the center of the knob of the
directional lever (1). Move the knob in the
operating direction and measure its travel.

WA470-7 30-73
30 Testing and adjusting
Steering system

Testing steering wheel (WA380-F151-001-K-00-A)

a Testing tools Measuring operating effort of steering wheel


Symbol Part No. Part name a Measure the operating effort of the steering
P 79A-264-0021 Push-pull scale wheel under the following conditions.
• Road surface: Flat, level, and dry paved
Testing (WA470-F151-384-K-00-A)
surface
Measuring play of steering wheel • Engine coolant temperature: 60 to 102°C
a Measure the play of the steering wheel under • Hydraulic oil temperature: 45 to 55 °C
the following conditions. • Tire inflation pressure: Specified pressure
• Engine speed: Low idle
• Engine speed: Stop
• Posture of machine: Straight travel (bucket empty)

Measuring method Measuring method


1. Move the steering wheel lightly to the right and 1. Install push-pull scale P to the steering wheel
left to find the neutral point in the steering knob.
mechanism and put mark (A) on the outer frame a Install the push-pull scale P to the center of
of the machine monitor. the knob.
2. Turn the steering wheel to the right until the 2. Start the engine.
operating effort starts to become heavy. Put
mark (B) at the position right above mark (A). a After starting the engine, raise the bucket
approximately 400 mm and remove the
frame lock bar.
3. Pull the push-pull scale N in the tangential
direction and read the value when the steering
wheel moves smoothly.
a Do not read the value indicated when the
steering wheel starts moving as the
operating effort.

3. Turn the steering wheel to the left (opposite to


step 2) until the operating effort starts to become
heavy. Put mark (C) at the position right above
mark (A), and measure the straight-line distance
between marks (B) and (C).

Measuring operating time of steering wheel


a Measure the operating time of the steering
wheel under the following conditions.
• Road surface: Flat, level, dry paved surface
• Engine coolant temperature: 60 to 102°C
• Hydraulic oil temperature: 45 to 55 °C
• Tire inflation pressure: Specified pressure
• Engine speed: at low idle and high idle

Measuring method
1. Start the engine.
a After starting the engine, raise the bucket
approximately 400 mm and remove the
frame lock bar.

30-74 WA470-7
30 Testing and adjusting
Steering system

2. Turn the steering wheel in order to bring the


machine posture to the right or left turn with the
steering wheel at its travel end.
3. Turn the steering wheel in the reverse direction
of it described above, and measure the time
taken by the steering wheel to come to the end
of the travel.
a Do not turn the steering wheel forcibly but
turn it at the speed of 60 turns per minute.
a Measurement should be taken when the
machine is turning both to the right and left
with the engine running at low idle and high
idle.

WA470-7 30-75
30 Testing and adjusting
Steering system

Testing work equipment control lever (WA380-PK00-001-K-01-A)

a Testing tools Push the point, 42 mm (z) up the center (c) of


Symbol side screw (2), toward tangential direction of
Part No. Part name
lever movement (right and left direction).
1 79A-264-0021 Push-pull scale
Y Commercially
2 Ruler
available

k Apply the frame lock bar.

a Check the work equipment control lever under


the following condition.
• Engine speed: Low idle
Testing (WA380-PK00-384-K-00-A)

1. Measuring operating effort of work equipment


control lever
Install and fix tool Y1 to the work equipment
control lever.
3-lever type
a Install tool Y1 to the position 12 mm down
from the top of the knob.
a Operate the control lever at the same speed
as that for the normal operation, with the
minimum value for the effort needed to
operate the knob.

2. Measuring travel of work equipment control lever


Check the travel of the work equipment control
lever at each point.
3-lever type
a Put a mark on the lever knob at 12 mm down
from the top and use scale Y2 for the
measurement.
Multi-function mono-lever type a If the travel is out of the standard range,
replace the lever.
a Install tool Y1 to the following position.
a Operate the control lever at the same speed
as that for the normal operation, with the
minimum value for the effort needed to
operate the knob.
1) RAISE
Push the lower end of kickdown switch (8
mm from center (a) of switch) horizontally
toward tangential direction of lever
movement.
2) LOWER
Push the point, 21 mm (y) under the lower
end (b) of cap (1), toward tangential direction
of lever movement.
3) TILT, DUMP

30-76 WA470-7
30 Testing and adjusting
Steering system

Multi-function mono-lever type


a Use scale Y2 for the measurement.
Mark and measure the positions as follows.
1) RAISE, LOWER
The position at 42 mm toward the lever top
end from the center (c) of side screw (2).
2) TILT, DUMP
The position at 21 mm down (y) from the
bottom (b) of cap (1).
a If the travel is out of the standard range,
replace the lever.

WA470-7 30-77
30 Testing and adjusting
Steering system

Testing and adjusting steering circuit oil pressure (WA470-F210-360-K-00-A)

a Tools for testing and adjusting a “Monitoring/Pre-defined“ (14/16) screen


Sym-
Part No. Part name
bol
799-261-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Q
799-401-3200 Adapter
2
07002-12024 O-ring

a Test the steering circuit pressure under the


following condition.
• Hydraulic oil temperature: 45 to 55°C
k Loosen the oil filler cap of the hydraulic tank
to release the pressure inside the hydraulic
tank, then operate the steering wheel 2 or 3
1. Start the engine, and run it at high idle, then turn
turns to release the remaining pressure in
the steering wheel to the right or left. Measure
the piping.
the oil pressure (maximum pressure at operating
steering) when the steering relief valve operates.
k Set frame lock bar (1) in position.
a When accurate measurement of steering circuit
oil pressure is required for the troubleshooting,
etc., refer "Testing by use of testing tools".

Testing by use of testing tools


1. Remove steering circuit pressure pickup plug (2)
on the left steering cylinder head side.

Testing (WA470-F210-362-K-00-A)
Testing steering relief pressure

Testing with machine monitor


Steering circuit oil pressure can be measured with
“Monitering/Pre-difined“ (14/16) or “Monitering“
(monitoring code: 95302) of the machine monitor. 2. Install nipple Q3 and hose [1] of hydraulic tester
a For the machine monitor operating method, see Q1, and connect gauge [2] to the hose.
the section of "Special functions of machine 3 Nipple:
monitor".
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
a The hose of digital hydraulic tester Q2 can
also be used.
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}.

30-78 WA470-7
30 Testing and adjusting
Steering system

2. Install adapter Q2, and connect hose (4) or (5)


(opposite side) to it.
3. Install hose [1] of hydraulic tester Q1and
connect gauge [2].
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.

3. Start the engine, turn the steering wheel to the


left with engine running at high idle. Measure the
oil pressure (maximum pressure at operating
steering) when the steering relief valve operates.
a When the gauge is connected to the steering
circuit pressure pickup port plug on the right
side steering cylinder head, measure the
4. Start the engine, and measure the oil pressure
pressure by turning the steering wheel to the
(maximum pressure at operating steering) when
right.
turning the steering wheel with engine running at
high idle.
• When measuring at hose (4): Turn the
steering wheel to the left.
• When measuring at hose (5): Turn the
steering wheel to the right.

4. After finishing test, remove the testing tools and


restore the machine.
3 Steering circuit pressure pickup plug:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}

Testing steering pilot circuit pressure 5. After finishing the measurement, remove the
1. Remove steering control circuit hose (4) or (5) measuring tools and restore the machine.
(opposite side) of steering valve assembly (3)
through the clearance between the front side of Testing steering control circuit pressure
the operator's cab and front frame. 1. Remove steering control circuit pressure pickup
port plug (6) of steering valve assembly (3)
through the clearance between the front side of
the operator's cab and front frame.

WA470-7 30-79
30 Testing and adjusting
Steering system

assembly (3) according to the following


procedure.

2. Install nipple Q3 and hose [1] of hydraulic tester


Q1, and connect gauge [2] to the hose.
a The hose of digital hydraulic tester Q2 can 2. Loosen lock nut (6) and turn adjustment screw
also be used. (7) to adjust the pressure.
a Use the oil pressure gauge of 6 MPa {60 kg/ a When the adjustment screw is:
cm2}. • turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
a Quantity of adjustment per turn of adjustment
screw:
Per turn: 17.8 MPa {181.5 kg/cm2}
3 Lock nut:
27 to 31 Nm {2.8 to 3.2 kgm}

3. Start the engine, keep the steering wheel in


neutral, then measure the oil pressure with
engine at low idle.

Adjusting steering control circuit pressure


a Adjusting steering control circuit pressure is not
available.

4. After finishing test, remove the testing tools and


restore the machine.
Adjusting (WA470-F210-27B-K-00-A)

k When adjusting the oil pressure, be sure to


stop the engine.

Adjusting steering relief pressure


1. If the steering relief pressure is incorrect, adjust
steering relief valve (8) of steering valve

30-80 WA470-7
30 Testing and adjusting
Steering system

Bleeding air from steering cylinder circuit. (WA380-F210-001-K-01-A)

a Before bleeding air, check that the hydraulic oil 3 Air bleeder:
level is proper. 7.8 to 9.8 Nm {0.8 to 1.0 kgm}
a If the steering valve or the steering cylinder is 4. Start the engine and run it at low idle for 5
removed and installed, bleed air from the minutes minimum.
steering circuit according to the following Bleeding air from cylinder circuit.
procedure. 1. Start engine, run engine at low idle for 5
Bleeding air (WA470-F210-231-K-00-A) minutes.
2. Run the engine at low idle, and turn the steering
Bleeding air from steering pump
wheel 4 to 5 times to the right and left.
1. Remove cover (1) located under the right side of
the hydraulic tank. a Stop the piston rod approximately 100 mm
before each stroke end and take care not to
relieve the circuit.
3. Run the engine at high idle and then, perform
the operation of Step 2.
4. Run the engine at low idle and operate the
piston rod to the end of its stroke to relieve the
circuit.

2. While the engine is stopped, loosen air bleeder


(2) of the steering pump and connect air bleeder
hose [1].

3. As oil containing no bubbles starts to flow out of


air bleeder(2), tighten air bleeder (2).

WA470-7 30-81
30 Testing and adjusting
Steering system

Testing and adjusting steering stopper valve (WA380-F5U0-001-K-00-A)

Testing (WA470-F5U0-365-K-00-A) 3. Stop the engine and then loosen stopper bolt (1)
until it touches the contact surface of steering
1. Align the front frame and rear frame.
stop valve (3).
2. Check that lock nut (2) on stopper bolt (1) is not
loose. a Use care not to loosen the stopper bolt
excessively. Excessive loosening can result
in pushing the spool at the tip of steering stop
valve (3) .
4. Start and run the engine at low idle, and then
return the steering wheel slowly to set the
machine to the straight travel condition. Then
stop the engine.
5. Turn stopper bolt (1) in the loosening direction
by 8.5 turns (approx. 15 mm), then fix it by lock
nut (2) .
a Adjust both the right and left sides by
following the procedure from steps 1 to 5.
3. Start the engine and turn the steering wheel to
the right and left. Check that a clearance is
maintained between the front frame stopper and
rear frame stopper.

k Measure the clearance while engine is


stopped.
a If the check can not be made because of
missing frame stopper and so on, do
necessary repair and then make sure that
the clearance is provided on both sides.
Adjustment (WA380-F5U0-270-K-00-A)
6. Start the engine, turn the machine and then
a When the clearance between the front frame
check that there is a clearance between the front
and rear frame is out of the specified range,
frame and rear frame when the turning is
adjust it in the following procedure.
stopped due to the contact of steering stop valve
1. Loosen lock nut (2) and then tighten stopper bolt (3) and stopper bolt (1).
(1) to set distance (a) to the minimum.

2. Run the engine at low idle and then bring the


front frame and rear frame into contact by
turning the steering wheel slowly.

k Use care in this operation so that your


body or arm are not caught between the
front and rear frames.

30-82 WA470-7
30 Testing and adjusting
Brake system

Brake system (ALL-G000-001-K-00-A)

Testing brake pedal (WA470-G4A1-360-K-00-A)

a Test the brake pedal under the following


conditions.
• Coolant temperature: 60 to 102°C
• Hydraulic oil temperature: 45 to 55°C
• Engine low idle
Testing (WA380-G4A1-361-K-00-A)

1. Install push gauge [1] to the operator's foot.


a Set the push gauge at a point 150 mm from
the fulcrum of the pedal.
2. Start the engine and measure the pedal
depressing angle (a1) while running the engine
at low idle.
3. Apply angle gauge [2] to the brake pedal and
measure neutral angle a1 and maximum
depressing angle a2.
• a2: Depressing angle at depressing effort of
323±30 N {32.9±3.0 kg}

WA470-7 30-83
30 Testing and adjusting
Brake system

Testing and adjusting brake pedal linkage (WA380-G4C0-001-K-00-A)

Testing (WA380-G4C0-361-K-00-A)

1. Check linkage mounting pin (5), pinhole of lever


(6), and lever bushing for play. Make
adjustments as necessary.
2. Measure the length of the link (a = 213 mm),
and check that it is within the standard value.
a Measure the length between the center of pin
(5) and the center of ball joint (3).
3. Measure the distance of movement of rod (8)
and check that clearance (b) is within the
standard value.
a When doing this, check that the brake pedal
hits the stopper.
4. Check bolts and nuts at each part and retighten
them if loosened.
Adjustment (WA380-G4C0-270-K-00-A)

1. Adjusting link length (a)


1) Remove pin (5) and ball joint (3), then
remove rod (1).
2) Loosen lock nut (4), then turn yoke (2) and
ball joint (3) to adjust the length.
3) After adjusting the length of link (a), connect
it to the brake pedal.
a Standard length (a): 213 mm
2. Adjusting play of rod (b)
1) Loosen locknut (7), turn rod (8) so that the tip
of the rod contacts the booster cylinder
piston, then turn rod (8) back 1/4 turn.
a Moving distance in 1/2 turn of rod: 0.75
mm
2) Turn back by 1/4 turn and tighten lock nut (7).
a Standard value (b): 0 to 0.3 mm

30-84 WA470-7
30 Testing and adjusting
Brake system

Testing braking performance (WA470-G000-360-K-00-A)

a Test the brake performance under the following


conditions.
• Road surface: Flat, horizontal, dry paved
surface
• Speed: Speed when applying brake: 20 km/h
• Tire inflation pressure: Specified pressure
• Tire size: 26.5 to 25
• Brake pedal depressing force: Specified
depressing force
323 ± 30 N {32.9 ± 3 kg}
• Delay in applying brakes: 0.1 sec
Testing (WA380-G000-38E-K-00-A)

1. Start the engine and drive the machine.


2. Move the gear speed switch to the 4th position and give the machine a run-up.
3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified depressing force.
a Before performing this test, fix the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.
4. Measure the distance between the point where the brake is applied and the point where the machine
stops.
a Repeat the preceding measurement three times and take the average.

WA470-7 30-85
30 Testing and adjusting
Brake system

Testing and adjusting of accumulator charge pressure (WA470-G2H0-360-K-00-A)

a Tools for testing and adjusting


Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
T
790-261-1204 Digital hydraulic tester

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Stop the engine, then depress the brake


pedal at least 100 times to release the
pressure inside the accumulator circuit.

a Measure the accumulator charge pressure


under the following conditions.
• Coolant temperature: 60 to 102°C
• Hydraulic oil temperature: 45 to 55°C
Testing (WA470-G2H0-362-K-00-A)

1. Remove cover (1) and (2) on the right side of the


machine.

3. Measure the accumulator charge cut-in


pressure.
Start and run the engine at low idle, and then
measure the oil pressure when the brake
pressure caution lamp on the machine monitor
panel goes out.
4. Measure the accumulator charge cut-out
pressure.
After the accumulator charge cuts in, measure
the oil pressure when the rising indicator of the
gauge suddenly shifts to drop.

2. Install hose [1] of hydraulic tester T to


accumulator charge pressure pickup nipple (3)
of the accumulator charge valve, and connect
them to gauge [2].
a The hose for digital hydraulic tester T2 can
also be used.
a Use gauge of 40 MPa {400 kg/cm2}.

5. After finishing test, remove the testing tools and


restore the machine.
Adjusting (WA470-G2H0-270-K-00-A)

a When the accumulator charge cut-out pressure


is adjusted, the cut-in pressure also changes in
proportion to the valve area ratio.

30-86 WA470-7
30 Testing and adjusting
Brake system

1. Loosen lock nut (6) of unload relief valve


(accumulator charge cut-out valve) (5), then turn
adjustment screw (7) to adjust.
a When the adjustment screw is:
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
a Quantity of pressure adjustment per turn of
adjustment screw:
1.45 MPa {14.8 kg/cm2}
3 Lock nut (4):
11.8 to 16.7 Nm {1.2 to 1.7 kgm}

a After finishing measuring, check the


accumulator charge cut-in and cut-out
pressures again according to the above
measuring procedure.

WA470-7 30-87
30 Testing and adjusting
Brake system

Testing of brake accumulator nitrogen gas pressure and procedure for


charging brake accumulator with nitrogen gas (WA470-G2G0-001-K-00-A)
a Testing tools
Testing nitrogen gas pressure in
Sym- Applicable accumulator (WA470-G2G0-280-K-00-A)
Part No. Part name
bol standard
Gas charge a The following testing procedure is applicable to
1 792-610-1702 -
tool an independent accumulator as well.
Nipple • Nitrogen gas cylinder (c) must be connected
792-610-1310 GOST
(for Russia) even when the gas pressure only is measured.
Nipple 1. Stop the engine and eliminate the pressure in
792-610-1320 CGA No. 351 the brake circuit completely by depressing the
(for US)
Nipple brake pedal until its reactive force disappears.
ASA B-571-
792-610-1330
ZE (for US) 1965 a Depressing the brake pedal roughly 30 times
2 DIN 477-1963 eliminates its reactive force and no oil
Nipple NEN 3268- pressure is left in the circuit.
792-610-1350 (for 1966 2. Remove plug (2) and cap (3) from accumulator
Germany) SIS-SMS (1).
2235/2238
Nipple BS 341
792-610-1360
(for UK) Part1-1962

k In order to prevent leaked nitrogen gas from


contacting your skin and clothing, be sure to
wear the appropriate protective items (such
as goggles, leather gloves and protective
clothing) and do the work from the windward
side as much as possible.

k When handling nitrogen in an ill-ventilated


location like in a room, you must improve
ventilation of the room and observe the local 3. Connect gas charge tool ZE1 to valve (4) of
regulation for labor safety and health to accumulator (1) according to the following
prevent oxygen deficiency disease and other procedure.
hazards. 1) Turn handle (a) of gas charge tool ZE1 fully
counterclockwise until it becomes
k The accumulator is charged with high-
immovable.
pressure nitrogen gas. Its inappropriate
2) Keep the valve and handle (b) of nitrogen
handling can cause an explosion accident,
gas cylinder (c) closed.
leading to serious personal injuries. The
3) After installing the attached extension of gas
following rules must be strictly observed
charge tool ZE1 to gas valve (4) of
when handling the gas.
accumulator (1), connect the gas charge tool
• Do not bring any open flame near the to the accumulator.
accumulator or expose it to fire. 4) Connect gas charge tool ZE1 and nitrogen
• Do not drill it, weld or fuse-cut it. gas cylinder (c).
• Do not give impacts to it by hitting or
rolling it. a Exercise care in the above operation
• Bleed the gas in it before disposing it. since the bending load applied to gas
• Decrease the charged gas pressure to the valve (4) can damage it.
level of atmospheric pressure before • 2 types of threads, w22-14 threads (male
disassembling or removing it. thread A type) and w23-14 threads
• The gas to be charged must be nitrogen (female thread B type), are available for
gas. the nitrogen gas cylinder. When using a
• Do not use explosive gases including cylinder with w23-14 threads (female
oxygen. thread B type), connect the hose by using
• The accumulator must be handled strictly the adapter.
following the procedure described in this
manual.

30-88 WA470-7
30 Testing and adjusting
Brake system

(The adapter comes with gas charge tool a Since the pressure indication varies
ZE1.) [Inside of Japan] depending on the ambient temperature at the
• Depending on the given specification of time of measurement, you must refer to the
the nitrogen gas cylinder, nipple ZE2 is following table when measuring the gas
used for connecting the hose. pressure.
Ambient
tempera- Gas pressure
ture Remarks
°C MPa kg/cm2
15 3.37 34.4
16 3.39 34.5
17 3.40 34.6
18 3.41 34.8
19 3.42 34.9
Base gas
20 3.43 35.0 pressure
21 3.44 35.1
22 3.46 35.2
23 3.47 35.4
24 3.48 35.5
25 3.49 35.6
26 3.50 35.7
27 3.52 35.8
28 3.53 36.0
29 3.54 36.1
30 3.55 36.2
31 3.56 36.4
32 3.57 36.6
33 3.58 36.7
34 3.60 36.8
4. Turn handle (a) of gas charge tool ZE1 35 3.61 36.9
clockwise gradually and read the gauge value. 36 3.63 37.0
37 3.64 37.2
k In order to prevent damage of gas valve 38 3.65 37.3
(4), it is prohibited to rotate handle (a) 1.5 39 3.67 37.4
turns or more after the pressure of the 40 3.68 37.5
charged gas is displayed. 41 3.69 37.6
• Check that no gas leakage is recognized. 42 3.70 37.7
43 3.71 37.8
44 3.72 37.9
45 3.73 38.0
Displayed gas pressure = Base gas pressure
x ((273 + t) / (273 + 20))
(Every number in the formulas is represented
in °C.)
5. If the indicated gas pressure is below or above
the targeted level, adjust it referring to "Charging
procedure of accumulator nitrogen gas".
a A certain amount of nitrogen gas is
discharged every time measurement is done
and the pressure decreases. Be sure to
replenish by the amount of the gas
discharged.

WA470-7 30-89
30 Testing and adjusting
Brake system

6. Turn handle (a) of gas charge tool ZE1 fully


counterclockwise until it becomes immovable.
7. Remove gas charge tool ZE1 from accumulator
(1) and restore it. See "Charging procedure of
accumulator nitrogen gas".
Procedure for charging accumulator
with nitrogen gas (WA470-G2G0-219-K-00-A)
a The following charging procedure is applicable
to an independent accumulator as well.
1. Stop the engine and eliminate the pressure in
the brake circuit completely by depressing the
brake pedal until its reactive force disappears.
a Depressing the brake pedal roughly 30 times
eliminates its reactive force and no oil
pressure is left in the circuit.
2. Remove plug (2) and cap (3) from accumulator
(1).

4. Open the valve of nitrogen gas cylinder (c)


slightly to discharge the gas with the pressure of
approximately 0.19 to 0.29 MPa {2 to 3 kg/cm2}.
5. Turn handle (b) clockwise to close the valve
when nitrogen gas starts to come out of handle
(b).
3. Connect gas charge tool ZE1 and nitrogen gas
6. Turn handle (a) clockwise slowly to gradually
cylinder (c) to valve (4) of accumulator (1)
open valve (4) of accumulator (1).
according to the following procedure.
1) Turn handle (a) of gas charge tool ZE1 fully a Exercise care in operating handle (a) since
counterclockwise until it becomes excessive turning of handle (a) can damage
immovable. the accumulator valve core, inducing gas
2) Turn handle (b) counterclockwise and leave leakage.
the valve open. 7. Open the valve of nitrogen gas cylinder (c)
3) After installing the attached extension of gas further to charge the nitrogen gas to the
charge tool ZE1 to gas valve (4) of accumulator.
accumulator (1), connect the gas charge tool 8. Close the valve of nitrogen gas cylinder (c) from
to the accumulator. time to time during this operation to check the
4) Connect gas charge tool ZE1 and nitrogen nitrogen gas pressure in the accumulator.
gas cylinder (c). a For the nitrogen gas pressure testing
• 2 types of threads, w22-14 threads (male procedure, see Item 4 of "Testing of
thread A type) and w23-14 threads accumulator nitrogen gas pressure".
(female thread B type), are available for 9. After the gas is charged up to the standard value,
the nitrogen gas cylinder. When using a close the valve of nitrogen gas cylinder (c).
cylinder with w23-14 threads (female • When the charged gas volume is excessive,
thread B type), connect the hose by using discharge excessive gas by turning handle
the adapter. (b) slowly counterclockwise while keep the
(The adapter comes with gas charge tool valve of nitrogen gas cylinder (c) being
ZE1.) [Inside of Japan] closed.
• Depending on the given specification of 10.Remove gas charge tool ZE1 from valve (4) of
the nitrogen gas cylinder, nipple ZE2 is accumulator (1) according to the following
used for connecting the hose. procedure.

30-90 WA470-7
30 Testing and adjusting
Brake system

1) Turn handle (a) counterclockwise to close


the accumulator valve.
2) Turn handle (b) counterclockwise to open the
valve and discharge remaining nitrogen gas
in gas charge tool ZE1 and hose.
3) Remove gas charge tool ZE1 from valve (4)
of the accumulator.
11.Apply suds to valve (4) of the accumulator to
make sure there is not leakage of nitrogen gas.
12.Install plug (2) and cap (3) to accumulator (1).
3 Plug
73.5 to 98.0 Nm {7.5 to 10.0 kgm}

13.Within a week from charging nitrogen gas,


check the performance of the brake according to
the following procedure to check that no
pressure drop of nitrogen gas is found.
a Check the brake function within 5 minutes
from stop of the engine. (If more than 5
minutes elapse from stop of the engine,
correct measurement becomes unavailable
because oil pressure in the brake circuit
drops.)
1) Place the machine on a flat ground and turn
the parking brake switch to "PARKING"
position.
2) Start and run the engine at medium speed for
a minute, then stop the engine.
3) Turn the starting switch to ON position and
depress the brake pedal repeatedly to record
the depressing frequency required for the
brake oil pressure caution lamp to light up.
• Depressing frequency is less than 5:
Accumulator gas pressure may be low
• Depressing frequency is 5 or more:
Accumulator gas pressure is normal.

WA470-7 30-91
30 Testing and adjusting
Brake system

Testing wheel brake oil pressure (WA470-G210-360-K-01-A)

a Tools for testing a When accurate measurement of brake oil


Sym- pressure is required for troubleshooting, etc.,
Part No. Part name refer "Testing by use of testing tools".
bol
1 401-799-2930 Adapter
Testing by use of testing tools
ZB 2 799-101-5002 Hydraulic tester 1. Remove inspection cover (1) of the front frame
3 790-261-1204 Digital hydraulic tester (front side).
Perform measurement at slack adjuster portion
k High pressurized oil in the accumulator may
on the left side of rear frame (rear side).
spout out because of a trouble in the brake-
related equipment even when the brake
k When removing the inspection cover with
pedal is not depressed. To prevent this,
depress the brake pedal at least 100 times the boom raised, place a stand under the
with the engine stopped to release the boom to support the boom securely.
accumulator circuit pressure.

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Perform measurement on both of front brake and


rear brake.
a Measure the wheel brake oil pressure under the
following condition.
• Coolant temperature: 60 to 102 ℃ 2. Remove hose (2). Install adapter ZB1, install
Testing (WA470-G210-362-K-00-A)
nipple [1] and hose [2] of hydraulic tester ZB2,
and then connect gauge [3] to the hose.
Testing with machine monitor
Brake oil pressure (front brake only) can be a The nipple and hose of digital hydraulic tester
measured with “Monitering/Pre-difined“ (12/16) or ZB3 can also be used.
“Monitering“ (monitoring code: 41201) of the a Use gauge [3] of 6 MPa {60 kg/cm2}.
machine monitor. (Front side)
a For the machine monitor operating method, see
the section of "Special functions of machine
monitor".
a “Monitoring/Pre-defined“ (12/16) screen

(Rear side)

1. Bleed air from the brake circuit. For details, see


Testing and adjusting "Bleeding air from wheel
brake circuit".
2. Start the engine and measure the wheel brake
oil pressure as the left brake pedal is depressed.

30-92 WA470-7
30 Testing and adjusting
Brake system

3. Bleed air from the brake circuit. For details, see


Testing and adjusting "Bleeding air from wheel
brake circuit".
4. Start the engine and measure the wheel brake
oil pressure as the left brake pedal is depressed.

5. After finishing test, remove the testing tools and


restore the machine.

WA470-7 30-93
30 Testing and adjusting
Brake system

Testing lowering of wheel brake pressure (WA470-G210-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
1 793-605-1001 Brake test kit
2 790-101-1430 Coupler
3 790-101-1102 Pump
U 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling

k High pressurized oil in the accumulator may


spout out because of a trouble in the brake- 3. Remove union, and install adapter U4, nipple U5
related equipment even when the brake and hoseU6, and then install brake test kit U1.
pedal is not depressed. To prevent this, a Use the O-ring fitted to the union.
depress the brake pedal at least 100 times
with the engine stopped to release the
accumulator circuit pressure.

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

a Measure the oil pressure of the front brakes


(right and left) and rear brakes (right and left)
similarly.
a Measure the wheel brake pressure lowering
under the following conditions.
• Coolant temperature: 60 to 102°C
• Hydraulic oil temperature: 45 to 55°C
Testing (WA470-G210-38F-K-00-A)

1. Remove inspection cover (1) of the front frame.

k When removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

2. Remove brake tube (2) on the testing side.

4. Loosen bleeder screw (4) to bleed air.

30-94 WA470-7
30 Testing and adjusting
Brake system

a Bleed air by operating pump U3.

5. Tighten bleeder screw (4), operate pump U3 to


increase the pressure to 4.9 MPa {50 kg/cm2},
and close stop-valve [1].

6. Leave the brake circuit pressurized for 5 minutes


and check lowering of the pressure.
a If the hose is moved while the pressure is
measured, the pressure fluctuates.
Accordingly, do not move the hose.
a After testing the pressure, operate pump U3
to lower the pressure in brake test kit U1, and
then remove brake test kit U1.
a After finishing testing, install the brake tube
and bleed air from the brake circuit.
7. After finishing test, remove the testing tools and
restore the machine.
Brake test kit

WA470-7 30-95
30 Testing and adjusting
Brake system

Testing wear of wheel brake disc (WA380-G167-001-K-00-A)

a Testing tools 2. Depress the brake pedal to the travel end.


Symbol 3. Push in shaft (2) and measure its projection (x)
Part No. Part name
(distance of wear) from end face (a) of guide (3)
Commercially Vernier calipers
V with vernier calipers V.
available
a Keep depressing the brake pedal while
k Place the machine on a level ground, lower
measuring the wear.
the work equipment to the ground, set the
parking brake switch and work equipment a If shaft (2) is projected from the end of guide
lock switch in the LOCK position, stop the (3) to the groove, replace the disc.
engine, and chock the wheels. • Projection x from (a): Amount of wear
• Projection y from (a): Wear limit (2.4 mm)
a There are inspection plugs on the right and left
sides of the front and rear axles. Perform the a If face (b) of the shaft is seen, the disc is
check at all of the four plugs similarly. worn to the repair limit.

Testing (WA470-G167-389-K-00-A)

1. Remove cap (1).

4. After finishing test, remove the testing tools and


restore the machine.
3 Cap (1):
29.4 to 39.2 Nm {3.0 to 4.0 kgm}

30-96 WA470-7
30 Testing and adjusting
Brake system

Bleeding air from wheel brake circuit (WA470-G200-360-K-00-A)

k Place the machine on a level ground, lower the work equipment to the ground, set the parking
brake switch and work equipment lock switch in LOCK position, stop the engine, and chock the
wheels.

a When brake circuit equipment is removed or installed, bleed air from the brake circuit according to the
following procedure.
a Take the similar procedure for the front brake circuit and rear brake circuit. (2 places each).
a Perform air bleeding in order of right side of rear axle o left side of rear axle o right side of front axle o
left side of front axle o slack adjuster.
Bleeding air (WA470-G200-231-K-00-A)

1. Start the engine to accumulate pressure in the


accumulator, and then stop the engine.
2. Remove inspection cover (1) of the front frame.

k When removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

5. Connect hose [1] to bleeder screw (3) of wheel


brake, and place one end of hose [1] in the oil
container.
6. Depress the brake pedal and then loosen
bleeder screw (3) to bleed air.
a Release the brake pedal slowly after
tightening bleeder screw (3).
3. Connect hose [1] to bleeder screw (2) of slack
adjuster, and place one end of hose [1] in the oil
container.

7. Repeat this operation until the oil flowing


through hose [1] becomes free from bubbles.
Then depress the pedal fully, and tighten
4. Depress the brake pedal, and then loosen bleeder screw (2) and (3) while the oil is flowing.
bleeder screw (2) to bleed air. 8. Bleed air from other brake cylinders by using the
same procedure.
a Release the brake pedal slowly after
tightening bleeder screw (2). a When a complete bleeding is required, it is
advisable to start the operation from the
brake cylinder situated farthest from the
brake pedal.

WA470-7 30-97
30 Testing and adjusting
Brake system

a If the pressure in the accumulator is


decreased, start the engine to charge the
accumulator. Then stop the engine and
perform air bleeding following the same
procedure as described above.
a After finishing bleeding air, run the engine at
low idle, and check the oil level in the
hydraulic tank. If the level is low, refill with oil
to the specified level.
Bleeding method after removal and installation
of cab
a Perform the following if removing cab for work.
1. Remove hoses (1) to (5) (5 pieces) from brake
valve.
2. Remove hoses of front brake (1), rear brake (2),
accumulator (4) and (5), and hydraulic tank (3).
3. Perform air blowing through inlet of hoses
removed from brake valve side. (Blow the air in)
4. Install hoses (1) to (5) removed.
5. Perform air bleeding according to procedure for
air bleeding.

30-98 WA470-7
30 Testing and adjusting
Brake system

Releasing remaining pressure in brake accumulator circuit (WA380-G2F0-001-K-00-A)

k Before disconnecting any of the following


brake accumulator circuits, release
remaining pressure in the brake circuit.

Releasing remaining pressure (WA380-


G2F0-22A-K-00-A)

• Between accumulator charge valve and brake


accumulator
• Between accumulator charge valve and parking
brake solenoid valve
• Between brake accumulator and brake valve
1. Stop the engine.
2. Depress the brake pedal at least 100 times to
release the pressure in the brake accumulator
circuit.

WA470-7 30-99
30 Testing and adjusting
Brake system

Testing parking brake performance (WA380-GJ20-001-K-00-A)

a Testing conditions
• Tire inflation pressure: Specified pressure
• Road surface: Flat, dry, paved road with (11
deg. 20') grade
• Machine: Operating condition
Testing (WA380-GJ20-38E-K-00-A)

1. Start the engine and set the machine in the


straight travel position, and then drive up a slope
of 1/5 gradient with no load in the bucket.
2. Depress the brake pedal to stop the machine,
set the directional lever in the" N (neutral)"
position, and stop the engine.
3. Turn the parking brake switch ON (to park), and
then release the brake pedal gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Test the parking brake performance on an
uphill and a downhill.

30-100 WA470-7
30 Testing and adjusting
Brake system

Testing parking brake oil pressure (WA470-GJB0-360-K-00-A)

a Testing tools a Use gauge of 6 MPa {60 kg/cm2}.


Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
W
793T-615-1730 Adapter
2
07002-11023 O-ring

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.
4. Start the engine, and run it at low idle, and
a Measure the parking brake oil pressure under measure the parking brake oil pressure.
the following condition.
• Torque converter oil temperature: 80 to 100°C k Keep depressing the brake pedal for
Testing (WA470-GJB0-362-K-00-A) safety.

1. Remove side cover (1) on left of rear frame. a Measure the oil pressure at when the parking
2. Remove parking brake oil pressure pickup plug brake switch is turned OFF.
(1).

5. After finishing test, remove the testing tools and


restore the machine.
3 Parking brake pressure pickup port
plug (1):
9.8 to 12.74 Nm {1.0 to 1.3 kgm}

3. Install adapter W2 and hose [1] of hydraulic


tester W1, and connect them to gauge [2].
3 Adapter:
9.8 to 12.74 Nm {1.0 to 1.3 kgm}
a The hose for digital hydraulic tester W2 can
also be used.

WA470-7 30-101
30 Testing and adjusting
Brake system

Testing wear of parking brake disc (WA380-GJ72-001-K-00-A)

a Testing tools and assembly, "Removal of parking brake discs


Sym- and plates".
Part No. Part name
bol • Judgement criteria of thickness(W): 2.97 mm
Commercially Vernier calipers
X a If the parking brake disc thickness is below
available
the service limit, replace the disc.
k Place the machine on a level ground, lower
the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a If the parking brake does not work effectively,


check the parking brake disc for wear according
to the following procedure.
Testing (WA470-GJ72-389-K-00-A)

1. Drain the oil from the transmission case.

6 Transmission case: 65 l (refill


capacity) • Refilling of oil (transmission case)
2. Remove one of 2 bolts (1). Refill with oil to the specified level through
the oil filler port. Run the engine to circulate
a Prepare an oil container to receive oil flew the oil through the system. Then check the
from the bolt mounting holes. oil level again.

3. Measure depth (a) from the end of cage (2) to


piston (3) by using vernier calipers X.
• Clearance (a): Max. 38.3 mm

4. If depth (a) is above the standard, remove


parking brake disc (4), and measure its
thickness (W) of disc, referring to Disassembly

30-102 WA470-7
30 Testing and adjusting
Brake system

Method of releasing parking brake manually (WA380-GJ20-001-K-01-A)

k Releasing the parking brake manually is a


means to move the machine from a
dangerous job site to a safe place. Apply this
means only in an emergency.

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a The parking brake is controlled hydraulically. If


you cannot release the parking brake because
of a failure in the transmission, emergency
release solenoid valve, etc., you can move the
machine by releasing the parking brake
manually.
How to release (WA470-GJ20-141-K-00-A)
Releasing method by using the parking brake
emergency release valve
1. Remove inspection cover (1) on the right side of
the machine.

3. Turn the starting switch to ON position, turn the


parking brake switch to ON position and then to
OFF position.
a The parking brake is released by the above
procedure.

Mechanical releasing method


1. Drain the oil from the transmission case.

2. Loosen lock nut (3) and grip (4) of parking brake 6 Transmission case: 65 l (refill
emergency release valve (2) and open the capacity)
release valve. 2. Remove 2 bolts (1). (Right and left)

3 Lock nut (3): a Prepare an oil container to receive oil flew


from the plug mounting holes.
19.6 ± 4.9 Nm {2.0 ± 0.5 kgm}
3 Grip (4):
19.6 ± 4.9 Nm {2.0 ± 0.5 kgm}

3. Remove mounting bolts (2) (2 pieces), and


tighten them alternately into mounting part of
bolt (1).

WA470-7 30-103
30 Testing and adjusting
Brake system

a Remove bolts (2) (2 pieces) on the diagonal


positions.
a Piston (3) is pulled back by tightening bolts
(2), then the parking brake is released.
a Tighten the bolts (2 pieces) gradually and
evenly. (Tighten the bolts approximately 3
turns after it contacts the seat surface.)

4. After finishing the work, restore the machine.


• Refilling of oil (transmission case)
After releasing the parking brake manually, refill
with oil to the specified level through the oil filler
port. Run the engine to circulate the oil through
the system. Then check the oil level again.

30-104 WA470-7
30 Testing and adjusting
Hydraulic system

Hydraulic system (D65-PM10-001-K-00-A)

Testing fan speed (WA380-B400-001-K-00-A)

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

a Test the cooling fan motor speed under the


following conditions.
Cooling fan maximum speed
• Engine at high idle
• Coolant temperature: Min. 95°C
• Hydraulic oil temperature: Min. 95°C
• Torque converter oil temperature: Min. 105°C
Cooling fan minimum speed
• Engine at low idle
• Coolant temperature: Max. 75°C
• Hydraulic oil temperature: Max. 75°C
• Torque converter oil temperature: Max. 85°C
• Air conditioner: OFF
Testing (WA470-B400-388-K-00-A)

1. Start the engine, and switch the machine


monitor to 01 “Monitoring/Pre-defined“ display of
the service mode.
a For the operating method, see "Special
functions of machine monitor".
a “Monitoring/Pre-defined“ (15/16)

2. While running the engine at low idle and high


idle, measure the cooling fan speed.
Cooling fan
Engine speed Standard value
speed
Max. speed High idle See standard
value table
Air
condi- See standard
tioner: value table
Min. speed OFF
Low idle
Air
condi- See standard
tioner: value table
ON

WA470-7 30-105
30 Testing and adjusting
Hydraulic system

Testing fan pump circuit oil pressure (WA380-B441-001-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
R
2 790-261-1204 Digital hydraulic tester

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.

k Loosen the cap of the hydraulic tank 3. Remove cover (2).


gradually to release the pressure in the tank.

a Measure the cooling fan pump circuit pressure


under the following conditions.
• Engine high idle
• Fan 100% mode
• Hydraulic oil temperature: 50°C
Testing (WA470-B441-362-K-00-A)
Testing fan drive pressure
1. Start the engine, and switch machine monitor to
“Fan 100% Mode“ display of "Adjustment"
function in the service mode.
a For the operating method, see "Special 4. Connect oil pressure gauge [2] of hydraulic
functions of machine monitor". tester R to oil pressure pickup nipple (3).
a If this mode is displayed, the fan speed is a Use the oil pressure gauge of 40 MPa {400
kept at 100% speed in accordance with the kg/cm2}.
engine speed, regardless of the condition of
the machine.

5. Run the engine at high idle and measure the


cooling fan pump circuit oil pressure.
2. Open radiator grille (1). Cooling fan pump circuit
oil pressure See standard value table

30-106 WA470-7
30 Testing and adjusting
Hydraulic system

4. Select "Manual Fan Reverse Mode" by


6. After finishing test, remove the testing tools and
operating the machine monitor.
restore the machine.
a For the selection procedure, see the
Testing cooling fan reverse solenoid output
pressure Operation and Maintenance Manual.
1. Open radiator grille (1). 5. Run the engine at high idle and measure the
cooling fan reverse solenoid output pressure.
a Measure the pressure in both fan reverse
mode and fan normal rotation mode and
confirm that the solenoid operates and the
specified oil pressure is generated in the fan
reverse mode.
Cooling fan reverse
solenoid output pressure See standard value table

2. Remove cover (2).

6. After finishing the measurement, remove the


testing tools and restore the machine.
3 Pickup port plug (4):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3. Remove pickup port plug (4) and connect oil
pressure gauge [2] of hydraulic tester R to it.
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.

WA470-7 30-107
30 Testing and adjusting
Hydraulic system

Bleeding air from hydraulic fan circuit (WA380-B441-001-K-01-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
S 2 790-261-1204 Digital hydraulic tester
3 790-261-1130 Coupling

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in LOCK position, stop the
engine, and chock the wheels.
2. Remove cover (2).
a Before bleeding air, check that the hydraulic oil
level is proper.
Bleeding air (WA470-B441-231-K-00-A)
Bleeding air from cooling fan pump
1. Remove cover (1) at the lower right of the
operator's cab.

3. Install hose [1] in hydraulic tester S1 to the fan


pump circuit pressure pickup port nipple (3), and
also connect air bleeder coupling S3 to the
outlet end of the hose.
a Put the outlet end of the hose in the oil
container.
2. Connect air bleeder hose [1], and loosen air
a The hose for digital hydraulic tester S2 can
bleeder (2) of the cooling fan pump.
also be used.

3. As oil containing no bubbles starts to flow out of


air bleeder(2), tighten air bleeder (2).
3 Air bleeder (2):
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
4. Start the engine, and run it at low idle for 5
minutes minimum.
Bleeding air from cooling fan motor circuit
1. Open radiator grille (1).

30-108 WA470-7
30 Testing and adjusting
Hydraulic system

4. Start the engine, then stop it when the oil flows


out of the outlet end of the hose.
5. After finishing bleeding the air, remove the
testing tools and restore the machine.

WA470-7 30-109
30 Testing and adjusting
Hydraulic system

Testing and adjusting work equipment EPC oil pressure (WA470-PL70-360-K-00-A)

a Testing tools
Sym-
Part No. Part name
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
Z
799-101-5220 Nipple
3
07002-11023 O-ring

k Loosen the oil filler cap slowly to release the


pressure inside the hydraulic tank.

k Turn the starting switch to ON position,


release the work equipment lock switch, and 4. Start and run the engine at high idle, and then
then operate the work equipment control operate the work equipment control lever and
lever 2 to 3 times to release the pressure in measure the EPC valve source pressure.
the PPC accumulator circuit.
EPC valve source 3.72 (+0.2/-0.2) MPa
a Measure the work equipment PPC oil pressure pressure {38 (+2/-2) kg/cm2}
under the following condition.
• Hydraulic oil temperature: 45 to 55°C
Testing (WA470-PL70-362-K-00-A)
EPC valve source pressure
1. Remove side cover (1) on the right of rear frame.

5. After finishing test, remove the testing tools and


restore the machine.
Testing EPC oil pressure (shut off valve output
pressure)
1. Remove inspection cover (1) of the front frame.
2. Remove oil pressure pickup port plug (3).
k When removing the inspection cover with
the boom raised, place a stand under the
boom to support the boom securely.

3. Install nipple Z3 and hose [1] of hydraulic tester


Z1 and connect them to gauge [2].
a The hose for digital hydraulic tester Z2 can
also be used.
a Use gauge of 6 MPa {60 kg/cm2}.

30-110 WA470-7
30 Testing and adjusting
Hydraulic system

8. After finishing the test, remove the testing tools


and restore the machine.
Measuring EPC valve output pressure
1. Remove inspection cover (4) of the front frame.

k When removing the inspection cover with


the boom raised, place a stand under the
boom to support the boom securely.

2. Disconnect EPC circuit hose (2) to be


measured.

2. Remove oil pressure pickup port plug (5) of EPC


valve output circuit to be measured.
a A: Attachment
B: Attachment
C: ECSS
3. Connect nipple and O-ring Z3.
D: Boom RAISE
E: Boom LOWER and boom FLOAT
F: Bucket TILT
G: Bucket DUMP

4. Install nipple and hose of hydraulic tester Z1,


and connect them to gauge G3.
a Use gauge of 6 MPa {60 kg/cm2}.
5. Start the engine.
6. Operate the work equipment lock switch to
release the lock of work equipment.
7. Run the engine at high idle, and measure EPC
valve source pressure (oil pressure) (shut off
valve output pressure).

k Do not operate the work equipment


control lever.
Work equipment EPC
valve oil pressure
See standard value table
(Shut off valve outlet
pressure)

WA470-7 30-111
30 Testing and adjusting
Hydraulic system

3. Install nipple Z3 and hose [1] of hydraulic tester


Z1 and connect them to gauge [2].
a The hose for digital hydraulic tester Z2 can
also be used.
a Use gauge of 6 MPa {60 kg/cm2}.

4. Start the engine, run it at high idle, and move the


work equipment lever to measure the EPC valve
output pressure.

5. After finishing test, remove the testing tools and


restore the machine.
Adjusting (WA470-PL70-270-K-00-A)

a The EPC relief valve is not adjustable.


1. Remove EPC relief valve cartridge assembly,
and replace it.
3 EPC relief valve cartridge assembly:
25 to 33.9 Nm {2.6 to 3.5 kgm}
3 Lock nut:
11.8 to 16.7 Nm {1.2 to 1.7 kgm}
a After the replacement, measure the EPC oil
pressure again.

30-112 WA470-7
30 Testing and adjusting
Hydraulic system

Testing and adjusting work equipment oil pressure (WA470-PM10-360-K-00-A)

a Tools for testing and adjusting k When removing the inspection cover with
Sym- the boom raised, place a stand under the
Part No. Part name boom to support the boom securely.
bol
1 799-101-5002 Hydraulic tester
2 790-261-1204 Digital hydraulic tester
799-101-5220 Nipple
ZA 3
07002-11023 O-ring
Differential pressure
4 799-401-2701 gauge

a Measure the work equipment oil pressure under


the following condition.
• Hydraulic oil temperature: 45 to 55°C
Preparation (WA470-PM10-330-K-00-A)
Combination of actuator and valve
Testing (WA470-PM10-362-K-00-A)
a Note that the valve which relieves the oil
pressure depends on the actuator. Testing work equipment relief pressure

a The number of each actuator in the following Testing with machine monitor
table shows the order from the top, when the Work equipment oil pressure can be measured with
control valve is seen from the front of the “Monitering/Pre-difined“ (9/16) or “Monitering“
machine. (As for the service actuator, an (monitoring code: 94700) of the machine monitor.
example of a single attachment installation is
a For the machine monitor operating method, see
shown.)
the section of "Special functions of machine
No. Actuator Valve to be relieved monitor".
1 Service Safety valve
a “Monitoring/Pre-defined“ (9/16) screen
Tilt Safety valve
3 Bucket
DUMP Main relief valve
Boom
2 (Lift cylinder) Main relief valve

1. Lower section (b) to the ground keeping bucket


(a) 30 to 50 mm off the ground.
2. Stop the engine and operate the work
equipment control lever to check that both parts
(a) and (b) of the bucket touch the ground.
a After lowering the bucket to the ground,
operate the work equipment control lever 2 to
3 times to release the remaining pressure in
the piping.
1. Start the engine, and raise the boom, and keep it
level. Then, measure the oil pressure with the
bucket dumped while running the engine at high
idle.
a When accurate measurement of work equipment
relief pressure is required for troubleshooting,
etc., refer "Testing by use of testing tools".

Testing by use of testing tools


1. Remove pump pressure pickup port plug (2)
from the work equipment control valve.

3. Remove inspection cover (1) of the front frame.

WA470-7 30-113
30 Testing and adjusting
Hydraulic system

a For the machine monitor operating method, see


the section of "Special functions of machine
monitor".
a “Monitoring/Pre-defined“ (9/16) screen

2. Install nipple ZA3 and hose [1] of hydraulic tester


ZA1 and connect them to gauge [2].
a The hose for digital hydraulic tester ZA2 can
also be used.
a Use the oil pressure gauge of 40 MPa {400
kg/cm2}. 1. Start the engine and raise the boom
approximately 400 mm. Then, measure the oil
pressure when all the levers are in NEUTRAL
position with the engine running at high idle.
a When accurate measurement of unload oil
pressure is required for troubleshooting, etc.,
refer "Testing by use of testing tools".

Testing by use of testing tools


1. Remove pump pressure pickup port plug (2)
from the work equipment control valve.

3. Start the engine, and raise the boom, and keep it


level. Then, measure the oil pressure with the
bucket dumped while running the engine at high
idle.

2. Install nipple ZA3 and hose [1] of hydraulic tester


ZA1, and connect them to gauge [2].
a The hose for digital hydraulic tester ZA2 can
also be used.
a Use the oil pressure gauge of 6 MPa {60 kg/
cm2}.
4. After finishing test, remove the testing tools and
restore the machine.
Testing unload oil pressure

Testing with machine monitor


Unload oil pressure can be measured with
“Monitering/Pre-difined“ or “Monitering“ (monitoring
code: 94700) of the machine monitor.

30-114 WA470-7
30 Testing and adjusting
Hydraulic system

2. Install nipple ZA3 and hose [1] of hydraulic tester


ZA1 and connect them to gauge [2] or
differential pressure gauge ZA4.
a When using the differential pressure gauge,
connect its high-pressure side to the pump
pressure side, and connect its low-pressure
side to the LS pressure side. The differential
pressure gauge requires 12 V power supply.
Thus, connect a battery.
a Use the gauge of 40 MPa {400 kg/cm2}.
Since the differential pressure is 1.5 MPa {15
3. Start the engine, and raise the boom kg/cm2} at maximum, use the gauge whose
approximately 400 mm. Then, measure the oil accuracy is the same throughout the
pressure when all the levers are in neutral measurement.
position with the engine running at high idle.

3. Start the engine and raise the boom


approximately 400 mm.
4. After finishing test, remove the testing tools and 4. Run the engine at high idle and then, under the
restore the machine. following condition, measure the pump
discharge pressure and LS pressure (actuator
Testing LS differential pressure
load pressure) simultaneously.
a Before measuring the LS control circuit oil • When all of control levers are in NEUTRAL
pressure, check that the work equipment relief and when boom lever is moved halfway
oil pressure and work equipment EPC oil
pressure are normal. a While measuring, take care not to move the
lift cylinder to the stroke end.
a To obtain the LS differential pressure, measure
the pump discharge pressure and LS pressure a Calculation of LS differential pressure:
(actuator load pressure) simultaneously and LS differential pressure = pump discharge
calculate the difference. pressure - LS pressure
1. Remove pump pressure pickup port plug (2) and a When the LS differential pressure is as
LS pressure pickup port plug (3) from the work follows, it is normal.
equipment control valve.
Operation of lever LS differential pressure
Unload pressure (see
All control levers in the standard values
NEUTRAL table)
Specified LS differential
Boom control lever in
pressure (see the
halfway
standard values table)

WA470-7 30-115
30 Testing and adjusting
Hydraulic system

a After finishing adjusting, measure the work


equipment relief valve pressure according to
the above measurement procedure.

Adjusting LS differential pressure


a LS differential pressure cannot be adjusted.

5. After finishing test, remove the testing tools and


restore the machine.
Adjusting work equipment relief pressure
1. Adjust main relief valve (5) of work equipment
control valve (4).

2. Loosen lock nut (6) and turn adjustment screw


(7) to adjust.
a When the adjustment screw is:
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure is
decreased.
a Quantity of adjustment per turn of adjusting
screw:
12.6 MPa {128 kg/cm2}
3 Lock nut:
29.4 to 39.2 Nm {3 to 4 kgm}

30-116 WA470-7
30 Testing and adjusting
Hydraulic system

Bleeding air from work equipment circuit (WA470-PM10-231-K-00-A)

Bleeding air from cylinder


1. Start the engine and run it at idle for
approximately 5 minutes.
2. Run the engine at low idle and then, raise and
lower the boom 4 to 5 times.
a Stop the piston rod approximately 100 mm
before each stroke end and take care not to
relieve the circuit.
3. Run the engine at high idle and then, perform
operation of Step 2. Then, retract the piston rod
to the stroke end at low speed to relieve the
circuit.
4. Perform the same operation as the one in Steps
2 and 3 for the bucket and steering cylinders as
well.
a When a cylinder is replaced, perform this
operation before connecting the piston rod.

WA470-7 30-117
30 Testing and adjusting
Hydraulic system

Releasing remaining pressure from work equipment circuit (WA470-PM10-22A-K-00-A)

Releasing remaining pressure between each


hydraulic cylinder and control valve
a If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure in the circuit according to
the following procedure.
1. Stop the engine.
2. Loosen the oil filler cap slowly to release the
pressure inside the tank.
3. Turn the starting switch to ON position.
4. Set the work equipment lock switch to OFF
position.
5. Release the remaining pressure by operating
the work equipment control lever.

Releasing remaining pressure in ECSS circuit


k When disconnecting the piping of ECSS
circuit (between the accumulator for ECSS
and work equipment control valve), release
the pressure of the accumulator for ECSS
according to the following procedure.

1. Remove inspection cover (1) of the front frame.

k When removing the inspection cover with


the boom raised, place a stand under the 4. After releasing the remaining pressure, tighten
boom to support the boom securely. plug (5)and lock nut (4) securely in this order.
a Loosen lock nut (4) to the maximum before
tightening plug (5). After tightening plug (5),
tighten lock nut (4).
3 Plug (5):
19.6 to 27.5 Nm {2.0 to 2.8 kgm}
3 Lock nut (4):
19.6 to 27.5 Nm {2.0 to 2.8 kgm}

2. Loosen lock nut (2) of ECSS bleeder plug (5) on


work equipment control valve (4).
3. Loosen bleeder plug (5) 1/2 to 1 turn to release
the accumulator pressure.
a When the work equipment control valve is
seen from the front of the machine, plug (5)
is installed to the left side of the control valve.

30-118 WA470-7
30 Testing and adjusting
Hydraulic system

Testing of ECSS accumulator nitrogen gas pressure and procedure for


charging accumulator with nitrogen gas (WA470-L370-360-K-00-A)
a Testing tools k Place the machine on a level ground, lower
Sym- the work equipment to the ground, and
Part No. Part name chock the wheels.
bol
Commercially Gas charge tool
1 a The following testing procedure is applicable to
available
Z- Commercially Pressure reducing valve an independent accumulator as well.
2
D available 1. Remove cap (2) from the filling port of
Commercially Charging hose accumulator (1).
3
available 2. Loosen hexagonal socket head bolt (3)
a For testing and adjusting HYDAC accumulators, counterclockwise ( approximately 1/2 turn)
commercially available tools are used. Please slightly by using hexagonal wrench with 6mm
contact one of distributors in your area. (SW6)
Model and type (reference)
FPU-1 250 F4.0 G6 A3 K
k In order to prevent leaked nitrogen gas from
contacting your skin and clothing, be sure to
wear the appropriate protective items (such
as goggles, leather gloves and protective
clothing) and do the work from the windward
side as much as possible.

k When handling nitrogen gas in an ill-


ventilated location like in a room, you must
improve ventilation of the room and observe
the rules stipulated in the Industrial Safety 3. Turn handle (4) of gas charge tool ZD1 fully
and Health Act to prevent oxygen deficiency counterclockwise until it becomes immovable.
disease and other hazards. 4. Close pressure relief valve (5).
5. Screw cap nut (6) into filling port of accumulator
k The accumulator is charged with high- (1) with hands. Adjust it so that a pressure
pressure nitrogen gas. Its inappropriate gauge (7) of gas charge tool ZD1 can be easily
handling can cause an explosion accident, seen.
leading to serious personal injury or death. 6. Slowly turn handle (4) counterclockwise to
The following rules must be strictly observed loosen the hexagonal socked head bolt (3), and
when handling the gas. open it.
• Do not bring any open flame near the 7. When pressure gauge (7) indicator reaches the
accumulator or expose it to fire. maximum value, turn handle (4) clockwise to the
• Do not drill it, weld or fuse-cut it. fully closed position.
• Do not give impacts to it by hitting or • The pressure shown at this time is the
rolling it. charge pressure of the accumulator.
• Bleed the gas in it before disposing it.

Testing nitrogen gas pressure in


accumulator (WA470-L370-280-K-00-A)
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.

k Cancel the work equipment lock switch while


starting switch is ON.

k Operate the work equipment control lever 2


to 3 times to release the pressure in the PPC
accumulator circuit.

WA470-7 30-119
30 Testing and adjusting
Hydraulic system

a Since the indicated value varies with the ambient a The following charging procedure is applicable
temperature, refer to the following table and to an independent accumulator as well.
check the gas pressure. 1. Remove cap (2) from the filling port of
Ambient accumulator (1).
tempera- Gas pressure 2. Loosen hexagonal socket head bolt (3)
ture Remarks
counterclockwise ( approximately 1/2 turn)
°C MPa kg/cm2 slightly by using hexagonal wrench with 6 mm
15 4.43 44.2 (SW6).
16 4.35 44.4
17 4.37 44.5
18 4.38 44.7
19 4.4 44.8
Base gas
20 4.41 45 pressure
21 4.43 45.2
22 4.44 45.3
23 4.46 45.5
24 4.47 45.6
25 4.49 45.8
26 4.5 45.9
27 4.52 46.1
3. Turn handle (4) of gas charge tool ZD1 fully
28 4.53 46.2 counterclockwise until it becomes immovable.
29 4.55 46.4 4. Close pressure relief valve (5).
30 4.56 46.5 5. Screw cap nut (6) into filling port of accumulator
31 4.58 46.7 (1) with hands. Adjust it so that a pressure
32 4.59 46.8 gauge (7) of gas charge tool ZD1 can be easily
33 4.61 47 seen.
34 4.62 47.2
35 4.64 47.3
36 4.65 47.5
37 4.67 47.6
38 4.68 47.8
39 4.7 47.9
40 4.71 48.1
41 4.73 48.2
42 4.74 48.4
43 4.76 48.5
44 4.77 48.7
45 4.79 48.8
6. Connect gas charge tool ZD1 and nitrogen gas
Procedure for charging accumulator
cylinder according to the following procedure.
with nitrogen gas (WA470-L370-219-K-00-A)
1) Connect cap nut (7) of pressure reducing
k Loosen the oil filler cap slowly to release the valve ZD2 to the nitrogen gas cylinder.
pressure inside the hydraulic tank.

k Cancel the work equipment lock switch while


starting switch is ON.

k Operate the work equipment control lever 2


to 3 times to release the pressure in the PPC
accumulator circuit.

k Place the machine on a level ground, lower


the work equipment to the ground, and
chock the wheels.

30-120 WA470-7
30 Testing and adjusting
Hydraulic system

5) Slowly turn handle (4) counterclockwise to


loosen the hexagonal socked head bolt (3),
and open it.

• 2 types of threads, W22-14 threads (male


thread A type) and W23-14 threads
(female thread B type), are available for
the nitrogen gas cylinder. When using a 6) Open shut off valve (11) of nitrogen gas
cylinder with W23-14 threads (female cylinder (10) further, to charge the
thread B type), connect the hose by using accumulator with nitrogen gas.
the adapter. 7) Repeat the above operations until it reaches
Connect cap nut (8) of charging hose to the filling pressure.
ZD3 to pressure reducing valve ZD2. 8) If the pressure in the accumulator is higher
2) Connect cap nut (9) of charging hose ZD3 to than the set pressure, open the pressure
pressure relief valve (5) of gas charging tool relief valve (5) of gas charge tool ZD1 to
ZD1. reduce the pressure.
9) During this operation, close shut off valve
(11) of nitrogen gas cylinder (10) from time to
time to check the nitrogen gas pressure in
the accumulator.
a For the procedure of testing nitrogen gas
pressure, see "Testing of accumulator
nitrogen gas pressure".
10)After it is charged up to the standard value,
close shut off valve (11) of nitrogen gas
cylinder (10).
• When it is charged excessively, open the
pressure relief valve (5) of gas charge
3) Slightly open shut off valve (11) of nitrogen tool ZD1 to reduce the pressure with shut
gas cylinder (10), and set the filling pressure off valve (11) of nitrogen gas cylinder (10)
of pressure reducing valve ZD2 not to closed.
damage the gas charging tool ZD1. a Since the indicated value varies with the
4) Close shut off valve (11) of nitrogen gas ambient temperature, refer to the following
cylinder (10), and check the pressure on the table and check the gas pressure.
gauge.
Ambient
tempera- Gas pressure
ture Remarks
°C MPa kg/cm2
15 2.89 29.5
16 2.90 29.6
17 2.91 29.7
18 2.92 29.8
19 2.93 29.9
Base gas
20 2.94 30.0 pressure
21 2.95 30.1
22 2.96 30.2

WA470-7 30-121
30 Testing and adjusting
Hydraulic system

Ambient
tempera- Gas pressure
ture Remarks
°C MPa kg/cm2
23 2.97 30.3
24 2.98 30.4
25 2.99 30.5
26 3.00 30.6
27 3.01 30.7
28 3.03 30.8
29 3.04 31.0
30 3.05 31.1
31 3.06 31.2 10.Within a week from charging nitrogen gas,
32 3.07 31.3 check that no pressure drop of nitrogen gas is
33 3.08 31.4 found.
34 3.09 31.5
a Check the brake function within 5 minutes
35 3.10 31.6
from stop of the engine. (If more than 5
36 3.11 31.7
minutes elapse from stop of the engine,
37 3.12 31.8 correct measurement becomes unavailable
38 3.13 31.9 because oil pressure in the brake circuit
39 3.14 32.0 drops.)
40 3.15 32.1 1) Place the machine on a level ground and
41 3.16 32.2 turn the parking brake switch to the “ON“
42 3.17 32.3 position.
43 3.18 32.4 2) Start and run the engine at medium speed for
44 3.19 32.5 a minute, then stop the engine.
45 3.20 32.6 3) Turn the starting switch to ON position and
7. Remove gas charge tool ZD1 from the depress the brake pedal repeatedly to record
accumulator according to the following how many times depressing are required for
procedure. the brake oil pressure caution lamp to light
up.
1) Slowly turn handle (4) clockwise, and tighten
• Number of times of depressing is less than 5:
the hexagonal socked head bolt (3).
Accumulator gas pressure may be low
2) Open pressure relief valve (5), and discharge
• Number of times of depressing is 5 or more:
nitrogen gas remaining in gas charge tool
Accumulator gas pressure is normal.
ZD1 and hose.
3) Remove gas charge tool ZD1 from the filling
port of the accumulator.

8. Apply suds to the filling port of the accumulator


to make sure there is no leakage of nitrogen
gas.
9. Install hexagonal socket head bolt (3) and cap
(2) to accumulator (1).

30-122 WA470-7
30 Testing and adjusting
Work equipment

Work equipment (ALL-L000-001-K-00-A)

Testing and adjusting bucket position detection lever (WA380-LEE1-001-K-00-A)

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing (WA470-LEE1-365-K-00-A)

1. Remove bucket positioner covers (1) and (2).

2. Make sure that clearance (a) between bucket


angle sensor (3) and detection lever (4) is within
the standard value.
• Clearance (a): 0.5 to 1 mm

Adjusting (WA470-LEE1-270-K-00-A)

a If clearance (a) does not conform to the standard


value, adjust it according to the following
procedure.
1. Loosen bolt (5).
2. Adjust position of detection lever (4) so that
clearance (a) between bucket angle sensor (3)
and detection lever (4) becomes in the specified
range. Then tighten bolt (5).

WA470-7 30-123
30 Testing and adjusting
Work equipment

Testing and adjusting boom position detection lever (WA380-L6WR-001-K-00-A)

k Place the machine on a level ground, lower


the work equipment to the ground, set the
parking brake switch and work equipment
lock switch in the LOCK position, stop the
engine, and chock the wheels.

Testing (WA470-L6WR-365-K-00-A)

1. Make sure that clearance (a) between boom


angle sensor (1) and detection lever (2) is within
the standard value.
• Clearance (a): 0.5 to 1 mm

Adjusting (WA470-L6WR-270-K-00-A)

a If clearance (a) does not conform to the standard


value, adjust it according to the following
procedure.
1. Loosen bolt (3).
2. Adjust position of detection lever (2) so that
clearance (a) between boom angle sensor (1)
and detection lever (2) becomes in the specified
range. Then tighten bolt (3).

30-124 WA470-7
30 Testing and adjusting
Electrical system

Electrical system (ALL-RA1D-001-K-00-A)

Adjusting replaced, reassembled or added sensor, controller, etc. with


machine monitor (WA500-RA1D-270-K-00-A)
1. Items to be set when sensor or controller is Adjust-
replaced, reassembled or added ment Contents of work
item
a If any of the following components and parts N Adjusting reference line
is replaced or reassembled, make an initial Adjusting work equipment pump swash
adjustment of the sensors, solenoids, etc. O plate
with the machine monitor.
*1 See "Bucket flat level adjustment"in the
a For details of adjustment items (A to O), see Operation section of the Operation and
"Adjustment items table". maintenance manual.
Corresponding chart of device, parts and *2 For setting procedures, see "Service News".
adjustment item
Device/Optional items replaced, Adjustment
disassembled, assembled or item
added (sequence)
Machine monitor A, L, B
Transmission D, C, E
Transmission controller A, B, D, C, E
Transmission ECMV solenoid D, C, E
Boom angle sensor F, I
Work equipment control valve H
Work equipment EPC solenoid H
Work equipment electric lever G
Work equipment controller A, B, F, G, H, I
Work equipment bucket angle F, I
sensor
Bucket I
Boom F, I
Addition or removal of optional
B
item
Rearview monitor M, N
Rearview camera N
Work equipment pump O
Adjustment items table
Adjust-
ment Contents of work
item
A Machine Model Select
B Option Select
Adjusting transmission ECMV electric
C
current
D T/M initial learning reset
E T/M initial learning
Adjustment of work equipment controller
F boom angle
Adjustment of work equipment EPC
G lever detent position
Adjustment of work equipment EPC
H starting current
I Setting of bucket positioner (*1)
Setting of service meter and travel
L odometer (*2)
M Initializing rearview monitor

WA470-7 30-125
30 Testing and adjusting
Electrical system

2. Adjustment based on user's report


If the user makes the following indications or
requests which may fall in the items below,
change or adjust the items with the machine
monitor.
a For details of adjustment items (P to X), see
"Adjustment items table".
Corresponding chart of indication or request
and adjustment item
Adjust-
Details of indication/ request ment
item
Wants to change the display unit of the
speedometer. P
Wants to suppress hunting. Q
Wants to change the travel speed at a
shifting point in auto shift mode. Q
Fine control performance or response of
boom RAISE and LOWER operation is R
poor.
Fine control is poor in the bucket tilt/
dump operation or the shock dump effort S
is weak.
Large shocks result at stopping the
boom RAISE and LOWER operations or T
substantial overrun occurs at stopping.
Interval change of automatic fan reverse
operation is desired. U
Duration change of automatic fan
reverse operation is desired. V
The value of travel speed indication is
too high or low. W
Change of E.C.S.S. operating travel
speed is desired. X

Adjustment items table


Adjust-
ment Contents of work
item
P Default setting/ selection of unit
Adjustment, adjustment of transmission
Q L mode shift point
Adjustment, changing of boom lever
R pattern
Adjustment, changing of bucket lever
S pattern
Adjustment, changing of boom stop
T
modulation
Adjustment, changing of fan reverse
U cycle
Adjustment, changing of fan reverse
V
duration
W Option setting/changing of tire size
Adjustment, setting of E.C.S.S.
X operating speed

30-126 WA470-7
30 Testing and adjusting
Electrical system

Special functions of machine monitor (WA500-Q170-042-K-00-A)

Machine monitor Switch panel


(a): LCD unit (d): Menu switch
(b): Meter unit (e): Enter switch
(c): LED unit (f): Return switch
• When the engine is started or the self-check of (g): Up switch
the emergency steering is taking place, the (h): Down switch
battery voltage may drop suddenly depending
on the ambient temperature and the condition of a In the User/ Service Menu, the switches that are
the battery. not shown in the graphic display at the bottom of
In this case, the display of the machine monitor LCD unit (a) does not function.
may go out transiently or restart but this (i) Air conditioner switch / Numeral input switches
phenomenon is not a failure.
a Air conditioner switch / numeral input switches
• When the starting switch passes through OFF
have 2 functions. One is graphically indicated on
position in the manual preheating, the meter unit
the switch, and the other is numeral input
only may re-boot (the pointer of the tachometer
function.
makes one round-swing and "88" are displayed
on the speedometer). This phenomenon is not a a The machine monitor automatically judges which
failure. function of each switch is currently enabled
according to the screen display of LCD unit (a).

WA470-7 30-127
30 Testing and adjusting
Electrical system

Ordinary functions and special functions of machine monitor (WA470-Q170-042-K-00-A)

The machine monitor has the ordinary functions and special functions to display the various types of
information on the LCD unit (a).
Some items are displayed automatically according to the internal setting of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The functions in this mode are displayed ordinarily. Display and setting of these functions are available
from the operator's switch operations.
(Display and setting of some functions require special operation of the switch.)
a For details of the operator mode, see Operation and Maintenance Manual.
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially. This function is used for special setting, testing, adjusting, or
troubleshooting.

Operator mode (outline) Service mode


A KOMATSU logo screen(PAGE 30-130) Monitoring/ Pre-defined(PAGE 30-145)
A Password input screen(PAGE 30-130) Monitoring(PAGE 30-150)
(Special operation)

Abnormality record (mechanical systems)(PAGE 30-


A Display of standard screen(PAGE 30-130) 160)
Abnormality record (electrical systems)(PAGE 30-
A Display of end screen(PAGE 30-131) 161)
Display of operation screen for engine
A shutdown secondary switch(PAGE 30-131) Maintenance Record(PAGE 30-163)
B Operation of air conditioner(PAGE 30-131) "Maintenance Mode Setting"(PAGE 30-164)
Displaying and setting user menu(PAGE 30-
B 132) o Phone number entry(PAGE 30-167)
C Display of ECO guidance(PAGE 30-132) Default (Machine Model Select)(PAGE 30-168)
Display of warning (caution and action level)
C (PAGE 30-135) Default (Option Select)(PAGE 30-169)
Overdue replacement item screen(PAGE 30-
C 137) Default (Unit)(PAGE 30-171)
Display of KDPF Regeneration(PAGE 30-
C 137) Default (Rear View Monitor Setting)(PAGE 30-172)
Default (Auto Idle Stop Timer Setting)(PAGE 30-
O (Special operation) 176)
LCD (Liquid Crystal Display) check function
D (PAGE 30-139) Testing (Cylinder Cut-out operation)(PAGE 30-177)
Function of checking service meter and
D odometer(PAGE 30-139) Testing (Regeneration for Service)(PAGE 30-178)
Function of usage limitation setting/ changing
D password(PAGE 30-140) Testing (KDPF Memory Reset)(PAGE 30-180)
Preparations for transmission ECMV current
adjustment(PAGE 30-181)
Adjustment (T/M Initial Learning)(PAGE 30-183)
Adjustment (T/M Initial Learning Reset)(PAGE 30-
185)
Adjustment (T/M Shift Point)(PAGE 30-185)
Adjustment (T/M Shift Point Data Clear)(PAGE 30-
187)
Adjustment (Boom Angle Sensor for EPC (Raise))
(PAGE 30-188)
Adjustment (Boom Angle Sensor for EPC (Lower))
(PAGE 30-189)
Adjustment (Boom Raise Adjustment)(PAGE 30-
190)

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30 Testing and adjusting
Electrical system

Adjustment (Boom Raise Adjustment)(PAGE 30-


192)
Adjustment (Bucket Tilt Adjustment)(PAGE 30-194)
Adjustment (Bucket Dump Adjustment)(PAGE 30-
196)
Adjustment (3rd Ext Adjustment)
Adjustment (3rd Ret Adjustment)
Adjustment (J/S Right Adjustment) *1
Adjustment (J/S Left Adjustment) *1
Adjustment (PCS Adjustment(Push) *1
Adjustment (PCS Adjustment(Pull) *1
Adjustment (Change of Boom Lever Pattern)(PAGE
30-198)
Adjustment (Change of Bucket Lever Pattern)
(PAGE 30-201)
Adjustment (Boom Stop Modulation)(PAGE 30-204)
Adjustment (2-Stage Low Idle Throttle Position)
(PAGE 30-205)
Adjustment "Steering Pump Displacement" *1
Adjustment (Fan Reverse Cycle)(PAGE 30-206)
Adjustment (Fan Reverse Duration)(PAGE 30-207)
Adjustment (ECSS Operating Speed)(PAGE 30-
209)
Adjustment (Fan 100% Mode)(PAGE 30-210)
No Injection(PAGE 30-211)
KOMTRAX Settings (terminal setting status)(PAGE
30-212)
KOMTRAX Settings (GPS & Communication
Status)(PAGE 30-213)
KOMTRAX Settings screen (Modem Status)(PAGE
30-213)
Service Message(PAGE 30-214)
(*1): These items are not used.

a Classification of operator mode


A: Display or function that is indicated or enabled from the time when the starting switch is turned to ON
position to the time when display changes to the standard screen, and display after starting switch is
turned to OFF position
B: Display/Function when machine monitor switch is operated
C: Display/Function when certain condition is satisfied
D: Display/Function that require special operations of switches

WA470-7 30-129
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Operator mode (outline) (WA470-Q193-042-K-01-A) Password input screen (WA380-Q180-044-K-06-A)


After KOMATSU logo mark is displayed, input
a Only outline of the operator mode is described in
screen of engine start lock password appears.
this section.
For details of each function and display, and a This screen is displayed only when the engine
their operation, see "Structure and function ", or start lock function is enabled.
the "Operation and Maintenance Manual". a When a correct password is input, the display
a In this section, the following displays or functions changes to the standard screen.
of the operator mode are explained (including a The machine monitor equips with several protect
some items which need special operations). functions by passwords other than the engine
Operator mode (outline) start lock. Those functions are independent from
each other.
KOMATSU logo screen(PAGE 30-130)
Password input screen(PAGE 30-130)
Display of standard screen(PAGE 30-130)
Display of end screen(PAGE 30-131)
Display of operation screen for engine shutdown
secondary switch(PAGE 30-131)
Operation of air conditioner(PAGE 30-131)
Displaying and setting user menu(PAGE 30-132)
Display of ECO guidance(PAGE 30-132)
Display of warning (caution and action level)(PAGE
30-135)
a The following screen may sometimes be
Overdue replacement item screen(PAGE 30-137)
displayed instead of the above Password input
Display of KDPF Regeneration(PAGE 30-137) screen.
O (Special operation) a If this screen is displayed, call the person
LCD (Liquid Crystal Display) check function(PAGE responsible for the operation of KOMTRAX in
30-139) your Komatsu distributor and ask for remedy.
Function of checking service meter and odometer
(PAGE 30-139)
Function of usage limitation setting/ changing
password(PAGE 30-140)

KOMATSU logo screen (HM300-Q180-044-K-00-A)


When starting switch is turned to ON position,
KOMATSU logo is displayed for 2 seconds.
a After the 2-seconds display, the screen changes
to "Password Input (if password is set)" screen
or "standard screen".

Display of standard screen (WA380-Q180-044-K-07-A)


If the machine monitor starts normally, the standard
screen is displayed.

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a For the displayed items, see "Structure and a The engine shutdown secondary switch is
function" or "Operation and Maintenance provided on the left wall of the front console.
Manual." This switch is used to stop the engine when it
does not stop after the starting switch is turned
to OFF position.

Display of end screen (HM300-Q180-044-K-08-A)


Turning the starting switch to the OFF position
closes the screen. If you turn the engine shutdown secondary switch to
OFF position, the KOMATSU logo appears once
a If a KOMTRAX message or one point advice on and then the display is switched to the standard
ECO guidance are prepared, they are displayed screen.
on the end screen for 5 seconds.
Operation of air conditioner (WA380-K500-100-K-00-A)
Operating the air conditioner switch on the standard
screen pops up the air conditioner display, allowing
you to adjust the air conditioner.
Operating the air conditioner switch in the user
menu pops up the air conditioner adjustment screen,
allowing you to adjust the air conditioner.

Display of operation screen for engine


shutdown secondary switch (WA380-AKHL-100-K-00-
A)
Turning on the engine shutdown secondary switch
displays the "Engine Shutdown Secondary Switch
Activated" screen on every screen except the end
screen after 3 seconds.

WA470-7 30-131
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a If other display is popped up by the user menu, a There are following items in the user menu.
the air conditioner adjustment screen does not • ECO Guidance
appear and operation of the air conditioner • Machine setting/information
becomes unavailable. • KDPF regeneration
• Maintenance
• Monitor setting
• Check message
[KOMTRAX message]
• There are 2 types of KOMTRAX message; one
is for the user and the other is for the technician.
• For user:
This is a user-directed message received from
the KOMTRAX base station. When this is
received, message pilot lamp is displayed on the
standard screen. Operate "Check Message" in
the user menu to read the message.
• For technician:
The standard screen does not display anything
when a message for the technician is received
from the KOMTRAX base station. Operate
“Service Message“ in the service menu to read
the message.
a For the details of user menu, see the "Operation
and Maintenance Manusl".

Display of ECO guidance (WA380-Q1L3-100-K-00-A)


When the machine remains in a certain operating
condition, the “ECO Guidance“ is displayed
automatically to urge the operator to perform
energy-saving operation.
Displaying and setting user menu (HM300-Q1C3- a “ECO Guidance“ appears when its display
100-K-00-A)
function is enabled in the user menu.
Press the menu switch while the standard screen is
displayed and the "User Menu" screen will appear. • Excessive Idling guidance
If the engine runs idle for 5 minutes or longer,
a While the machine is traveling, pressing the the Excessive Idling guidance is displayed on
menu switch does not display the user menu. the monitor.
If you start the machine travel while the user
a The Excessive Idling guidance disappears if
menu is displayed, the display returns to the
you depress the accelerator pedal or start
standard screen.
traveling the machine.
a The guidance is not displayed while warm up
or KDPF regeneration is in progress.

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30 Testing and adjusting
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• Deterrence guidance on “Hydraulic Relief deterrence guidance on “Excessive Stepping


Pressure Event“ on Accelerator Event“ is displayed.
If hydraulic relief of work equipment
a The deterrence guidance on “Excessive
continues for 8 seconds or longer, the
Stepping on Accelerator Event“
guidance on “Hydraulic Relief Pressure
disappears automatically in 10 seconds.
Event“ is displayed.
a The deterrence guidance on “Hydraulic
Relief Pressure Event“ disappears
automatically in 10 seconds.
a “Hydraulic Relief Pressure Event“ occurs
when a fully-extended hydraulic cylinder
is extended further or a fully-retracted
hydraulic cylinder is retracted further. For
example, it occurs when the bucket
control lever is set to the TILT position
even though the bucket is fully tilted.

• Guidance on “Recommendation of 4th Gear“


If the upshifting is suppressed due to manual
shifting or use of the shift hold switch for 30
seconds or longer while traveling in 3rd gear
and the travel speed is increases, the
deterrence guidance on “Recommendation
of 4th Gear“ is displayed on the monitor.
a “Recommendation of 4th Gear“
disappears automatically in 10 seconds.
a It also disappears by shifting up the gear
speed switch to the 4th position.
• Deterrence guidance on “Dragging of Brake
Event“ a The guidance does not appear for 2
If the accelerator pedal is kept depressed for hours after it appeared previously even if
3 seconds or longer while the brake is its display condition is satisfied.
applied during travel, the deterrence
guidance on “Dragging of Brake Event“ is
displayed.
a The deterrence guidance on “Dragging of
Brake Event“ disappears automatically in
10 seconds.

• Guidance on “Recommendation of Lockup“


If lock up is suppressed for 20 seconds or
longer due to lock up switch placed in OFF
position after the travel speed increases
enough while traveling, the guidance on
“Recommendation of Lockup“ is displayed on
• Deterrence guidance on “Excessive the monitor.
Stepping on Accelerator Event“ a The “Recommendation of Lockup“
If the accelerator pedal is depressed disappears automatically in 10 seconds.
excessively at directional changes, the

WA470-7 30-133
30 Testing and adjusting
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a It disappears if the lockup switch is set to


ON.
a The guidance does not appear for 2
hours after it appeared previously even if
its display condition is satisfied.

• Deterrence guidance on “Excessive Digging


Event“
If the machine continues digging operation
for 8 seconds or longer, the guidance on
“Excessive Digging Event“ is displayed on
the monitor.
a The deterrence guidance on “Excessive
Digging Event“ disappears automatically
in 10 seconds.

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Display of warning (caution and action level) (WA500-Q1FC-044-K-00-A)


If the controller detects a failure on the machine, a
warning is displayed on the standard screen.
(1): Caution lamp
Action level (L01: Goes out in 2 seconds, L02 to
L04: Remains lit until the failure is eliminated)
(3): Centralized warning lamp
(4): Guidance icon
• If 3 or more failure codes occurred
simultaneously, all of corresponding caution
lamp (1) are displayed repeatedly in order.

If you press enter switch (D) while guidance icon (4)


is displayed, “Error List“ appears.
• Remedies that displayed action levels requires
(a): Caution lamp operator to do (The following table is an excerpt
(b): Action level (3 digits) from the Operation and Maintenance Manual)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
• This screen appears when trouble (failure code)
occurs only if its action level is set.
• The telephone number is displayed only when
the telephone number is registered in the
service mode.
• If 5 or more failure codes occurred
simultaneously, the display can be changed by
using Up switch (A) or Down switch (B)
• As the information of the displayed failure code
is recorded in the “Abnormality Record“ in the
service mode, check the details in the service
mode.
• “Error List“ is replaced with the standard screen
if the machine travel is started or a switch is left
untouched for 30 seconds.

WA470-7 30-135
30 Testing and adjusting
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List of action levels and corresponding remedies


Degree Centra-
of Action lized Alarm Color of
urgen- warning Remedies
level buzzer caution
cy lamp
Stop the machine immediately, and perform
Sounds checking and maintenance.
L04 Lights up continu- Red
ously Check the failure code and contact your Komatsu
distributor for inspection and maintenance.
Cease the work and after moving the machine to a
Sounds safe place stopping it there, perform checking and
L03 Lights up intermit- Red maintenance.
tently Check the failure code and contact your Komatsu
High distributor for inspection and maintenance.
When an overrun-related caution is displayed,
I operate the machine reducing the engine speed
| and machine travel speed.
| When an overheat-related caution is displayed,
| stop the machine at a safe place and run the
Sounds engine at medium speed with no load.
| L02 Lights up intermit- Red
O tently When an emergency steering-related caution is
displayed, refrain from using the emergency
Low steering for a long time.
If the condition is not improved, check the failure
code and contact your Komatsu distributor for
inspection and maintenance.
Some functions may be restricted for use, but the
machine can operate. Whenever finished working,
L01 Goes out - Yellow perform the inspection and maintenance.
As needed, ask your Komatsu distributor for
inspection and maintenance.

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Overdue replacement item screen (WA380-Q180- k If there is a thatched roof, dead leaves,
044-K-08-A) paper, or other combustibles near the
If a maintenance item that is near or exceeded the machine, set "Regeneration Disable" to
set interval, the controller displays the maintenance prevent a fire caused by the high-
caution for 30 seconds after the starting switch is temperature exhaust gas generated
turned to ON position to urge the operator to during the KDPF regeneration. For the
perform maintenance. setting procedure, see the Operation and
a The yellow caution is displayed if the remaining Maintenance Manual.
time of any item before the maintenance is 30 KDPF (Komatsu Diesel Particulate Filter) is the
hours (default value) or less, and the red caution device for capturing soot in the exhaust gas to
is displayed if the remaining time of any item is 0 clean the gas. If a certain level of soot
hour or less. accumulates on the filter, KDPF automatically
a You can check the maintenance information by starts the purification treatment of burning the
pressing the menu switch while guidance icon trapped soot in order to maintain the
(a) is displayed. performance of its filter in good condition. This
purification treatment is called "regeneration."
a To reset the remaining time left after finishing the If an operation that may lower the filtering
maintenance, further operations are required at performance of the KDPF continues for a long
the User menu. period of time, the regeneration may be
a Perform setting and changing of the performed to protect the KDPF system,
maintenance function at the service menu. regardless the amount of the accumulated soot.

During the KDPF regeneration, KDPF pilot lamp


Display of KDPF Regeneration (WA470-A9H0-251-K- (1) lights up on the standard screen and idling
01-A) speed becomes approximately 1,000 rpm.
1. “KDPF Regeneration“
a Even if KDPF regeneration pilot lamp (1)
lights up, you can continue your work without
k The exhaust gas temperature of this
stopping the machine unless the KDPF soot
model during KDPF regeneration may
accumulation caution lamp (2) lights up.
sometimes be higher than that of the
conventional models. High temperature
may continue even after finishing the
regeneration. Do not approach the
exhaust pipe to avoid getting burned. In
addition, to prevent a fire, do not bring
any combustibles near the exhaust pipe
outlet.

WA470-7 30-137
30 Testing and adjusting
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a Although “KDPF Regeneration“ is normally If you stop the machine, KDPF Regeneration
performed automatically, it may not be able screen appears once for every 2 hours after
to burn soot as intended or improve the the occurrence. If you do not perform “KDPF
purifying performance sufficiently depending Regeneration“, the display is replaced with
on the operating conditions. In such case, the standard screen in 30 seconds.
the KDPF soot accumulation caution lamp
(2) lights up. If the lamp lights up, stop the
machine at a safe place and perform the
manual stationary regeneration. For details
of the procedure, see the Operation and
Maintenance Manual.
2. Manual stationary regeneration
There are 2 levels of monitor displays to require
the manual stationary regeneration, depending
on the degree of emergency.

k If you continue your work despite KDPF


soot accumulation caution lamp (2) lights
up in red, it may cause the damage of the
KDPF and engine. a If KDPF soot accumulation caution lamp
(2) lights up in yellow, stop the machine
Be sure to perform the manual stationary on a safe place after the work and
regeneration whenever KDPF soot perform the manual stationary
accumulation caution lamp (2) lights up. regeneration.
1) When degree of urgency is low 2) When level of urgency is high
When KDPF soot accumulation caution lamp If KDPF soot accumulation caution lamp (2)
(2) lights up in yellow (Action Level (3): L01), lights up in red (Action Level (3): L03), the
the following screen is displayed first. following screen is displayed.

The action level caution lamp goes out in 2 After the machine is stopped, the screen
seconds and the following standard screen changes to “KDPF Regeneration“ screen in 3
appears. seconds. Then “KDPF Regeneration“ screen
and standard screen with the caution lamp lit
are alternately displayed until the manual
stationary regeneration is performed.

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a The engine maximum output and a The entire LCD is not turned to white when the
maximum speed are limited to protect the engine is running.
engine and KDPF system.
a If there is a display error in the LCD, only that
a The manual stationary regeneration ends part is indicated in black.
when the soot accumulation is reduced to
a If you press any of Up switch (A), Down switch
2 g/l maximum and approximately 35
(B), Return switch (C), Enter switch (D) and
minutes (the time varies depending of the
Menu switch (E), the display is returned to the
soot accumulation reduced in the
original screen.
regeneration) has elapsed from the start
of the regeneration. Reference: On the LCD panel sometimes, there
may be black spots (spots not lit) and bright spots
k If the work is continued without (remaining constantly lit) as one of its
performing the manual stationary characteristics.
regeneration and the soot quantity If the number of the bright spots and black spots
exceeds the allowable limit, action does not exceed 10, the LCD panel is not faulty or
level "L04" lights up and the repair of defective.
the machine will be required.

Function of checking service meter and


a If KDPF soot accumulation caution lamp odometer (HM300-Q1MB-100-K-00-A)
(2) lights up in red, immediately stop the When the following operation is performed with the
machine on a safe place and perform the stating switch being turned to OFF position, only the
manual stationary regeneration. service meter and odometer are displayed.
• Switch operation: Press Down switch (B) and Up
LCD (Liquid Crystal Display) check switch (A) at the same time.
function (HM300-Q1LE-100-K-00-A)
If you perform the following operation when the
ordinary screen is displayed, entire LCD (Liquid
Crystal Display) lights up in white.
• Switch operation: Press Up switch (A) while
pressing Down switch (B) and release Up switch
(A) first.

WA470-7 30-139
30 Testing and adjusting
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a This operation of the switches is not


accepted until 10 minutes elapse after the
starting switch is turned to ON position.

a There is some time lag in start of the LCD, so


hold down the switches until the LCD displays
normally.
a If you release one of the switches, the monitor
goes out.
Reference: If you use the machine monitor for a
long time, bright spots (spots that remain being lit)
may appear on the screen. If the number of the
bright spots is 10 or less; the LCD panel is not faulty
or defective.

2. After the "Usage Limitation Password" screen is


displayed, input the current password by using
the numeral input switches and validate it with
the function switch.
Return switch (C): Clears input numbers/
Returns the display to the standard screen
Enter switch (D): Validates the entered
password
Function of usage limitation setting/ changing a Default password: [000000]
password (WA380-Q19X-100-K-00-A)
As a result of "Usage Limitation Setting", the a When the input password is correct, the
password input screen is displayed when you screen changes to the next screen.
perform the maintenance resetting. Set the usage a When the input password is incorrect, the
limitation according to the following procedure. message to request inputting the password
1. While the standard screen is displayed, perform again is displayed.
the following operation.
• Switch operation: Press "5" of numeral input
switches (E) 3 times while pressing Down
switch (B).

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30 Testing and adjusting
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3. After the "Usage Limitation Setting" screen is password with the numeral input switches (E)
displayed, select a desired setting by using the and validate it with the function switch.
function switch. Return switch (C): Deletes input numbers/
Up switch (A): Moves your selection to the Returns the display to the previous screen
immediate above item Enter switch (D): Validates the entered
Down switch (B): Moves selection to the below password
item
a Default password: [000000]
Return switch (C): Cancels selection and returns
the display to the previous screen a When the input password is correct, the
Enter switch (D): Validates the selection screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
a Set a new password of 4 to 6 digits (If it has
only 3 or less digits or has 7 or more digits, it
is not accepted).

4. Selecting "Usage Limitation ON/OFF"


After the "Usage Limitation ON/OFF" screen is
displayed, select a desired setting using the
function switch.
• OFF: Password input screen is not displayed
• ON: Displays the password input screen
when you perform maintenance resetting
Up switch (A): Moves selection to the above When the "Usage Limitation New Password
item Input" screen is displayed again for
Down switch (B): Moves selection to the below confirmation, input a new password with the
item numeral input switches (E) and validate it
Return switch (C): Cancels selection and returns with the function switch.
the display to the previous screen
• Return switch (C): Clears input numbers/
Enter switch (D): Validates the selection
Returns the display to the standard screen
• Enter switch (D): Validates the entered
password

a The password for the Usage Limitation and


the engine start lock password are not
identical.
5. Changing a password
After the "Usage Limitation New Password
Input" screen is displayed, input a new

WA470-7 30-141
30 Testing and adjusting
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a If the input password is different from the one


input before, the message to request
inputting again is displayed.

If the usage limitation screen is displayed


after the screen to notify completion of
setting is displayed, the password is
changed successfully.

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Service mode (WA470-Q194-100-K-00-A)


To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1. Checking of display of screen, and switch
operation
While the standard screen is displayed, perform
the following switch operations.
Switch operation: While pressing Down switch
(B), press air conditioner/ numeral input
switches (E) "1" o "2" o "3" in order.
a This switch operation is accepted only while a The following shows the items selectable on
the standard screen is displayed. “Service Menu“ screen (including some items
which need special operations).
No. Menu items
01 Monitoring/ Pre-defined(PAGE 30-145)
02 Monitoring(PAGE 30-150)
Abnormality record (mechanical systems)
(PAGE 30-160)
03 Abnormality record (electrical systems)(PAGE
30-161)
04 Maintenance Record(PAGE 30-163)
05 "Maintenance Mode Setting"(PAGE 30-164)
06 Phone number entry(PAGE 30-167)
Default (Machine Model Select)(PAGE 30-
168)
Default (Option Select)(PAGE 30-169)
Default (Unit)(PAGE 30-171)
07
Default (Rear View Monitor Setting)(PAGE
30-172)
Default (Auto Idle Stop Timer Setting)(PAGE
30-176)
Testing (Cylinder Cut-out operation)(PAGE
30-177)
08 Testing (Regeneration for Service)(PAGE 30-
178)
Testing (KDPF Memory Reset)(PAGE 30-180)
Preparations for transmission ECMV current
adjustment(PAGE 30-181)
2. Selecting the service menu Adjustment (T/M Initial Learning)(PAGE 30-
When “Service Menu“ screen is displayed, the 183)
service mode is selected. Select a desired Adjustment (T/M Initial Learning Reset)
service menu. (PAGE 30-185)
Up switch (A): Moves the selection up by one Adjustment (T/M Shift Point)(PAGE 30-185)
item Adjustment (T/M Shift Point Data Clear)
Down switch (B): Moves the selection down by (PAGE 30-187)
one item 09 Adjustment (Boom Angle Sensor for EPC
Return switch (C): Returns the display to the (Raise))(PAGE 30-188)
standard screen (operator mode) Adjustment (Boom Angle Sensor for EPC
Enter switch (D): Validates the selection (Lower))(PAGE 30-189)
Adjustment (Boom Raise Adjustment)(PAGE
a If you enter a 2-digit item number with the 30-192)
numeral input switches (E), the entered item Adjustment (Boom Raise Adjustment)(PAGE
is directly selected. 30-192)
Adjustment (Bucket Tilt Adjustment)(PAGE
30-194)

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Electrical system

No. Menu items


Adjustment (Bucket Dump Adjustment)(PAGE
30-196)
Adjustment (3rd Ext Adjustment) *1
Adjustment (3rd Ret Adjustment) *1
Adjustment (J/S Right Adjustment) *1
Adjustment (J/S Left Adjustment) *1
Adjustment (PCS Adjustment(Push) *1
Adjustment (PCS Adjustment(Pull) *1
Adjustment (Change of Boom Lever Pattern)
(PAGE 30-198)
Adjustment (Change of Bucket Lever Pattern)
(PAGE 30-201)
Adjustment (Boom Stop Modulation)(PAGE
30-204)
Adjustment (2-Stage Low Idle Throttle
Position)(PAGE 30-205)
Adjustment "Steering Pump Displacement" *1
Adjustment (Fan Reverse Cycle)(PAGE 30-
206)
Adjustment (Fan Reverse Duration)(PAGE
30-207)
Adjustment (ECSS Operating Speed)(PAGE
30-209)
Adjustment (Fan 100% Mode)(PAGE 30-210)
10 No Injection(PAGE 30-211)
KOMTRAX Settings (terminal setting status)
(PAGE 30-212)
KOMTRAX Settings (GPS & Communication
11 Status)(PAGE 30-213)
KOMTRAX Settings screen (Modem Status)
(PAGE 30-213)
12 Service Message(PAGE 30-214)
(*1): These items are not used.
a The items written in ( ) are the menus on the
next hierarchy to “Survice Menu“ screen.

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Monitoring/ Pre-defined (WA500-Q1S1-100-K-00-A)


The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
various parts of the machine and the information
from the controllers which is controlling switches,
etc.
In the "Monitoring/ Pre-defined", frequently used
monitoring items in daily work are selected
beforehand.
1. Selecting menu
Select “Monitoring/Pre-defined“ on “Service
Menu“ screen.

a For the items not displayed in “Monitoring/


Pre-defined“, you can freely select and check
from “Monitoring/Custom“ items.

2. Checking Monitoring/Pre-defined information


“Monitoring/Pre-defined“ screen displays the
following information and allows switching
among the monitoring items.
(a): Monitoring information
(b): Power mode pilot lamp
(c): Shift indicator
(d): Engine coolant temperature
(e): Torque converter oil temperature
(f): Hydraulic oil temperature
(g): Fuel level
(h): Current number of pages / total number of
pages
Up switch (A): Moves selection to the previous
page (screen)
Down switch (B): Moves selection to the next
page (screen)
Return switch (C): Returns to the service menu
Enter switch (D): Validates your selection
Menu switch (E): Switches between the Hold
and the Releasing hold
(If the Hold is selected, a diagonal line appears
on the HOLD portion.)

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List of Monitoring/ Pre-defined items


(SI unit is the default value)
Monitoring/ Pre-defined screen (1/16) Machine basics 1
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 04107 Coolant Temperature °C ENG
3 37200 Engine Oil Pressure kPa ENG
4 03203 Battery Power Supply V T/M
5 30100 T/C Oil Temperature °C T/M
6 04401 Hydr. Oil Temperature °C T/M
Monitoring/ Pre-defined screen (2/16) Machine basics 2
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 48400 Crankcase Pressure kPa ENG
3 47300 KDOC 1 Inlet Temperature °C KDPF
4 36500 Charge Pressure-A kPa ENG
5 18500 Charge Temperature °C ENG
6 18400 Intake Temperature °C ENG
Monitoring/ Pre-defined screen (3/16) Engine fuel injection system
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 47300 KDOC 1 Inlet Temperature °C KDPF
3 36400 Rail Pressure MPa ENG
4 36200 Rail Pressure Command MPa ENG
5 17201 PCV Close Timing CA ENG
Monitoring/ Pre-defined screen (4/16) Engine, EGR, KVGT actuator
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 48100 Turbo Speed r/min ENG
3 18100 EGR Valve Position mm ENG
4 48600 EGR Solenoid Current mA ENG
5 48700 KVGT Position mm ENG
6 48800 KVGT Solenoid Current mA ENG
Monitoring / Pre-defined screen (5/16) Engine temperature system
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 48100 Turbo Speed r/min ENG
3 04107 Coolant Temperature °C ENG
4 18400 Intake Temperature °C ENG
5 18500 Charge Temperature °C ENG

30-146 WA470-7
30 Testing and adjusting
Electrical system

Monitoring/ Pre-defined screen (6/16) Engine intake and exhaust pressure system
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 37400 Ambient Pressure kPa ENG
3 36500 Charge Pressure-A kPa ENG
4 48100 Turbo Speed r/min ENG
5 48200 Mass Air Flow kg/min ENG
Monitoring/ Pre-defined screen (7/16) Engine post-treatment system
Applicable
No. ID Monitoring item Unit (SI)
component
1 47000 KDPF Outlet Pressure kPa KDPF
2 47100 KDPF Delta Pressure kPa KDPF
3 47200 KDPF 1 Outlet Temperature °C KDPF
4 47300 KDOC 1 Inlet Temperature °C KDPF
5 47400 KDOC 1 Outlet Temperature °C KDPF
6 47600 Dosing Fuel Pressure kPa KDPF
Monitoring/ Pre-defined screen (8/16) Engine
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 37200 Engine Oil Pressure kPa ENG
3 48400 Crankcase Pressure kPa ENG
4 47300 KDOC 1 Inlet Temperature °C KDPF
5 36500 Charge Pressure-A kPa ENG
6 48100 Turbo Speed r/min ENG
Monitoring/ Pre-defined screen (9/16) Work equipment, power train hydraulic system
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 32601 T/C Input Oil Pressure MPa T/M
3 32603 T/C Output Oil Pressure MPa T/M
4 95302 Steering Pump Pressure MPa BBC
5 94700 Loader Pump Pressure MPa BBC
Monitoring/ Pre-defined screen (10/16) Transmission clutch operation system
Applicable
No. ID Monitoring item Unit (SI)
component
1 41802 Fill Time (1st) msec T/M
2 41803 Fill Time (2nd) msec T/M
3 41804 Fill Time (3rd) msec T/M
4 41805 Fill Time (4th) msec T/M
5 41806 Fill Time (Reverse) msec T/M
6 41808 Fill Time (Forward) msec T/M

WA470-7 30-147
30 Testing and adjusting
Electrical system

Monitoring / Pre-defined screen (11/16) Transmission clutch operation system


Applicable
No. ID Monitoring item Unit (SI)
component
1 31602 ECMV Current (1st) mA T/M
2 31603 ECMV Current (2nd) mA T/M
3 31604 ECMV Current (3rd) mA T/M
4 31605 ECMV Current (4th) mA T/M
5 31606 ECMV Current (Reverse) mA T/M
6 31608 ECMV Current (Forward) mA T/M
Monitoring / Pre-defined screen (12/16) Transmission clutch operation system
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 31609 ECMV Current (Lockup) mA T/M
3 32500 T/M Oil Temperature °C T/M
4 41201 Brake Oil Pressure MPa T/M
5 41203 Brake Cut Off Pressure MPa T/M
6 30202 Brake Oil Temperature °C MON
Monitoring/ Pre-defined screen (13/16) EPC
Applicable
No. ID Monitoring item Unit (SI)
component
1 41900 Boom Raise EPC Current mA BBC
2 41901 Boom Lower EPC Current mA BBC
3 41902 Bucket Tilt EPC Current mA BBC
4 41903 Bucket Dump EPC Current mA BBC
5 04306 Battery Charge Volt (MON) V MON
Monitoring/ Pre-defined screen (14/16) Steering
Applicable
No. ID Monitoring item Unit (SI)
component
1 04401 Hydr. Oil Temperature °C T/M
2 95302 Steering Pump Pressure MPa BBC
3 95600 Steering Pump EPC Current mA BBC
Monitoring/ Pre-defined screen (15/16) Hydraulic fan (1)
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 04107 Coolant Temperature °C ENG
3 04401 Hydr. Oil Temperature °C T/M
4 30100 T/C Oil Temperature °C T/M
5 10007 Radiator Fan Speed Command r/min T/M
6 10009 Radiator Fan Speed r/min T/M
Monitoring/ Pre-defined screen (16/16) Hydraulic fan (2)
Applicable
No. ID Monitoring item Unit (SI)
component
1 01002 Engine Speed r/min ENG
2 10007 Radiator Fan Speed Command r/min T/M
3 10009 Radiator Fan Speed r/min T/M
4 41400 Rad. Fan Pump EPC Sol. Current mA T/M
5 31646 Fan Reverse Solenoid Current mA T/M

30-148 WA470-7
30 Testing and adjusting
Electrical system

a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
KDPF: The engine controller is in charge of detecting the monitoring information.
T/M: The transmission controller is in charge of detecting the monitoring information.
BBC: The work equipment controller is in charge of detecting the monitoring information.
MON: The monitor controller is in charge of detecting the monitoring information.

WA470-7 30-149
30 Testing and adjusting
Electrical system

Monitoring (WA380-Q19L-100-K-00-A) a Selection with switch operation: Select the


The machine monitor can monitor the condition of component in charge with menu switch (E),
the machine in real time by receiving signals from select the item with Up switch (A) or Down
various switches, sensors, and actuators installed to switch (B) and validate your selection with
various parts of the machine and the information the enter switch (D).
from the controllers which is controlling switches,
a Selection through entry of a monitoring code:
etc.
If you input a monitoring code (5 digit) using
The monitoring function allows you to select a numeral input switches (F), the target item is
desired monitoring item. selected directly. So validate it with the enter
1. Selecting menu switch (D).
Select “Monitoring/Custom“ on “Service Menu“
a If the color of the selected box changes from
screen.
yellow to red, the selection of the item of that
box is entered.
a Up to 6 monitoring items are selectable at a
time. However, all the six items may not be
selected depending on the condition of
display of the selected item.

2. Selecting monitoring item


When the “Monitoring Selection Menu“ screen is
displayed, select the item to monitor.
UP switch (A): Moves the selection up by one
item.
DOWN switch (B): Moves the selection down by
one item 3. Deciding monitoring items
Return switch (C): Clears input numbers/ After selecting monitoring items, execute the
Returns the display to “Service Menu“ screen monitoring according to the following operations.
Enter switch (D): Validates the selection • Switch operation: Double-click the enter
Menu switch (E): Moves your selection to the switch (D).
immediate right item Or hold down the enter switch (D) (for
approximately 2 seconds).
Or enter [99999] by using numeral input
switch (F) and press the enter switch.
a If monitoring items are selected up to the limit
number, monitoring is executed
automatically.

a In setting of the monitoring, each time menu


switch (E) is pressed, sequential switching
among "ENG"o"KDPF"o"T/
M"o"BBC"o"MON"o" ENG" takes place in
this order.

30-150 WA470-7
30 Testing and adjusting
Electrical system

4. Performing monitoring Up switch (A): MEMORY (saves the selected


After the “Monitoring“ screen is displayed, item)
perform the necessary operation of the machine Down switch (B): CLEAR (clears the selected
and check the monitoring information. item)
“Monitoring“ screen displays the following
information.
(a): Monitoring information
(b): Power mode pilot lamp
(c): Shift indicator
(d): Engine coolant temperature
(e): Torque converter oil temperature
(f): Hydraulic oil temperature
(g): Fuel level
a Monitoring information is indicated by value,
ON/OFF, or special display.
a The unit to be displayed can be set to “SI“ or
“Non-SI“ with the “Default“ function in the
service mode. a When a monitoring item is saved, a
confirmation screen appears asking whether
the saved item should be displayed or not,
when “Monitoring“ is selected again.
a When an item is saved, it can be displayed
as many times as required unless it is
cleared.
a If another item is saved while having the
previous item saved, the previously saved
item is overwritten by the latest one.
a The saved monitoring item can be cleared by
the Down switch, and by the following setting
change as well. Validating operation also
5. Holding monitoring information clears the selected item.
In the monitoring information, Hold and Hold
• Default (Machine Model Select)
releasing can be made.
• Default (Option Select)
Menu switch (E): Switches between the Hold
and the Releasing hold
(If the Hold is selected, a diagonal line is drawn
on the HOLD portion.)
Return switch (C): Returns the display to the
Monitoring Selection Menu screen

6. Saving of monitoring item


A selected monitoring item can be saved or
cleared.

WA470-7 30-151
30 Testing and adjusting
Electrical system

Table of Monitoring items (WA470-Q19L-208-K-00-A)

Unit (Default: SI)


Applicable
Code Monitoring item (Display on screen) compo- Remarks
No. SI Non-SI nent
00201 Machine ID - - ENG
20216 ECM Build Version - - ENG
20217 Calibration Data Version - - ENG
18900 ECM Internal Temp °C °F ENG
20400 ECM S/N - - ENG
01002 Engine Speed r/min rpm ENG
36700 Engine Torque Ratio % % ENG
31701 Throttle Position % % ENG
03000 Throttle Position Sensor Volt V V ENG
17500 Engine Power Mode - - ENG
36400 Rail Pressure MPa psi ENG
36401 Rail Pressure Sensor Volt V V ENG
36200 Rail Pressure Command MPa psi ENG
04107 Coolant Temperature °C °F ENG
04105 Coolant Temp Sensor Volt V V ENG
37200 Engine Oil Pressure kPa psi ENG
37201 Eng Oil Pressure Sensor Volt V V ENG
37400 Ambient Pressure kPa psi ENG
37401 Ambient Pressure Sensor Volt V V ENG
36500 Charge Pressure-A kPa psi ENG
36501 Charge Pressure Sensor Volt V V ENG
03203 Battery Power Supply V V ENG
37300 Fuel Rate l/h gal/h ENG
31706 Final Throttle Position % % ENG
18400 Intake Temperature °C °F ENG
18401 Intake Temp Sensor Volt V V ENG
18500 Charge Temperature °C °F ENG
18501 Charge Temp Sensor Volt V V ENG
18100 EGR Valve Position mm in ENG
18101 EGR Valve Pos Sensor Volt V V ENG
18300 Idle Validation Sw 1 - - ENG
18301 Idle Validation Sw 2 - - ENG
18600 Inject Fueling Command mg/st mg/st ENG
17201 PCV Close Timing CA CA ENG
18700 Engine Output Torque Nm lbft ENG
08402 Droop switch - - ENG
48400 Crankcase Pressure kPa psi ENG
48401 Crankcase Pressure Sens Volt V V ENG
48100 Turbo Speed r/min rpm ENG
48200 Mass Air Flow kg/min lb/min ENG
48700 KVGT Position mm in ENG
48701 KVGT Position Sensor Volt V V ENG
48600 EGR Solenoid Current mA mA ENG
48800 KVGT Solenoid Current mA mA ENG
48900 Engine Operation Mode - - ENG
47000 KDPF Outlet Pressure kPa psi KDPF
47001 KDPF Out Pressure Sensor Volt V V KDPF
47100 KDPF Delta Pressure kPa psi KDPF
47101 KDPF Delta Press. Sensor Volt V V KDPF
47200 KDPF 1 Outlet Temperature °C °F KDPF

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30 Testing and adjusting
Electrical system

Unit (Default: SI)


Applicable
Code Monitoring item (Display on screen) compo- Remarks
No. SI Non-SI nent
47201 KDPF 1 Outlet Temp Sens Volt V V KDPF
47300 KDOC 1 Inlet Temperature °C °F KDPF
47301 KDOC 1 Inlet Temp Sens Volt V V KDPF
47400 KDOC 1 Outlet Temperature °C °F KDPF
47401 KDOC 1 Outlet Temp Sens Volt V V KDPF
47500 Dosing Fuel Rate l/h gal/h KDPF
47600 Dosing Fuel Pressure kPa psi KDPF
47601 Dosing Fuel P Sens Volt V V KDPF
47700 Soot Level Estimation g/l g/gal KDPF
41600 Engine Power Mode - - T/M
31200 T/M Input Shaft Speed r/min rpm T/M
31400 T/M Output Shaft Speed r/min rpm T/M
10009 Radiator Fan Speed r/min rpm T/M
10007 Radiator Fan Speed Command r/min rpm T/M
30100 T/C Oil Temperature °C °F T/M
30101 T/C Oil Temp. Sensor Volt V V T/M
04401 Hydr. Oil Temperature °C °F T/M
04404 Hydr. Temp. Sensor Volt V V T/M
32500 T/M Oil Temperature °C °F T/M
32501 T/M Oil Temp. Sensor Volt V V T/M
32601 T/C Input Oil Pressure kPa psi T/M
32602 T/C In. Oil Press Sensor Volt V V T/M
32603 T/C Output Oil Pressure kPa psi T/M
32604 T/C Out. Oil Press Sensor Volt V V T/M
41201 Brake Oil Pressure kPa psi T/M
41202 Brake Oil Press Sensor Volt V V T/M
41203 Brake Cut Off Pressure kPa psi T/M
93700 T/C Speed Ratio % % T/M
93501 T/C Output Shaft Torque Nm lbft T/M
91105 Shift Lever Volt V V T/M
31602 ECMV Current (1st) mA mA T/M
31603 ECMV Current (2nd) mA mA T/M
31604 ECMV Current (3rd) mA mA T/M
31605 ECMV Current (4th) mA mA T/M
31606 ECMV Current (Reverse) mA mA T/M
31608 ECMV Current (Forward) mA mA T/M
Displays only when optional
31609 ECMV Current (Lockup) mA mA T/M setting is enabled.
Displays only when optional
93300 ECSS Current mA mA T/M setting is enabled.
41400 Rad. Fan Pump EPC Sol. Current mA mA T/M
31646 Fan Reverse Solenoid Current mA mA T/M
38902 Trigger Compensation (1st) - - T/M
38903 Trigger Compensation (2nd) - - T/M
38904 Trigger Compensation (3rd) - - T/M
38905 Trigger Compensation (4th) - - T/M
38906 Trigger Compensation (Reverse) - - T/M
38907 Trigger Compensation (Forward) - - T/M
41802 Fill Time (1st) msec msec T/M
41803 Fill Time (2nd) msec msec T/M
41804 Fill Time (3rd) msec msec T/M

WA470-7 30-153
30 Testing and adjusting
Electrical system

Unit (Default: SI)


Applicable
Code Monitoring item (Display on screen) compo- Remarks
No. SI Non-SI nent
41805 Fill Time (4th) msec msec T/M
41806 Fill Time (Reverse) msec msec T/M
41808 Fill Time (Forward) msec msec T/M
44201 Throttle Lower Limit Command % % T/M
44200 Throttle Higher Limit Command % % T/M
36000 Throttle Adjustment Command % % T/M
17302 Dynamic Torque Command % % T/M
T/M Initial Learning Status - - T/M
F Clutch ON/OFF T/M
R Clutch ON/OFF T/M
94100 1st Clutch ON/OFF T/M
2nd Clutch ON/OFF T/M
3rd Clutch ON/OFF T/M
4th Clutch ON/OFF T/M
Clutch Fill SW Input - - T/M
F Clutch ON/OFF T/M
R Clutch ON/OFF T/M
02216 1st Clutch ON/OFF T/M
2nd Clutch ON/OFF T/M
3rd Clutch ON/OFF T/M
4th Clutch ON/OFF T/M
T/M Con. SW Input 1 - - T/M
Main FNR Signal F ON/OFF T/M
Main FNR Signal N ON/OFF T/M
Main FNR Signal R ON/OFF T/M
02211 Displays only when optional
Option FNR Signal F ON/OFF T/M setting is enabled.
Displays only when optional
Option FNR Signal N ON/OFF T/M setting is enabled.
Displays only when optional
Option FNR Signal R ON/OFF T/M setting is enabled.
T/M Con. SW Input 2 - - T/M
Shift Lever 1 ON/OFF T/M
Shift Lever 2 ON/OFF T/M
02212 Shift Lever 3 ON/OFF T/M
Shift Lever 4 ON/OFF T/M
Kick Down Switch ON/OFF T/M
Hold Switch ON/OFF T/M
T/M Con. SW Input 3 - - T/M
Displays only when optional
Shift Up Switch N. O. ON/OFF T/M setting is enabled.
02213 Displays only when optional
Shift Down Switch N. O. ON/OFF T/M setting is enabled.
Shift Mode Switch Manual ON/OFF T/M
Shift Mode Switch H. ON/OFF T/M
T/M Con. SW Input 4 - - T/M
Starter Status ON/OFF T/M
Displays only when optional
ECSS Switch ON/OFF T/M setting is enabled.
02214
Displays only when optional
Lock Up Switch ON/OFF T/M setting is enabled.
T/M Cut Off Switch ON/OFF T/M

30-154 WA470-7
30 Testing and adjusting
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Unit (Default: SI)


Applicable
Code Monitoring item (Display on screen) compo- Remarks
No. SI Non-SI nent
T/M Cut Off Set Switch ON/OFF T/M
Displays only when optional
Option FNR Switch ON/OFF T/M setting is enabled.
T/M Con. SW Input 5 - - T/M
02215
Parking Brake Switch ON/OFF T/M
T/M Con. Switch Output 1 - - T/M
Neutral Safety Relay ON/OFF T/M
03705
T/M Cut Off Indicator ON/OFF T/M
Backup Lamp Relay ON/OFF T/M
T/M Con. Switch Output 2 - - T/M
03706
Parking Brake Relay ON/OFF T/M
20414 Assembly P/N (T/M Con.) - - T/M
20413 Serial No. (T/M Con.) - - T/M
20201 Software P/N (T/M Con.) - - T/M
20223 Application Version (T/M Con.) - - T/M
20224 Data Version (T/M Con.) - - T/M
06002 Boom Angle deg deg BBC
06005 Boom Angle Sensor Volt V V BBC
55600 Bucket Link Angle deg deg BBC
55601 Bucket Link Angle Sensor Volt V V BBC
55700 Bucket Tilt Set Angle deg deg BBC
55800 Tilt Cylinder Stroke mm in BBC
95302 Steering Pump Pressure MPa psi BBC
95303 Steering Pump Pres. Sensor Volt V V BBC
07703 Emerg. Steering Pressure MPa psi BBC
07705 Emerg. Steering Press S. Volt V V BBC
94700 Loader Pump Pressure MPa psi BBC
94701 Loader Pump Pres. Sensor Volt V V BBC
94702 Loader Pump MAX. Flow cc/rev cc/rev BBC
40400 Boom Bottom Pressure MPa psi BBC
40402 Boom Bottom Pres. Sensor Volt V V BBC
Displays only when optional
40500 Boom Head Pressure MPa psi BBC setting of load meter is
enabled.
Displays only when optional
40501 Boom Head Pres. Sensor Volt V V BBC setting of load meter is
enabled.
42000 Boom Lever Volt (Main) V V BBC
42001 Boom Lever Volt (Sub) V V BBC
42104 Boom Lever Stroke % % BBC
55900 Boom Speed Command % % BBC
42002 Bucket Lever Volt (Main) V V BBC
42003 Bucket Lever Volt (Sub) V V BBC
42106 Bucket Lever Stroke % % BBC
55901 Bucket Speed Command % % BBC
Displays according to the
42006 3rd Lever Volt (Main) V V BBC optional setting of work
equipment control
Displays according to the
42007 3rd Lever Volt (Sub) V V BBC optional setting of work
equipment control

WA470-7 30-155
30 Testing and adjusting
Electrical system

Unit (Default: SI)


Applicable
Code Monitoring item (Display on screen) compo- Remarks
No. SI Non-SI nent
Displays according to the
42107 3rd Lever Stroke % % BBC optional setting of work
equipment control
Displays according to the
55902 3rd EPC Speed Command % % BBC optional setting of work
equipment control
Displays only when optional
42004 Bucket Lever Volt (Main) V V BBC setting is enabled.
Displays only when optional
42005 Bucket Lever Volt (Sub) V V BBC setting is enabled.
Displays only when optional
42110 J/S Lever Stroke % % BBC setting is enabled.
Displays only when optional
55905 J/S Speed Command % % BBC setting is enabled.
41900 Boom Raise EPC Current mA mA BBC
41901 Boom Lower EPC Current mA mA BBC
41902 Bucket Tilt EPC Current mA mA BBC
41903 Bucket Dump EPC Current mA mA BBC
Displays according to the
41906 3rd Extend EPC Current mA mA BBC optional setting of work
equipment control
Displays according to the
41907 3rd Retract EPC Current mA mA BBC optional setting of work
equipment control
Displays only when optional
41904 J/S R. H. EPC Current mA mA BBC setting is enabled.
Displays only when optional
41905 J/S L. H. EPC Current mA mA BBC setting is enabled.
94500 Loader Pump EPC Current mA mA BBC
95600 Steering Pump EPC Current mA mA BBC
94900 Work Status - - BBC
BBC Output 1 - - BBC
Work Equipment Lock Sol. ON/OFF BBC
03707 Work Equipment Lock Ind. ON/OFF BBC
Bucket Tilt Detent Sol. ON/OFF BBC
Boom Detent Sol. ON/OFF BBC
Displays only when optional
BBC Output 2 - - BBC setting is enabled.
03708 Emergency S/T Press SW ON/OFF BBC
Displays only when optional
J/S Solenoid Cut Relay ON/OFF BBC setting is enabled.
BBC Input 1 - - BBC
Key SW C ON/OFF BBC
02217
Eng. Power Mode Switch ON/OFF BBC
Work Equipment Lock SW ON/OFF BBC
"BBC Input 2" - - BBC
02218 Boom Positioner Set SW ON/OFF BBC
Bucket Positioner Set SW ON/OFF BBC
BBC Input 3 - - BBC
Emergency Steering SW ON/OFF BBC
Displays only when optional
02219 Quick Coupler Release SW ON/OFF BBC setting is enabled.
Quick Coupl. Rel. SW OFF ON/OFF BBC
BR Signal ON/OFF BBC

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30 Testing and adjusting
Electrical system

Unit (Default: SI)


Applicable
Code Monitoring item (Display on screen) compo- Remarks
No. SI Non-SI nent
20416 Assembly P/N (BBC) - - BBC
20415 Serial No. (BBC) - - BBC
20202 Software P/N (BBC) - - BBC
20225 Application Version (BBC) - - BBC
20226 Data Version (BBC) - - BBC
01001 Engine Speed (Tachometer) r/min r/min MON
40000 Travel Speed (Speedometer) km/h MPH MON
04200 Fuel Level Sensor Volt V V MON
04201 Fuel Level Sensor Resistance 1z 1z MON
04202 Fuel Level % % MON
30202 Brake Oil Temperature °C °F MON
30205 Brake Oil Temp. Sensor Volt V V MON
40300 Battery Liquid Level Sensor V V MON
55400 Tachograph Output Pulse Hz Hz MON
55401 Speed Recorder Output Pulse Hz Hz MON
03220 Controller Battery Volt (MON) V V MON
04306 Battery Charge Volt (MON) V V MON
Monitor Input 1 - - MON
Right Turn Signal ON/OFF MON
Left Turn Signal ON/OFF MON
04507 Head Light SW ON/OFF MON
High Beam Status ON/OFF MON
Night Lighting SW ON/OFF MON
Daytime Lighting SW ON/OFF MON
Monitor Input 2 - - MON
Seat Belt SW ON/OFF MON
04508 Engine Starter ON/OFF MON
ENG Shutdown Secondary ON/OFF MON
Preheater Relay ON/OFF MON
Monitor Input 3 - - MON
04509 Air Cleaner Clog Sig ON/OFF MON
Coolant Level Sensor ON/OFF MON
Monitor Input 4 - - MON
Front Brake Oil Press ON/OFF MON
04510 Rear Brake Oil Press ON/OFF MON
Parking Brake Press SW ON/OFF MON
Eng Oil Pressure Sensor Volt ON/OFF MON
Monitor 1st & 2nd Row SW - - MON
SW1 ON/OFF MON
SW2 ON/OFF MON
04504 SW3 ON/OFF MON
SW4 ON/OFF MON
SW5 ON/OFF MON
SW6 ON/OFF MON
Monitor 3rd & 4th Row SW - - MON
SW7 ON/OFF MON
SW8 ON/OFF MON
04505 SW9 ON/OFF MON
SW10 ON/OFF MON
SW11 ON/OFF MON
SW12 ON/OFF MON

WA470-7 30-157
30 Testing and adjusting
Electrical system

Unit (Default: SI)


Applicable
Code Monitoring item (Display on screen) compo- Remarks
No. SI Non-SI nent
Monitor 5th Row SW - - MON
SW13 ON/OFF MON
04506
SW14 ON/OFF MON
SW15 ON/OFF MON
Monitor Output - - MON
04700 Buzzer ON/OFF MON
Personal Code Relay ON/OFF MON
00205 Selected Model (MON) - - MON
20227 Assembly P/N (MON) - - MON
20402 Serial No. (MON) - - MON
20228 Software P/N (MON) - - MON
20221 Application Version (MON) - - MON
20278 Data Version 1 (MON) - - MON
20279 Data Version 2 (MON) - - MON
55300 Aircon Compressor Status ON/OFF MON
55000 Aircon Outside Temp. Code - - MON
55001 Aircon Outside Temp. °C °F MON
55100 Aircon Inside Temp. Code - - MON
55101 Aircon Inside Temp. °C °F MON
55200 Aircon Mode Data (MON) - - MON
55201 Aircon Mode Data (Aircon ECU) - - MON
20266 Assembly P/N (Rearview Mon.) - - MON
20421 Serial No. (Rearview Mon.) - - MON
20267 Software P/N (Rearview Mon.) - - MON
20268 Software Version(Rearview Mon.) - - MON
Displays only when optional
20260 Assembly P/N (KOMTRAX) - - MON setting of KOMTRAX
terminals is enabled.
Displays only when optional
20418 Serial No. (KOMTRAX) - - MON setting of KOMTRAX
terminals is enabled.
Displays only when optional
20261 Software P/N (KOMTRAX) - - MON setting of KOMTRAX
terminals is enabled.
Displays only when optional
20273 Program Version (KOMTRAX) - - MON setting of KOMTRAX
terminals is enabled.
Displays only when ID Key
20262 Assembly P/N (ID Key Con.) - - MON
Con. is connected
Displays only when ID Key
20419 Serial No. (ID Key Con.) - - MON
Con. is connected
Displays only when ID Key
20263 Software P/N (ID Key Con.) - - MON
Con. is connected

a Listing order in the table of monitoring items


The monitoring items are listed in the order of the display on the monitoring item selection menu screen.
a Unit
SI or Non-SI is selectable for the unit displayed on the screen.
(Switch of the displayed unit is made by using “Unit“ of “Defoult“ of the service menu.)
"mg/st" in the unit indicates the mass per stroke (milligram/stroke).

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30 Testing and adjusting
Electrical system

a Applicable component
ENG: The engine controller is in charge of detecting the monitoring information.
KDPF: The engine controller is in charge of detecting the monitoring information.
T/M: The transmission controller is in charge of detecting the monitoring information.
BBC: The work equipment controller is in charge of detecting the monitoring information.
MON: The monitor controller is in charge of detecting the monitoring information.
Note 1: “Fuel Rate“ (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is a theoretical value,
it is slightly different from the actual fuel consumption ratio).

WA470-7 30-159
30 Testing and adjusting
Electrical system

Abnormality record (mechanical a If you enter a 2-digit item number with the
systems) (WA380-Q1S2-100-K-00-A) numeral input switches (E), the entered item
The machine monitor logs the past and currently is directly selected.
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check the mechanical system abnormality record,
perform the following procedures.
a For the failure code list, see "40 Failure code list
for troubleshooting".
1. Selecting menu
Select "Abnormality Record" on the "Service
Menu" screen.

2. Selecting sub menu


When the "Abnormality Record" screen is
displayed, select "Mechanical Systems".
3. Information displayed on "Abnormality Record"
Up switch (A): Moves selection to the above
screen
item
On the "Mechanical Systems" abnormality
Down switch (B): Moves selection to the below
record screen, the following information is
item
displayed.
Return switch (C): Returns the display to the
(a): Occurrence order of abnormalities from
service menu screen
latest one/ Total number of abnormalities in the
Enter switch (D): Validates the selection
log
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at first occurrence
(f): Service meter reading at last occurrence
Up switch (A): Moves the display to the previous
page (screen)
(if abnormality record extends to multiple pages)
Down switch (B): Move the display to the next
page (screen)
(if abnormality record extends to multiple pages)
Return switch (C): Return to the "Abnormality
Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.

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a If the number of occurrence is 1 (first Down switch (B): Moves the selection down by
occurrence), the service meter reading at the one item
first occurrence and that at the last Return switch (C): Returns to the “Service Menu“
occurrence are the same. screen
Enter switch (D): Validates the selection
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or correction a If you enter a 2 digit item number with the
of it is not confirmed. numeral input switches (F), the entered item
is directly selected.
a An abnormality record of the mechanical
system cannot be deleted.
a For all of the failure codes that the machine
monitor can record, see the failure code list.

Abnormality record (electrical


systems) (WA380-Q1S3-100-K-00-A)
The machine monitor logs the past and currently
occurring failures classifying them into the
mechanical system abnormality and electrical
system abnormality.
To check “Electrical Systems“ abnormality record,
perform the following procedures.
a For the failure code list, see "40 Failure code list 3. Information displayed on "Abnormality Record"
for troubleshooting". screen
1. Selecting menu On “Electrical Systems“ abnormality record
Select “Abnormality Record“ on “Service Menu“ screen, the following information is displayed.
screen. (a): Occurrence order of abnormalities from
latest one/ Total number of records
(b): Failure code
(c): Detail of failure
(d): Number of occurrences (displayable range:
0 to 65,535 times)
(e): Service meter reading at the first occurrence
(f): Service meter reading at the last occurrence
Up switch (A): Moves your selection to the item
right above the current one (when 2 or more
abnormalities are recorded)
Down switch (B): Moves your selection to the
item right below the current one (when 2 or more
abnormalities are recorded)
Return switch (C): Returns to “Abnormality
2. Selecting sub menu
Record“ screen
After “Abnormality Record“ screen is displayed,
select “Electrical Systems“ a If no abnormality is recorded, “No Error“ is
Up switch (A): Moves the selection up by one displayed.
item

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a On the electrical systems abnormality record a The screen is in the clear mode if graphic
screen, up to 20 cases currently stored are mark [CLEAR] is indicated at the bottom
displayed. of the screen.
If the number of abnormality records Up switch (A): Moves your selection to
increases to 21 or beyond, the latest the item right above the current one
occurrence code is displayed and the oldest (when 2 or more abnormalities are
one is deleted. recorded)
a If the number of occurrence is 1 (first Down switch (B): Moves your selection to
occurrence), the time of the first occurrence the item right below the current one
is identical with the time being read on the (when 2 or more abnormalities are
service meter at the first occurrence. recorded)
Return switch (C): Returns to
a If [E] is displayed on the left of a failure code,
“Abnormality Record“ screen
the abnormality is still occurring or correction
of it is not confirmed. Enter switch (D): Clears the information
one by one
a For all of the failure codes that the machine
Menu switch (E): Clears all information at
monitor can record, see the failure code list.
once
a When clearing the information one by
one: Select the item to be cleared by
using Up switch (A) or Down switch (B)
and press the enter switch (D) to clear it.
a When clearing all the information at once:
Press menu switch (E) to clear all the
items regardless of the selection of the
individual item.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
4. Clearing abnormality record
1) While “Electrical Systems“ screen is
displayed, perform the following operation.
Switch operation: While pressing Down
switch (B), press numeral input switches (F)
in the sequence of "1"o"2"o"3".

3) After the “Electrical Sys. Error Reset“ screen


is displayed, operate the switches.
Return switch (C): Returns to “Electrical Sys.
Error Reset“ screen
Enter switch (D): Clears the information.

2) Check that the display on the screen


becomes the clear mode, then clear the
individual information one by one or all
together.

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a The following figure shows the screen 2. Selecting maintenance record item
when an individual item is cleared (it is After the “Maintenance Record“ screen is
slightly different from the screen when all displayed, select the item to confirm.
the item are cleared at once). Up switch (A): Moves the selection up by one
item
Down switch (B): Moves the selection down by
one item
Return switch (C): Returns the display to the
“Service Menu“ screen
Enter switch (D): Validates the selection

4) If the screen to notify completion of clearing


is displayed and then “Electrical Sys. Error
Reset“ screen is displayed, the clearing of
the abnormality record is completed.

a If you enter a 2-digit item number with the


numeral input switches (E), the entered item
is directly selected.

Maintenance Record (WA470-Q19Z-100-K-00-A)


The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
If you reset the data from the user menu after a
maintenance operation, the number of maintenance a Setting for the following items is available in
performed is recorded in this section. “Maintenance Record“.
1. Selecting menu No. Maintenance record items
Select “Maintenance Record“ on “Service Menu“ 49 Air Cleaner Cleaning/Change
screen. 41 Fuel Pre-Filter
01 Engine Oil
02 Engine Oil Filter
13 Transmission Oil Filter
03 Fuel Main Filter
12 Transmission Oil
15 Axle Oil
10 Hydraulic oil
04 Hydraulic Oil Filter
05 Hydraulic Oil Tank Breather
47 KCCV Filter

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No. Maintenance record items Enter switch (D): Validates the selection
48 KDPF Filter Cleaning
52 Fuel Doser Cleaning
3. Information displayed in “Maintenance Record“
screen
The following information is displayed.
(a): Maintenance items
(b): Number of replacements up to now
(c): Service meter reading (SMR) at the last
replacement

a If you enter a 2-digit item number with the


numeral input switches (E), the entered item
is directly selected.

"Maintenance Mode Setting" (WA380-Q1F1-100-K-00-


A)
The actuating condition of the maintenance
reminder function in the operator mode can be set
and changed by using this menu.
• To enable or disable the function
• Change set replacement interval (by item)
• Initialize all of set change intervals
1. Selecting menu
Select "Maintenance Mode Setting" on the
"Service Menu" screen.

2. Selecting sub menu


On the "Maintenance Mode setting" screen
displayed, select the item to change the setting.
Up switch (A): Moves selection to the above
item
Down switch (B): Moves selection to the below
item
Return switch (C): Returns the display to the
"Service Menu" screen

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a Setting for the following items is available in a Even if ON/OFF of each item has been set, if
"Maintenance Mode Setting". the above setting is changed, it overrides the
Maintenance Mode Setting item individual setting.
No.
Maintenance Mode a The maintenance function for cleaning KCCV
On/Off filter, KDPF filter and fuel doser remains
"Maintenance Mode
00 Maintenance enabled even if "OFF" is selected.
Change"
Notice Time
Setting
"Air Cleaner OFF/ON Set
49 Cleaning / Change
Interval" Set Value
"Fuel Pre Filter OFF/ON Set
41 Change Interval" Set Value
"Engine Oil Change OFF/ON Set
01
Interval" Set Value
"Engine Oil Filter OFF/ON Set
02 Change Interval" Set Value
"Transmission Oil OFF/ON Set
13 Filter Change
Interval" Set Value
4. Description of maintenance mode change
"Fuel Main Filter OFF/ON Set procedure (Maintenance Notice Time Setting)
03 Change Interval" Set Value Select "Maintenance Notice Time Setting" of
"Transmission Oil ON/OFF Set "Maintenance Mode Change" and proceed to its
12 Change Interval" Set Value setting.
"Axle Oil Change OFF/ON Set
15
Interval" Set Value
"Hydraulic Oil OFF/ON Set
10 Change Interval" Set Value
"Hydraulic Oil Filter OFF/ON Set
04 Change Interval" Set Value
"Hydraulic Oil Tank OFF/ON Set
05 Breather Change
Interval" Set Value
99 Returns all to Default Values

a KCCV filter, KDPF filter cleaning, and fuel


doser cleaning settings cannot be changed.
3. Description of maintenance mode change
procedure (Maintenance Mode On/Off) • Default value: "Maintenance Notice Time" set
Select "Maintenance Mode On/Off" of in machine monitor (Recommended by the
"Maintenance Mode Change" and proceed to its manufacturer and not changeable).
setting. • Set value: Maintenance interval that can be
• ON: Functions of all maintenance items freely set. Maintenance reminder function
become enabled in operator mode. works according to this set time in operator
• OFF: Functions of all maintenance items mode (which is set in increments of 10
become disabled in operator mode. hours).
Up switch (A): Moves selection to the above Up switch (A): Increases the set value
item Down switch (B): Decreases the set value
Down switch (B): Moves selection to the Return switch (C): Cancels setting before
below item validated and return to the "Maintenance
Return switch (C): Cancels selection and Mode Change" screen.
returns to the "Maintenance Mode Change" Enter switch (D): Validates selection and
screen returns to the "Maintenance Mode Change"
Enter switch (D): Validates selection and screen
returns to the "Maintenance Mode Change"
screen

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• "Default": Maintenance notice time set in


machine monitor (recommended by the
manufacturer and not changeable).
• "Set": Maintenance interval that can be freely
set. Maintenance reminder function works
according to this set time in operator mode
(which is set in increments of 25 hours).
Up switch (A): Increases the "Set"
Down switch (B): Decreases the "Set"
Return switch (C): Cancels selection before
validated and return to each maintenance
item screen
Enter switch (D): Validates selection and
5. Description of setting of individual maintenance return to each maintenance item screen
item (ON/OFF setting)
Select "ON/OFF setting" for individual a When your selection is validated with Enter
maintenance item and proceed to its setting. switch (D) and the display returns to the
• ON: Function of each maintenance item "Maintenance Mode Setting" screen, your
selected is enabled in the operator mode setting is validated.
• OFF: Function of each maintenance item a If currently selected "ON" for an item is
selected is disabled in the operator mode changed to "OFF" after operation of an hour
Up switch (A): Moves selection to the above or longer, such change is recognized as a
item reset operation.
Down switch (B): Moves selection to the
below item
Return switch (C): Cancels selection and
returns to each maintenance item screen
Enter switch (D): Validates selection and
return to each maintenance item screen

7. Function to return all of the values to Default


Values
After selecting "All Default Value", and the
screen is displayed, set it by using the switches.

6. Description of setting of individual maintenance


item (Set Value) Select "Set Value" for individual
maintenance item and proceed to its setting.

• If the operation for this function is executed,


the set values of all the maintenance items
are initialized (returned to the default values).

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Return switch (C): Returns the display to Menu switch (E): Clears all the input phone
"Maintenance Mode Setting" screen numbers.
Enter switch (D): Executes initialization Numeral input switch (F): Inputs the phone
number.
a The initialization work is completed if the
Initialization Completion screen appears
sometime after pressing Enter switch (D)
being followed by the Maintenance Mode
Setting screen.

Phone number entry (HM300-Q19A-110-K-00-A)


The telephone number, which is displayed together
with the “Error List“ in the operator mode, can be
input and changed according to the following
procedure.
If a telephone number is not input with this function,
no telephone number is displayed in the operator
mode.
1. Selecting menu a Up to 14 digits can be input from the left.
Select “Phone Number Entry“ on the “Service Input nothing in the surplus places.
Menu“ screen. a When you entered a value that contains a
wrong number, move the input position (with
yellow background) to that digit and overwrite
it with the correct number.
a If you press Enter switch (D) without inputting
a digit, no phone number is displayed in the
operator mode since there is no phone
number information.

2. Registering and changing phone number


After the “Phone Number Entry“ screen is
displayed, register or change the phone number
Up switch (A): Moves the input position to the
immediate left place (if not blank).
Down switch (B): Moves the input position to the
immediate right place (if not blank).
Return switch (C): Cancels the entry and returns
to the “Service Menu“ screen.
Enter switch (D): Validates the entry.

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Default (Machine Model Select) (WA470-Q1GB-100-K-


00-A)
Use the menu of "Default" to check or change
various settings of the machine monitor and
machine.
When a controller is replaced with a new one, the
machine model selection function informs the new
control of the machine model to which it is now
installed.
1. Selecting menu
Select “Default“ on “Service Menu“ screen.

2) When the machine model selection is


enabled, select the model.
Up switch (A): Moves the selection up by one
item
Down switch (B): Moves the selection down
by one item
Return switch (C): Cancels the selection and
returns the display to “Default“ screen
Enter switch (D): Validates the selection

2. Selecting sub menu


After the “Default“ screen is displayed, select
“Machine Model Select“.

a If you press the enter switch (D) to


validate “Machine Model Select“, the
followings are performed.
• “Monitoring/Custom“: Currently stored
items are cleared
3. Selecting machine model • “Maintenance Mode Setting“:
1) When “Machine Model Select“ screen is “Maintenance Mode On/Off“ and
displayed, perform the following operation. “Maintenance Notice Time Setting“
• Switch operation: While pressing DOWN are returned to the default values of
switch (B), press numeral input switches the model.
(E) "1" o "2" o "3" in order. • “Default“ (Option Select): Default
value of the selected model are
restored
• “ECO Guidance“: All of the fuel
consumption data are reset
a This screen is displayed when the service
menu is opened for the first time after the
monitor controller is replaced to the one
that has not been used for the machine
model selection before. Therefore, select
the model first (the screen display may be
somewhat different from the actual one).

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Select “Option Select“ on “Default“ screen.

3) When the screen that urges you to turn the


starting switch to OFF position appears, turn
3. Selecting optional equipment
the starting switch to OFF position once and
turn it to ON position again. Then perform the 1) After “Option Select“ screen is displayed,
following "Default (Option Select)." check the optional equipment installed to the
machine concerned and set each item.
a When the current settings are acceptable,
select either one of the items and press
the enter switch (D) without making any
modification, and your settings will be
reflected on the machine.

Default (Option Select) (WA470-Q1GC-100-K-00-A)


Use the menu of "Default" to check or change
various settings of the machine monitor and
machine.
When all the settings relevant to the current optional
equipment are reset due to the machine model
selection or when an option equipment is added a Optional device installation setting table
later, the optional equipment selection function is Default
Item name setting Remarks
used to select the said optional equipment and
enable its function. Work See "(2) Setting Work
1. Selecting menu Equipment TYPE A Equipment Control"
Select “Default“ on “Service Menu“ screen. Control
Select "JAPAN SPEC" or
Quick
Coupler NO ADD "OTHERS" when optional
equipment is installed.
Semi-auto Select "ADD" and do not
digging ADD change it.
Select "ADD" when
Load Meter NO ADD optional equipment is
installed.
Set the following items
according to the boom
Lift Arm specification.
Standard
Model • If standard boom is
used, select
"Standard".
2. Selecting sub menu

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Default Default
Item name setting Remarks Item name setting Remarks
• If high lift boom Komatsu
Select "ADD" and do not
(optional) is used , Smart ADD change it.
select "High Lift". Loader Logic
Select "ADD" when Auto Idle Select "ADD" on machines
Auto Grease NO ADD optional equipment is Stop Setting NO ADD for North America.
installed. 2) Setting of work equipment control
Battery Select "NO ADD" and do Select “Work Equipment Control“ and set
Electrolyte NO ADD not change it.
Level Sensor one of TYPE A to G.
If difference is recognized Up switch (A): Moves the selection up by one
in the travel speed display, item
Tire Size adjust it with this function. Down switch (B): Moves the selection down
Compensa- 0% Increasing the setting by by one item
tion 1% increases the travel Return switch (C): Cancels the selection and
speed by 1% against the returns the display to “Option Select“ screen
one at 0%. Enter switch (D): Validates the setting and
Tire Type Select "B" when 26.5 tires returns the display to “Option Select“ screen
A
are installed.
Emergency Select "ADD" when
Steering ADD optional equipment is
installed.
When the multi-function
lever (joystick lever is not
installed) or directional
J/S or FNR (FNR) switch (on the right)
NON
SW is installed, select "OPT
FNR". When the joystick
steering is installed, select
"J/S FNR".
Select "ADD" and do not
Lift Up Mode ADD change it.
Select "ADD" and do not
ECSS ADD change it.
Select "ADD" and do not
T/C Lockup NO ADD
change it.
Prohibition of
Select "NO ADD" and do
use of 4th NO ADD not change it.
speed
Set as follows according to
installed optional
equipment and
destination.
• Set to "HEATER" if
machine is equipped
with optional
Tow Stage equipment and used in • TYPE A
NO ADD Japan.
Low Idle Main Valve Type: 2 spool
• Set to "KOHAG" if
Lever Type: 2 levers
machine is equipped
with optional • TYPE B
equipment and used Main Valve Type: 2 spool
outside Japan. Lever Type: MF lever
• Select "NON" when • TYPE C
optional equipment is Main Valve Type: 3 spool
not installed. Lever Type: 3 levers
F1 PWR Select "ADD" and do not • TYPE D
ADD change it.
CUT Main Valve Type: 3 spool
Lever Type: MF lever + PCS
• TYPE E
Non Use

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• TYPE F
Non Use
• TYPE G
Non Use
a Depending on the set type of the work
equipment control, the following optional
equipment selections will be fixed and
unchangeable.
• Semi-auto Digging
• Boom specification
3) Setting tire size compensation
Select and set “Tire Size Compensation“.
Up switch (A): Increases the set value by 1% 4. Reflecting setting
Down switch (B): Decreases the set value by If you exit “Option Select“ screen by using the
1% return switch after completing the setting of the
Return switch (C): Cancels the setting items, a screen appears to urge you to turn the
operation before validation and returns the starting switch to OFF position. Turn the starting
display to “Option Select“ screen switch to OFF position once and “Option Select“
Enter switch (D): Validates the setting and is completed.
returns the display to “Option Select“ screen
a When you do not press the enter switch (no
change is made) even once for any item,
even if you exit “Option Select“ screen, this
screen does not appear.

4) Selection of optional item setting/ not setting


Among the items included in "List of installed
optional devices and their setting", the items
applied the option setting/ not setting
selection must select either one of them. Default (Unit) (WA470-Q1F3-100-K-00-A)
Up switch (A): Moves the selection up by one Use the menu of "Default" to check or change
item various settings of the machine monitor and
Down switch (B): Moves the selection down machine.
by one item
The unit selecting function is used to select the unit
Return switch (C): Cancels the selection and
of the data to be displayed in monitoring, etc.
returns the display to “Option Select“ screen
Enter switch (D): Validates the setting and 1. Selecting menu
returns the display to “Option Select“ screen Select “Default“ on “Service Menu“ screen.

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a Switching of the unit is not available inside


Japan.

2. Selecting sub menu


Select “Unit“ on “Default“ screen.

Default (Rear View Monitor Setting) (WA470-


Q1GD-100-K-00-A)
Use the menu of "Default" to check or change
various settings of the machine monitor and
machine.
The rearview monitor setting function is used for the
setting required for the removal or installation of the
rearview monitor of camera.
1. Selecting menu
Select “Default“ on “Service Menu“ screen.

3. Selecting unit
After “Unit“ screen is displayed, select the unit to
be set.
Up switch (A): Moves the selection up by one
item
Down switch (B): Moves the selection down by
one item
Return switch (C): Cancels the selection and
returns the display to “Default“ screen
Enter switch (D): Validates the setting and
returns the display to “Default“ screen
2. Selecting sub menu
Select “Rear View Monitor Setting“ on “Default“
screen.

3. Setting rearview monitor (setting of camera 1)


ON/OFF setting of the rearview camera can be
set.

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1) Select “Camera1 setting“ on “Rear View


Monitor Setting“ screen.

4. “Rear View Monitor Setting“ (Guide Line Position


Adjustment)
The position of the guide line displayed on the
2) Setting of camera 1.
rearview monitor can be adjusted.
• "Unavailable": Camera is unavailable
• "Available": Camera is available a Be sure to readjust the guide line position
Up switch (A): Moves the selection up by one with this function whenever the rearview
item camera position is changed due to its
Down switch (B): Moves the selection down removal or installation.
by one item a If the above adjustment is not done at all, you
Return switch (C): Cancels the selection and cannot select “Monitor Setting“ o “Rear View
returns the display to “Rear View Monitor Monitor Setting“ o “Guide Line Display“ in
Setting“ screen the user menu (guide line is not displayable).
Enter switch (D): Validates the setting and
1) After the “Rear View Monitor Setting“ screen
returns the display to “Rear View Monitor
is displayed, select “Guide Line Position
Setting“ screen
Adjustment“.
a Reverse images (mirror images) are
a Perform this adjustment with the rearview
displayed on the rearview monitor.
monitor displayed.
a Switching to the normal images (visual (In the user menu, select and turn OFF
images) is not available. “Monitor Setting“ o “Rear View Monitor
a The factory default is "Available". Setting“ o “Reverse-interlock enabled
mode“.)
a When "Unavailable" is selected for
camera 1, this item is not selectable.

2) After “Guide Line Position Adjustment“


screen is displayed, adjust the horizontal and
vertical positions at each point of the guide
line displayed on the rearview monitor
according to the following procedure.
1] Select point 1 from the "Guide Line
Position Adjustment" screen.

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30 Testing and adjusting
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Up switch (A): Moves the selection up by


one item
Down switch (B): Moves your selection to
the item directly below the current one
Return switch (C): Cancels the selection
and returns the display to “Rear View
Monitor Setting“ screen
Enter switch (D): Validates your selection
and returns the display to the Point
Position Adjustment screen

3] Validate the setting with the enter switch


(D).
4] Above operation allows you to adjust the
vertical position of "Point 1". So, by using
the brightness adjustment switch of the
rearview monitor, align (b) portion at 1.5
m from the rear edge of the machine.
Brightness adjustment switch + (E):
Moves the point upward.
Brightness adjustment switch - (F):
Moves the point downward.

2] This screen allows adjusting the


horizontal position of "Point 1". So, using
the brightness adjustment switch of the
rearview monitor, align (a) portion with the
outside width of the tire.
Brightness adjustment switch + (E):
Moves the point rightward.
Brightness adjustment switch - (F):
Moves the point leftward.

5] When the vertical position adjustment is


over, validate the setting with the enter
switch (D).
6] The display returns to the Point Selection
screen. On this screen, adjust the guide
line positions at points 2 to 4 by using the
same procedure.

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5. Initializing rearview monitor


This function allows initializing the rearview
monitor setting.
a Whenever you have replaced the rearview
monitor, you must initialize the rearview
monitor with this function.
1) After the “Rear View Monitor Setting“ screen
is displayed, select“Rear View Monitor
Initialize“.

3) Check that the positional relationship


between the guide line and machine is as
shown in the following figure.
(c): Outer face of tire (green line)
(d): 1.5 m from machine rear edge (yellow
line)
(e): Outer face of tire (green line)

2) The screen to confirm that want to perform


the initialization appears. Answer
affirmatively to it and start your operation.
Return switch (C): Returns the display to
“Rear View Monitor Setting“ screen
Enter switch (D): Executes the initialization
a If the enter switch (D) is pressed to
execute the initialization, the following
“Rear View Monitor Setting“ is returned to
the default values.
4) When the setting of “Reverse-interlock
• “Reference Line“: Not displayed
enabled mode“ of the user menu was
• “Reverse-interlock enabled mode“:
changed at the first, return it to the original
ON
condition and the guide line position
• “Camera1 Setting“: Used
adjustment is completed.
• “Guide Line Position Adjustment“: Not
set

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Select “Auto Idle Stop Time Fixing“ on “Default“


screen.

a When the Initialization Completion screen


appears sometime after pressing the
enter switch (D), display “Rear View 3. Setting auto idle stop time
Monitor Setting“ and the initialization is Select a time on “Auto Idle Stop Time Fixing“
completed. screen.

a The value selected here will become the


Default (Auto Idle Stop Timer Setting) (WA470-
Q1GE-100-K-00-A) maximum value of auto idle stop time that
Checking and change of auto idle stop setting range can be selected in the user menu.
are performed in "Default". a The maximum value of the auto idle stop
This is to select the range of auto idle stop time time must be set after checking compliance
setting that can be selected in the user mode. with the applicable law, which differs by
region.
a This item is displayed only when "Auto Idle Stop
Setting" is set to "ADD".
1. Selecting menu
Select “Default“ on “Service Menu“ screen.

2. Selecting sub menu

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Testing (Cylinder Cut-out operation) (HM300-


AD00-34F-K-00-A)
In the machine monitor, the cylinder cut-out mode
operation and the KDPF regeneration operation can
be executed as well as their cancellation.
Cylinder Cut-out mode operation means to run the
engine with one or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to identify a
cylinder that does not output power normally
(combustion in it is abnormal).
1. Selecting menu
Select “Diagnostic Tests“ on “Service Menu“
screen. a This operation may be performed while the
engine is running.
a If background (a) of the selected cylinder
number becomes white after you press Enter
switch (D), the cylinder is cut out.
a If the machine monitor cuts out a cylinder but
the engine controller cannot cut out that
cylinder, the background (a) of the cylinder
number becomes yellow.
a The number of cylinders cut out may be one
or more.

2. Selecting sub menu


After “Diagnostic Tests“ screen is displayed,
select “Cylinder Cut-out“.

4. Releasing cut-out cylinder


When changing a cylinder to be cut out or when
the cylinder cut-out operation is finished, select
the cut-out cylinder(s) to be released.

3. Selecting cylinder to be cut-out a This operation may be performed while the


After the “Cylinder Cut-out“ screen is displayed, engine is running.
select a cylinder to be cut out. a If background (a) of the selected cylinder
Up switch (A): Moves selection to the left number changes to gray when you press
Down switch (B): Moves selection to the right Enter switch (D), the cylinder is released the
Return switch (C): Returns the display to the cut-out.
Diagnostic Test screen
Enter switch (D): Validates the selection a If the machine monitor releases a cut-out
Menu switch (E): Switches between the Hold cylinder but the engine controller cannot
and the Releasing hold release the cut-out cylinder, the background
(If the Hold is selected, a diagonal line appears (a) of the cylinder number becomes red.
on the HOLD portion.)

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a The cut-out cylinder mode operation is not


automatically released after the screen
returns to the operator mode. Accordingly, be
sure to perform the releasing operation after
the cylinder cut-out mode operation is
finished.
5. Holding displayed data
If you press menu switch (E) during the cylinder
cut-out operation, the displayed information is
held anew (b) (display of the real-time
information is maintained on the left side).
If you press menu switch (E) while the data is
held, the data holding function is canceled.
2. Selecting sub menu
a The holding function is available for a After “Diagnostic Tests“ screen is displayed,
cylinder, regardless of whether it is cut out or select “Regeneration for Service“.
not.
a While the manual stationary regeneration is
turned on or stopped from “KDPF
Regeneration“ of the user menu, you cannot
select “Regeneration for Service“.

[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Decrease in engine speed
2) The quantity of final injection rate 3. Setting regeneration for service
command increases. When “Regeneration for Service“ screen is
• If the engine is running at around high idle, displayed, the following informations are
however, the engine speed may not displayed corresponding to the KDPF
decrease because for the reason of engine regeneration condition. Set the KDPF
control. regeneration according to the given messages.
• In this case, lower the engine speed by (a): Soot accumulation level
adjusting the accelerator pedal depressing, (b): Regenerating condition of KDPF
and make the judgment observing increase (c): Selectable items
of the final fuel injection volume command. (d): Message

Testing (Regeneration for Service) (WA500-A9H0-


252-K-00-A)
In the machine monitor, the cylinder cut-out mode
operation and the KDPF regeneration operation can
be executed as well as their cancellation.
Active regeneration for service refers to the method
of burning soot by performing the KDPF
regeneration, regardless of the soot accumulation.
It is used before cleaning of KDPF is performed or
after replacement of the engine controller.
1. Selecting menu
Select “Diagnostic Tests“ on “Service Menu“
screen.

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1) KDPF active regeneration (manual stationary a The active regeneration for service
regeneration) automatically stops in 40 minutes.
Select “Manual Stationary Regeneration“ on However, if the regeneration is started
“Regeneration for Service“ screen. with the soot accumulation of
Return switch (C): Returns the display to approximately 4 g/liter and if the soot
“Diagnostic Tests“ screen accumulation still remains at above 2 g/
Enter switch (D): Executes “Manual liter after 40 minutes from the start, the
Stationary Regeneration“ regeneration is continued until the soot
accumulation decreases to 1.99 g/liter.
a The screen displays “Monitoring
Selection Menu“ screen by the following
switch operations while the regeneration
for service is in progress.
• Switch operation: While pressing
Down switch (B), press numeral input
switches (E) "1" o "2" o "3" in order.
To return the regeneration for service
screen from monitoring screen, press
the return switch (C).
a For the monitoring operating, see
"Monitoring" of "Ordinary functions and
special functions of machine monitor".
2) Finishing regeneration
When “Regeneration for Service“ is
completed, “Regeneration completed“ is
displayed on the screen.

a “Manual Stationary Regeneration“ can be


executed only when your foot is released
from the accelerator pedal, the gear shift
lever is set to the N (NEUTRAL) position
3) Stopping regeneration
and the parking brake switch is turned to
Press the enter switch (D) during the manual
the PARKING position.
stationary regeneration, and “Stop manual
a It can not be executed as well, when the stationary regeneration?“ is displayed on the
fuel level caution lamp is lit or a KDPF- screen and you can stop the regeneration.
related error is detected. Return switch (C): Does not stop
regeneration (manual stationary
a Before performing the manual stationary
regeneration is continued)
regeneration, make sure the surrounding
Enter switch (D): Stops regeneration
environment is safe, no people and no
combustibles are in the area.
When you have to move the machine
again for the sake of security, move it to a
safe place and repeat the operation from
the start.
a While the manual stationary regeneration
is taking place, idling speed reaches
approximately 1,000 rpm.

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3. Selecting reset item


Testing (KDPF Memory Reset) (HM300-A9H0-271-K- On the “KDPF Memory Reset“ screen, select an
00-A)
item to be reset.
In the machine monitor, the cylinder cut-out mode
Up switch (A): Moves selection to the above
operation and the KDPF regeneration operation can
item
be executed as well as their cancellation.
Down switch (B): Moves selection to the below
KDPF memory reset function is used for resetting item
the KDPF information stored on the machine. This Return switch (C): Returns the display to the
function is used when a KDPF-related part is Diagnostic Tests screen
cleaned or replaced. Enter switch (D): Validates the selection
The following items can be reset.
• Reset after KDPF change: It is done after the
KDPF is replaced with another one.
• Reset after KDPF cleaning: It is done after the
KDPF is replaced or cleaned.
• Reset after KDOC change: It is done after the
KDOC is replaced with another one.
• Fuel doser reset: It is done after cleaning of the
fuel doser.
1. Selecting menu
Select “Diagnostic Tests“ on the “Service Menu“
screen.

2. Selecting sub menu


After the “Diagnostic Tests“ screen is displayed, The screen confirms if you want to execute the
select 03 “KDPF Memory Reset“. resetting. Answer affirmatively to it and start your
operation.
Return switch (C): Returns the display to the
previous screen
Enter switch (D): Executes the reset

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Preparations for transmission ECMV current


adjustment (WA380-CN16-330-K-00-A)
a The adjustment work must be performed at the
specified oil temperature. So adjust the
transmission oil temperature according to the
following procedure while checking that nothing
abnormal is displayed on the machine monitor.
1. Select “Monitoring/Custom“ on “Service Menu“
screen.

a When the reset is finished normally, “Reset


Done“ is displayed on the screen. If the reset
is not finished properly, "Reset failed" is
displayed on the screen.

Adjusting (WA500-Q170-270-K-00-A)
The machine monitor implements the initial setting
after disassembly or replacement of the
transmission or hydraulic components, to
compensate installation errors or manufacturing
variations of individual parts. 2. Move to the tab of T/M by using menu switch (E)
and select T/M Oil Temperature.
a Adjusting function
No. Adjustment item
1 ECMV Automatic Compensation
2 T/M Initial Learning
3 T/M Initial Learning Reset
4 T/M Shift Point
5 T/M Shift Point Data Clear
6 Boom Angle Sensor for EPC (Raise)
7 Boom Angle Sensor for EPC (Lower)
8 Boom Raise Adjustment
9 Boom Lower Adjustment
10 Bucket Tilt Adjustment
11 Bucket Dump Adjustment
12 3rd Ext Adjustment *1
13 3rd Ret Adjustment *1
14 J/S Right Adjustment *1
15 J/S Left adjustment *1
16 PCS Adjustment(Push) *1
17 PCS Adjustment(Pull) *1
18 Change of Boom Lever Pattern
19 Change of Bucket Lever Pattern
20 Boom Stop Modulation
21 2-Stage Low Idle Throttle Position
22 Steering Pump Displacement *1
23 Steering Pump Displacement *1
Fan Reverse Cycle Checking transmission oil pressure control
24
1. Start the engine, depress the brake pedal fully
25 Fan Reverse Duration and then, release the parking brake.
26 ECSS Operating Speed 2. Set the transmission shift mode to "Manual", and
27 Fan 100% Mode move the directional lever to F (FORWARD),
(*1): These items are not used.

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and set the gear speed switch to 4th (4th • Parking brake switch: ON
speed). • Directional lever: N position
3. Referring to "Preparation for transmission ECMV • Engine: Low idle
current adjustment", check that the transmission • Accelerator pedal: Released
oil temperature is within the range from 55 to 70° 1. Selecting menu screen
C. If the temperature is not within the range 55 to Select “Adjustment“ on “Service Menu“ screen.
70°C, perform torque converter stall operation to
adjust the oil temperature to 55 to 70 °C.
4. Return the directional lever to "N" (Neutral),
leave the machine for 3 minutes, and check that
the oil temperature remains within the range 55
to 70 °C.
5. Operate the directional lever and gear speed
switch as shown in the following table to
circulate the oil around inside of the
transmission.
Order 1 2 3 4
Gear
speed N2 F2 F1 F2
Holding Min. 2 Min. 2 Min. 2 Min. 2 2. Selecting sub menu
time seconds seconds seconds seconds
After the “Adjustment“ screen is displayed,
Order 5 6 7 8 select “ECMV Automatic Compensation“.
Gear
speed F3 F4 F3 F2
Holding Min. 2 Min. 2 Min. 2 Min. 2
time seconds seconds seconds seconds
Order 9 10 11
Gear
speed N2 R2 N2
Holding Min. 2 Min. 2 Min. 2
time seconds seconds seconds

a Perform these operations with the engine at low


speed, manual shift switch at ON position, and
torque converter lockup sitch at OFF position.
a Check that the machine is in normal condition 3. When "START" is displayed, press Enter switch
(no error indication is displayed on the machine (D) to start the adjustment.
monitor).
a Be careful not to overheat the torque converter
during torque converter stall operation.

Adjustment (ECMV automatic


compensation) (WA380-CN16-270-K-00-A)
a Adjustment is performed 4 times automatically
against the F, R, 1st, 2nd, 3rd, and 4th valves
respectively.
Refer to "Preparation for adjusting transmission
ECMV electric current", and select the
monitoring code of transmission oil temperature.
• Monitoring code: 32500 “T/M Oil
Temperature“
a Do not start the engine at this point in time.
Start the engine, set the machine to the following
condition, and check that the transmission oil
temperature is between 55 to 70°C.

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• The codes displayed when it ends normally


or abnormally
Code Condition
"0 : OK" Normal end
"1 : NG (Out of Condition)"
"2 : NG (No fill)" Abnormal end
"3 : NG (Over the Value)"
• When "0" (normal end) is displayed:
Adjustment work ends normally.
• When "1" is displayed:
Adjust the transmission oil temperature
accurately and check the conditions set on
a The adjustment must be consecutively the machine again, then repeat the work
performed 4 times on the target clutch and from step 1.
the screen as shown in the table below is • When "2" is displayed:
displayed. Perform the troubleshooting for failure codes
[15S*LH] and [DXH*KA] and when the
2nd condition is checked to be normal, repeat the
No. Valve 1st time 3rd time 4th time
time work from step 1 (symbols indicated with *
1 F F-1 F-2 F-3 F-4 vary depending on the target clutch of
2 R R-1 R-2 R-3 R-4 adjustment).
3 1st 1-1 1-2 1-3 1-4 • When "3" is displayed:
4 2nd 2-1 2-2 2-3 2-4 Perform the troubleshooting for failure code
5 3rd 3-1 3-2 3-3 3-4 [15S*L1] and when the condition is checked
6 4TH 4-1 4-2 4-3 4-4 to be normal, repeat the work from step 1
(symbols indicated with * vary depending on
4. The screen indicates for each adjustment work
the target clutch of adjustment).
whether it ends normally or abnormally.
5. When the adjustment work ends normally, turn
1) The screen when it ends normally the starting switch to OFF position and the
compensation value will be recorded on the
transmission controller in approximately 3
seconds.
a When you have to turn the starting to ON
position soon after the adjustment is finished,
hold the starting switch in OFF position for 10
seconds minimum just to be sure, then turn it
to ON position.

Adjustment (T/M Initial Learning) (WA380-CN16-270-


K-01-A)

a Before performing this adjustment, be sure to


perform "Adjustment (ECMV Automatic
2) The screen when it ends abnormally
Compensation)".
a Before starting the learning work, check that the
transmission oil temperature is set to the
specified temperature referring to "Preparation
for transmission ECMV current adjustment". (An
adjustment performed at an unspecified
temperature may induce time lags and gearshift
shocks.)
a Implement the gearshift operation using actual
travel, bench travel or while pressing the wheel
brake.

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k Be sure to perform the learning work in a 4. Operate the directional (FNR) lever and gear
place where an ample traveling area is speed switch according to the following table to
available while paying attention to safety in perform the initial learning.
the surrounding area.
a When setting N2 for the first time, shift
1. Selecting menu screen directional lever to N position after setting
Select “Adjustment“ on “Service Menu“ screen. gearshift switch to F2 or R2.
(Since gear speed is not changed if gearshift
switch is set to 2 after shifting directional
lever to N position, set gearshift switch to 2
first, and then shift directional lever to N
position.
If directional lever is shifted to N position
while gearshift switch is set at other than 2,
operate directional lever to F position or R
position once. Then operate directional lever
to N position after setting gearshift switch to
F2 or R2.)
Order 1 2 3 4
Gear
2. Selecting sub menu speed N2 F2 F1 F2
After the “Adjustment“ screen is displayed, Holding Min. 5 Min. 5 Min. 5 Min. 3
select “T/M Initial Learning“. time seconds seconds seconds seconds
Order 5 6 7 8
Gear
speed F3 F4 F3 F2
Holding Min. 3 Min. 3 Min. 3 Min. 3
time seconds seconds seconds seconds
Order 9 10 11
Gear
speed N2 R2 N2
Holding Min. 3 Min. 3 Min. 3
time seconds seconds seconds

a Hold the gear shift lever in each gear speed


for more than the specified time.
3. Start the engine, set the machine to the following 5. When the display for each clutch becomes ON,
condition, and check that the transmission oil initial learning is complete. Exit by using the
temperature is between 55 to 70°C. return switch.
• Engine: Low idle If any of the display is still OFF, initial learning is
• Transmission shift mode: Manual not completed. Repeat step 4.
• Transmission cut-off: OFF
• Lockup: OFF

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Adjustment (T/M Initial Learning Reset) (WA380-


CN16-271-K-00-A)

a This function is used to initialize the data


obtained by using “T/M Initial Learning“ function.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “T/M Initial Learning Reset“.

5. After the initialization, check that the initialization


condition is “1: Learning Not Done Yet“.

3. Check the initialization condition shown in the


left display area. If “0: Learning Completed“ is
displayed there, proceed to the next step and
initialize the learned data.

Adjustment (T/M Shift Point) (WA380-CN1X-270-K-00-


A)

a This function is used to set the offset value that


is added to the value of the shift point when the
shift mode is positioned at "L". However, the
correction amount to the shift point of auto kick
down to the 1st speed is also applied in the "H
mode".
a The factory default setting of the correction
amount is always 0.
4. While “T/M Initial Learning Reset“ is displayed, a While the shift points depend on the engine
press Enter switch (D) to display the Initialization mode, the same offset values set by this function
Operation screen. When the screen appears, are applied to all engine modes.
press Enter switch (D) again to start the
initialization.

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a The following shift patterns are not included in


shift points applicable to this shift point
adjustment function.
1. The shift point that is used when the hunting
prevention function is in operation
2. Downshift points below 1,000 rpm
a After the shift point adjustment is done, be sure
to check the result on the machine.
a This operation allows you to change the
threshold travel speed (shift point) when "L
mode" is selected for the auto shift mode. Shift
points for following gear shift patterns can be
changed. a Shift Point adjustment screen is displayed.
F2T/CoF3T/C
F3T/CoF4T/C
F4T/CoF3T/C
F4T/CoF2T/C
F3T/CoF2T/C
F2L/UoF3T/C
F3L/UoF4T/C
F4T/CoF3L/U
F3T/CoF2L/U
F2L/U ON
F2L/U OFF
3. Press numeric keypad (E) on “T/M Shift Point“
F3L/U ON
adjustment screen (any of 0 to 9).
F3L/U OFF
a The setting input screen is displayed.
F4L/U ON
Up switch (A): Switches sign between "+"
F4L/U OFF
and "-"
AUTO F1 K/D
Down switch (B): Enters decimal point
• Change the speed to change F2T/CoF3T/C
Return switch (C): Returns the display to
according to the following procedure. The other
“Adjustment“ screen
shift patterns can be also adjusted similarly.
1. Select menu screen and press the enter switch Enter switch (D): Validates the setting
(D). a Input a set value with numeral input switches
Select “Adjustment“ on “Service Menu“ screen. (E) and accept the setting with the enter
switch (D).

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “T/M Shift Point“.

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4. The input value is displayed at the right part of 2. Selecting sub menu
the screen. If this value is correct, press the After the “Adjustment“ screen is displayed,
enter switch (D) again. select “T/M Shift Point Data Clear“.

5. When the input numeric value is displayed in the 3. When “T/M Shift Point Data Clear“ screen is
left display area, the setting is complete. displayed, press enter switch (D).
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

Adjustment (T/M Shift Point Data Clear) (WA380-


CN1Y-270-K-00-A)

a This function is used to set all adjustments made


at "T/M Shift Point " back to zero.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

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30 Testing and adjusting
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4. The confirmation screen is displayed. Validate


the setting by pressing enter switch (D) again.

3. Press Enter switch (D) after raising the boom to


the upper limit position (cylinder stroke end).
5. When "1" is displayed at the left part of the
screen, T/M Shift Point Data Clear is complete.
a When all of the memory is cleared, the set
values will become the default value (0).
a The data will not be cleared if the return
switch is pressed during the process.

Adjustment (Boom Angle Sensor for EPC


(Raise)) (WA470-CN1Z-270-K-00-A)
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

4. If the display in the left window changes to "1",


adjustment is complete.

2. Selecting sub menu


After “Adjustment“ screen is displayed, select
“Boom Angle Sensor for EPC (Raise)“.

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5. If the display in the left window changes to "2",


the boom angle voltage is out of the specified
value and the adjustment is not made.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

3. Press Enter switch (D) after lowering the boom


to the lower limit position (cylinder stroke end).

6. When the adjustment does not end successfully,


check the boom angle sensor voltage on
“Monitoring/Custom“ screen.
7. Adjust the installed position of the boom angle
sensor so that the voltage displayed on
“Monitoring/Custom“ screen is within the
following range, and then perform the sensor
adjustment again.
Boom
Boom position Voltage range
specification
STD 3.77 ± 0.3 V
Top
Hi Lift 3.88 ± 0.3 V

Adjustment (Boom Angle Sensor for EPC


(Lower)) (WA470-CN21-270-K-00-A)
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

4. When "1" is displayed in the display area, this


adjustment is complete.

2. Selecting sub menu


After “Adjustment“ screen is displayed, select
“Boom Angle Sensor for EPC (Lower)“.

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5. If the display changes to "2", the boom angle


voltage is out of the specified value and the
adjustment is not made.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “Boom Raise Adjustment“.

6. When the adjustment does not end successfully,


check the boom angle sensor voltage on
“Monitoring/Custom“ screen.
7. Adjust the installed position of the boom angle
sensor so that the voltage displayed on
“Monitoring/Custom“ screen is within the
following range, and then perform the sensor
adjustment again.
Boom 3. Move the boom lever to RAISE, stop and hold
Boom position Voltage range
specification the lever just before the boom RAISE detent
STD 1.38 ± 0.3 V position. While holding the lever at that position,
Bottom
Hi Lift 1.49 ± 0.3 V press Enter switch (D).

Adjustment (Boom Raise Adjustment) (WA380-


CN22-270-K-00-A)

a This function is used to perform calibration in


order to correct dispersion at just before the
boom lever RAISE detent and the starting
current.
Correcting the position just before the boom
lever RAISE detent
a Perform this adjustment with the engine stopped
after the bucket is lowered to the ground.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

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a Do not move the lever to RAISE detent a If the return switch is pressed while the
position. calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

Adjusting starting current of boom RAISE EPC


a Perform this adjustment with the engine running.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

4. When "1" is displayed in the display area, this


adjustment is complete.

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “Boom Raise Adjustment“.

5. If "2" is displayed, the signal voltage of lever


angle is out of the standard voltage range. This
adjustment is not performed.

3. Set the bucket in DUMP posture and lower the


boom to lift the front wheels off the ground.
4. With the engine running at high speed, start to
lower the boom (to lower the machine) gradually.
5. Return the lever finely. When the boom stops
moving (front wheels are off ground), hold the

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Electrical system

lever at the current position. While holding the Correcting the position just before the boom
lever at that position, press enter switch (D). lever LOWER detent
a Perform this adjustment with the engine stopped
after the bucket is lowered to the ground.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

6. When "1" is displayed in the display area, this


adjustment is complete.

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “Boom Lower Adjustment“.

7. If "2" is displayed, the signal voltage of lever


angle is out of the standard voltage range. This
adjustment is not performed.
If the return switch is pressed while the
calibration is continued, the calibration currently
taking place is stopped even if it is not
completed. 3. Move the boom lever to FLOAT, stop and hold
the lever just before the boom FLOAT detent
position. While holding the lever at that position,
press Enter switch (D).

Adjustment (Boom Raise Adjustment) (WA380-


CN23-270-K-00-A)

a This function is used to perform calibration in


order to correct dispersion at just before the
boom lever LOWER detent and the starting
current.

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4. When "1" is displayed in the display area, this 2. Selecting sub menu
adjustment is complete. After the “Adjustment“ screen is displayed,
select “Boom Lower Adjustment“.

5. If "2" is displayed, the signal voltage of lever


angle is out of the standard voltage range. This 3. Set the boom almost horizontal with the bucket
adjustment is not performed. empty.
4. With the engine running at high speed, start to
a If the return switch is pressed while the
lower the boom gradually.
calibration is continued, the calibration
5. Return the lever finely. When the boom stops
currently taking place is stopped even if it is
moving, hold the lever at the current position.
not completed.
While holding the lever at that position, press
enter switch (D).

Adjusting starting current of boom LOWER EPC


6. When "1" is displayed in the display area, this
a Perform this adjustment with the engine running. adjustment is complete.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

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7. If "2" is displayed, the signal voltage of lever 2. Selecting sub menu


angle is out of the standard voltage range. This On the “Adjustment“ screen, select “Bucket Tilt
adjustment is not performed. Adjustment“.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

3. Move the bucket lever to TILT, stop and hold the


lever at the near point just before the Bucket
TILT detent position. While holding the lever at
that position, press Enter switch (D).

Adjustment (Bucket Tilt Adjustment) (WA380-


CN24-270-K-00-A)

a This function is used to perform calibration in


order to correct dispersion of the near-point for
boom lever TILT detent and the starting current.

Correcting near-point for bucket lever TILT


detent
a Perform this adjustment with the engine stopped
after the bucket is lowered to the ground.
1. Selection of menu screen
Select “Adjustment“ on the “Service Menu“
screen.

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a Do not set the lever to the bucket TILT detent a If the return switch is pressed while the
position. calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

Adjusting starting current of bucket Tilt EPC


a Perform this adjustment with the engine running.
1. Selection of menu screen
Select “Adjustment“ on the “Service Menu“
screen.

4. When "1" is displayed in the display area, this


adjustment is complete.

2. Selecting sub menu


On the “Adjustment“ screen, select “Bucket Tilt
Adjustment“.

5. When "2" is displayed, the signal voltage of lever


angle is out of the standard voltage range. This
adjustment is not performed.

3. Set the bucket in DUMP posture and lower the


boom to lift the front wheels off the ground.
4. With the engine running at high speeds, start to
tilt the bucket (to lower the machine) gradually.

WA470-7 30-195
30 Testing and adjusting
Electrical system

5. Return the lever finely. When the boom stops Adjustment (Bucket Dump
moving (front wheels are off ground), hold the Adjustment) (WA380-CN25-270-K-00-A)
lever at the current position. While holding the a This function is used to perform calibration in
lever at that position, press enter switch (D). order to correct dispersion of the starting current
of the bucket DUMP lever.
a Perform this adjustment with the engine running.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

6. When "1" is displayed in the display area, this


adjustment is complete.

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “Bucket Dump Adjustment“.

7. If "2" is displayed, the signal voltage of lever


angle is out of the standard voltage range. This
adjustment is not performed.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed. 3. Set the empty bucket almost horizontal.
4. With the engine running at high speed, start to
dump the bucket gradually.
5. Return the lever finely. When the bucket stops
moving, hold the lever at the current position.
While holding the lever at that position, press
Enter switch (D).

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30 Testing and adjusting
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6. When "1" is displayed in the display area, this


adjustment is complete.

7. If "2" is displayed, the signal voltage of lever


angle is out of the standard voltage range. This
adjustment is not performed.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

WA470-7 30-197
30 Testing and adjusting
Electrical system

Adjustment (Change of Boom Lever Pattern) (WA500-CN26-270-K-00-A)

a This function is used to modify the fine-controllability and response of the boom by changing the data on
EPC output current to the boom lever stroke.
a Characteristics of tables 0 to 4 are summarized as shown in the table below. (table when shipped: 2)

a Table No. and function


Table No. Function Outline
Fine control has The controllability is enhanced further than the No. 1.
0 priority. Speed change becomes more drastic as the stroke grows bigger.
Fine control has
1 Improved controllability when lever is operated with short travel.
priority.
This table allows compatibility between controllability and response
2 Standard ability in both RAISE and LOWER operations.
3 Response priority Shorter lever travel and faster lever movement enhance response.
Response is further improved because of the faster speed by the fewer
lever travel than that of No. 3.
4 Response priority If this table is used, boom speed changes sharply when control lever is
moved in short distances. Accordingly, improper lever operation can
cause substantial shocks when stopping boom.

a Normally, change is made to tables No. 1 to No. 3. When selecting No. 0 or No. 4 table, thorough
preliminary performance check and operator evaluation are required.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

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2. Selecting sub menu


After “Adjustment“ screen is displayed, select
“Change of Boom Lever Pattern“.

a The adjustment screen for “Change of Boom


Lever Pattern“ is displayed.

4. The input value is displayed at the right part of


the screen. If this value is correct, press the
enter switch (D) again.

3. Press numeral input switch (E) on “Change of


Boom Lever Pattern“ adjustment screen. (Any
switch of "0" to "9" is accepted.)
a The setting input screen is displayed.
Up switch (A): Switches sign between "+"
and "-"
Down switch (B): Enters decimal point
Return switch (C): Returns the display to
“Adjustment“ screen
Enter switch (D): Validates the setting 5. When the input numeric value is displayed in the
left display area, the setting is complete.
a Input a set value with numeral input switches
(E) and accept the setting with the enter
switch (D).

WA470-7 30-199
30 Testing and adjusting
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a If the return switch is pressed while the


calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

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30 Testing and adjusting
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Adjustment (Change of Bucket Lever Pattern) (WA500-CN27-270-K-00-A)

a This function is used to modify the fine-controllability, response and shock dump of the bucket by changing
the data on EPC output current to the bucket lever stroke.
a Characteristics of tables 0 to 2 are summarized as shown in the table below. (table when shipped: 1)

a Table No. and function


Table No. Function Outline
Fine control has Both in bucket dump and tilt operations, this table improves controllability
0 priority. when lever is operated with short travel.
This table satisfies both of controllability and response in bucket dump
1 Standard operation as well as bucket tilt operation.
Shorter lever travel and faster lever movement enhance response.
2 Response priority It makes it easier to dump load by swinging the bucket as well as shock
dump and leveling of load with the tilted end of the bucket.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

WA470-7 30-201
30 Testing and adjusting
Electrical system

2. Selecting sub menu


After “Adjustment“ screen is displayed, select
“Change of Bucket Lever Pattern“.

a The adjustment screen for “Change of


Bucket Lever Pattern“ is displayed.

4. The input value is displayed at the right part of


the screen. If this value is correct, press the
enter switch (D) again.

3. Press numeral input switch (E) on the “Change


of Bucket Lever Pattern“ adjustment screen.
(Any switch of "0" to "9" is accepted.)
a The setting input screen is displayed.
Up switch (A): Switches sign between "+"
and "-"
Down switch (B): Enters decimal point
Return switch (C): Returns the display to
“Adjustment“ screen
Enter switch (D): Validates the setting 5. When the input numeric value is displayed in the
left display area, the setting is complete.
a Input a set value with numeral input switches
(E) and accept the setting with the enter
switch (D).

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30 Testing and adjusting
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a If the return switch is pressed while the


calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

WA470-7 30-203
30 Testing and adjusting
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Adjustment (Boom Stop Modulation) (WA380-


CN28-270-K-00-A)

a When the boom lever is operated for sudden


stop, this function modifies the speed reduction
rate of the stop modulation, which is prepared
for reducing shocks resulting from stopping, by
applying the stop modulation to EPC output
current.
a This data change does not affect the stop
modulation of the boom when it is stopped
automatically by the remote positioner or kickout
function.
a Before starting a modification of the modulation 2. Selecting sub menu
by using this function, “Change of Boom Lever After the “Adjustment“ screen is displayed,
Pattern“ and operator's evaluation must be done select “Boom Stop Modulation“.
first.
a The stop modulation function acts in the same
way in both the raise and lower directions.
a The data when shipped out is "10".
Modula-
tion Condition Remarks
quantity
The stop
Stopping shocks
modulation is not
can result if the
activated. Boom
0 operator does not
stops without
take reasonable
delaying to the
care.
boom lever stroke.
It allows a Adjustment screen of “Boom Stop
compatibility Modulation“ is displayed.
between delay in -
10
response at stop
and stopping
shocks
When the lever is
returned to
It reduces stopping
NEUTRAL, the
shocks against
boom delays
20 sudden stop
stopping and
operation by
exceeds the
operator.
target stop
position.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.
3. Press numeric keypad (E) on the “Boom Stop
Modulation“ adjustment screen (any of o to 9).
a The setting input screen is displayed.
Up switch (A): Switches sign between "+"
and "-"
Down switch (B): Enters decimal point
Return switch (C): Returns the display to
“Adjustment“ screen
Enter switch (D): Validates the setting

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30 Testing and adjusting
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a Input a set value with numeral input switches


(E) and accept the setting with the enter
switch (D).

Adjustment (2-Stage Low Idle Throttle


Position) (WA380-AF71-270-K-00-A)
Adjust “2-Stage Low Idle Throttle Position“
according to the following procedure.
a The throttle position adjusted at this stage is
reflected on low idle throttle position when
directional lever is shifted to FORWARD or
REVERSE position.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

4. The input value is displayed at the right part of


the screen. If this value is correct, press the
enter switch (D) again.

2. Selecting sub menu


After “Adjustment“ screen is displayed, select “2-
stage Low Idle Throttle Position“.

5. When the input numeric value is displayed in the


left display area, the setting is complete.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

WA470-7 30-205
30 Testing and adjusting
Electrical system

a “2-stage Low Idle Throttle Position“ adjusting


screen is displayed after selecting.

7. Press the return switch to exit the adjustment


mode.
3. Press a numeric keypad (any of 0 to 9) on a If the return switch is pressed while the
adjustment screen of “2-stage Low Idle Throttle calibration is continued, the calibration
Position“. currently taking place is stopped even if it is
not completed.
a The numeral input screen is displayed.
a When setting a higher value than the default
value (12.0%), thoroughly check the
operation of the machine and receive
operator's feedback.

Adjustment (Fan Reverse Cycle) (WA380-B71E-270-


K-00-A)

a The adjusted value with this function is applied


to “Machine Setting/Information“ in user mode,
and to “Mode D” of “Automatic Fan Reverse
Mode“.
a Adjust “Fan Reverse Duration“ too, also applied
to “Mode D”.
4. Input desired value with numeral input switches 1. Selecting menu screen
and press the Enter switch. Select “Adjustment“ on “Service Menu“ screen.
Up switch: Switches + and -
Down switch: Enters decimal point
5. The value input with numeral input switches is
displayed in the display area at the right part of
the screen. If this value is correct, press the
Enter switch again.

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “Fan Reverse Cycle“.
a While “Mode D” is selected in user mode, this
adjustment function is not able to select. So
6. When the input numeric value is displayed in the select other item than “Mode D” when
left display area, the setting is complete. perform adjustment.

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30 Testing and adjusting
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4. The input value is displayed at the right part of


a “Fan Reverse Cycle“ adjustment screen is
the screen. If this value is correct, press the
displayed.
enter switch (D) again.

3. Press numeral input switch (E) on the “Fan


5. When the input numeric value is displayed in the
Reverse Cycle“ adjustment screen. (Any switch
left display area, the setting is complete.
of "0" to "9" is accepted.)
a If the return switch is pressed while the
a The setting input screen is displayed.
calibration is continued, the calibration
Up switch (A): Switches sign between "+" currently taking place is stopped even if it is
and "-" not completed.
Down switch (B): Enters decimal point
Return switch (C): Returns the display to
“Adjustment“ screen
Enter switch (D): Validates the setting
a Input a set value with numeral input switches
(E) and accept the setting with the enter
switch (D).

Adjustment (Fan Reverse Duration) (WA380-B71F-


270-K-00-A)

a The adjusted value with this function is applied


to “Machine Setting/Information“ in user mode,
and to “Mode D” of “Automatic Fan Reverse
Mode“.
a Adjust it in “Fan Reverse Cycle“ too, since it is
applied to “Mode D” as well.

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30 Testing and adjusting
Electrical system

1. Selecting menu screen a The setting input screen is displayed.


Select “Adjustment“ on “Service Menu“ screen. Up switch (A): Switches sign between "+"
and "-"
Down switch (B): Enters decimal point
Return switch (C): Returns the display to
“Adjustment“ screen
Enter switch (D): Validates the setting
a Input a set value with numeral input switches
(E) and accept the setting with the enter
switch (D).

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “Fan Reverse Duration“.
a While “Mode D” is selected in user mode, this
adjustment function is not able to select. So
select other item than “Mode D” when
perform adjustment.

a “Fan Reverse Duration“ adjustment screen is


displayed. 4. The input value is displayed at the right part of
the screen. If this value is correct, press the
enter switch (D) again.

3. Press numeral input switch (E) on the “Fan


Reverse Duration“ adjustment screen. (Any
switch of "0" to "9" is accepted.) 5. When the input numeric value is displayed in the
left display area, the setting is complete.

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30 Testing and adjusting
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a If the return switch is pressed while the


calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

3. Press numeral input switch (E) on the “ECSS


Operating Speed“ adjustment screen. (Any
switch of "0" to "9" is accepted.)
a The setting input screen is displayed.
Up switch (A): Switches sign between "+"
Adjustment (ECSS Operating Speed) (WA380-
L3B1-270-K-00-A) and "-"
1. Selecting menu screen Down switch (B): Enters decimal point
Select “Adjustment“ on “Service Menu“ screen. Return switch (C): Returns the display to
“Adjustment“ screen
Enter switch (D): Validates the setting
a Input a set value with numeral input switches
(E) and accept the setting with the enter
switch (D).

2. Selecting sub menu


After the “Adjustment“ screen is displayed,
select “ECSS Operating Speed“.

a “ECSS Operating Speed“ screen is


displayed.
4. The input value is displayed at the right part of
the screen. If this value is correct, press the
enter switch (D) again.

WA470-7 30-209
30 Testing and adjusting
Electrical system

5. When the input numeric value is displayed in the 2. Selecting sub menu
left display area, the setting is complete. After the “Adjustment“ screen is displayed,
select “Fan 100% Mode“.
a If the return switch is pressed while the
calibration is continued, the calibration
currently taking place is stopped even if it is
not completed.

3. When the enter switch (D) is pressed, "1" is


displayed at the left part of the screen, and the
fan 100% mode is set.

Adjustment (Fan 100% Mode) (WA380-B71G-270-K-00-


A)
This adjustment code is used to forcibly set the
cooling fan speed to approximately 100%
regardless of the actual oil and coolant
temperatures.
a Use this adjustment code for testing, adjusting,
or troubleshooting as needed.
a Since the cooling fan speed still depends on the
throttle position in this mode, depress the
accelerator pedal to check the maximum speed.
1. Selecting menu screen
Select “Adjustment“ on “Service Menu“ screen.

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30 Testing and adjusting
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4. When the enter switch (D) is pressed again, "0"


is displayed at the left part of the screen, and the
fan mode returns to the normal mode.
a If the return switch (C) pressed to exit from
the “Adjustment“ screen, the fan mode
returns to the normal mode even if it is set to
the 100% mode.

No Injection (HM300-AD00-25L-K-00-A)
If the engine is operated after long storage of the
machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this, the
machine monitor has a function to crank the engine
without injecting fuel to lubricate the engine before 3. Starting no-injection cranking
starting it. If No Injection cranking (no fuel injection to every
cylinder) is enabled, a message to notify that is
Set the no-injection cranking while the engine is
displayed on the screen. Under this condition,
stopped.
turn the starting switch to the START position
1. Selecting menu and crank the engine.
Select “No Injection“ on “Service Menu“ screen.
a While the screen is changing to the following
screen, the screen of “Getting Ready.“ is
displayed.
a Do not crank the engine for 20 seconds or
longer to protect the starting motor.

2. Displaying confirmation screen


When “No Injection“ screen is displayed, a
message "Begin Injectionless Cranking?" is
displayed. Perform the operation as follows.
• Return switch (C): Does not execute No
Injection (returns the display to the Service 4. Finishing no-injection cranking
Menu screen) After the cranking is over, turn the starting switch
• Enter switch (D): Executes No Injection. to OFF position.
a You cannot change the screen described
above to another screen.

WA470-7 30-211
30 Testing and adjusting
Electrical system

a When you want to turn the starting switch to Select “KOMTRAX Settings“ on “Service Menu“
ON position again, set a sufficient time (1 screen.
minute minimum) before doing so.
5. Prohibiting no-injection cranking
Even if the operator tries to perform the No
Injection cranking while the engine is running,
the message "The engine is operating" is
displayed and the no-injection cranking does not
become effective.
a This function can be selected even when the
engine is running. However, if you execute
the no-injection cranking, a message “Please
turn the key off once.“ appears on the
screen.

2. Selecting sub menu


Select “Terminal Status“ on “KOMTRAX
Settings“ screen.

Also, if the no-injection cranking is operated


while "Check" screen appears, the function does
not become effective in the following case.
• The communication between the monitor and
engine controller is not normal. 3. Contents displayed on Terminal Status screen
• Perform an engine start operation before the On the “Terminal Status“ screen, the following
message “No injection is possible“ appears. items of information are displayed.
• “Terminal Type“: Model name of the
KOMTRAX communication modem
• “KOMTRAX Communication“: Status of radio
station establishment underway
• “GMT Time“: Greenwich Mean Time (add 9
hours to it for Japan time)
Return switch (C): Returns the display to the
“KOMTRAX Settings“ screen

KOMTRAX Settings (terminal setting


status) (HM300-Q210-110-K-00-A)
The setting and operating conditions of KOMTRAX
can be checked on the display of “KOMTRAX
Settings“.
Terminal setting status is used to check the setting
condition of the KOMTRAX terminal.
1. Selecting menu

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30 Testing and adjusting
Electrical system

On the “GPS & Communication Status“ screen,


the following items of information are displayed.
• Positioning: GPS positioning status
• Communication: Communication
environment and connecting condition of the
communication modem
• Number of message(s) not yet sent: Number
of mails that are saved in the machine
monitor and have not yet been transmitted
Return switch (C): Returns the display to the
KOMTRAX Settings screen.

KOMTRAX Settings (GPS & Communication


Status) (HM300-Q210-110-K-01-A)
The setting and operating conditions of KOMTRAX
can be checked through the display of KOMTRAX
Settings.
GPS & Communication Status is used to check the
positioning and communication condition of the
KOMTRAX terminal.
1. Selecting menu
Select “KOMTRAX Settings“ on the “Service
Menu“ screen.

2. Selecting sub menu KOMTRAX Settings screen (Modem


After the “KOMTRAX Settings“ screen is Status) (HM300-Q210-110-K-02-A)
displayed, select “GPS & Communication Settings and operating status of KOMTRAX can be
Status“. checked on the "KOMTRAX Settings" screen.
Modem information is used to check the IP address
of the KOMTRAX communication modem.
1. Selecting menu
Select “KOMTRAX Settings“ on the “Service
Menu“ screen.

3. Contents of display of GPS & Communication


Status

WA470-7 30-213
30 Testing and adjusting
Electrical system

2. Selecting sub menu


After the “KOMTRAX Settings“ screen is Service Message (HM300-Q210-100-K-00-A)
displayed, select “Modem Status“. Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
checked with this function.
If a received message includes a setting operation,
a return mail can be sent by using the numeral input
switches as well.
1. Selecting menu
Select “Service Message“on “Service Menu“
screen.

3. Details displayed on Modem Status screen


IP addresses (2 systems) of the modem are
displayed.
Return switch (C): The display is returned to
KOMTRAX settings screen
a An IP address is a unique number assigned
to each modem that is used when
communication between the modem and
2. Displaying message (read only)
server is established.
If a message is received, the description in the
message is displayed. If there is no
message,“No message.“ is displayed.
Return switch (C): Returns to the “Service Menu“
screen
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message pilot lamp does not
light up when it is received unlike the
operator mode.

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30 Testing and adjusting
Electrical system

3. Display of message (with return mail function)


If the “Numeric Input“ is displayed at the bottom
of the text, enter the number by using numeral
input switches (F) and validate it by using the
enter switch (D). Then, the information is
returned to the KOMTRAX base station.
Return switch (C): Returns the display to the
“KOMTRAX Settings“ screen
Enter switch (D): Validates the input value and
returns it
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message pilot lamp does not
light up when it is received unlike the
operator mode.

WA470-7 30-215
30 Testing and adjusting
Electrical system

Adjusting rearview camera angle (WA470-Q162-360-K-00-A)

a Adjust the camera so that persons in the area


(w) of 1 meter around the machine is displayed
on the monitor in the operator's cab.

a Machine is displayed partially on the


machine monitor screen.

a If the image displayed on the monitor is out of


position, adjust the installation angle (A) of the
rear view camera.
a Angle (A) can be adjusted in the range of 34.0 to
49.0 degrees.

2. After adjusting, tighten mounting bolts (1).

Adjusting (WA380-Q162-270-K-01-A)

1. Loosen mounting bolts (1) (3 places) and adjust


them within the range of angle (A).

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30 Testing and adjusting
Electrical system

Handling voltage circuit of engine controller (PC220-AP40-2A4-K-00-A)

1. Disconnecting or connecting work of the


connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in the
OFF position and the system operating lamp
goes out.

k Before connecting the wiring harness


connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. Perform the measuring operation with the T-
adapter inserted or connected to the connector
between the engine controller and engine when
you perform the troubleshooting.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.

WA470-7 30-217
30 Testing and adjusting
Electrical system

Handling battery disconnect switch (WA470-AW1P-100-K-00-A)

1. When the battery disconnect switch is turned to


OFF position, be sure to remove switch key (1).

kA hazard can result if an unauthorized


person turns switch key (1) ON carelessly.
2. You can prevent an abnormal end of the
operation due to cut-off of the battery power
supply circuit while the controllers are in
operation by checking the operating status of
each controller with system operating lamp (2).
1) Before cutting off the battery power supply
circuit, turn the starting switch to OFF
position, and check that system operating
lamp (2) goes out, then turn the battery
disconnect switch to OFF position.
2) If you turn the battery disconnect switch to
OFF position (battery power supply circuit is
cut off) while system operating lamp (2) lights
up, Controller data lost error can occur. Do
not operate the battery disconnect switch as
long as system operating lamp (2) lights up.
3) System operating lamp (2) goes out in 2
minutes longest after the starting switch is
turned to OFF position.
4) System operating lamp (2) may sometimes
light up while the starting switch is turned to
OFF position because KOMTRAX terminal
may maintain its communication under this
condition.
5) The system operating lamp (2) may look
slightly luminous in the dark after it is turned
off. It is due to the minute leakage of current
and not an abnormal phenomenon.
• After the starting switch is turned to OFF
position, KOMTRAX terminal repeats the
start and stop to maintain the periodic
communication.
• The start and stop cycle (sleep cycle) of
KOMTRAX terminal varies depending on
the factors including the communication
status and machine stop time. So the
lamp can be lighting as long as
approximately an hour.
6) When you want to cut off the battery circuit
for maintenance but system operating lamp
(2) keeps on lighting up, turn the starting
switch to ON position once, then turn it to
OFF position. The lamp will go out in 2
minutes maximum.
After the system operating lamp (2) goes out,
turn the battery disconnect switch to OFF
position immediately.

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30 Testing and adjusting
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Testing diodes (ALL-E300-001-P-00-A)

a Test the diode array (8-pin) and the single diode


(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.

2. When using analog tester


1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
a The continuity direction of the single diode is the anode (P) side of the diode and apply
indicated on the surface of the diode. the black (-) lead to the cathode (N) side.
Testing (PC220-E300-36J-P-00-A) 2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
1. When using a digital tester apply the black (-) lead to the anode (P)
1) Select the diode range screen to check the side.
displayed values. 3) Evaluate the condition of the diode by the
a When an ordinary circuit tester is used, movement of the pointer.
the voltage of the internal battery is • The pointer does not move by the above
indicated. 1] connection, but it does by the 2]
2) Apply the red (+) lead of the multimeter to the connection: Normal (however, the
anode (P) side of the diode and apply the movement of the pointer (resistance)
black (-) lead to the cathode (N) side and varies by type of tester, or selection of
check the indicated value. measuring range).
3) Evaluate the condition of the diode by the • The pointer moves by either connection
indicated value. of the above 1], and 2]:
• Indicated value does not change: No Defective (internal short circuit)
continuity (defective) • The pointer moves by neither connection
• Indicated value changes: Continuity the above 1], nor 2]: Defective (internal
(normal) (note) open circuit)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
• The indicated value is 0 or approximate
0:
The diode has internal short circuit
(defective).

WA470-7 30-219
30 Testing and adjusting
Pm clinic

Pm clinic (ALL-2160-001-A-00-A)

Pm Clinic service (WA470-2160-209-A-00-A)


Machine serial
WA470-7 #10001 and up #
number
Time check Engine serial
No. SAA6D125E-6

Work order No. Date of inspection Service meter reading Inspector


Year
Month Day Hours

Questions asked to operator, walk around inspection


Was there any abnormality before inspection started? Ambient temperature
Max. °C
Min. °C
Altitude m

Maximum coolant temperature Do lighted segments of torque converter


(overheated)? oil temperature gauge reach HIGH
(during operation) (overheating)? (during operation)

a If the machine is cold, warm it up fully


a Standard values at working mode P are shown.

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30 Testing and adjusting
Pm clinic

Check sheet (WA470_7-2160-033-A-00-A)

WA470-7 #10001 and up


1. Engine
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
• Power mode
800 to 850 800 to 850
• Low idle
1) Set working mode to power
mode, and start engine.
2) Set the work equipment
lock switch to OFF position
(release).
3) Set the boom at the lowest
position.
(Boom angle: Max. -35.5
degrees)
(Bucket is level and 2,120 to 2,220 2,120 to 2,220
approximately 100 mm off
the ground)
4) Set work equipment lock
Engine switch to LOCK position. rpm
speed (*1) 5) Depress the accelerator
pedal gradually while
operating bucket lever
tilting. Measure the engine
speed at high idle.
• Power mode
• Torque converter stall (gear 1,735 to 1,835 1,685 to 1,885
speed: F4)
• Power mode
• Hydraulic stall (Bucket 2,010 to 2,210 1,910 to 2,310
CURL relief)
• Power mode
• Torque converter stall (gear
1,545 to 1,745 1,445 to 1,845
speed: F4) and hydraulic
stall (Bucket CURL relief)
kPa
Blowby Torque converter stall (gear Max. 1.96 3.92
pressure speed: F4) {mmH2-
{Max. 200} {400}
O}
• High idle
• Engine oil 290 to 690 180
tempera-
SAW5W-30LA ture: Min. {3.0 to 7.0} {18}
Engine oil kPa
SAW5W-40LA 80°C
pressure
(*1) SAE10W-30LA • Low idle {kg/cm 2}

SAE15W-40LA • Engine oil Min. 80 50


tempera-
ture: Min. {Min. 1.0} {0.5}
80°C
Boost kPa Min. 127 100
Torque converter stall (gear
pressure
speed: F4) {mmHg} {Min. 950} {750}
(*1)
Exhaust
tempera- Whole speed range (20°C) °C Max. 650 650
ture
*1: Items which can be inspected in special functions of machine monitor

WA470-7 30-221
30 Testing and adjusting
Pm clinic

2. Transmission valve
a When shifting transmission gear to forward or reverse, apply brake securely.
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
2.12 to 2.52 2.12 to 2.52
Low idle
{21.5 to 25.5} {21.5 to 25.5}
Main relief
pressure Engine 2.35 to 2.75 2.35 to 2.75
speed: • Torque
2,000 rpm converter oil {24.0 to 28.0} {24.0 to 28.0}
Torque tempera-
converter Engine ture: 60 to
0.1 to 0.88 0.1 to 0.88
inlet speed: 80°C
pressure 2,000 rpm • {1.0 to 9.0} {1.0 to 9.0}
(*1) Transmis-
Torque sion:
converter Engine Neutral
0.06 to 0.71 0.06 to 0.71
outlet speed:
pressure 2,000 rpm {0.6 to 0.7} {0.6 to 0.7}
(*1)
MPa
2.2 to 2.5 2.2 to 2.5
1st {kg/cm2}
{22.5 to 25.5} {22.5 to 25.5}
2.2 to 2.5 2.2 to 2.5
2nd • Torque
converter oil {22.5 to 25.5} {22.5 to 25.5}
tempera- 2.15 to 2.45 2.15 to 2.45
3rd
ECMV ture: 60 to {22 to 25} {22 to 55}
output 80°C 2.15 to 2.45 2.15 to 2.45
4th • Engine
(clutch) speed: {22 to 25} {22 to 25}
pressure 2,000 rpm 1.91 to 2.21 1.91 to 2.21
F (forward)
Manual {19.5 to 22.5} {19.5 to 22.5}
switch at 1.91 to 2.21 1.91 to 2.21
R (reverse) ON
{19.5 to 22.5} {19.5 to 22.5}
L/C 1.51 to 1.81 1.51 to 1.81
(lockup) {15.5 to 18.5} {15.5 to 18.5}
*1: Items which can be inspected in special functions of machine monitor
3. Steering
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Secure frame with frame lock bar.
• Hydraulic oil temperature:
Steering 23.3 to 25.7
45 to 55°C MPa 22.0 to 25.7
relief
• Engine speed: High idle {237.5 to
pressure {kg/cm2} {225 to 262.5}
• Maximum pressure at 262.5}
(*1)
operation
*1: Items which can be inspected in special functions of machine monitor

30-222 WA470-7
30 Testing and adjusting
Pm clinic

4. Brake
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Torque converter oil
Parking temperature: 60 to 80°C MPa Min. 2.32 Min. 2.32
brake inlet
Engine speed: Low idle {kg/cm } {Min. 23.5}
2 {Min. 23.5}
pressure
As parking brake is released
Tire inflation pressure:
Specified pressure
Parking
Flat paved road with a slope of
brake — Stopped Stopped
1/5 (11 degrees 20 minutes)
perfor-
and dry surface
mance
Set machine in operating
condition.
Parking
brake disc mm 3.12 to 3.28 2.97
thickness
Charge 5.9 to 6.4 5.4 to 6.88
cut-in
Hydraulic oil temperature: 45 (60 to 65) {55 to 70}
pressure
to 55°C
Charge 9.8 to 10.78 9.4 to 11.3
Engine speed: Low idle
cut-out
pressure {100 to 110} {95 to 115}
Hydraulic oil temperature: 45 MPa
Brake oil to 55°C 4.4 to 5.2 Min. 4.2
pressure {kg/cm 2}
{44.8 to 53} {Min. 42.7}
Engine speed: Low idle
Engine stopped
Drop of Measure lowering of oil Max. 0.49 Max. 0.49
brake oil pressure from 4.9 MPa {50 kg/
pressure cm2} after depressing brake {Max. 5} {Max. 5}
pedal for 5 min.
Tire inflation pressure:
Specified pressure
Test on flat, level, straight, and
dry paved road.
Wheel Travel speed at beginning of
brake brake application 20 km/h:
Delay in applying brakes Max. m Max. 5 Max. 5
perfor-
mance 0.1sec.
Brake pedal depressing force:
Specified depressing effort 293
to 353Nm {29.9 to 35.9 kg}
Measure braking distance.
Use disc wear indicator for Shaft
Wear of measurement. Protrusion of protrusion
wheel Oil pressure: 4.9 MPa {50 kg/ mm shaft reaches wear
brake disc cm }2 limit position
Pedal depressed completely 0 [Max. 2.4]

WA470-7 30-223
30 Testing and adjusting
Pm clinic

5. Work equipment
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Work
equipment 32.5 to 36.1 29.9 to 36.1
relief Bucket relief
pressure {332 to 368} {305 to 368}
(*1) MPa
Work Power mode {kg/cm2}
equipment Boom control 1.27 to 1.47 1.17 to 1.57
valve LS Hydraulic oil
lever: Half
differential temperature: {13 to 15} {12 to 16}
stroke
pressure 45 to 55°C
Boom Engine speed: Raising time 5.4 to 6.4 Max. 7.7
speed High idle
Lowering time 2.6 to 3.6 Max. 4.4
Bucket full
Bucket tilt sec 2.1 to 2.7 Max. 3.2
stroke time
back Level o apply
speed a load 1.2 to 1.8 Max. 2.0
afterward
Hydraulic oil Retraction of
Hydraulic temperature: lift cylinder rod Max. 30 Max. 36
drift in 45 to 55°C mm/15
Retraction of
work min.
bucket Max. 20 Max. 24
equipment Engine
stopped cylinder rod
*1: Items which can be inspected in special functions of machine monitor
6. Hydraulic fan
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
• Engine speed: High idle
• Coolant temperature: Min.
Cooling 95°C
fan • Hydraulic oil temperature:
Min. 50°C 1,200 to 1,400 1,100 to 1,500
maximum
speed (*1) • Torque converter oil
temperature: Min. 105°C
• Can be substituted with fan
100% mode rpm
• Engine low idle
• Coolant temperature: Max.
Cooling 70°C
fan • Hydraulic oil temperature:
minimum 125 to 225 75 to 275
Max. 70°C
speed (*1) • Torque converter oil
temperature: Max. 88°C
• Air conditioner: OFF
• Engine speed: High idle
Cooling 12.9 to 15.7 12.2 to 16.4
• Hydraulic oil temperature:
fan drive
50°C {131 to 161} {124 to 168}
pressure
• Fan 100% mode (*2)
Cooling MPa
• Fan rotating in reverse
fan {kg/cm2}
• Engine: High idle 2.16 to 2.86 1.98 to 3.04
reverse
• Hydraulic oil temperature:
solenoid {22.0 to 29.2} {20.2 to 31.0}
50°C
output
• Fan 100% mode (*2)
pressure
*1: Items which can be inspected in special functions of machine monitor
*2: For the fan 100% mode, see "Testing and adjusting", "Special functions of machine monitor".

30-224 WA470-7
30 Testing and adjusting
Pm clinic

7. Axle
Un-
Standard Ac-
Repair limit Test ac-
Item Condition Unit value for new cep-
results cep-
machine table
table
Draining of Front axle
differential
Must be no excessive metal
Visual —
Rear axle particles
check of
plug
MEMO

WA470-7 30-225
30 Testing and adjusting
Pm clinic

30-226 WA470-7
SHOP MANUAL

WHEEL LOADER
WA470-7
Model Serial Number

WA470-7 10001 and up

40 Troubleshooting
6 40 Troubleshooting

WA470-7 40-1
40 Troubleshooting
Table of contents

Table of contents (ALL-0310-002-A-00-A)


40 Troubleshooting............................................................................................................................ 40-1
Table of contents ........................................................................................................................ 40-2
General information on troubleshooting ...................................................................................... 40-11
Troubleshooting points ....................................................................................................... 40-11
Sequence of events in troubleshooting................................................................................. 40-13
Check before troubleshooting.............................................................................................. 40-15
Inspection procedure before troubleshooting ........................................................................ 40-17
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedures for troubleshooting ................................................................. 40-40
Symptom and troubleshooting numbers ............................................................................... 40-43
Information in troubleshooting table ..................................................................................... 40-46
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-62
T-branch box and T-branch adapter table ............................................................................. 40-98
Fuse location table ........................................................................................................... 40-104
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-107
Precautions on troubleshooting of machine monitor ............................................................ 40-110
Processing procedure of harness checker for troubleshooting of machine monitor LCD
unit .................................................................................................................... 40-112
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-117
Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-118
Failure codes table........................................................................................................... 40-119
Troubleshooting by failure code (Display of code) ...................................................................... 40-133
Failure code [1500L0] Double Engagement of T/M Clutches ................................................ 40-133
Failure code [15SAL1] Release Trouble of ECMV (Forward) ................................................ 40-134
Failure code [15SALH] Malfunction of ECMV (Forward)....................................................... 40-136
Failure code [15SBL1] Release Trouble of ECMV (Reverse)................................................ 40-138
Failure code [15SBLH] Malfunction of ECMV (Reverse) ...................................................... 40-140
Failure code [15SEL1] Release Trouble of ECMV (1st)........................................................ 40-142
Failure code [15SELH] Malfunction of ECMV (1st) .............................................................. 40-144
Failure code [15SFL1] Release Trouble of ECMV (2nd)....................................................... 40-146
Failure code [15SFLH] Malfunction of ECMV (2nd) ............................................................. 40-148
Failure code [15SGL1] Release Trouble of ECMV (3rd) ....................................................... 40-150
Failure code [15SGLH] Malfunction of ECMV (3rd).............................................................. 40-152
Failure code [15SHL1] Release Trouble of ECMV (4th) ....................................................... 40-154
Failure code [15SHLH] Malfunction of ECMV (4th) .............................................................. 40-156
Failure code [2F00MA] Failure of Parking Brake Circuit ....................................................... 40-158
Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) ............................................. 40-162
Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) .............................................. 40-164
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-166
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-167
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-168
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-169
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-170
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-171
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-172
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-173
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-174
Failure code [989A00] Engine Overrun Prevention Activated ............................................... 40-175
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-176
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-177
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-178
Failure code [A1U0N3] HC Desorb Request 1 .................................................................... 40-179
Failure code [A1U0N4] HC Desorb Request 2 .................................................................... 40-181
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-183
Failure code [B@BAZG] Eng Oil Press Low ....................................................................... 40-185

40-2 WA470-7
40 Troubleshooting
Table of contents

Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-186


Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-188
Failure code [B@BCZK] Eng Water Level Low ................................................................... 40-189
Failure code [B@CENS] T/C Oil Temp. Overheat................................................................ 40-191
Failure code [B@HANS] HYD Oil Temp. Overheat .............................................................. 40-192
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-193
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-194
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-196
Failure code [CA131] Throttle Sensor High Error................................................................. 40-198
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-200
Failure code [CA135] Eng Oil Press Sensor High Error........................................................ 40-202
Failure code [CA141] Eng Oil Press Sensor Low Error ........................................................ 40-204
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-206
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-208
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-210
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-212
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-214
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-216
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-218
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-220
Failure code [CA234] Eng Overspeed ................................................................................ 40-221
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-222
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-223
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-224
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-225
Failure code [CA273] PCV2 Short Error ............................................................................. 40-226
Failure code [CA274] PCV2 Open Error ............................................................................. 40-227
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-228
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-230
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-232
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-234
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-236
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-238
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-240
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-241
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-242
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-244
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-246
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-248
Failure code [CA431] Idle Validation Sw Error..................................................................... 40-249
Failure code [CA432] Idle Validation Process Error ............................................................. 40-252
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-255
Failure code [CA442] Battery Voltage High Error................................................................. 40-257
Failure code [CA449] Rail Press Very High Error................................................................. 40-258
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-259
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-261
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-263
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-265
Failure code [CA553] Rail Press High Error ........................................................................ 40-267
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-268
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-269
Failure code [CA559] Rail Press Low Error......................................................................... 40-270
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-274
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-275
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-277
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-279
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-281
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-283
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-284

WA470-7 40-3
40 Troubleshooting
Table of contents

Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-285
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-286
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-288
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-289
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-292
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-295
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-296
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-298
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-300
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-302
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-304
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-306
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-309
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-312
Failure code [CA1923] Dosing Fuel Valve 1 High Error ........................................................ 40-317
Failure code [CA1924] Dosing Fuel Valve 1 Low Error......................................................... 40-319
Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ................................................. 40-322
Failure code [CA1927] Dosing Fuel Press Sens High Error .................................................. 40-324
Failure code [CA1928] Dosing Fuel Press Sens Low Error................................................... 40-326
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-328
Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ...................................................... 40-329
Failure code [CA1977] Fuel Doser Open/Short Error ........................................................... 40-331
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-333
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-335
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-337
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-339
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-340
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-342
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-344
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-346
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-348
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-350
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-352
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-353
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-355
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-357
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-359
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-361
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-362
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-364
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-366
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-368
Failure code [CA2732] Dosing Fuel Valve 2 High Error ........................................................ 40-371
Failure code [CA2733] Dosing Fuel Valve 2 Low Error......................................................... 40-373
Failure code [CA2741] Dosing Fuel Valve Swap Error ......................................................... 40-375
Failure code [CA2765] Inj Trim Data Error .......................................................................... 40-377
Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ...................................................... 40-378
Failure code [CA2881] Dosing Fuel Pressure Low Error 1.................................................... 40-381
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-386
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-388
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-390
Failure code [CA3167] Fuel Doser Degradation .................................................................. 40-393
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-396
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-399
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-402
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-405
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-409
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-412
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-415

40-4 WA470-7
40 Troubleshooting
Table of contents

Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-418
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-421
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-425
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-430
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-433
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-437
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-442
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-446
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-449
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-454
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-456
Failure code [D150KA] Disconnection of Emerg. Steering Relay .......................................... 40-458
Failure code [D150KB] Ground Fault of Emerg. Steering Relay ............................................ 40-460
Failure code [D150KY] Hot Short of Emergency Steering Relay ........................................... 40-462
Failure code [D160KA] Disconnection of Backup Lamp Relay Output ................................... 40-464
Failure code [D160KB] Ground Fault of Backup Lamp Relay Output..................................... 40-466
Failure code [D160KY] Hot Short of Backup Lamp Relay Output .......................................... 40-468
Failure code [D191KA] Disconnection of Neutral Output Relay............................................. 40-470
Failure code [D191KB] Ground Fault of Neutral Output Relay .............................................. 40-472
Failure code [D191KY] Hot Short of Neutral Output Relay.................................................... 40-474
Failure code [D192KA] Disconnection of ECSS Solenoid..................................................... 40-476
Failure code [D192KB] Ground Fault of ECSS Solenoid ...................................................... 40-478
Failure code [D192KY] Hot Short of ECSS Solenoid ........................................................... 40-479
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-480
Failure code [D1E6KA] Disconnection of Parking Brake Relay ............................................. 40-482
Failure code [D1E6KB] Ground Fault of Parking Brake Relay............................................... 40-484
Failure code [D1E6KY] Hot Short of Parking Brake Relay .................................................... 40-486
Failure code [D5ZHKA] Failure of Key SW C Signal ............................................................ 40-488
Failure code [D5ZHKB] Key SW C Signal Short Circuit........................................................ 40-490
Failure code [D5ZHKZ] Failure of Key SW C Signal ............................................................ 40-492
Failure code [D5ZHL6] Disconnection of Key SW C ............................................................ 40-494
Failure code [D811MC] KOMTRAX Error............................................................................ 40-496
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-497
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ...................................... 40-498
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-500
Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 .......................................................... 40-502
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-503
Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) ..................................... 40-505
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-506
Failure code [DAF0MC] Monitor Error ................................................................................ 40-507
Failure code [DAF3KK] Controller Power Source Low (MON)............................................... 40-508
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-510
Failure code [DAFDKB] Monitor 12V Power Output Short Circuit .......................................... 40-511
Failure code [DAFGMC] GPS Module Error........................................................................ 40-513
Failure code [DAFLKA] Operating Lamp Open Circuit (MON)............................................... 40-514
Failure code [DAFLKB] Operating Lamp Short Circuit (MON)............................................... 40-516
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-518
Failure code [DAQ0KK] Controller Power Source Low (T/M) ................................................ 40-519
Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) ....................................... 40-522
Failure code [DAQ0MC] T/M Con Error .............................................................................. 40-523
Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) .............................................. 40-524
Failure code [DAQ2KK] Solenoid Power Source Low (T/M) ................................................. 40-526
Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay .......................................... 40-529
Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) .......................................... 40-531
Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) ................................................ 40-532
Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) ................................................ 40-534
Failure code [DAQQKR] CAN2 Discon (Transmission Con) ................................................. 40-536
Failure code [DAQRKR] CAN1 Discon (Transmission Con) ................................................. 40-537
Failure code [DAQRMA] Inconsistency of Option Selection (T/M) ......................................... 40-538

WA470-7 40-5
40 Troubleshooting
Table of contents

Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-539


Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-540
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-541
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-546
Failure code [DB90KK] Drop in BBC Controller Main Power Source ..................................... 40-551
Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) ...................................... 40-553
Failure code [DB90MC] BBC Error..................................................................................... 40-554
Failure code [DB91KA] Disconnection of Key SW ACC (BBC) ............................................. 40-555
Failure code [DB92KK] Solenoid Power Source Low (BBC) ................................................. 40-557
Failure code [DB95KX] Failure of 5 V Power Source 1......................................................... 40-559
Failure code [DB96KX] Failure of 5 V Power Source 2......................................................... 40-561
Failure code [DB99KQ] Inconsistency of Model Selection (BBC) .......................................... 40-563
Failure code [DB9LKA] Operating Lamp Open Circuit (BBC)................................................ 40-564
Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) ................................................ 40-566
Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) .................................................. 40-568
Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) .................................................. 40-569
Failure code [DB9RMA] Inconsistency of Option Selection (BBC)......................................... 40-570
Failure code [DBE5KX] Failure of 5V Power Source............................................................ 40-571
Failure code [DBE6KX] Failure of 24 V Power Source ......................................................... 40-573
Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW ..................................... 40-575
Failure code [DDAAL6] Discon of Engine Shutdown Secondary Switch ................................ 40-577
Failure code [DDB6L4] Neutral Signal Malfunction .............................................................. 40-579
Failure code [DDD1LD] Failure of Bucket Positioner Set Switch ........................................... 40-582
Failure code [DDK3KA] FNR SW Input Signal Disconnection............................................... 40-584
Failure code [DDK3KB] FNR SW Input Signal Short Circuit.................................................. 40-587
Failure code [DDK6KA] FNR Lever Input Signal Disconnection ............................................ 40-589
Failure code [DDK6KB] FNR Lever Input Signal Short Circuit............................................... 40-592
Failure code [DDNRKY] Hot Short of Work Equipment Lock SW .......................................... 40-594
Failure code [DDT0L4] Failure of Shift Mode Select SW ...................................................... 40-596
Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal...................................... 40-598
Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal ........................................... 40-600
Failure code [DDW9LD] Ground Fault of Kickdown Switch................................................... 40-602
Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW ................................................ 40-604
Failure code [DF10KA] Disconnection of Shift Lever Input ................................................... 40-606
Failure code [DF10KB] Ground Fault of Shift Lever Input ..................................................... 40-608
Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor........................................... 40-611
Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor ............................................ 40-613
Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor .......................................... 40-615
Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor ......................................... 40-617
Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor .................................................. 40-618
Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor ........................................... 40-620
Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor............................................. 40-623
Failure code [DH21KA] Failure of Loader Pump Press. Sensor ............................................ 40-625
Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit........................................ 40-627
Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit ............................................... 40-629
Failure code [DHPCKX] Out of Range of Boom Bottom Press. Sensor.................................. 40-631
Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor .................................... 40-633
Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor...................................... 40-635
Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor ..................................... 40-637
Failure code [DHT7KX] Out of Range of T/C Output Pressure Sensor .................................. 40-639
Failure code [DHT8KA] Failure of Steering Pump Press. Sensor .......................................... 40-641
Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit...................................... 40-643
Failure code [DHT8ZG] Steering Oil Pressure Low.............................................................. 40-645
Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor ......................................... 40-646
Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit ............................................ 40-648
Failure code [DJF1KA] Disconnection of Fuel Level Sensor ................................................. 40-650
Failure code [DK55KA] Failure of FNR Lever Potentio ......................................................... 40-652
Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit ........................................... 40-655
Failure code [DK55L5] Failure of FNR Lever Potentio.......................................................... 40-657

40-6 WA470-7
40 Troubleshooting
Table of contents

Failure code [DK59KA] Failure of Boom Lever Potentio (Main) ............................................. 40-658
Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) ......................................... 40-661
Failure code [DK59L8] Boom Lever Potentio (Main & Sub) Disagree .................................... 40-664
Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub).............................................. 40-668
Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) .......................................... 40-671
Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) ........................................... 40-674
Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) ....................................... 40-677
Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub) Disagree .................................... 40-680
Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) ............................................ 40-684
Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) ........................................ 40-687
Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) ................................................ 40-690
Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) ............................................ 40-693
Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree........................................ 40-695
Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub).................................................. 40-698
Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub).............................................. 40-701
Failure code [DKA0KA] Failure of Boom Angle Sensor ........................................................ 40-703
Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit .......................................... 40-705
Failure code [DKA0L0] Boom Angle Sensor Dislocation ...................................................... 40-707
Failure code [DKA1KA] Failure of Bucket Angle Sensor....................................................... 40-709
Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit......................................... 40-711
Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor........................................ 40-713
Failure code [DLF1LC] Failure of T/M Input Speed Sensor................................................... 40-715
Failure code [DLM3KA] Disconnection of Radiator Fan Speed Sensor.................................. 40-717
Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor............................................. 40-719
Failure code [DLT3KA] Disconnection of Output Speed Sens. (Main).................................... 40-721
Failure code [DLT3LC] Failure of Output Speed Sensor (Main)............................................. 40-723
Failure code [DPQ1KR] LIN Discon (Switch Panel) ............................................................. 40-725
Failure code [DPQ2KR] LIN Discon (LED Unit) ................................................................... 40-728
Failure code [DPQ3KR] LIN Discon (Rear View Monitor) ..................................................... 40-731
Failure code [DSJ0KR] CAN2 Discon (Meter Unit) .............................................................. 40-734
Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator .............................................. 40-736
Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. .......................................... 40-738
Failure code [DV00KB] Ground Fault of Buzzer Output........................................................ 40-740
Failure code [DW4PKA] Disconnection of Boom EPC Solenoid (Raise) ................................ 40-742
Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid (Raise).................................. 40-744
Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) ....................................... 40-746
Failure code [DW4QKA] Disconnection of Boom EPC Solenoid (Lower) ............................... 40-748
Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid (Lower) ................................. 40-750
Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) ...................................... 40-752
Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) .......................................... 40-754
Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid (Tilt) .................................... 40-756
Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt).......................................... 40-758
Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) ..................................... 40-760
Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid (Dump) ................................ 40-762
Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) ..................................... 40-764
Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid ......................................... 40-766
Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. .......................................... 40-768
Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol................................................. 40-770
Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid ......................................... 40-771
Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid........................................... 40-773
Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid ................................................ 40-775
Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) ...................................... 40-777
Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) ........................................ 40-779
Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) ............................................. 40-781
Failure code [DWN8KA] Disconnection of Detent Solenoid (Bucket) ..................................... 40-783
Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket)....................................... 40-785
Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) ............................................ 40-787
Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol....................................... 40-789
Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. ....................................... 40-791

WA470-7 40-7
40 Troubleshooting
Table of contents

Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. ....................................... 40-793
Failure code [DXA1KA] Disconnection of Loader Pump EPC Solenoid ................................. 40-795
Failure code [DXA1KB] Ground Fault of Loader Pump EPC Solenoid ................................... 40-797
Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid ........................................ 40-799
Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. ...................................... 40-801
Failure code [DXANKB] Ground Fault of Steering Pump EPC Solenoid ................................ 40-803
Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid...................................... 40-805
Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) ..................................... 40-806
Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) ....................................... 40-808
Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) ............................................ 40-810
Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st)............................................ 40-812
Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) ............................................. 40-814
Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st)................................................... 40-816
Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd)........................................... 40-818
Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) ............................................ 40-820
Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd).................................................. 40-822
Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) ........................................... 40-824
Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) ............................................. 40-826
Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) .................................................. 40-828
Failure code [DXH7KA] Disconnection of ECMV Solenoid (Reverse).................................... 40-830
Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) ..................................... 40-832
Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse)........................................... 40-834
Failure code [DXH8KA] Disconnection of ECMV Solenoid (Forward) .................................... 40-836
Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward)...................................... 40-838
Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) ........................................... 40-840
Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) ........................................... 40-842
Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th)............................................. 40-844
Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) .................................................. 40-846
Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) ....................................... 40-848
Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT)......................................... 40-850
Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) .............................................. 40-852
Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) ...................................... 40-854
Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) ........................................ 40-856
Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) ............................................. 40-858
Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor........................................... 40-860
Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor .......................................... 40-863
Failure code [DY30ME] Emerg. Steering Long-Time Activated ............................................. 40-867
Failure code [LA00L3] Failure of Fan Reverse .................................................................... 40-869
Troubleshooting of electrical system (E-mode) .......................................................................... 40-870
E-1 Engine does not start.................................................................................................. 40-870
E-2 Manual preheating system does not work..................................................................... 40-876
E-3 Automatic preheating system does not work................................................................. 40-879
E-4 While preheating is working, preheating monitor does not light up .................................. 40-881
E-5 All of LCD unit, LED unit, and meter unit on machine monitor display nothing .................. 40-883
E-6 LCD unit on machine monitor displays nothing.............................................................. 40-886
E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or
flickers) .............................................................................................................. 40-888
E-8 LCD on machine monitor does not display properly ....................................................... 40-890
E-9 Meter unit display on machine monitor is abnormal ....................................................... 40-892
E-10 Night lighting lamp of meter unit on machine monitor is abnormal ................................. 40-895
E-11 Caution LED on machine monitor is abnormal............................................................. 40-898
E-12 LED of switch panel on machine monitor is abnormal or switches does not operate
properly ............................................................................................................. 40-900
E-13 Two switches operation of switch panel on machine monitor does not function .............. 40-902
E-14 Switch panel buzzer of machine monitor is abnormal................................................... 40-905
E-15 Rear view monitor does not light up or backlight flickers............................................... 40-907
E-16 Rear view monitor images are not displayed clearly..................................................... 40-910
E-17 Rear view monitor brightness cannot be adjusted........................................................ 40-913
E-18 Night lighting lamp of rear view monitor is abnormal .................................................... 40-916

40-8 WA470-7
40 Troubleshooting
Table of contents

E-19 Some items of gauges and caution lamps on machine monitor are not displayed
properly ............................................................................................................. 40-918
E-20 Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position .............................................................................................................. 40-919
E-21 When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
light ................................................................................................................... 40-923
E-22 Air cleaner clogging indicator lamp does not light ........................................................ 40-925
E-23 Radiator coolant level caution lamp does not light ....................................................... 40-926
E-24 Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil
temperature caution lamp does not light................................................................ 40-928
E-25 Indication of torque converter oil temperature gauge does not increase, or torque
converter oil temperature caution lamp does not light ............................................. 40-930
E-26 Fuel level gauge does not indicate correct level .......................................................... 40-931
E-27 Seat belt caution lamp indication is abnormal.............................................................. 40-933
E-28 Horn does not sound ................................................................................................ 40-934
E-29 Horn does not stop sounding..................................................................................... 40-937
E-30 Alarm buzzer does not sound .................................................................................... 40-939
E-31 When starting switch is in ON position, alarm buzzer does not stop sounding ................ 40-940
E-32 Kickdown does not work when kickdown switch is turned ON....................................... 40-941
E-33 The hold switch does not work when it is pressed........................................................ 40-943
E-34 Parking brake does not work even if it is applied, or the brake drags when parking brake
is released and FR drive is operated..................................................................... 40-945
E-35 Transmission cut-off mode is not selected or not released............................................ 40-948
E-36 Transmission cut-off setting cannot be released .......................................................... 40-950
E-37 Directional selector (FNR) switch mode is not selected or not released ......................... 40-952
E-38 When operating engine power selection switch, engine power selection function does not
operate properly ................................................................................................. 40-954
E-39 Flow of loader pump does not increase from the minimum rate..................................... 40-956
E-40 ECSS function cannot be selected or cannot be released ............................................ 40-957
E-41 None of headlamp, clearance lamp, and tail lamp lights ............................................... 40-959
E-42 Clearance lamp and tail lamp do not light up or go out ................................................. 40-961
E-43 Both High and Low beams of headlamp do not light up or go out .................................. 40-964
E-44 Low beam of headlamp does not light up or go out ...................................................... 40-968
E-45 High beam of headlamp does not light up or go out ..................................................... 40-970
E-46 Front working lamp does not light up or go out ............................................................ 40-972
E-47 Rear working lamp does not light up or go out............................................................. 40-975
E-48 All of turn signal lamps and hazard lamps do not light up or go out................................ 40-978
E-49 Turn signal lamps do not light up or go out .................................................................. 40-981
E-50 Hazard lamp does not light up or go out...................................................................... 40-984
E-51 Brake lamp does not light or stays lighted ................................................................... 40-987
E-52 Backup lamp does not light up or does not go out........................................................ 40-990
E-53 Backup buzzer does not sound or continues to sound ................................................. 40-993
E-54 Front wiper does not operate ..................................................................................... 40-995
E-55 Rear wiper does not operate ..................................................................................... 40-998
E-56 Window washer does not operate ............................................................................ 40-1000
E-57 Fuel feed pump does not operate or stop automatically ............................................. 40-1003
E-58 KOMTRAX system does not operate properly........................................................... 40-1005
Troubleshooting of hydraulic and mechanical system (H-mode) ................................................ 40-1007
Information described in troubleshooting table (H-mode) ................................................... 40-1007
System chart of hydraulic and mechanical systems........................................................... 40-1008
Failure mode and cause table ..........................................................................................40-1011
H-1 Machine does not move off ....................................................................................... 40-1019
H-2 Torque converter lockup clutch is not disengaged (engine stalls).................................. 40-1022
H-3 Torque converter lockup clutch is not engaged ........................................................... 40-1023
H-4 Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
shift ................................................................................................................. 40-1024
H-5 Large shock is made when machine starts or gear is shifted ........................................ 40-1027
H-6 Machine starts or gear speed shifts with long time lag ................................................. 40-1029
H-7 Torque converter oil temperature is high..................................................................... 40-1031

WA470-7 40-9
40 Troubleshooting
Table of contents

H-8 Machine does not turn .............................................................................................. 40-1033


H-9 Turning response is poor .......................................................................................... 40-1035
H-10 Steering wheel is heavy to turn................................................................................ 40-1037
H-11 Machine sways or large shocks are made while machine turns .................................. 40-1038
H-12 Turning radius differs between right and left turns...................................................... 40-1040
H-13 Wheel brakes do not work or are weak..................................................................... 40-1041
H-14 Wheel brakes are not released or drag..................................................................... 40-1043
H-15 Parking brake does not work or it is weak ................................................................. 40-1044
H-16 Parking brake is not released or drags (including emergency release system) ............. 40-1045
H-17 Boom does not rise ................................................................................................ 40-1046
H-18 Boom moves slow or boom lacks lifting force ............................................................ 40-1048
H-19 Rising boom slows down at certain height ................................................................ 40-1050
H-20 Lift cylinders do not serve to hold bucket on ground .................................................. 40-1051
H-21 Hydraulic drift of boom is large ................................................................................ 40-1052
H-22 Boom moves up and down during operation ............................................................. 40-1053
H-23 Bucket does not tilt back ......................................................................................... 40-1054
H-24 Bucket moves slow or lacks tilt-back force................................................................ 40-1056
H-25 Bucket decelerates during tilt-back operation............................................................ 40-1058
H-26 Bucket cylinder does not hold bucket on ground ....................................................... 40-1059
H-27 Hydraulic drift of bucket is large ............................................................................... 40-1060
H-28 Bucket tilts back and forth during carrying load (work equipment valve in
HOLD) ............................................................................................................. 40-1061
H-29 Boom and bucket control levers do not move smoothly and are heavy to move ........... 40-1062
H-30 Operating work equipment causes engine speed to lower significantly or engine to
stall ................................................................................................................. 40-1063
H-31 Large shocks are made when work equipment starts to move and stops ..................... 40-1064
H-32 When certain work equipment stalls hydraulically, other work equipment
moves ............................................................................................................. 40-1066
H-33 E.C.S.S. (travel damper) does not work and machine pitches and bounces................. 40-1067
H-34 Bucket does not stop at the position which is set with remote bucket positioner ........... 40-1068
H-35 Fan speed is abnormal (too high or low, or fan does not rotate) .................................. 40-1069
H-36 Unusual noise is heard from around fan ................................................................... 40-1070
Troubleshooting of engine (S-mode)....................................................................................... 40-1071
Information mentioned in troubleshooting table (S mode)................................................... 40-1071
S-1 When starting switch is turned to START position, engine is not cranked....................... 40-1072
S-2 The engine cranks but exhaust smoke does not come out ........................................... 40-1073
S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start
but does not) .................................................................................................... 40-1074
S-4 Engine startability is poor .......................................................................................... 40-1075
S-5 Engine does not pick-up smoothly ............................................................................. 40-1077
S-6 Engine stops during operation ................................................................................... 40-1079
S-7 Engine runs rough or is unstable ............................................................................... 40-1081
S-8 Engine lacks power .................................................................................................. 40-1082
S-9 KDPF gets clogged in a short time ............................................................................. 40-1084
S-10 Engine oil consumption is excessive ........................................................................ 40-1086
S-11 Engine oil becomes contaminated early.................................................................... 40-1087
S-12 Fuel consumption is excessive ................................................................................ 40-1088
S-13 Oil is in coolant (or coolant spurts or coolant level goes down).................................... 40-1089
S-14 Oil pressure drops .................................................................................................. 40-1090
S-15 Fuel mixes into engine oil........................................................................................ 40-1091
S-16 Water mixes into engine oil (milky) ........................................................................... 40-1092
S-17 Coolant temperature rises too high (overheating) ...................................................... 40-1093
S-18 Unusual noise is heard ........................................................................................... 40-1094
S-19 Vibration is excessive ............................................................................................. 40-1095
S-20 Air cannot be bled from fuel circuit ........................................................................... 40-1096
S-21 Active regeneration is executed frequently ............................................................... 40-1097
S-22 Active regeneration takes a long time....................................................................... 40-1098
S-23 White smoke is exhausted during active regeneration ............................................... 40-1099

40-10 WA470-7
40 Troubleshooting
General information on troubleshooting

General information on troubleshooting (ALL-5100-001-A-00-A)

Troubleshooting points (ALL-5130-42A-A-00-A)

(Rev. 2011/09)

k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.

k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.

k Ifthe 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.

k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.

k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.

Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1)Is there any sign of irregularities of the machine?
2)Make checks before starting day's work.
3)Make checks of other items.
4)Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.

WA470-7 40-11
40 Troubleshooting
General information on troubleshooting

a The basic procedure for troubleshooting is as follows.


1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.

40-12 WA470-7
40 Troubleshooting
General information on troubleshooting

Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)

(Rev. 2011. 7)

WA470-7 40-13
40 Troubleshooting
General information on troubleshooting

40-14 WA470-7
40 Troubleshooting
General information on troubleshooting

Check before troubleshooting (WA500-5150-208-A-00-A)

No. Item Criteria Remedy


1 Check of unusual noise and smell ― Repair
2 Check of engine for dirt ― Remove
a: Engine, lubricating oil, and coolant

3 Check of engine for water leakage ― Repair


4 Check of engine for oil leakage ― Repair
5 Check of fuel line for leakage ― Repair
6 Check of radiator for clogging ― Remove
7 Check of fuel level and type ― Refilling of oil
8 Check of foreign material in fuel ― Clean and drain
9 Check of fuel pre-filter ― Replace
10 Check of fuel main filter ― Replace
11 Check of engine oil level (in oil pan) and type Between H and L Refilling of oil
Refilling with
12 Check of coolant level (in sub tank) Between H and L
coolant
Air cleaner clogging
monitor does not Clean or replace
13 Check of air cleaner for clogging
light up on the
machine monitor.
1 Check of unusual noise and smell ― Repair
Check for oil leakage ― Repair
b: Hydraulic and mechanical equipment

2
3 Check of hydraulic oil level Between H and L Refilling of oil
4 Check of hydraulic oil strainer ― Clean or replace
5 Check of hydraulic oil filter ― Replace
6 Check of transmission case oil level Between H and L Refilling of oil
7 Check of axle case oil level (front and rear) Between H and L Refilling of oil

8 Perform air bleeding. ― Bleeding air

Retighten or
1 Check of battery terminal for looseness and corrosion ―
replace
Retighten or
2 Check of alternator terminal for looseness and corrosion ―
replace
Check of starting motor terminal for looseness and Retighten or
3 ―
corrosion replace
c: Electrical equipment

Charge or
4 Check of battery voltage (with engine stopped) 20 to 30 V replace
5 Check of battery electrolyte level Between H and L Add or replace
Check of wiring harness for discoloration, burnt areas and
6 cover peeling ― Repair or replace
Check for coming off of wiring harness clamp and sagging
7 of wiring harness ― Repair
8 Check of grounding ― Repair
9 Check for loose connector and damaged lock ― Repair or replace
Check of connector pin for corrosion, bends and ― Repair or replace
10
deformation
Dry, clean or
11 Check of connector for water and foreign material ― replace

WA470-7 40-15
40 Troubleshooting
General information on troubleshooting

No. Item Criteria Remedy


12 Check of wiring harness for open or short circuit ― Repair or replace
c: Electrical equipment

Check of fuse and slow-blow fuse for blowout and ― Replace


13
corrosion
27.5 to 29.5 V after
Check of alternator voltage (when engine speed is
14 medium or higher) few minutes Replace
operation
Check of battery relay operation sound (when starting
15 switch is turned to ON or OFF position) ― Replace

16 Check, clean rear view camera ― Clean or repair

1 Check of undercarriage ― Repair


d: Exterior parts

2 Check of handrails and steps ― Repair

3 Check of mirrors ― Clean or repair

1 Check of gauges and monitors ― Clean or replace


e: Interior parts

2 Check of seat belt ― Repair

40-16 WA470-7
40 Troubleshooting
General information on troubleshooting

Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)

Walk-around check (WA500-5150-289-A-00-A)

Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles around hot engine parts such as the engine, KDPF, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.

a a1 and a2, —, b1, b2, — refer to the symbols in the table on the previous page.
a1. and b1. Check for unusual noise and smell Check and remove any accumulated dirt and
Check for unusual noise and smell. combustibles (dead leaves, twigs, etc.) around the
battery.
Some causes of unusual noise and smell can
damage the machine if they are left as they are. c16. Check and cleaning of rear view camera
Therefore, stop the machine immediately when you Check the rear view camera for any defect, and
find any abnormality. repair any failures.
a2. Check around engine and dirt removal d1. Check of undercarriage (track, sprocket,
Check and remove any accumulated dirt around the idler and guard) for abnormalities, wear, loose
engine and any combustibles (dead leaves, twigs, bolts and oil leakage from roller
etc.) on hot engine parts such as the engine, KDPF, Repair any abnormalities.
turbocharger, etc. d2. Check of handrails and steps for
a3. Check for water leakage around engine abnormalities and loose bolts
a4. Check for oil leakage around engine Repair any abnormalities and retighten any loose
Check any oil leaks from the engine and any water bolts.
leaks from the cooling system. If any of them is d3. Check and cleaning of rear view mirrors
abnormal, carry out a repair. Check and repair any abnormalities and breakage
a5. Check for leakage from fuel line of the rear view mirrors.
Check any fuel leaks and damaged hoses and Clean the mirror surfaces and adjust their angles so
tubes. If any of them is abnormal, carry out a repair. that the operator can see the area behind machine
a6. Check of radiator and dirt removal at the operator's seat.
Check and remove any accumulated dirt and e1. Check of gauges and monitors for
combustibles (dead leaves, twigs, etc.) around the abnormalities
radiator. Check the gauges and monitors inside the operator
a14. Check around KDPF and dirt removal cab. If any of them is abnormal, replace it.
Check and remove any accumulated dirt and Clean up the surfaces.
combustibles (dead leaves, twigs, etc.) around e2. Check of seat belt and mounting hardware
KDPF. Check the hooks, locks and hook fittings for
a15. Check around KDPF for gas leakage damage. If any of them has a problem, replace.
Check piping between the turbocharger and KDPF
and joints of KDPF for gas leakage (sticking soot,
etc.) If any abnormality is found, repair.
b2. Check of work equipment, cylinders, linkage
and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and
hoses for cracks and excessive wear, check that the
clearance between them is within the normal range,
and then repair any abnormalities.
b3. Check of hydraulic equipment, hydraulic
tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal

WA470-7 40-17
40 Troubleshooting
General information on troubleshooting

Testing in accordance with testing procedure (WA470-5150-280-A-00-A)

a: Engine, lubricating oil, and coolant


a7. Check of fuel level and type
k Fuel is highly flammable and dangerous.
Never bring flames near fuel.

k When adding fuel, never spill it or let it


overflow.

k Wipe off any spilled fuel. If fuel spills over


soil or sand, remove all the fuel and soil or
sand together.

1. Turn the engine starting switch to ON position


and check the fuel level with fuel gauge (G) on a9. Check of fuel pre-filter
monitor panel. k Immediately after the engine is stopped, its
After checking, turn the switch back to OFF parts and oil are still very hot, and may cause
position. burn injury. Accordingly, wait until all parts
have cooled down before starting the work.

k High pressure is generated inside the engine


fuel piping system when the engine is
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter .

k Never bring flames near fuel.

a A special filter with high-efficiency filtering


properties is adopted for Komatsu genuine fuel
pre-filter cartridges. Be sure to use Komatsu
2. If fuel level is low, open fuel filler cap (F) at the genuine parts when replacing.
rear right of machine, and add fuel through filler a The common rail fuel injection system used on
port to the level enough to perform the check. this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel pre-filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign
material to enter the fuel system. If any dust or
other material sticks to any part, wash the part
thoroughly with clean fuel.
• Prepare a container to receive drained oil.
• Prepare a filter wrench.
a8. Check of foreign material in fuel 1. Stop the engine and wait until the temperature of
each part to drop.
1. Prepare a container to receive drained fuel.
2. Open the engine side cover on the right side of
Place it under the fuel tank.
the machine.
2. Open drain valve (1) on the right side of the fuel
3. Place a container to receive fuel under fuel pre-
tank, and drain the water mixed in the fuel and
filter cartridge (1).
sediments at the bottom of the tank.
4. Loosen drain valve (2) to drain water and
3. Close drain valve (1) when all of mixed water
sediments from transparent cup (3), and also
and deposits are drained.
drain all the fuel from filter cartridge (1).

40-18 WA470-7
40 Troubleshooting
General information on troubleshooting

5. Remove drain hose (4). Reuse the drain hose leads to leakage of fuel. If the filter cartridge is
and clip. too loose, fuel will also leak from the packing.
6. By using the filter wrench, turn filter cartridge (1) Therefore, be sure to observe the fastening
counterclockwise to remove it. The filter angle.
cartridge (1) is one with transparent cup (3). 10.Fasten it by using filter wrench 1/2 to 3/4 turns.
7. Make sure that drain valve (2) which is provided At that time, take care not to damage or deform
in the lower part of transparent cup (3) of the the filter cartridge.
new filter cartridge is firmly tightened. 11.Install drain hose (4).
12.After replacing the filter cartridge, start the
3 Tightening torque of drain valve:
engine and run it at low idle for 10 minutes.
2.5 to 3.4 Nm {0.25 to 0.35 kgm} Check for fuel leakage from the filter seal
surface and transparent cup mounting face. If
there is any leakage of fuel, check the fastening
condition of the filter cartridge.
If the fuel still leaks, follow Step 1 to 6 to remove
the filter cartridge, then check the packing
surface for damage or foreign material. If any
damage or foreign material is found in the
packing, replace the cartridge with a new one,
then repeat Steps 7 to 10.
a10. Check of fuel main filter
k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
8. Clean the filter holder, fill the new filter cartridge have cooled down before starting the work.
with clean fuel, apply thin film of oil to the
packing surface, then install it to the filter holder. k High pressure is generated inside the engine
fuel piping system when the engine is
k When adding fuel, do not remove cap (A) running. Stop the engine and wait at least 30
at the center. Always fill fuel from dirty seconds until the inner pressure is released
side of eight small holes (B). and then replace the filter .

k After adding fuel, remove cap (A) at the k Never bring flames near fuel.
center and install fuel filter.
k When using fuel feed pump, be sure not to
k Always fill with clean fuel. Be careful not loosen air bleeding plug in fuel circuit. While
to let any dirt or dust get into the fuel. In the fuel feed pump is in operation, pressure
particular, since center portion is the is applied to the fuel circuit. Do not loosen
clean side, do not remove cap (A) when the air bleeding plug at this time, since the
adding fuel. Be careful not to let dirt or fuel may spout out.
dust get into the center clean side.
a A special filter with high-efficiency filtering
properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts.
a During testing or maintenance of the fuel system,
take extreme care not to allow any foreign
9. When installing, fasten it by finger until the material to enter the fuel system. If any dust or
packing surface contacts the seal surface of the other material sticks to any part, wash the part
filter holder. If the filter cartridge is fastened too thoroughly with clean fuel.
much, the packing will be damaged and this

WA470-7 40-19
40 Troubleshooting
General information on troubleshooting

• Prepare a container to receive drained oil. a Continue the supply of fuel until the fuel
• Prepare a filter wrench. gauge monitor turns to blue.
1. Stop the engine and wait until the temperature of (Check the fuel level with monitor after
each part to drop. turning the starting switch to ON position.)
2. Open the engine side cover on the right side of 8. Open the side cover on the right side of engine.
the machine. 9. Tilt switch (2) for the fuel feed pump in the
3. Place a container to receive drained oil under engine room to ON position.
filter cartridge (1).
a The fuel feed pump operates and lamp (3)
flashes.

4. By using the filter wrench, turn filter cartridge (1)


counterclockwise to remove it.
a The timer built in this switch automatically
5. Clean the filter holder, apply the thin film of oil to
starts up and stops the fuel feed pump (see
the packing surface of the new filter cartridge, the figure).
then install the filter cartridge to the filter holder.
a Operation of the fuel feed pump stops while
k Do not fill the new filter cartridge with the lamp is flashing. It is, however, not a
fuel. failure.
a If you set the switch to OFF position while the
k Remove cap (A) at the center, and then lamp is lighted, the lamp goes out and the
install the filter cartridge. fuel feed pump stops.

6. When installing, fasten it by finger until the 10.After the specified time (approximately 6
packing surface contacts the seal surface of the minutes and 30 seconds), lamp (3) goes out
filter holder. Then fasten filter cartridge 1/2 to 3/4 automatically and the fuel feed pump stops.
turns. If the filter cartridge is fastened too much, a11. Check of engine oil level (in oil pan) and
the packing will be damaged and this leads to type
leakage of fuel. If the filter cartridge is too loose,
fuel will also leak from the packing. Therefore, k Immediately after the engine is stopped, its
be sure to observe the fastening angle. parts and oil are still very hot, and may cause
7. Supply fuel to the fuel tank. burn injury. Accordingly, wait until all parts
have cooled down before starting the work.

40-20 WA470-7
40 Troubleshooting
General information on troubleshooting

a When checking the oil level after the engine has


been operated, wait for at least 15 minutes after
stopping the engine.
a If the machine is at an angle, make it level
before checking.
a If the coolant level is low, add coolant.

6 Engine oil: Approximately 38 l


1. Stop the engine and wait until the temperature of
each part to drop.
2. Open the engine side cover at the rear right side
of the machine.
3. Pull out dipstick (G) and wipe the oil off with a a When the ambient temperature is low, water
cloth. or emulsified matter may stick to the dipstick,
4. Fully insert dipstick (G) into the dipstick pipe, oil filler cap, etc. or the drained oil may be
then remove it. milky white because of water vapor in the
blowby gas. However, if the coolant level is
normal, it is not a problem.
a If the coolant level is low, add coolant.
a12. Check of coolant level (in sub tank)
k The radiator cap does not need to be opened
for standard checks. When checking the
coolant level, check the sub-tank when the
engine is cooled down.

k Immediately after the engine is stopped, the


coolant is still very hot and the pressure is
accumulated in the radiator. If the cap is
5. The oil level should be between the H and L opened under these conditions, you may be
marks on dipstick (G). If the oil level is below the scalded. If you need to remove the radiator
L mark, add oil through oil filler port (F). cap, wait until the temperature drops before
you do. Then turn the cap slowly to release
the pressure and remove it with care.

1. Open platform cover (1) on the right side of


machine.
2. Check that the coolant level is between the
FULL and LOW marks of the sub-tank. If the
coolant level is low, open the cover on top of the
platform and refill both sub-tanks with coolant
through the coolant filler ports (2) to the FULL
level.
3. After refilling with coolant, tighten the cap
securely.
4. If the sub-tank is empty, leakage of coolant is
a The labels ENGINE STOPPED and ENGINE suspected. If any abnormality is found in the
IDLING are stamped on respective sides of check for leakage, repair it immediately. If no
the dipstick. abnormality is found, check the level of the
coolant in the radiator. If it is low, add coolant to
a When checking the oil level after stopping the radiator and then to the sub-tank. If the
the engine, use the side with the stamped amount of added coolant is larger than usual,
mark ENGINE STOPPED . check for leakage of coolant. Check the coolant
6. If the oil level is above the H line, drain the for any abnormality such as mixing of oil, etc.
excess oil from drain plug (P), then check the oil
level again.
7. If the oil level is correct, tighten oil filler cap (F)
securely and close the engine side cover.

WA470-7 40-21
40 Troubleshooting
General information on troubleshooting

If air cleaner clogging caution lamp (1) lights up on


the machine monitor, clean the air cleaner element.
a Do not clean the air cleaner element until the air
cleaner clogging caution lamp lights up.
If you clean the element frequently before the air
cleaner clogging caution lamp lights up, the air
cleaner will not deliver optimum performance
and the cleaning efficiency will be reduced. In
addition, dust attached to the element can drop
into the inner element more frequently during the
cleaning process.
a Dust indicator (2) for indicating seriousness of
clogging of air cleaner (indicates clogging in five
steps) is installed in the engine hood on the left
side of machine. It helps to check cleanliness of
the air cleaner and its replacement timing.

a.13 Check of air cleaner for clogging


k When using compressed air for cleaning, put
on personal protective items such as
protective eyeglasses, gloves, dust mask,
etc. to protect yourself from dirt that will fly Cleaning and replacement of outer element
out. 1. Fully open air engine side cover on the right side
of engine hood.
k When removing the outer element from the
2. Remove clips (4) (3 places) of cover (3) and
air cleaner body, do not forcibly pull it out,
remove the cover (3).
otherwise it can be dangerous. Be careful not
to fall from a high location on unsafe
scaffolding as a reaction when pulling out
the outer element.

k If performing testing, cleaning, or


maintenance while the engine running, dust
may enter into the engine and engine may be
damaged. Be sure to stop the engine before
performing these works.

40-22 WA470-7
40 Troubleshooting
General information on troubleshooting

3. Remove the outer element (6).


a Never remove inner element (7). If it is
removed, dirt will enter and can cause an
engine trouble.
4. Hold inner element (7) so that it does not come
out, and clean the inside of the air cleaner body
and the cover.
5. Use a dry cloth or compressed air to clean off
the dirt stuck to the cover (2) and vacuator valve
(5).
6. Check that there are no cracks in the lip of the
vacuator valve (5). If any cracks are found,
replace it with a new one.
8. Install cleaned outer element to the air cleaner
body.
9. Check that O-ring (8) is fitted to cover (2).
10.Set so that vacuator valve (5) of cover (2) is at
the bottom, and insert it into the air cleaner body.
11.Fit clips (4) (3 places) of cover (2) to the
protruding portion of the air cleaner body to lock
in position.
12.After cleaning or replacing the element, press
the button of dust indicator to restore the red
indication to normal indication.
a If the dust indicator still indicates the 5th level
even when the button is pressed after
7. Blow dry compressed air (less than 0.2 MPa cleaning the element, replace the element.
{2.1kg/cm2}) from the inside of the outer element a Even when the element is cleaned or
along the folds. Then blow it from outside along replaced with a new one, the dust indicator
the folds, and finally blow it from the inside may go to the 3rd position.
again.
a After clearing the element, throw light on its
inside using a light bulb to check it. If it has a
small hole or thin part, replace it.
a Do not tap or hit the element against any
other object when cleaning it.
a Do not use the element if its folds or gasket
or seal are damaged.

WA470-7 40-23
40 Troubleshooting
General information on troubleshooting

9. After replacing the element, restore the red


indication of the indicator to normal indication.
b. Hydraulic and mechanical equipment
b3. Check of hydraulic oil level
k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
have cooled down before starting the work.

k When removing the oil filler cap, the oil may


spout out. Turn it slowly to release the
internal pressure, then remove it.
Replacement of inner element
1. Lower the bucket to the ground, wait for at least
a Do not clean and reuse the inner element. 5 minutes after stopping the engine before
Replace the inner element with a new one at the checking.
same time as you replace the outer element. 2. Check the oil level with sight gauge (G) of
1. Fully open air engine side cover on the right side hydraulic tank. The oil level is appropriate when
of engine hood. it is nearby the top of the sight gauge (G).
2. Remove clips (4) (3 places) of cover (3) and
a Since it may damage the oil circuit and cause
remove the cover (3).
the oil to spurt out, when the refilled oil
exceeds the top level of the sight gauge (G),
stop the engine and wait for the hydraulic oil
to cool down.Then drain excess oil through
the drain plug.
3. Loosen bolt, and turn and open cover (1).

3. Remove the outer element (6).


4. Remove the inner element (7).

4. If the oil level is not nearby the top of the sight


gauge (G), add oil through oil filler port (F) at the
top of the hydraulic tank.

5. Cover air connector side (outlet side) with a


clean cloth or tape.
6. Clean up the inside of air cleaner body, and
remove the cover installed at step 5.
7. Install a new inner element to connector and
tighten nut.
8. Install the outer element.
b4. Check of hydraulic oil strainer

40-24 WA470-7
40 Troubleshooting
General information on troubleshooting

k Immediately after the engine is stopped, its


parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
have cooled down before starting the work.

k When you remove the oil filler cap, oil may


spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.

1. Lower bucket to the ground with its bottom level,


apply parking brake, and stop engine.
2. Loosen bolts and remove cover (1).

8. Remove bolts (4) (6 pieces) and remove cover


(5).
9. Hold the top of rod (6) and pull it up to remove
strainer (7).
10.Remove any dirt stuck to strainer (7), then wash
it in flushing oil. If strainer (7) is damaged,
replace it with a new one.

3. Remove the cap of oil filler port (F).

11.Refill with the specified quantity of hydraulic oil


through oil filler port (F), then install the cap.
b.5 Check of hydraulic oil filter
k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until all parts
4. Place a container under drain plug (2) to catch have cooled down before starting the work.
drained oil.
k When you remove the oil filler cap, oil may
6 Hydraulic oil: approximately. 173 l spurt out. Be careful to rotate it slowly, and
5. Remove drain plug (2). release inner pressure gradually.
6. Open drain valve (3) gradually to drain oil.
7. After draining the oil, close drain valve (3) and 1. Lower the bucket to the ground with its bottom
tighten drain plug (2). level, turn the parking brake switch to ON
Tightening torque position, and apply the parking brake.
Drain plug (2): 68.6 ± 9.8 Nm {7.0 ± 1.0 kgm} 2. Stop the engine and wait for the temperature of
Drain valve (3): 63.7 ± 14.7 Nm {6.5 ± 1.5 kgm} each part to drop.
3. Loosen bolt and remove cover (1).

WA470-7 40-25
40 Troubleshooting
General information on troubleshooting

Be sure to bleed air while running the engine at


low idle.

4. Remove mounting bolts (3) of filter cover (2) on


the top of the tank, then remove cover.
When doing this work, cover may jump out 12.Make sure that hydraulic oil is added to the
under the force of spring (4), so hold cover down specified level.
when removing bolts. 13.Next, increase the engine speed, and repeat air
5. Remove spring (4) and bypass valve (5), then bleed according to procedures of 10 above until
pull out element (6). no air comes out from plug (7).
6. Check inside of the tank for foreign material, 14.After completing air bleeding, tighten plug (7).
then remove foreign material if any.
7. Install new element (6), then set bypass valve 3 Tightening torque: 11.3 ± 1.5 Nm {1.15
(5), spring (4), and cover (2) to tank. ± 0.15 kgm}
When doing this, if O-ring of cover is damaged 15.Be sure that hydraulic oil is added to the
or deteriorated, replace it with a new one. specified level.
16.Check the filter cover mount for oil leakage.
17.Install cover (1).
b6. Check of transmission case oil level
k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until they have
cooled down before starting the work.

• Perform this operation when ooze of oil on the


transmission case is recognized or when oil in
the coolant is recognized.
1. Stop the engine.
• You cannot measure the exact oil level until
8. While pressing down cover, tighten mounting 12 hours elapses after the engine is stopped
bolts evenly. because of the oil remaining in various parts.
9. Make sure that hydraulic oil is added to the 2. Remove oil filler cap (F).
specified level. 3. Pull out dipstick (G) and wipe the oil off with a
10.Run the engine at low idle, and extend and cloth.
retract each of the steering, bucket, and boom 4. Fully insert dipstick (G) into the dipstick pipe,
cylinders 4 to 5 times, and be careful not to then remove it.
move them to the stroke end (stop • Whenever inserting the dipstick, be sure to
approximately 100 mm before the stroke end). insert it into the dipstick pipe in the filler pipe.
a If the engine is run at a high speed
immediately after startup or a cylinder is
moved up to its stroke end, air taken inside
the cylinder may cause damage to the piston
packing.
11.Next, move each of the steering, bucket, and
boom cylinders to the stroke end 3 or 4 times.
Stop the engine and loosen air bleeding plug (7)
to bleed air from the hydraulic tank, and then
tighten plug (7).

40-26 WA470-7
40 Troubleshooting
General information on troubleshooting

• When checking the oil level after leaving the


engine to running at idle.
(when the entire transmission is in heat balance
like immediately after the actual operation)
(1) Run the engine at low idle and wait at least
15 minutes.
(2) Check the level when the indication of the
torque converter oil temperature gauge is at the
mid of the lowest range.

5. The oil level should be between the H and L


marks on dipstick (G). If the oil level is below the
L mark, add oil through oil filler port (F).
The following levels are marked on the dipstick.
(A): ENG STOP (Engine is stopped)
(B): ENG LOW IDLE (Engine is running at low
idle)

• When check it after the temperature is increased


with the torque converter stall.
(1) Wait until the indication of the torque
converter oil temperature gauge moves in
between the lowest and the 2nd lowest by
increasing temperature with the torque converter
stall.
(2) Run the engine at low idle for approximately
5 minutes and check the oil level.

6. If the oil level is above the H line, drain the


excess oil from drain valve (P), then check the
oil level again.

b7 Check of axle case oil level (front and rear)


k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
burn injury. Accordingly, wait until they have
7. If the oil level is at the correct level, insert cooled down before starting the work.
dipstick (G) in the dipstick pipe and close the
cap. This check is required if ooze of oil is recognized on
Checking of the oil level must be done at "ENG the axle case.
STOP" position after 12 hours or more elapsed after Place the machine on a level ground before starting
the engine is stopped. The oil level check can be the check.
performed when the engine is running at low idle as (If the machine is at an angle, exact measurement
well. In this case, observe the following. of oil level is impossible.)

WA470-7 40-27
40 Troubleshooting
General information on troubleshooting

1. Stop the engine and remove plug (1). a Since lubricating oil of a different brand is
used for the axle with ASD (Anti-Slip
a Remove mud and dirt from around plug (1),
Differential), be sure to use the specified
then remove plug.
lubricating oil.
2. Wipe off oil on dipstick (G) attached to plug (1)
5. If the oil level is above the top groove (H), drain
by using a piece of cloth.
the excess oil from drain plug (P), then check
A: Front
the oil level again.
6. If the oil level is appropriate, install plug (1).
3 Tightening torque: 127 to 177 Nm {13
to 18 kgm}
b8. Bleeding air
• For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".
• For the bleeding air from the hydraulic system,
see Testing and adjusting, "Bleeding air from
each part".)
c. Electric equipment
c1. Check of battery terminal for looseness and
B: Rear
corrosion
• Check battery terminals for looseness and
corrosion.
• Check and remove any accumulated dirt and
combustibles (dead leaves, twigs, etc.) around
the batteries.
c2. Check of alternator terminal for looseness
and corrosion
• Remove the engine undercover.
• Check alternator terminals B, R and E for open
circuit, loosening and corrosion.
c3. Check of starting motor terminal for
looseness and corrosion
3. Set oil level gauge (G) as shown in the figure to
• Check starting motor terminals B, C and R for
the right.
open circuit, loosening and corrosion.
(2): Axle
c4. Check of battery voltage (with engine
(3): Spot-faced surface
stopped)
4. Oil level is appropriate if it is between two
grooves (H) and (L) of oil level gauge. • Check the battery voltage by using the battery
If the oil does not reach the lower groove (L), tester while the engine is stopped.
supply axle oil from oil filler port (F). c5. Check of battery electrolyte level
• Check before operating the machine.
k Do not use the battery if the battery
electrolyte level is below the LOWER LEVEL
line. This will accelerate deterioration of the
inside of the battery and reduce the service
life of the battery. In addition, it may cause an
explosion.

k Since the battery produces combustible gas


that can explode, do not bring any open
flame near it.

k Battery electrolyte is dangerous. Take care


that it does not come in contact with your
eyes or skin. If it does, wash it away with
water and contact your doctor.

40-28 WA470-7
40 Troubleshooting
General information on troubleshooting

a Do not add the battery fluid above the UPPER • (B) Low: Since the electrolyte level does not
LEVEL line. If done, the fluid may leak and the reach the sleeve bottom, the shape of the
coating surface may be damaged or the parts electrode plates will appear straight.
may be corroded. 3. After adding the refined water, tighten the cap.
a To avoid freezing, add the purified water (such
as a commercial battery fluid) before starting the
work in the next day.
• When checking the electrolyte level through the
side face of the battery
1. Wipe and clean the battery surface, especially
around the battery level lines with a wet cloth,
and check to see that the battery fluid is
between the UPPER LEVEL and LOWER
LEVEL lines.
a Do not clean the battery with a dry cloth
since static electricity may cause an
explosion.
a If the fluid exceeds the UPPER LEVEL,
remove the fluid using a dropping pipette or
others until the fluid drops to the UPPER
LEVEL. When you have removed the fluid
from the battery, neutralize it with the baking
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
2. If the battery fluid drops below the center a If discolored or burnt, the circuit may be shorted
position between the UPPER LEVEL and or grounded.
LOWER LEVEL lines, remove the cap and add • Check the wiring harnesses and cables for
the fluid (such as a commercial battery fluid) damage and peeling of the covers.
immediately until the fluid reaches the UPPER • If any abnormality is found, repair or replace the
LEVEL. wiring harness or cables.
a After adding the refined water, tighten the c7. Check for coming off of wiring harness
cap securely. clamp and sagging of wiring harness
a If the fluid exceeds the UPPER LEVEL, • Check wiring harness for sagging and looseness
remove the fluid using a dropping pipette or due to coming off of harness clamp
others until the fluid drops to the UPPER a In particular, carefully check the wiring harness
LEVEL. When you have removed the fluid around the hot and movable parts.
from the battery, neutralize it with the baking • If removed from the clamp, secure it with the
soda (sodium bicarbonate) and wash it away clamp.
with a large quantity of water.
• When electrolyte level cannot be checked
through the side face of the battery
1. Remove the cap from the top of battery.
2. Observe fluid level port (3), and check the fluid
level. If the fluid level is below sleeve (4), always
add the fluid (such as a commercial battery fluid)
until it reaches the bottom of sleeve (4) (the
UPPER LEVEL).
• (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.

WA470-7 40-29
40 Troubleshooting
General information on troubleshooting

c8. Check of grounding


a Take special care not to cause a loose cable
connection and corrosion.
• Check connection of ground terminal (F40) in
the left side of front frame.

• Remove cover (1) under the left of the operator's


cab.

• Check connection of ground cables (E14A),


(E14B) and (E14C) of engine controller.
a The engine ground terminal locates under the
hydraulic oil tank.
• Check the connection of engine ground
terminals (3) and (4).

• Check the connection of ground terminal (L100).


• Check the connection of cab ground (2).

• Open the both right and left engine side covers.


• Check the connection of ground terminals (R50)
and (R22).

40-30 WA470-7
40 Troubleshooting
General information on troubleshooting

• Open the engine left side cover.


• Check the connectors for unlocking, and check
• Check connection of ground terminal (E15).
the lock and connector housing for cracking.
• Remove cover (1) and fuel feed pump switch (2).

a Transmission ground terminal is located on the


left side of transmission. • Check lock screws (4) to (6) of engine controller
• Check the connection of transmission ground (3) for looseness.
(TGN). a Use a hexagonal wrench with 4 mm width
across flats.

c9. Check for loose connector and damaged


lock. • Check lock screws (8) to (10) of transmission
• Check the connection of male and female controller (7) for looseness.
connectors by pulling them by hand. a Use a hexagonal wrench with 4 mm width
• If the connection is loose, secure it. across flats.
• Check the lock screws of work equipment
controller (11) in the similar way.

WA470-7 40-31
40 Troubleshooting
General information on troubleshooting

c10. Check the connector pins for corrosion, • Wipe and remove any foreign material with a
bending and deformation. cloth or others, and blow the air to clean the
connector.
• Disconnect the connectors, and check their pins
for corrosion, bending, sinking than other pins,
and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
• Disconnect connectors, and check them for
insertion of water or foreign materials.
c12. Check of wiring harness for open or short
circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.

a If found, the seals may be damaged. Check the


seals for damage.
• If the seal is defective, repair or replace it.
• Dry the inside of the connector with a dryer.

• Visually check wiring harnesses for peeling of


harness covers and the pins for contact with
adjacent pins due to defective crimping.
c13. Check of slow-blow fuse for blowout and
corrosion
a When replacing a fuse, be sure to turn off the
power (turn the starting switch to OFF position)
and turn the battery disconnect switch to OFF
position.

40-32 WA470-7
40 Troubleshooting
General information on troubleshooting

• A fusible link is a large-capacity fuse. 3. Start and warm up the engine and measure the
• If a fuse is corroded and coated with white voltage while running the engine at a medium or
powder, or there is any play between the fuse a higher speed.
and fuse holder, replace the fuse. • If the voltage is abnormal, repair or replace
• Replace each fuse with the one of the same the alternator.
capacity.
Open the engine left side cover and remove cover
(1).

c 15. Check of battery relay operation sound


(when starting switch is turned to ON or OFF
position)
There are slow-blow fuses (2) to (4): 50 A, and (5): 1. Open the engine left side cover.
120 A. 2. Turn the starting switch to the ON and OFF
positions, and check whether the battery relay
operation sound is heard or not.
• If the operation sound is not heard, check the
related circuits, referring to troubleshooting
for E-1 described in the E mode
troubleshooting.
• If the relating circuit is normal, replace the
battery relay.

Remove the cover from the rear of operator cab,


and you can access to fuse box 1 and fuse box 2.

c14. Check of alternator voltage (when engine


speed is medium or higher)
1. Open upper right of the engine side cover.
2. Connect the positive (+) lead of the multimeter to
alternator terminal (B) and connect the negative
(-) lead to the chassis ground.

WA470-7 40-33
40 Troubleshooting
General information on troubleshooting

Preparation work for troubleshooting of electrical system (WA380-C050-42C-K-01-A)

a When carrying out troubleshooting of an electric 5) Disconnect connectors M01B (7), L18A (8),
circuit related to the transmission controller, and L18B (9).
monitor controller, engine controller, work 6) Remove cover (10).
equipment controller , or KOMTRAX
communication MODEM, expose the related
connectors according to the following procedure.
a Disconnect and connect the connectors, which
have a special locking device, according to the
following procedure.
Preparation (WA470-C050-42C-K-00-A)

1. Work equipment controller


1) Fold operator's seat (1) forward.
2) Remove box mounting bolts (2) (4 pieces)
and remove the box.
7) Disconnect connectors L71 (12), L72 (13),
and L73 (14) of work equipment controller
(11), and insert or connect T-adapters for
troubleshooting.

3) Remove top cover mounting bolts (3) (4


pieces), and remove top cover (4). [*1]

a Install top cover (4) so that the whole


circumference of clearance (a) becomes
Min. 2 mm.

4) Remove bolts (5) and (6) (2 pieces each).

2. Engine controller
1) Open the right engine side cover.
a The engine controller is mounted on the
engine (front of the machine).
2) Remove cover (1) and fuel feed pump switch
(2).

40-34 WA470-7
40 Troubleshooting
General information on troubleshooting

3) Insert or connect T-adapters for 4) Remove bolts (5) and (6) (2 pieces each).
troubleshooting to connectors J1 (3), J2 (4),
and EC3 (5) of engine controller.
a Since the connectors is secured with
screws, loosen them before
disconnecting the connector.
a When restore them, tighten the screws to
the specified torque.
3 Screw:
3 ± 1 Nm {0.3 ± 0.1 kgm}

5) Disconnect connectors M01B (7), L18A (8),


and L18B (9).
6) Remove cover (10).

3. Transmission controller
1) Fold operator's seat (1) forward.
2) Remove box mounting bolts (2) (4 pieces)
and remove the box.

7) Disconnect connectors L61 (12), L62 (13),


and L63 (14) of transmission controller (11),
and insert or connect T-adapters for
troubleshooting.

3) Remove top cover mounting bolts (3) (4


pieces), and remove top cover (4). [*1]

WA470-7 40-35
40 Troubleshooting
General information on troubleshooting

5) Disconnect connectors M01B (7), L18A (8),


and L18B (9).
6) Remove cover (10).

4. Monitor controller
1) Fold operator's seat (1) forward.
2) Remove box mounting bolts (2) (4 pieces)
and remove the box. 7) Unlock connectors (11) and (12).
a Shift lever (c) inward while pressing tab
(b). (as shown in the right of the following
figure)

3) Remove top cover mounting bolts (3) (4


pieces) and remove top cover (4). [*1]

8) Disconnect connectors MCM2 (11), MCM1B


(12), and MCM1A (13) of monitor controller
(14), and insert or connect T-adapters for
troubleshooting.

4) Remove bolts (5) and (6) (2 pieces each).

a Install top cover (4) so that the whole


circumference of clearance (a) becomes
Min. 2 mm.

40-36 WA470-7
40 Troubleshooting
General information on troubleshooting

5. KOMTRAX communication module 6. Ambient pressure sensor (PAMB)


1) Fold operator's seat (1) forward. Engine Ne speed sensor (NE)
2) Remove box mounting bolts (2) (6 pieces) Crankcase pressure sensor (PCCV)
and remove cover (3). Engine oil pressure sensor (POIL)
Charge (Boost) pressure sensor (PIM)
Fuel dosing pressure sensor (PDOSER)
Mass air flow and temperature sensor (R93)
Shut off valve solenoid #1 (SOV1)
Shut off valve solenoid #2 (SOV2)
Fuel dosing solenoid (DOSER)
KDPF differential pressure and outlet pressure
sensor (E25)
a Disconnection and connection of connectors
Since the connectors of ambient pressure
sensor and engine Ne speed sensor have a
special lock mechanism, disconnect them in
the order of (a) to (c), and connect them in
3) Remove bolts (4) (5 pieces) and remove
the order of (d) to (f) as shown in the
cover (5).
following figure.
Disconnection: (a) Slide the lever, (b) unlock,
and (c) disconnect the connectors.
Connection: (d) Connect the connectors, (e)
engage the lock, and (f) slide the lever.

4) Disconnect connectors L80A (7), L80B (8) of


KOMTRAX communication module (6), and
insert or connect T-adapters for
troubleshooting.

7. Bkup (camshaft) speed sensor (G)


Supply pump PCV1 (PCV1)
Supply pump PCV2 (PCV2)

WA470-7 40-37
40 Troubleshooting
General information on troubleshooting

a Disconnection and connection of connectors a Precautions for disconnection of connectors


Since the connectors of Bkup speed sensor The direction of the lock for connector may
and supply pump PCV have a special lock be changed toward the difficult direction
mechanism, disconnect them in the order of (facing to the bottom or to the engine side)
(a) to (b), and connect them in the order of for unlocking depending on the position
(c) to (d) as shown in the following figure. where the sensor is screwed in.
Disconnection: (a) Unlock and (b) disconnect In such a case, turn the lock to the direction
the connectors. (a) by using the needle nose pliers with
Connection: (c) Connect the connectors and curved tip (commercially available) [1], then
(d) engage the lock. the lock can be canceled easily.
Since the lock is canceled with "click" sound,
listen the sound and disconnect the
connectors.

8. Common rail pressure sensor (FUEL RAIL


PRESS)
a Disconnection and connection of connectors
Since the connectors of common rail a Precautions for connecting connectors
pressure sensor have a special lock When connecting connectors, pay attention
mechanism, disconnect them in the order of not to connect the connectors reverse.
(a) to (b), and connect them in the order of Engage lock portion (e) on the harness side
(c) to (d) as shown in the following figure. to triangle notch portion (f). (Pay attention not
Disconnection: (a) Unlock and (b) disconnect to take square guide portion (g) on the
the connectors. opposite side of triangle notch portion (f) by
mistake.)
Connection: (c) Connect the connectors and
(d) engage the lock.

9. Engine coolant temperature sensor (TWTR)


Charge (Boost) temperature sensor (TIM)

40-38 WA470-7
40 Troubleshooting
General information on troubleshooting

a Disconnection and connection of connectors


Since the connectors of engine coolant
temperature sensor have a special lock
mechanism, disconnect them in the order of
(a) to (b), and connect them in the order of
(c) to (d) as shown in the following figure.
Disconnection: (a) Unlock and (b) disconnect
the connectors.
Connection: (c) Connect the connectors and
(d) engage the lock.

a Removal and installation of sensor body


Since a deep socket is necessary when
removing and installing the engine coolant
temperature sensor, see "Tools for testing,
adjusting, and troubleshooting".

WA470-7 40-39
40 Troubleshooting
General information on troubleshooting

Classification and procedures for troubleshooting (HM300-5160-40D-A-00-A)


Classification of troubleshooting codes
Mode Content
Display of code Troubleshooting by failure code
E mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical systems
S-mode Troubleshooting of engine

Procedure for troubleshooting


If a phenomenon which appears a source of a trouble occurs on the machine, go to the corresponding
troubleshooting section according to the following procedure.
1. Procedure for troubleshooting when user code and failure code are displayed on machine monitor:
If a user code and a failure code are displayed on the standard screen of the machine monitor, perform the
troubleshooting for the corresponding "Display of code" according to the displayed failure code.
a If multiple failures occur simultaneously, all failure codes are displayed repeatedly in order. Record all
failure codes on a paper.
2. Procedure for troubleshooting when user code and failure code are not displayed on machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1].)
1) If a failure code is displayed, perform troubleshooting for the corresponding "Display of code"
according to the failure code.
a If an electrical system failure code is displayed delete all the codes once and reproduce them, and
then see if the failure is still detected. (See [*2].)
a A failure code of the mechanical system cannot be deleted.
2) If no failure code is found in the abnormality record, a failure that the machine cannot find out by itself
may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon which is assumed to show the failure again and select the same
phenomenon from the table of "Phenomenon to be assumed a failure and troubleshooting number",
and then perform troubleshooting corresponding to that phenomenon in the "E-mode", "H-mode", or
"S-mode".
3. Action to take after failure is eliminated
Clear all the failure codes in the electrical system abnormality record, referring to the next page.
[*1], [*2]
1. On the normal operation screen, hold down inverted triangle key [▽] (6), and press numeric keys [1], [2]
and [3] in this order.
• (4) is the Enter switch (check mark).
• (5) is the Return switch.
• (7) is the Menu switch (to clear all).

2. Press the inverted triangle key [▽] twice on the Service Menu screen to select "03 Abnormality Record".
3. Press the Enter key (check mark) to validate it, and go to the "Abnormality Record" screen.

40-40 WA470-7
40 Troubleshooting
General information on troubleshooting

4. Press the Enter key (check mark) on the "Abnormality Record" screen, and go to the "Mechanical
Systems" screen.

5. Press the inverted triangle key [▽] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.
a A failure code of the mechanical system cannot be deleted.
6. Return to the "Abnormality Record" screen by pressing the Return key (explained above).
7. Go to the "Electrical system abnormality record" similarly to steps 2 and 3.

8. Press the inverted triangle key [▽] and make sure that the following failure codes are not generated.
Record all failure codes on a paper.

WA470-7 40-41
40 Troubleshooting
General information on troubleshooting

a If "E" is displayed at the left to the failure code, this code is "active" (that is, this failure still continues or
its recovery is not verified yet). If "E" is not displayed, the failure code is "inactive" and the code will be
cleared in the subsequent clearing step. Be sure to record this failure code on a paper.

9. Hold down the inverted triangle key [▽], and press numeric keys [1], [2] and [3] in this order to go to the
"Clear mode". (Same as 1)
10.Press the Menu switch of the switch panel (as explained above).

11.Press the Enter key (check mark) to clear all failure codes.
12.Return to the "Electrical Systems" screen by pressing the Return key (explained above). Check if a failure
code is still displayed or not, and record it on a paper.
13.Return to the "Abnormality Record" screen by pressing the Return key (explained above).

40-42 WA470-7
40 Troubleshooting
General information on troubleshooting

Symptom and troubleshooting numbers (WA470-5540-441-A-00-A)

Troubleshooting
No. Symptom of failure
Index
Action level and failure code
Action level is displayed on machine monitor. Press Enter switch (check
1 mark) to display "Occurred error list". Perform
Failure code is displayed on mechanical system abnormality record. troubleshooting for
2
failure code.
3 Failure code is displayed on electrical system abnormality record.
Symptom related to engine
4 Engine does not start E-1, S-1
5 Engine does not crank when starting switch is turned to "START" position. E-1, S-1
6 Engine cranks but no exhaust smoke comes out. S-2
7 Fuel is being injected but engine does not start. S-3
8 Engine startability is poor. S-4
9 Engine does not pick up smoothly. S-5
10 Engine stops during operation. S-6
11 Engine runs rough or is unstable. S-7
12 Engine lacks power. S-8
13 KDPF gets clogged in a short time S-9
14 Engine oil consumption is excessive. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive. S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down). S-13
18 Engine oil pressure drops. S-14
19 Fuel mixes into engine oil. S-15
20 Water mixes into engine oil (milky). S-16
21 Coolant temperature rises too high (overheating). S-17
22 Unusual noise is heard. S-18
23 Vibration is excessive. S-19
24 Air cannot be bled from fuel circuit. S-20
25 Active regeneration of KDPF is performed frequently. S-21
26 Active regeneration takes time. S-22
27 White smoke is exhausted during active regeneration. S-23
28 Manual preheating system does not work. E-2
29 Automatic preheating system does not work. E-3
30 While preheating is working, preheating monitor does not light up. E-4
When operating engine power mode selector switch, engine mode selector
31 function does not operate properly. E-38
32 Fuel feed pump does not operate properly. E-57
Symptom related to travel
33 Machine does not move off. H-1
34 Torque converter lockup clutch is not disengaged (engine stalls). H-2
35 Torque converter lockup clutch is not engaged. H-3
Travel speed is slow, bucket thrust force is weak, gradability is low, or gear
36 speed does not shift. H-4
37 Large shocks are made when machine starts or gear is shifted. H-5
38 Machine starts or gear speed shifts with long time lag. H-6
39 Torque converter oil temperature is high. H-7
Steering component
40 Machine does not turn. H-8
41 Turning response is poor. H-9
42 Steering wheel is heavy to turn. H-10
43 Machine sways or large shocks are made while machine turns. H-11
44 Turning radius differs between right and left turns. H-12

WA470-7 40-43
40 Troubleshooting
General information on troubleshooting

Troubleshooting
No. Symptom of failure
Index
Brake component
45 Wheel brakes do not work or they are weak. H-13
46 Wheel brakes are not released or drag. H-14
47 Parking brake does not work or it is weak. H-15
Parking brake is not released or it drags (including emergency release
48 system) H-16
Symptom related to work equipment
49 Boom does not rise. H-17
50 Boom moves slow or boom lacks lifting force. H-18
51 Rising boom slows down at certain height. H-19
52 Lift cylinders do not serve to hold bucket on ground H-20
53 Hydraulic drift of boom is large. H-21
54 Boom moves up and down during operation. H-22
55 Bucket does not tilt back. H-23
56 Bucket moves slow or bucket lacks tilt back force. H-24
57 Bucket decelerates during tilt-back operation. H-25
58 Bucket cylinder does not hold bucket on ground. H-26
59 Hydraulic drift of bucket is large. H-27
Bucket tilts back and forth during carrying load (work equipment valve in
60 HOLD). H-28
61 Boom and bucket control levers do not move smoothly and heavy to move. H-29
Operating work equipment causes engine speed to lower significantly or
62 engine to stall. H-30
63 Large shocks are made when work equipment starts and stops working. H-31
When single work equipment is relieved hydraulically, other work equipment
64 H-32
moves.
65 E.C.S.S. (travel damper) does not work and machine pitches and bounces. H-33
Bucket does not stop at the position which is set with remote bucket
66 positioner H-34
Symptom related to fan
67 Fan speed is abnormal (too high or low, or fan does not rotate) H-35
68 Unusual noise is heard from around fan. H-36
Symptom related to machine monitor
All of LCD unit, LED unit, and meter unit on machine monitor displays
69 nothing. E-5
70 LCD unit on machine monitor displays nothing. E-6
Backlight of LCD unit on machine monitor is abnormal (backlight goes out or
71 flickers). E-7
72 LCD on machine monitor does not display properly. E-8
73 Meter unit display on machine monitor is abnormal E-9
74 Night lighting lamp of meter unit on machine monitor is abnormal. E-10
75 Caution LED on machine monitor is abnormal E-11
LED of switch panel on machine monitor is abnormal or switches does not
76 operate properly. E-12
77 2 switches operation of switch panel on machine monitor does not function. E-13
78 Switch panel buzzer of machine monitor is abnormal. E-14
79 Rearview monitor does not light up or backlight flickers. E-15
80 Rearview monitor images are not displayed clearly. E-16
81 Rearview monitor brightness cannot be adjusted. E-17
82 Night lighting lamp of rearview monitor is abnormal. E-18
Some items of gauges and caution lamps on machine monitor are not
83 displayed properly. E-19

40-44 WA470-7
40 Troubleshooting
General information on troubleshooting

Troubleshooting
No. Symptom of failure
Index
Parking brake indicator lamp does not light when the parking brake is set to
84 ON (Parking) position (stays in NEUTRAL). E-20
When brake accumulator oil pressure drops, the brake oil pressure caution
85 lamp does not light. E-21
86 Air cleaner clogging indicator lamp does not light. E-22
87 Radiator coolant level caution lamp does not light. E-23
Indication of hydraulic oil temperature gauge does not increase, or hydraulic
88 oil temperature caution lamp does not light. E-24
Indication of torque converter oil temperature gauge does not increase, or
89 torque converter oil temperature caution lamp does not light. E-25
90 Fuel level gauge does not indicate correct level. E-26
91 Seat belt caution lamp indication is abnormal. E-27
92 Alarm buzzer does not sound. E-30
93 When starting switch is in ON position, alarm buzzer does not stop sounding. E-31
"Procedure for testing
Air conditioner does not operate normally (including failure codes related to
94 and troubleshooting" in
air conditioner).
Chapter 80
Others
95 Horn does not sound. E-28
96 Horn does not stop sounding. E-29
97 Kickdown does not work when kickdown switch is turned ON. E-32
98 The hold switch does not work when it is pressed. E-33
Parking brake does not work even if it is applied, or the brake drags when
99 traveling in forward or reverse while parking brake is released. E-34
100 Transmission cut-off mode is not selected or not released. E-35
101 Transmission cut-off position cannot be released. E-36
102 Direction selector (FNR) switch mode is not selected or not released. E-37
103 Flow of loader pump does not increase from the minimum rate. E-39
104 ECSS function cannot be selected or cannot be released. E-40
105 None of headlamp, clearance lamp, and tail lamp lights. E-41
106 Clearance lamp and tail lamp does not light up. E-42
107 Both "High and Low beams" of headlamp do not light up or go out. E-43
108 The headlamp "Low beam" does not light up or go out. E-44
109 The headlamp "High beam" does not light up or go out. E-45
110 Front working lamp does not light up or go out. E-46
111 Rear working lamp does not light up or go out. E-47
112 All of turn signal lamps and hazard lamps do not light up or go out. E-48
113 Turn signal lamps do not light up or go out. E-49
114 Hazard lamp does not light up or go out. E-50
115 Brake lamp does not light up or stays lighted. E-51
116 Backup lamp does not light or continues to light. E-52
117 Backup buzzer does not sound or continues to sound. E-53
118 Front wiper does not operate. E-54
119 Rear wiper does not operate. E-55
120 Window washer does not operate. E-56
121 KOMTRAX system does not operate normally. E-58

WA470-7 40-45
40 Troubleshooting
General information on troubleshooting

Information in troubleshooting table (ALL-5170-421-A-01-A)

(Rev. 2011/12)

a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
5 Hot short circuit head bolt or bolt hole which has no rust, etc.
• Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness
6 • Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power circuit comes into
contact with the power circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)

40-46 WA470-7
40 Troubleshooting
General information on troubleshooting

No. Cause Procedure, measuring location, criteria and remarks


<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
7 Defective controller • When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
female connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.

Related circuit diagram


This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The “/“ in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.

WA470-7 40-47
40 Troubleshooting
General information on troubleshooting

Connector list and layout (WA470-C050-055-K-00-A)

Number
Connector No. Connector type of pins
Equipment name Address
1.PS DT 2 1st solenoid AE-9
1.SW DT 2 1st fill switch AE-8
2.PS DT 2 2nd solenoid AJ-4
2.SW DT 2 2nd fill switch AJ-4
3.PS DT 2 3rd solenoid AJ-4
3.SW DT 2 3rd fill switch AJ-3
4.PS DT 2 4th solenoid AE-8
4.SW DT 2 4th fill switch AE-8
AL1 DT 8 Air conditioner unit O-3
AR1 DT 6 Intermediate connector H-2
BREAKOUT
(E24) FRAMATOME 24 Intermediate connector AO-6
B-RES DT 3 Terminating resistor (120 z) AL-3
C01 PA 9 Radio Z-9
C02 M 2 Speaker (R.H.) AC-9
C03 M 2 Speaker (L.H.) AD-8
C04 DT 2 Front working lamp (R.H.) Y-8
C05 DT 2 Front working lamp (L.H.) AD-5
C07 KES 1 2 Room lamp AD-7
C08 M 1 Door switch (R.H.) Y-8
C09 M 1 Door switch (L.H.) AD-6
C10 2 Cigarette lighter O-2
C12 M 6 Front wiper motor M-3
C15 M 4 Rear wiper motor AD-5
C18 DT 2 Warning lamp AA-9
C18A M 1 Revolving warning lamp AB-9
C22 DT 3 Revolving warning lamp AA-9
C25 DT 4 Intermediate connector Y-8
C29 M 1 Rear glass heater Y-6
C33 1 Rear glass heater AD-7
C35 1 Rear glass heater AB-9
C39 Terminal 1 Ground (radio body) Z-8
C40 Terminal 1 Ground AC-8
C91 M 1 Intermediate connector (warning lamp) Y-6
C140 DT 4 Intermediate connector W-9
C141 DT 6 Intermediate connector W-9
CL1 SWP 8 Intermediate connector Y-4
CL2 SWP 12 Intermediate connector Y-5
CL21 SWP 6 Intermediate connector V-9
CL24 X 2 Intermediate connector Q-7
CL27 SWP 6 Side wiper Y-4
CN1 DT 2 Injector #1 AK-8
CN2 DT 2 Injector #2 AK-8
CN3 DT 2 Injector #3 AK-9
CN4 DT 2 Injector #4 AL-9
CN5 DT 2 Injector #5 AM-9
CN6 DT 2 Injector #6 AN-9
COMBI DT 3 Front right combination lamp C-6
COMBI DT 3 Front left combination lamp F-1
D04 YAZAKI 2 Diode X-4

40-48 WA470-7
40 Troubleshooting
General information on troubleshooting

Number
Connector No. Connector type of pins
Equipment name Address
D05 YAZAKI 2 Diode W-4
D06 YAZAKI 2 Diode W-6
D07 YAZAKI 2 Diode W-4
D08 YAZAKI 2 Diode W-4
D09 YAZAKI 2 Diode W-4
D11 YAZAKI 2 Diode W-6
D12 YAZAKI 2 Diode W-6
DIODE DT 2 Diode AH-1
DOSER FRAMATOME 2 HC dosing solenoid AM-4
E01 DT 2 Intermediate connector I-2
E02 Terminal 1 Alternator terminal E L-6
E04 Terminal 1 Alternator terminal R L-5
E05 Terminal 1 Heater relay K-1
E06 Terminal 1 Heater relay L-3
E06A DT 2 Diode K-4
E07A Terminal 1 Heater relay L-2
E07B Terminal 1 Electrical intake air heater (ribbon heater) I-9
E10 DT 2 Freon compressor magnet clutch I-9
E14A Terminal 1 Ground AL-1
E14B Terminal 1 Ground AL-2
E14C Terminal 1 Ground AN-6
E15 Terminal 1 Ground J-3
E25 FRAMATOME 4 KDPF pressure sensor AO-6
E26 DT 4 KDPF temperature sensor AN-6
E27 DT 2 Engine oil level sensor L-3
E28 DT 12 Pump timer switch AO-6
E29 DT 2 Fuel feed pump AM-1
E33 DT 6 Intermediate connector I-1
E45 DT 2 Dust indicator H-9
EC3 DRC 60 Engine controller AN-6
EGR-SOL DT 2 EGR valve solenoid AL-5
ER1 DT 12 Intermediate connector I-3
ER2 DT 12 Intermediate connector I-3
ER3 DT 2 Intermediate connector I-2
ER4 DT 6 Intermediate connector L-2
F.PS DT 2 F solenoid AE-9
F.SW DT 2 F fill switch AE-9
F01 DT 6 Intermediate connector C-7
F02 DT 6 Intermediate connector E-8
F03 2 Horn A-2
F04 2 Horn B-4
F10 DT 3 Ladder pump pressure sensor C-1
F11 DT 3 Boom potentiometer sensor C-7
F12 DT 3 Boom bottom pressure sensor D-1
F13 DT 3 Boom head pressure sensor E-1
F20 DT 2 E.C.S.S. solenoid A-3
F21 DT 2 Bucket TILT EPC A-3
F22 DT 2 Bucket DUMP EPC A-1
F23 DT 2 Boom RAISE EPC A-3
F24 DT 2 Boom LOWER EPC A-1
F25 DT 2 3rd ATT EXT EPC A-2
F26 DT 2 3rd ATT RET EPC B-4

WA470-7 40-49
40 Troubleshooting
General information on troubleshooting

Number
Connector No. Connector type of pins
Equipment name Address
F29 DT 2 Diode A-4
F30 DT 3 Intermediate connector D-8
F31 DT 2 Boom EPC cut-off solenoid A-4
F32 DT 3 Bucket angle signal B-1
F40 Terminal 1 Ground (front frame) F-1
FR1 DT 12 Intermediate connector E-1
FR2 DT 8 Intermediate connector E-1
FR3 DT 12 Intermediate connector E-1
FR4 DT 6 Intermediate connector F-1
FS6 X 1 Intermediate connector W-2
FS7 X 1 Intermediate connector W-2
FS8 Terminal 15 Fuse box X-7
FS9 Terminal 15 Fuse box X-8
G SUMITOMO 3 G sensor AM-5
G04 DT 2 Rear working lamp (L.H.) L-7
G05 DT 2 Rear working lamp (R.H.) J-9
G06 DT 4 Rearview camera K-9
GR1 DT 12 Intermediate connector L-6
G-RES DT 2 Fuel supply pump pull-up resistor AL-2
HEAD DT 3 Right headlamp C-5
HEAD DT 3 Left headlamp F-1
INJ DTA 12 Intermediate connector AN-9
J01 20 Junction connector X-2
J02 20 Junction connector T-2
J03 20 Junction connector X-2
J04 20 Junction connector X-2
J05 20 Junction connector X-2
J06 20 Junction connector T-2
J07 20 Junction connector T-2
J08 20 Junction connector T-2
J09 20 Junction connector V-5
J1(EC1) DRC 60 Engine controller AO-6
J1939 3 CAN_C AN-9
J10 20 Junction connector X-2
J11 20 Junction connector X-2
J12 20 Junction connector T-2
J13 20 Junction connector T-2
J14 20 Junction connector T-2
J15 20 Junction connector T-2
J16 20 Junction connector O-4
J17 20 Junction connector O-4
J18 20 Junction connector R-2
J19 20 Junction connector O-4
J2(EC2) DRC 60 Engine controller AN-6
J20 20 Junction connector X-2
J21 20 Junction connector X-2
J22 20 Junction connector V-5
J41 20 Junction connector V-4
J42 20 Junction connector V-4
J43 20 Junction connector V-4
J44 20 Junction connector V-4
JC01 8 Junction connector AO-7

40-50 WA470-7
40 Troubleshooting
General information on troubleshooting

Number
Connector No. Connector type of pins
Equipment name Address
JC02 8 Junction connector AO-7
JL1 DT 8 Intermediate connector U-8
JL2 12 Joystick lever switch U-8
JL3 Relay 6 Joystick safety relay V-7
JT1 DT 8 Junction connector AG-1
JT2 DT 6 Junction connector AI-2
L02 DT 12 Gear speed switch O-2
L04 SWP 12 Lighting switch O-1
L05 DT 2 Horn switch N-1
L09 DT 2 Brake lamp switch T-2
L11 2 Air suspension seat S-2
L14 DT 4 Boom lever M-8
L15 DT 4 Bucket lever M-8
L17 DT 6 DC/DC converter U-8
L18A YAZAKI 2 12 V socket R-8
L18B YAZAKI 2 12 V socket Q-8
L19 M 4 Flasher unit U-2
L20 M 2 Alarm buzzer X-8
L21 S 10 Wiper switch O-1
L23 DT 4 4th EPC lever O-7
L28A DT 4 Boom EPC lever N-6
L28B 2 Boom EPC lever M-8
L29A DT 4 Bucket EPC lever O-7
L29B 2 Bucket EPC lever M-8
L30 DT 4 3rd EPC lever O-7
L31 KES 1 6 Wiper timer V-4
L32 DT 12 Intermediate connector P-8
L33 DT 12 Intermediate connector O-7
L34 DT 12 Intermediate connector P-7
L35 DT 12 Intermediate connector P-7
L36A DT 4 Intermediate connector V-2
L40 DT 3 Intermediate connector M-1
L41 VCH 10 Multi-coupler switch M-1
Intermediate connector (load meter printer wiring
L44 M 6 harness) R-8
L50 Terminal 1 Ground O-5
L51 Terminal 1 Ground O-6
L52 Terminal 1 Ground V-3
L61 DRC 24 Transmission and fan pump controller S-9
L62 DRC 40 Transmission and fan pump controller S-9
L63 DRC 40 Transmission and fan pump controller S-9
L71 DRC 24 Work equipment controller S-9
L72 DRC 40 Work equipment controller T-9
L73 DRC 40 Work equipment controller T-9
L80A 070 18 KOMTRAX terminal V-6
L80B 070 12 KOMTRAX terminal V-5
L100 Terminal 1 Ground (floor) V-3
L111 Relay 5 Relay No. 13 (turn signal lamp and hazard lamp 1) X-8
L112 Relay 5 Relay No. 12 (fan pump) V-6
L113 Relay 5 Relay No. 11 (personal lock) V-7
L114 Relay 5 Relay No. 5 (beacon lamp) X-7
L115 Relay 5 Relay No. 5 (yellow working lamp) V-7

WA470-7 40-51
40 Troubleshooting
General information on troubleshooting

Number
Connector No. Connector type of pins
Equipment name Address
L116 Relay 5 Relay No. 21 (neutral safety) X-9
L117 Relay 5 Relay No. 20 (backup lamp) W-9
L118 Relay 5 Relay No. 19 (stop lamp) W-9
L119 Relay 5 Relay No. 18 (horn) W-9
L120 Relay 5 Relay No. 17 (parking brake) V-9
L121 Relay 5 Relay No. 14 (neutral hold) V-8
L122 Relay 6 Relay No. 3 (turn signal lamp and hazard lamp 2) V-7
L125 Relay 5 Relay No. 6 (preheat) V-8
L126 Relay 5 Relay No. 6 (emergency steering) V-9
L127 Relay 5 Relay No. 15 (front working lamp) V-9
L128 Relay 5 Relay No. 9 (rear working lamp) V-8
L129 Relay 5 Relay No. 4 (rear heated wire glass) X-6
L131 Relay 5 Relay No. 7 (headlamp) V-8
L132 DT 6 Intermediate connector U-2
L133 Relay 5 Relay No. 8 (automatic idle stop parking brake) V-8
L180 DT 2 Intermediate connector S-2
L/C.PS DT 2 Torque converter lockup solenoid AE-9
LDR_L DT 3 Left LED tail and step lamp L-7
LDR_R DT 3 Right LED tail and step lamp K-9
LDW_L DT 2 Left LED backup lamp L-6
LDW_R DT 2 Right LED backup lamp K-9
LDY_L DT 2 Left turn signal lamp L-6
LDY_R DT 2 Right turn signal lamp K-9
LR1 DRC 70 Intermediate connector C-9
LR2 DT 12 Intermediate connector A-8
LR3 DT 12 Intermediate connector C-9
LR4 DT 12 Intermediate connector C-9
LR5 X 1 Intermediate connector U-2
LR6 #8 1 Intermediate connector A-8
LR7 #8 1 Intermediate connector B-9
LR8 #8 1 Intermediate connector B-9
LR9 #8 1 Intermediate connector B-9
LR11 DT-P 2 Intermediate connector C-8
LR12 #8 1 Intermediate connector A-8
LT1 24-31 31 Intermediate connector U-2
M01A M 3 AUX jack Z-9
M01B M 3 AUX jack Y-5
MCM1_A AMP 80 Monitor controller Q-8
MCM1_B AMP 40 Monitor controller Q-8
MCM2 8 Monitor controller R-8
MDM1 8 Machine monitor N-3
MDM2 AMP 6 Machine monitor N-3
MDM3 AMP 8 Machine monitor N-3
MOM1 AMP 6 Switch panel O-2
NE FRAMATOME 3 Ne speed sensor AM-1
PAMB FRAMATOME 3 Ambient pressure sensor AM-5
PB.PS DT 2 Parking brake solenoid AJ-2
PB.SW DT 2 Parking brake indicator switch AH-1
PCCV FRAMATOME 3 Crankcase pressure sensor AK-9
PCV1 SUMITOMO 2 Supply pump PCV1 AM-5
PCV2 SUMITOMO 2 Supply pump PCV2 AN-5
PD DT 6 Accelerator pedal O-2

40-52 WA470-7
40 Troubleshooting
General information on troubleshooting

Number
Connector No. Connector type of pins
Equipment name Address
PDOSER FRAMATOME 3 Shut off valve pressure sensor AP-5
PDV DT 2 Accelerator pedal O-3
PFUEL AMP 3 Common rail pressure sensor AO-7
PIM FRAMATOME 3 Boost pressure sensor AO-9
POIL FRAMATOME 3 Engine oil pressure sensor AL-5
R.PS DT 2 R clutch solenoid AJ-5
R.SW DT 2 R clutch fill switch AJ-5
R01 Terminal 1 Battery relay L-2
R02 Terminal 1 Slow blow fuse K-3
R03 Terminal 1 Slow blow fuse L-3
R04 Terminal 1 Slow blow fuse K-1
R05 Terminal 1 Slow blow fuse J-3
R06A Terminal 1 Slow blow fuse J-3
R06B Terminal 1 Slow blow fuse K-3
R07 Terminal 1 Battery relay I-2
R08 Terminal 1 Emergency steering relay I-2
R10 Terminal 1 Slow blow fuse K-3
R11 Terminal 1 Slow blow fuse J-3
R13 Terminal 1 Emergency steering relay I-1
R14 Terminal 1 Emergency steering relay J-1
R15 Terminal 1 Battery relay K-1
R16 Terminal 1 Battery relay K-1
R20 DT 6 Intermediate connector K-4
R21 DT 6 Intermediate connector B-5
R22 Terminal 1 Ground A-5
R29 DT 2 Fan pump EPC G-9
R32 DT2 2 Coolant level sensor F-9
R33 DT 2 Fuel level sensor L-1
R37 DT 2 Emergency steering pressure sensor G-1
R43 KES_1 2 Front windshield washer H-2
R45 KES_1 2 Rear windshield washer H-2
R47 DT 2 Hydraulic oil temperature sensor E-9
R50 Terminal 1 Ground (rear frame) K-4
R52 DT 2 Front brake pressure switch D-8
R54 DT 2 Rear brake pressure switch E-8
R58 DT 2 Backup alarm buzzer J-9
R59 DT 2 Fan solenoid L-8
R60 DT 2 Brake oil temperature sensor H-2
R61 DT 2 Operating lamp B-7
R71 DT 2 Loader pump EPC G-9
R73 DT 3 Brake oil temperature sensor G-1
R86 3 Steering pump pressure sensor F-9
R87 DT 2 Service connector C-8
R89 DT 2 Fan speed sensor L-8
R90 DT 2 Steering pump EPC H-2
R91 DT 3 Torque converter outlet pressure sensor G-1
R93 FRAMATOME 4 Mass air flow sensor I-9
R96 Terminal 1 Heater relay L-1
R100A DT 8 Intermediate connector F-1
REV IN DT 2 Transmission input shaft speed sensor AI-8
REV OUT DT 2 Transmission output shaft speed sensor AE-6
RVC_1 DT 4 Intermediate connector A-9

WA470-7 40-53
40 Troubleshooting
General information on troubleshooting

Number
Connector No. Connector type of pins
Equipment name Address
RVM1 AMP 12 Rearview monitor O-5
RVM2 AMP 8 Rearview monitor O-6
S_F1 SWP 6 Front working lamp switch M-1
S_F2 SWP 6 Rear working lamp switch M-2
S_F3 SWP 6 Beacon lamp switch M-2
S_F3A SWP 6 Revolving warning lamp switch Q-2
S_F4 SWP 6 ECCS on-off switch M-1
S_F6 SWP 6 Auto greasing switch M-1
S_F7 SWP 6 Daytime light switch N-1
S_FA SWP 6 Parking brake switch N-3
S_FB SWP 6 Hazard lamp M-2
S_FS SWP 6 Engine shutdown secondary switch M-2
S_OH1 SWP 6 Yellow working lamp AA-9
S_OH2A DT 3 Intermediate connector (for Japan) AB-9
S_OHA SWP 6 Rear window glass Z-9
S_RH1 SWP 6 Transmission cut-off/cut-off set switch M-9
S_RH2 SWP 6 Power mode selector switch N-9
S_RH3 SWP 6 Transmission shift mode selector switch N-9
S_RH4 SWP 6 Torque converter lockup switch N-9
S_RH5 SWP 6 Directional selector switch actuation switch N-9
S_RH6 SWP 6 Remote positioner switch O-9
S_RH7 SWP 6 2-stage low idle switch O-9
S_RH8 SWP 6 Emergency steering operation check O-9
S_RHA DT 2 Horn N-6
S_RHB DT 4 Right FNR switch N-6
S_RHC SWP 6 Boom lock switch M-8
S_RV SWP 6 Camera brightness adjustment switch O-5
S40 DT 6 Starting switch N-3
SBS DT2 2 Seat belt switch T-2
SEGR DT 4 EGR valve position sensor AK-5
SI_CH DT 2 SI unit selection switch S-2
SOV1 FRAMATOME 2 Shut off valve solenoid #1 AO-6
SOV2 FRAMATOME 2 Shut off valve solenoid #2 AM-5
SV DT 12 KOMNET SV connector X-8
SVGT DT 3 VGT valve position sensor AM-5
TC.T DT 2 Torque converter outlet oil temperature sensor G-9
TCIN.P DT2 3 Torque converter inlet pressure sensor AI-8
TEL DT 12 Intermediate connector S-2
TGN Terminal 1 Ground (transmission) AJ-2
TIM PKD 2 Boost temperature sensor AO-8
TM.T DT 2 Transmission lubricating oil sensor AG-8
TWTR PKD 2 Coolant temperature sensor AN-1
VGT-REV DT 2 KVGT speed sensor AP-5
VGT-SOL DT 2 KVGT solenoid AK-6

40-54 WA470-7
40 Troubleshooting
General information on troubleshooting

Layout of connectors (1/7)

WA470-7 40-55
40 Troubleshooting
General information on troubleshooting

Layout of connectors (2/7)

40-56 WA470-7
40 Troubleshooting
General information on troubleshooting

Layout of connectors (3/7)

WA470-7 40-57
40 Troubleshooting
General information on troubleshooting

Layout of connectors (4/7)

40-58 WA470-7
40 Troubleshooting
General information on troubleshooting

Layout of connectors (5/7)

WA470-7 40-59
40 Troubleshooting
General information on troubleshooting

Layout of connectors (6/7)

40-60 WA470-7
40 Troubleshooting
General information on troubleshooting

Layout of connectors (7/7)

WA470-7 40-61
40 Troubleshooting
General information on troubleshooting

Connector contact identification (ALL-5310-030-A-00-A)

(Rev. 2009. 04)

a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.

40-62 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-63
40 Troubleshooting
General information on troubleshooting

40-64 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-65
40 Troubleshooting
General information on troubleshooting

40-66 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-67
40 Troubleshooting
General information on troubleshooting

40-68 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-69
40 Troubleshooting
General information on troubleshooting

40-70 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-71
40 Troubleshooting
General information on troubleshooting

40-72 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-73
40 Troubleshooting
General information on troubleshooting

40-74 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-75
40 Troubleshooting
General information on troubleshooting

40-76 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-77
40 Troubleshooting
General information on troubleshooting

40-78 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-79
40 Troubleshooting
General information on troubleshooting

40-80 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-81
40 Troubleshooting
General information on troubleshooting

40-82 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-83
40 Troubleshooting
General information on troubleshooting

40-84 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-85
40 Troubleshooting
General information on troubleshooting

40-86 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-87
40 Troubleshooting
General information on troubleshooting

40-88 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-89
40 Troubleshooting
General information on troubleshooting

40-90 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-91
40 Troubleshooting
General information on troubleshooting

40-92 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-93
40 Troubleshooting
General information on troubleshooting

40-94 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-95
40 Troubleshooting
General information on troubleshooting

40-96 WA470-7
40 Troubleshooting
General information on troubleshooting

WA470-7 40-97
40 Troubleshooting
General information on troubleshooting

T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)

(Rev. 2009. 03)

a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit

Identification symbol
Number of pins

Out of kit
799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part number Part name

799-601- T-box (for ECONO) 21 q q q q q


2600
799-601- T-box (for MS) 37 q
3100
799-601- T-box (for MS) 37 q
3200
799-601- Plate for MS (14-pin) q
3380
799-601- Adapter for BENDIX (MS) 24 MS-24P q
3410
799-601- Adapter for BENDIX (MS) 24 MS-24P q
3420
799-601- Adapter for BENDIX (MS) 17 MS-17P q
3430
799-601- Adapter for BENDIX (MS) 17 MS-17P q
3440
799-601- Adapter for BENDIX (MS) 5 MS-5P q
3450
799-601- Adapter for BENDIX (MS) 10 MS-10P q
3460
799-601- Adapter for BENDIX (MS) 5 MS-5P q
3510
799-601- Adapter for BENDIX (MS) 17 MS-17P q
3520
799-601- Adapter for BENDIX (MS) 19 MS-19P q
3530
799-601- Adapter for BENDIX (MS) 14 MS-14P q
2910
799-601-
Case q
3470
799-601- Adapter for MIC 5 MIC-5P q q q
2710
799-601- Adapter for MIC MIC-
13 q q q
2720 13P
799-601- Adapter for MIC MIC-
17 q q q q q q
2730 17P
799-601- Adapter for MIC MIC-
21 q q q q q q
2740 21P
799-601- Adapter for MIC 9 MIC-9P q q q q
2950
799-601- Adapter for ECONO ECONO
2 q q
2750 2P
799-601- Adapter for ECONO ECONO
3 q q
2760 3P
799-601- Adapter for ECONO ECONO
4 q q
2770 4P

40-98 WA470-7
40 Troubleshooting
General information on troubleshooting

T-adapter kit

Identification symbol
Number of pins

Out of kit
799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part number Part name

799-601- Adapter for ECONO ECONO


8 q q
2780 8P
799-601- Adapter for ECONO ECONO
12 q q
2790 12P
799-601- Adapter for DLI 8 DLI-8P q q
2810
799-601- Adapter for DLI 12 DLI-12P q q
2820
799-601- Adapter for DLI 16 DLI-16P q q
2830
799-601- Extension cable (ECONO type) ECONO
12 q q q
2840 12P
799-601-
Case q
2850
799-601- q
T-box (for DRC60, ECONO) 60
4350
799-601- q
Case
4360
799-601- Adapter for X (T-adapter) 1 q q
7010
799-601- Adapter for X 2 X2P q q q q
7020
799-601- Adapter for X 3 X3P q q q q
7030
799-601- Adapter for X 4 X4P q q q q
7040
799-601- Adapter for SWP 6 SW6P q q q
7050
799-601- Adapter for SWP 8 SW8P q q q
7060
799-601- Adapter for SWP 12 SW12P q
7310
799-601- Adapter for SWP 14 SW14P q q
7070
799-601- Adapter for SWP 16 SW16P q
7320
799-601- Adapter for M (T-adapter) 1 q q
7080
799-601- Adapter for M 2 M2P q q q q
7090
799-601- Adapter for M 3 M3P q q q q
7110
799-601- Adapter for M 4 M4P q q q q
7120
799-601- Adapter for M 6 M6P q q q q
7130
799-601- Adapter for M 8 M8P q
7340
799-601- Adapter for S 8 S8P q q q q
7140
799-601- Adapter for S (White) 10 S10P q q q q
7150

WA470-7 40-99
40 Troubleshooting
General information on troubleshooting

T-adapter kit

Identification symbol
Number of pins

Out of kit
799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part number Part name

799-601- Adapter for S (Blue) 12 S12P q q q


7160
799-601- Adapter for S (Blue) 16 S16P q q q q
7170
799-601- Adapter for S (White) 16 S16PW q
7330
799-601- Adapter for S (White) 12 S12PW q
7350
799-601- Adapter for AMP040 8 A8P q
7180
799-601- Adapter for AMP040 12 A12P q q
7190
799-601- Adapter for AMP040 16 A16P q q q q
7210
799-601- Adapter for AMP040 20 A20P q q q q
7220
799-601-
Short connector for X 2 q q q q
7230
799-601-
Case q q
7240
799-601-
Case q
7270
799-601- Adapter for 070 10 07-10 q
7510
799-601- Adapter for 070 12 07-12 q
7520
799-601- Adapter for 070 14 07-14 q
7530
799-601- Adapter for 070 18 07-18 q
7540
799-601- Adapter for 070 20 07-20 q
7550
799-601- Adapter for relay 5 REL-5P q
7360
799-601- Adapter for relay 6 REL-6P q
7370
799-601- Adapter for JFC 2 q
7380
799-601- q
Adapter for DTM 2 DTM2 q
9010
799-601- q q q
Adapter for DT 2 DT2 q
9020
799-601- q
Adapter for DT 3 DT3 q
9030
799-601- q q q
Adapter for DT 4 DT4 q
9040
799-601- q
Adapter for DT 6 DT6 q
9050
799-601- q
Adapter for DT (gray) 8 DT8GR q
9060
799-601- q
Adapter for DT (black) 8 DT8B q
9070

40-100 WA470-7
40 Troubleshooting
General information on troubleshooting

T-adapter kit

Identification symbol
Number of pins

Out of kit
799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part number Part name

799-601- q
Adapter for DT (green) 8 DT8G q
9080
799-601- q
Adapter for DT (Brown) 8 DT8BR q
9090
799-601- DT12G- q
Adapter for DT (gray) 12 q
9110 R
799-601- q
Adapter for DT (black) 12 DT12B q
9120
799-601- q
Adapter for DT (green) 12 DT12G q
9130
799-601- q
Adapter for DT (Brown) 12 DT12BR q
9140
799-601- Adapter for HD30-18 8 D18-8 q q
9210
799-601- Adapter for HD30-18 14 D18-14 q q
9220
799-601- Adapter for HD30-18 20 D18-20 q q
9230
799-601- Adapter for HD30-18 21 D18-21 q q
9240
799-601- Adapter for HD30-24 9 D24-9 q q
9250
799-601- Adapter for HD30-24 16 D24-16 q q
9260
799-601- Adapter for HD30-24 21 D24-21 q q
9270
799-601- Adapter for HD30-24 23 D24-23 q q
9280
799-601- Adapter for HD30-24 31 D24-31 q q
9290
799-601- q
Plate for HD30 (24-pin) q q
9310
799-601- q
T-box (for ECONO) 24 q q
9320
799-601-
Case q
9330
799-601-
Case q
9340
799-601- q
Adapter for DRC 40 DRC-40
9350
799-601- q
Adapter for DRC 24 DRC-24
9360
799-601- Socket for engine (CRI-T2) 2 G q
9410*
Adapter for engine (CRI-T2) q q
799-601- Adapter for engine (CRI-T3)
PFUEL 3 A3
9420
Oil pressure sensor
799-601- Socket for engine (CRI-T2) q q
2 P
9430* Socket for engine(CRI-T3) PCV
799-601- Socket for engine (CRI-T2) 1, 2, 3
3 q
9440*

WA470-7 40-101
40 Troubleshooting
General information on troubleshooting

T-adapter kit

Identification symbol
Number of pins

Out of kit
799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part number Part name

795-799- Socket for engine (HPI-T2) 2 S q


5520*
Socket for engine (HPI-T2) q q
795-799- Socket for engine (CRI-T3) 2 C
5530*
Temperature sensor
795-799- Socket for engine (HPI-T2) q q
2 A
5540* Socket for engine(CRI-T3) TIM
795-799- Cable for engine (HPI-T2) 3 q
5460
795-799- Cable for engine (HPI-T2) 3 q
5470
795-799- Cable for engine (HPI-T2) 3 q
5480
799-601- q q
Adapter for engine (140-T3) PIM 4 ITT3N
4110
799-601- Adapter for engine (CRI-T3) NE, q q
3 FCIN
4130 CAM
799-601- Adapter for engine (CRI-T3) q q
3 FCIG
4140 Ambient pressure
799-601- Adapter for engine (CRI-T3) q q
3 FCIB
4150 POIL
799-601- Adapter for engine (CRI-T3) q q
2 4160
4160 Oil pressure switch
799-601- Adapter for engine (CRI-T3) q q
3 4180
4180 PEVA
799-601- Socket for engine (CRI-T3) q q
3 1, 2, 3L
4190* Rail pressure
799-601- Socket for engine (CRI-T3) 1, 2, 3, q q
4
4230* Air intake pressure/temperature 4C
799-601- Socket for engine (CRI-T3) q q
3 1, 2, 3A
4240* PAMB
799-601- q q
Socket for engine (CRI-T3) PIM 3 1, 2, 3B
4250*
799-601- 1, 2, 3, q q
Socket for engine (CRI-T3) G 3
4330* G
799-601- Socket for engine (CRI-T3) q q
2 2, PA
4340* Pump actuator
799-601- Socket for engine (CRI-T3)(95) 1, 2, 3,
4 q
4380* Air intake pressure/temperature 4T
799-601- q q
Adapter for controller (ENG) 4 DTP4
4260
799-601- q
Adapter for controller (ENG) 50 DRC50
4211
799-601- q
Adapter for controller (ENG) 60 DRC60
4220
799-601- Socket for controller (95 ENG) 60 q
4390*
799-601- Box for controller (PUMP) 1-
q
4280* 21

40-102 WA470-7
40 Troubleshooting
General information on troubleshooting

T-adapter kit

Identification symbol
Number of pins

Out of kit
799-601-2500

799-601-2700

799-601-2800

799-601-7000

799-601-7100

799-601-7400

799-601-7500

799-601-8000

799-601-9000

799-601-9100

799-601-9200

799-601-9300

799-601-4101

799-601-4201
Part number Part name

799-601- Adapter for controller (HST) 16 HST16A q


9720
799-601- Adapter for controller (HST) 16 HST16B q
9710
799-601- Adapter for controller (HST) 26 HST26A q
9730
2,
799-601- Multi-adapter for pins DT2 to 4
3, q
9890 and DTM2
4
*: Shows not T-adapter but socket.

WA470-7 40-103
40 Troubleshooting
General information on troubleshooting

Fuse location table (WA470-5530-04D-A-00-A)

Connection table of fusible links and fuse boxes


a This connection table shows the devices to which each power supply of the fusible links and fuse boxes
supplies power.
a The switched power supply is the power (battery relay output) which is supplied while the stating switch is
in ON position and the continuous power supply is the power (battery direct output) which is supplied while
the starting switch is in the OFF or ON position.
a When performing the troubleshooting related to the electrical system, check the fusible links and fuses to
see if the power is supplied properly.
Fuse box 1
Type of power Fuse
Fuse No. Destination of power
supply capacity
1 15 A Horn circuit
2 20 A Transmission controller (A) circuit
3 5A Parking brake circuit
4 5A Emergency steering circuit
Switched power Work equipment positioner circuit
5 15 A
supply Work equipment controller (A) circuit
Slow-blow fuse (50 6 10 A Backup lamp and brake lamp circuit
A) 7 30 A Wiper and washer circuit
8 20 A Air conditioner circuit (blower)
9 5A Air conditioner compressor
10 10 A Monitor controller circuit
11 30 A Main lamp circuit
Switched power 12 10 A Clearance lamp (right) circuit
supply
13 10 A Clearance lamp (left) circuit
Lamp switch
Switched power 14 15 A Headlamp (right) circuit
supply
15 15 A Headlamp (left) circuit
Headlamp relay
Fuse box 2
Type of power Fuse
Fuse No. Destination of power
supply capacity
1 20 A Starting switch B-terminal circuit
2 10 A Hazard lamp circuit
Continuous power Monitor controller circuit (UNSW)
3 10 A
supply
4 10 A Room lamp circuit and system operating circuit
Slow-blow fuse (50
A) 5 15 A Transmission controller circuit
6 30 A Engine controller circuit (UNSW)
7 10 A Spare 1
8 10 A Front working lamp circuit
9 10 A Rear working lamp circuit
Switched power
10 30 A Radio circuit and 12 V converter circuit
supply
11 10 A Turn signal lamp circuit
Slow-blow fuse (50
A) 12 20 A Yellow revolving warning lamp circuit
13 20 A Air suspension system
14 30 A Rear heated wire glass circuit
Switched power
supply
15 5A ACC input of engine controller and monitor controller
Starting switch
ACC

40-104 WA470-7
40 Troubleshooting
General information on troubleshooting

Slow-blow fuse
Type of power Fuse
Fuse No. Destination of power
supply capacity
Spare 1, engine controller circuit, transmission controller
Continuous power circuit, work equipment controller circuit, room lamp circuit,
supply 2 50 A machine monitor circuit, KOMTRAX circuit, hazard lamp
circuit, starting switch B-terminal circuit
Main lamp circuit, machine monitor circuit, air conditioner
circuit, wiper and washer circuit, backup lamp and brake
lamp circuit, work equipment positioner circuit, work
3 50 A
equipment controller circuit, emergency steering circuit,
parking brake circuit, transmission controller circuit, horn
Switched power circuit
supply Rear heated wire glass circuit, air suspension seat and
yellow revolving warning lamp circuit, turn signal lamp
4 50 A circuit, radio circuit, 12V converter circuit, rear working
lamp circuit, front working lamp circuit
5 120 A Heater relay circuit
• Fuse box position and No.
a The fuse box is located at the rear of operator's seat.

• Slow-blow fuse mounting position

WA470-7 40-105
40 Troubleshooting
General information on troubleshooting

a Open the left engine hood, remove cover (1), and then you'll see 50 A slow-blow fuses (2) to (4), and 120
A fuse (5).

40-106 WA470-7
40 Troubleshooting
General information on troubleshooting

Precautions for KDPF (KCSF and KDOC) Cleaning and


Replacement (PC220-A9H0-2A4-K-00-A)
1. Related information From service menu of machine monitor,
display the "Diagnostic Tests" screen, open
k Since KDPF and KDOC are heated to 500° "KDPF Memory Reset", and then perform
C or above, take care not to get burn "KDOC Cleaning" (reset after KDOC
injury. cleaning).
• Resetting after KDPF (KCSF) change
• Soot accumulation at KCSF inside the KDPF
From service menu of machine monitor,
is classified into 8 levels. The current soot
display the "Diagnostic Tests" screen, open
level can be checked on the machine
"KDPF Memory Reset", and then perform
monitor by selecting the "Diagnostic Test"
"KDPF Change" (resetting after KDPF
screen from the service menu, and then
change).
selecting the "Regeneration for Service"
screen. a When KCSF in KDPF is replaced, always
perform resetting procedures for KDPF
a If the soot accumulation reaches level 4 or 5,
cleaning and KDPF change, and then
failure code [CA2639] is displayed.
perform manual stationary regeneration from
a If the soot accumulation reaches level 6 or 7, "Regeneration for Service" to eliminate
failure code [CA1921] is displayed. moisture from KCSF.
a If the soot accumulation reaches level 8, • Resetting after KDOC change
failure code [CA1922] is displayed. From service menu of machine monitor,
display the "Diagnostic Tests" screen, open
• If the soot accumulation reaches level 8, the
"KDPF Memory Reset", and then perform
KDPF is completely clogged with soot, and
"KDOC Change" (reset after KDOC change).
inspection, cleaning, or replacement is
required. a When KDOC in KDPF is changed, resetting
• Manual stationary regeneration can be procedure for KDOC change must be
performed to burn away soot in the KCSF performed though manual stationary
when the soot accumulation is up to level 7. regeneration is not necessary.
2. When cleaning and replacing KCSF
a At soot accumulation levels 4 to 7, manual
stationary regeneration can also be 1) Regular cleaning at 4500H
performed from the user mode. 1] Check the soot accumulation level. If the
• Procedure of performing manual stationary level is not zero, repeat "Regeneration for
regeneration from Regeneration for Service Service" until the level returns to zero.
2] Stop the engine and wait until the
a When soot accumulation is at level 3 or lower, temperature of piping around the engine
the manual stationary regeneration can be cools down. Remove the KDPF, and then
performed only from "Regeneration for remove the KCSF.
Service". 3] Clean the KCSF by using an ash cleaner,
1) Start the engine. which is equipped at certain workshops.
2) Make sure that machine is in safe condition. (when the removed KCSF is cleaned and
3) From the service menu of the machine reused)
monitor, display the "Diagnostic Tests" 4] Install the cleaned KCSF to the machine.
screen, open "Regeneration for service", and (when the removed KCSF is cleaned and
then perform the "Manual Stationary reused)
Regeneration". 5] Install the replacement KCSF to the
machine (when the KCSF is replaced
a Time required for manual stationary
with a new one).
regeneration depends on the accumulated
6] Turn the starting switch to the ON
soot in KCSF, however, it is estimated as
position. From the KDPF reset screen,
follows.
perform resetting after KDPF cleaning.
• If soot accumulation is level 4: Approx. 40 7] Start the engine and run at low idle to
minutes to 1 hour warm up.
• If soot accumulation is level 5: Approx. 1 to 2 8] Perform regeneration for service.
hours 2) If cracks or damages are found during
• Resetting after KDPF (KCSF) cleaning inspection

WA470-7 40-107
40 Troubleshooting
General information on troubleshooting

1] Stop the engine and wait until the Case 1-4] From the KDPF reset screen, perform
temperature of piping around the engine resetting after KDPF change.
cools down. Remove the KDPF, and then Case 1-5] Start the engine and run at low idle to
remove the KCSF. warm up.
2] Install the replacement KCSF (new or Case 1-6] Perform Regeneration for Service.
reused) to the machine. (In this case, Regeneration for Service may
3] Turn the starting switch to the ON continue for about 2 hours, since it is set to
position. From the KDPF reset screen, terminate when the soot accumulation drops to 2
perform resetting after KDPF cleaning. g/l.)
4] From the KDPF reset screen, perform Case 1-7] When Regeneration for Service is
resetting after KDPF change. completed, check that failure codes (CA1922,
5] Start the engine and run at low idle to CA1921, and CA2639) are not displayed.
warm up. <Case 2> When Regeneration for Service is
6] Perform regeneration for service. performed (KDPF removal unnecessary)
3) If Soot Level High Error 2 (CA1922) is
a If the following conditions are met, the total
displayed
soot sediment is not beyond the limit (9 g/l),
1] Stop the machine and check that failure but the differential pressure has increased
code (CA1922) is displayed on the due to clogging caused by uneven
machine monitor. accumulation of soot. In this case, actual
2] Check the abnormality record for failure regeneration will not result in abnormal
codes "CA2639: Manual Stationary burning. Regeneration for Service can be
Regeneration Request", "CA1921: KDPF performed safely without replacing the KCSF,
Soot Level High Error 1", and "CA1922: and the KCSF can be continuously used
KDPF Soot Level High Error 2"on the after the regeneration.
machine monitor.
• After checking that no sensor related failures
<Case 1> When KDPF is removed and KCSF is
are present, perform this work if any of the
replaced
following is met.
a If the following conditions are met, soot • Time between activation of "CA2639: Manual
accumulation is beyond the limit to burn Stationary Regeneration Request (L01)" and
away by regeneration. The KDPF must be "CA1921: KDPF Soot Level High Error 1
removed to change the KCSF. (L03)" < 360 sec. (KOMTRAX history) or <
• Time between activation of "CA2639: Manual 0.1 h (Abnormality record screen on monitor)
Stationary Regeneration Request (L01)" and • "Time between activation of "CA1921: KDPF
"CA1921: KDPF Soot Level High Error 1 Soot Level High Error 1 (L03)" and "CA1922:
(L03)" X 360 sec. (KOMTRAX history) or X KDPF Soot Level High Error 2 (L04)" <
0.1 h (Abnormality record screen on monitor) 360sec. (KOMTRAX history) or < 0.1 h
and (Abnormality record screen on monitor)
• Time between activation of "CA1921: KDPF [Contents of work]
Soot Level High Error 1 (L03)" and "CA1922: Case 2-1] Start the engine and run at low idle to
KDPF Soot Level High Error 2 (L04)" X360 warm up. From the KDPF reset screen, perform
sec. (KOMTRAX history) or X 0.1 h resetting after KDPF cleaning.
(Abnormality record screen on monitor) Case 2-2] Perform Regeneration for Service.
[Contents of work] (In this case, Regeneration for Service may
Case 1-1] Stop the engine and wait until the continue for about 2 hours, since it is set to
temperature of piping around the engine cools terminate when the soot accumulation drops to 2
down, then remove KCSF. g/l.)
Case 1-2] Install the replacement KCSF (new or Case 2-3] When Regeneration for Service is
reused). completed, check that failure codes (CA1922,
Case 1-3] Turn the starting switch to the ON CA1921, and CA2639) are not displayed.
position. From the KDPF reset screen, perform 3. When cleaning and replacing KDOC
resetting after KDPF cleaning. 1) If cracks or damages are found during
inspection
a When resetting after KDPF cleaning is
performed, changes in ( ) are reflected. 1] If cracks or damages are found in the
(Soot accumulation amount: 9 g/lo8.1 g/l; KDOC, replace it with a new one.
Action level: L04oL03; Failure code: 2] From the KDPF reset screen, perform
CA1922oCA1921) resetting after KDOC change.

40-108 WA470-7
40 Troubleshooting
General information on troubleshooting

2) When Regeneration Ineffective (CA1691) is


displayed
1] Stop the machine and check that failure
code (CA1691) is displayed on the
machine monitor.
(CA2637 may be displayed at the same
time.)
2] Check the exhaust gas color.
3] With CA1691 displayed, perform
Regeneration for Service for 40 minutes.
(Since this is done for drying the KDOC,
fuel is not injected during the
regeneration)
4] Stop the engine and wait until the
temperature of piping around the engine
cools down. Remove the KDOC and
check it for cracks or damages.
<Case 1> If cracks or damages are found in
KDOC
Case 1-1] Replace KDOC with a new one.
Case 1-2] From the KDPF reset screen,
perform resetting after KDOC change.
<Case 2> If cracks or damages are not found
in KDOC
Case 2-1] Clean KDOC and reinstall it.
Case 2-2] From the KDPF reset screen,
perform resetting after KDOC cleaning.
Case 2-3] Perform Regeneration for Service
twice for 40 minutes each. (Fuel is injected
during regeneration)
*When performing Regeneration for Service
several times, stop the engine each time
before repeating the regeneration.
Case 2-4] If failure code "CA2637: KDOC
Face Plugging" is displayed after
Regeneration for Service is completed, the
catalyst performance of KDOC is
deteriorated. Replace KDOC with a new one.

WA470-7 40-109
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Precautions on troubleshooting of machine monitor (WA500-Q180-2A4-K-00-A)

• The machine monitor consists of various independent units that send and receive data to/from the monitor
controller through LIN communication (see the next page).
• As the result, troubleshooting of the machine monitor and related units involves complicated procedures
(see E-5 to E-20 of E-mode troubleshooting).
• Each unit related to the machine monitor has many new type of connectors (see Table 1).
• When performing the troubleshooting of the machine monitor LCD unit (see E-6 to E-8 of E-mode
troubleshooting), refer to "Processing procedure of harness checker for troubleshooting of machine
monitor LCD unit".
Table 1. Detail of connectors related to machine monitor
Con- Num- Manu- Connector
Name of unit nector ber of Type code factur- type, etc. Tool New Remarks
name pins er
MX40008U- –
LCD unit MDM1 8 JAE q
Ma- Q1
chine 070 T-
LED unit MDM2 6 175954-1 AMP q
moni- connector adapter
tor 070 T-
Meter unit MDM3 8 175955-1 AMP q
connector adapter
– MCM1 Measuring
81 Same as
A tool is not a T-
those used
adapter, so
TYCO- in pump Box-type
AMP operating
– MCM 1241434 controller of socket
40 voltage
B hydraulic
cannot be
excavators
measured.
See
Monitor controller "Processing
procedure of
harness
– MX40008N- Harness checker for
MCM2 8 JAE q
Q1 checker troubleshoot-
ing of
machine
monitor LCD
unit".
070 T-
– Switch panel MOM1 6 175954-1 AMP q
connector adapter
070 T-
– RVM1 12 175957-1 AMP
connector adapter
Rear view monitor
070 T-
– RVM2 8 175955-1 AMP q
connector adapter

40-110 WA470-7
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Configuration drawing of machine monitor and related units

WA470-7 40-111
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General information on troubleshooting

Processing procedure of harness checker for troubleshooting of


machine monitor LCD unit (HM300-Q000-330-K-00-A)
1. Purpose
This section describes the processing procedure of the monitor harness checker (jig) by using a mass-
produced harness between machine monitor LCD unit and monitor controller.
• The machine monitor receives data from the monitor controller and displays the information on its LCD
unit.
• The monitor harness checker allows you to measure the output voltage from the monitor controller and
determine whether cause of failure is in the monitor controller or not.
• Use the monitor harness checker for troubleshooting of the machine monitor LCD unit. (See E-6 to E-8
of E-mode troubleshooting.)

2. Outline
Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
Before being modified

O
After being modified
• Part to be modified is portion P.

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40 Troubleshooting
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• Cut off the wiring harness at the connector (having no crimped portion), install a heat shrink tube to
each cable to prevent short circuit, and then install a check pin to each cable.
Finished harness checker

Fig. 1 Mass-produced harness between machine monitor LCD unit and monitor controller: 7831-47-8710
a Determine the pin number of each check pin by checking the cable color indicated at portion Q in the
figure or by checking the number of pin on the opposite side to which the cable is connected.

WA470-7 40-113
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General information on troubleshooting

3. Preparation
• Materials to be prepared
No. Part name Type Manufacturer Quantity
Japan Aviation
1 Wiring harness 7831-47-8710 1
Electronics Industry
2 Check pin TJ-1-W *1 SATO PARTS 8
Heat shrink tube f5 (Min. 35 mm in Sumitomo Electric
3 SUMI-F2Z-5x0.25 *1 1
length) Industries
Heat shrink tube f5 (Min. 140 mm in Sumitomo Electric
4 SUMI-F2Z-3.5x0.25 *1 1
length) Industries
Labels (with numbers <1> to <8> 1 label each (8
5 printed on them) *2 – –
labels in total)
6 Vinyl tape – – 1
7 Nipper – – 1
8 Wire stripper (for AWG 20-34) – – 1
9 Cutter – – 1
10 Soldering iron – – 1
11 Solder – – 1
12 Dryer *3 – – 1
*1 Can be substituted with an equivalent
*2 They are attached for easy understanding of harness pin number. You may mark numbers on labels.
*3 Can be substituted with a heat gun.
4. Work procedure
• Modification of cables with pin Nos. 3 to 8
1) Use a nipper to cut off the wiring harness at the root of the connector that does not have crimped
portion ((07) in the Fig. 1).

2) Use a wire stripper to remove covers of cables with pin Nos. 3 to 8, 5 mm from the cut end.
a take care not to cut the wire inside the cover.
3) Make six 15-mm heat shrink tubes f3.5 (A).

4) Pass a heat shrink tube (A) over any one of the cut cables, and solder a check pin to the cable.

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5) Slide heat shrink tube (A) of the cable to which the check pin is soldered in step 4) to a position where
the check pin conductor is covered, and use a dryer to contract heat shrink tube (A).
6) Attach the label so that the pin number of the cable is easily read.
a Determine the pin number of each check pin by checking the cable color indicated at portion Q of
Fig. 1 or by checking the number of pin on the opposite side to which the pin is connected.

7) Repeat steps 4 to 6 for other cables with pin Nos. 3 to 8.


8) Remove tape (B) winding around the conduit to an appropriate position because it is an obstacle for
the work.

• Modification of cables with pin Nos. 1 and 2


1. Strip the cover of shield cable 35 mm in length with your nail.
a take care not to cut the wire inside the cover.
2. Tear off shield cable (C) with your fingers and wind it around the cover.
3. Strip aluminum leaf and yellow thin paper (D) with your nail, and wind it around the cover.

4. Strip the covers of cables with pin Nos. 1 and 2, 5 mm in length by using a wire stripper.
5. Make one 35-mm heat shrink tube f5 (E).
6. Pass the cut heat shrink tube (E) over the cables with pin Nos. 1 and 2.

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7. Make two 25-mm heat shrink tubes f3.5 (F).


8. Pass the cut heat shrink tube (F) over each of the cables with pin Nos. 1 and 2.
9. Solder the check pin to each of the cables with pin Nos. 1 and 2.
10.Slide heat shrink tube (F) to a position where the check pin conductor is covered, and use a dryer to
contract the heat shrink tube.
11.Attach the label so that the pin number of the cable is easily read.
a Determine the pin number of each check pin by checking the cable color indicated at portion Q of Fig. 1
or by checking the number of pin on the opposite side to which the cable is connected.

12.Slide heat shrink tube f5 (E) to a position where it overlaps heat shrink tube f3.5 (F) for cables with pin
Nos. 1 and 2, and then use a dryer to contract heat shrink tube (E).
13.Cut off tape (B) that was stripped from the conduit at an appropriate position, From that position, Wrap
vinyl tape around the cables with pin Nos. 3 to 8 to bind them. This completes the work.

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Fabrication of dummy temperature sensor (for KDOC and KDPF


temperature sensors) (HM300-A9J2-304-K-00-A)
• Use this dummy temperature sensor in troubleshooting for KDPF-related failure codes.
• To fabricate dummy temperature sensor, purchase KDPF temperature sensor consolidating box that are
installed on KDPF, and modify it (break up KDPF temperature sensor consolidating box and take out 4-pin
connector section).
• Dummy temperature sensor

WA470-7 40-117
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Fabrication of short-circuit connector (for CA1883 and CA3135) (HM300-A9J2-


304-K-01-A)

a KDPF differential pressure sensor is the same as KDPF outlet pressure sensor.
• CA1883 Short-circuit connector for KDPF delta pressure sensor

• CA3135 Short-circuit connector for KDPF outlet pressure sensor

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Failure codes table (WA470-5520-441-A-00-A)

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [1500L0] Double Engagement of Electrical
1500L0 T/M Clutches(PAGE 40-133) TM L04 system
Failure code [15SAL1] Release Trouble of Electrical
15SAL1 ECMV (Forward)(PAGE 40-134) TM L03 system
Failure code [15SALH] Malfunction of ECMV Electrical
15SALH (Forward)(PAGE 40-136) TM L01 system
Failure code [15SBL1] Release Trouble of Electrical
15SBL1 ECMV (Reverse)(PAGE 40-138) TM L03 system
Failure code [15SBLH] Malfunction of ECMV Electrical
15SBLH (Reverse)(PAGE 40-140) TM L01 system
Failure code [15SEL1] Release Trouble of Electrical
15SEL1 ECMV (1st)(PAGE 40-142) TM L03 system
Failure code [15SELH] Malfunction of ECMV Electrical
15SELH (1st)(PAGE 40-144) TM L01 system
Failure code [15SFL1] Release Trouble of Electrical
15SFL1 ECMV (2nd)(PAGE 40-146) TM L03 system
Failure code [15SFLH] Malfunction of ECMV Electrical
15SFLH (2nd)(PAGE 40-148) TM L01 system
Failure code [15SGL1] Release Trouble of Electrical
15SGL1 ECMV (3rd)(PAGE 40-150) TM L03 system
Failure code [15SGLH] Malfunction of ECMV Electrical
15SGLH (3rd)(PAGE 40-152) TM L01 system
Failure code [15SHL1] Release Trouble of Electrical
15SHL1 ECMV (4th)(PAGE 40-154) TM L03 system
Failure code [15SHLH] Malfunction of ECMV Electrical
15SHLH (4th)(PAGE 40-156) TM L01 system
Failure code [2F00MA] Failure of Parking Electrical
2F00MA Brake Circuit(PAGE 40-158) MON L03 system
Failure code [2G42ZG] Accumulator Oil Mechanical
2G42ZG Pressure Low (Front)(PAGE 40-162) MON L03 system
Failure code [2G43ZG] Accumulator Oil Mechanical
2G43ZG Pressure Low (Rear)(PAGE 40-164) MON L03 system
Failure code [879AKA] A/C Inner Sensor Electrical See Chapter
879AKA Open Circuit(PAGE 40-166) MON – 80, Other
system
items
Failure code [879AKB] A/C Inner Sensor Short Electrical See Chapter
879AKB Circuit(PAGE 40-167) MON – 80, Other
system
items
Failure code [879BKA] A/C Outer Sensor Electrical See Chapter
879BKA Open Circuit(PAGE 40-168) MON – 80, Other
system
items
Failure code [879BKB] A/C Outer Sensor Electrical See Chapter
879BKB Short Circuit(PAGE 40-169) MON – 80, Other
system
items
Failure code [879CKA] Ventilating Sensor Electrical See Chapter
879CKA Open Circuit(PAGE 40-170) MON – 80, Other
system
items
Failure code [879CKB] Ventilating Sensor Electrical See Chapter
879CKB Short Circuit(PAGE 40-171) MON – 80, Other
system
items
Failure code [879DKZ] Sunlight Sensor Open Electrical See Chapter
879DKZ or Short Circuit(PAGE 40-172) MON – 80, Other
system
items
Failure code [879EMC] Ventilation Damper Electrical See Chapter
879EMC Abnormality(PAGE 40-173) MON L01 system 80, Other
items

WA470-7 40-119
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Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [879FMC] Air Mix Damper Electrical See Chapter
879FMC Abnormality(PAGE 40-174) MON L01 system 80, Other
items
Failure code [989A00] Engine Overrun Mechanical
989A00 Prevention Activated(PAGE 40-175) TM L02 system
Failure code [989L00] Engine Controller Lock Electrical
989L00 MON –
Caution 1(PAGE 40-176) system
Failure code [989M00] Engine Controller Lock Electrical
989M00 MON –
Caution 2(PAGE 40-177) system
Failure code [989N00] Engine Controller Lock Electrical
989N00 MON –
Caution 3(PAGE 40-178) system
Failure code [A1U0N3] HC Desorb Request 1 Electrical
A1U0N3 (PAGE 40-179) ENG L01 system
Failure code [A1U0N4] HC Desorb Request 2 Electrical
A1U0N4 (PAGE 40-181) ENG L03 system
Failure code [AA10NX] Air Cleaner Clogging Mechanical
AA10NX (PAGE 40-183) MON L01 system
Failure code [B@BAZG] Eng Oil Press Low Electrical
B@BAZG ENG L03
(PAGE 40-185) system
Failure code [B@BAZK] Eng Oil Level Low Mechanical
B@BAZK MON L01
(PAGE 40-186) system
Failure code [B@BCNS] Eng Water Overheat Electrical
B@BCNS ENG L02
(PAGE 40-188) system
Failure code [B@BCZK] Eng Water Level Low Mechanical
B@BCZK MON L01
(PAGE 40-189) system
Failure code [B@CENS] T/C Oil Temp. Mechanical
B@CENS MON L02
Overheat(PAGE 40-191) system
Failure code [B@HANS] HYD Oil Temp. Mechanical
B@HANS MON L02
Overheat(PAGE 40-192) system
Failure code [CA115] Eng Ne and Bkup Speed Electrical
CA115 Sens Error(PAGE 40-193) ENG L04 system
Failure code [CA122] Chg Air Press Sensor Electrical
CA122 High Error(PAGE 40-194) ENG L03 system
Failure code [CA123] Chg Air Press Sensor Electrical
CA123 Low Error(PAGE 40-196) ENG L03 system
Failure code [CA131] Throttle Sensor High Electrical
CA131 Error(PAGE 40-198) ENG L03 system
Failure code [CA132] Throttle Sensor Low Electrical
CA132 Error(PAGE 40-200) ENG L03 system
Failure code [CA135] Eng Oil Press Sensor Electrical
CA135 High Error(PAGE 40-202) ENG L01 system
Failure code [CA141] Eng Oil Press Sensor Electrical
CA141 Low Error(PAGE 40-204) ENG L01 system
Failure code [CA144] Coolant Temp Sens Electrical
CA144 High Error(PAGE 40-206) ENG L01 system
Failure code [CA145] Coolant Temp Sens Low Electrical
CA145 Error(PAGE 40-208) ENG L01 system
Failure code [CA153] Chg Air Temp Sensor Electrical
CA153 High Error(PAGE 40-210) ENG L03 system
Failure code [CA154] Chg Air Temp Sensor Electrical
CA154 Low Error(PAGE 40-212) ENG L03 system
Failure code [CA187] Sensor 2 Supply Volt Electrical
CA187 Low Error(PAGE 40-214) ENG L03 system
Failure code [CA221] Ambient Press Sensor Electrical
CA221 High Error(PAGE 40-216) ENG L03 system

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Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [CA222] Ambient Press Sensor Electrical
CA222 Low Error(PAGE 40-218) ENG L03 system
Failure code [CA227] Sensor 2 Supply Volt Electrical
CA227 High Error(PAGE 40-220) ENG L03 system
Failure code [CA234] Eng Overspeed(PAGE Mechanical
CA234 40-221) ENG L02 system
Failure code [CA238] Ne Speed Sensor Electrical
CA238 Supply Volt Error(PAGE 40-222) ENG L01 system
Failure code [CA239] Ne Speed Sens Supply Electrical
CA239 Volt High Error(PAGE 40-223) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
CA271 (PAGE 40-224) ENG L03 system
Failure code [CA272] IMV/PCV1 Open Error Electrical
CA272 (PAGE 40-225) ENG L03 system
Failure code [CA273] PCV2 Short Error(PAGE Electrical
CA273 40-226) ENG L03 system
Failure code [CA274] PCV2 Open Error(PAGE Electrical
CA274 40-227) ENG L03 system
Failure code [CA322] Inj #1(L#1) Open/Short Electrical
CA322 Error(PAGE 40-228) ENG L03 system
Failure code [CA323] Inj #5(L#5) Open/Short Electrical
CA323 Error(PAGE 40-230) ENG L03 system
Failure code [CA324] Inj #3(L#3) Open/Short Electrical
CA324 Error(PAGE 40-232) ENG L03 system
Failure code [CA325] Inj #6(L#6) Open/Short Electrical
CA325 Error(PAGE 40-234) ENG L03 system
Failure code [CA331] Inj #2(L#2) Open/Short Electrical
CA331 Error(PAGE 40-236) ENG L03 system
Failure code [CA332] Inj #4(L#4) Open/Short Electrical
CA332 Error(PAGE 40-238) ENG L03 system
Failure code [CA343] ECM Critical Internal Electrical
CA343 Failure(PAGE 40-240) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
CA351 Error(PAGE 40-241) ENG L03 system
Failure code [CA352] Sensor 1 Supply Volt Electrical
CA352 Low Error(PAGE 40-242) ENG L03 system
Failure code [CA356] Mass Air Flow Sensor Electrical
CA356 High Error(PAGE 40-244) ENG L03 system
Failure code [CA357] Mass Air Flow Sensor Electrical
CA357 Low Error(PAGE 40-246) ENG L03 system
Failure code [CA386] Sensor 1 Supply Volt Electrical
CA386 High Error(PAGE 40-248) ENG L03 system
Failure code [CA431] Idle Validation Sw Error Electrical
CA431 (PAGE 40-249) ENG L01 system
Failure code [CA432] Idle Validation Process Electrical
CA432 Error(PAGE 40-252) ENG L03 system
Failure code [CA441] Battery Voltage Low Electrical
CA441 Error(PAGE 40-255) ENG L04 system
Failure code [CA442] Battery Voltage High Electrical
CA442 Error(PAGE 40-257) ENG L04 system
Failure code [CA449] Rail Press Very High Electrical
CA449 Error(PAGE 40-258) ENG L03 system
Failure code [CA451] Rail Press Sensor High Electrical
CA451 Error(PAGE 40-259) ENG L03 system
Failure code [CA452] Rail Press Sensor Low Electrical
CA452 Error(PAGE 40-261) ENG L03 system

WA470-7 40-121
40 Troubleshooting
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Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [CA515] Rail Press Sens Sup Electrical
CA515 Volt High Error(PAGE 40-263) ENG L03 system
Failure code [CA516] Rail Press Sens Sup Electrical
CA516 Volt Low Error(PAGE 40-265) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
CA553 (PAGE 40-267) ENG L01 system
Failure code [CA555] Crankcase Press High Electrical
CA555 Error 1(PAGE 40-268) ENG L01 system
Failure code [CA556] Crankcase Press High Electrical
CA556 Error 2(PAGE 40-269) ENG L03 system
Failure code [CA559] Rail Press Low Error Electrical
CA559 (PAGE 40-270) ENG L01 system
Failure code [CA595] Turbo Speed High Error Electrical
CA595 2(PAGE 40-274) ENG L01 system
Failure code [CA687] Turbo Speed Low Error Electrical
CA687 (PAGE 40-275) ENG L01 system
Failure code [CA689] Eng Ne Speed Sensor Electrical
CA689 Error(PAGE 40-277) ENG L01 system
Failure code [CA691] Intake Air Temp Sens Electrical
CA691 High Error(PAGE 40-279) ENG L01 system
Failure code [CA692] Intake Air Temp Sens Electrical
CA692 Low Error(PAGE 40-281) ENG L01 system
Failure code [CA697] ECM Internal Temp Electrical
CA697 Sensor High Error(PAGE 40-283) ENG L01 system
Failure code [CA698] ECM Int Temp Sensor Electrical
CA698 Low Error(PAGE 40-284) ENG L01 system
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-285) ENG L01 system
Failure code [CA778] Eng Bkup Speed Electrical
CA778 Sensor Error(PAGE 40-286) ENG L01 system
Failure code [CA1117] Persistent Data Lost Electrical
CA1117 Error(PAGE 40-288) ENG L04 system
Failure code [CA1664] KDOC Malfunction Electrical
CA1664 (PAGE 40-289) ENG L03 system
Failure code [CA1691] Regeneration Electrical
CA1691 Ineffective(PAGE 40-292) ENG L03 system
Failure code [CA1695] Sensor 5 Supply Volt Electrical
CA1695 High Error(PAGE 40-295) ENG L03 system
Failure code [CA1696] Sensor 5 Supply Volt Electrical
CA1696 Low Error(PAGE 40-296) ENG L03 system
Failure code [CA1843] Crankcase Press Sens Electrical
CA1843 High Error(PAGE 40-298) ENG L01 system
Failure code [CA1844] Crankcase Press Sens Electrical
CA1844 Low Error(PAGE 40-300) ENG L01 system
Failure code [CA1879] KDPF Delta P Sensor Electrical
CA1879 High Error(PAGE 40-302) ENG L03 system
Failure code [CA1881] KDPF Delta P Sensor Electrical
CA1881 Low Error(PAGE 40-304) ENG L03 system
Failure code [CA1883] KDPF Delta P Sens In Electrical
CA1883 Range Error(PAGE 40-306) ENG L03 system
Failure code [CA1921] KDPF Soot Load High Electrical
CA1921 Error 1(PAGE 40-309) ENG L03 system
Failure code [CA1922] KDPF Soot Load High Electrical
CA1922 Error 2(PAGE 40-312) ENG L04 system
Failure code [CA1923] Dosing Fuel Valve 1 Electrical
CA1923 High Error(PAGE 40-317) ENG L03 system

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Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [CA1924] Dosing Fuel Valve 1 Electrical
CA1924 Low Error(PAGE 40-319) ENG L03 system
Failure code [CA1925] Dosing Fuel Valve 1 In Electrical
CA1925 Range Error(PAGE 40-322) ENG L03 system
Failure code [CA1927] Dosing Fuel Press Electrical
CA1927 Sens High Error(PAGE 40-324) ENG L01 system
Failure code [CA1928] Dosing Fuel Press Electrical
CA1928 Sens Low Error(PAGE 40-326) ENG L01 system
Failure code [CA1942] Crankcase Press Sens Electrical
CA1942 In Range Error(PAGE 40-328) ENG L01 system
Failure code [CA1963] Dosing Fuel Valve 1 Electrical
CA1963 Servo Error(PAGE 40-329) ENG L03 system
Failure code [CA1977] Fuel Doser Open/Short Electrical
CA1977 Error(PAGE 40-331) ENG L03 system
Failure code [CA1993] KDPF Delta Pressure Electrical
CA1993 Low Error(PAGE 40-333) ENG L03 system
Failure code [CA2185] Throt Sensor Sup Volt Electrical
CA2185 High Error(PAGE 40-335) ENG L03 system
Failure code [CA2186] Throt Sensor Sup Volt Electrical
CA2186 Low Error(PAGE 40-337) ENG L03 system
Failure code [CA2249] Rail Press Very Low Electrical
CA2249 Error(PAGE 40-339) ENG L03 system
Failure code [CA2265] Fuel Feed Pump Open Electrical
CA2265 Error(PAGE 40-340) ENG L01 system
Failure code [CA2266] Fuel Feed Pump Short Electrical
CA2266 Error(PAGE 40-342) ENG L01 system
Failure code [CA2271] EGR Valve Pos Sens Electrical
CA2271 High Error(PAGE 40-344) ENG L03 system
Failure code [CA2272] EGR Valve Pos Sens Electrical
CA2272 Low Error(PAGE 40-346) ENG L03 system
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Error(PAGE 40-348) ENG L03 system
Failure code [CA2353] EGR Valve Solenoid Electrical
CA2353 Short Error(PAGE 40-350) ENG L03 system
Failure code [CA2357] EGR Valve Servo Error Electrical
CA2357 (PAGE 40-352) ENG L03 system
Failure code [CA2381] KVGT Pos Sens High Electrical
CA2381 Error(PAGE 40-353) ENG L03 system
Failure code [CA2382] KVGT Pos Sens Low Electrical
CA2382 Error(PAGE 40-355) ENG L03 system
Failure code [CA2383] KVGT Solenoid Open Electrical
CA2383 Error(PAGE 40-357) ENG L03 system
Failure code [CA2386] KVGT Solenoid Short Electrical
CA2386 Error(PAGE 40-359) ENG L03 system
Failure code [CA2387] KVGT Servo Error Electrical
CA2387 (PAGE 40-361) ENG L03 system
Failure code [CA2555] Grid Htr Relay Volt Low Electrical
CA2555 Error(PAGE 40-362) ENG L01 system
Failure code [CA2556] Grid Htr Relay Volt Electrical
CA2556 High Error(PAGE 40-364) ENG L01 system
Failure code [CA2637] KDOC Face Plugging Electrical
CA2637 (PAGE 40-366) ENG L01 system
Failure code [CA2639] Manual Stationary Electrical
CA2639 Regeneration Request(PAGE 40-368) ENG L01 system
Failure code [CA2732] Dosing Fuel Valve 2 Electrical
CA2732 High Error(PAGE 40-371) ENG L03 system

WA470-7 40-123
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Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [CA2733] Dosing Fuel Valve 2 Electrical
CA2733 Low Error(PAGE 40-373) ENG L03 system
Failure code [CA2741] Dosing Fuel Valve Electrical
CA2741 Swap Error(PAGE 40-375) ENG L03 system
Failure code [CA2765] Inj Trim Data Error Electrical
CA2765 (PAGE 40-377) ENG L01 system
Failure code [CA2878] Dosing Fuel Valve 2 Electrical
CA2878 Servo Error(PAGE 40-378) ENG L03 system
Failure code [CA2881] Dosing Fuel Pressure Electrical
CA2881 Low Error 1(PAGE 40-381) ENG L03 system
Failure code [CA3133] KDPF Outlet Press Electrical
CA3133 Sens High Error(PAGE 40-386) ENG L03 system
Failure code [CA3134] KDPF Outlet Press Electrical
CA3134 Sens Low Error(PAGE 40-388) ENG L03 system
Failure code [CA3135] KDPF Outlet Press Electrical
CA3135 Sens In Range Error(PAGE 40-390) ENG L03 system
Failure code [CA3167] Fuel Doser Electrical
CA3167 Degradation(PAGE 40-393) ENG –
system
Failure code [CA3251] KDOC Inlet Temp High Electrical
CA3251 Error(PAGE 40-396) ENG L03 system
Failure code [CA3253] KDOC Temp Error - Electrical
CA3253 Non Regeneration(PAGE 40-399) ENG L03 system
Failure code [CA3254] KDOC Outlet Temp Electrical
CA3254 High Error 1(PAGE 40-402) ENG L01 system
Failure code [CA3255] KDPF Temp Error - Electrical
CA3255 Non Regeneration(PAGE 40-405) ENG L03 system
Failure code [CA3256] KDPF Outlet Temp Electrical
CA3256 High Error 1(PAGE 40-409) ENG L01 system
Failure code [CA3311] KDOC Outlet Temp Electrical
CA3311 High Error 2(PAGE 40-412) ENG L03 system
Failure code [CA3312] KDPF Outlet Temp Electrical
CA3312 High Error 2(PAGE 40-415) ENG L03 system
Failure code [CA3313] KDOC Inlet Temp Electrical
CA3313 Sensor Low Error(PAGE 40-418) ENG L03 system
Failure code [CA3314] KDOC Inlet Temp Sens Electrical
CA3314 High Error(PAGE 40-421) ENG L03 system
Failure code [CA3315] KDOC Inlet Temp Sens Electrical
CA3315 In Range Error(PAGE 40-425) ENG L03 system
Failure code [CA3316] KDOC Outlet Temp Electrical
CA3316 Sens Low Error(PAGE 40-430) ENG L03 system
Failure code [CA3317] KDOC Outlet Temp Electrical
CA3317 Sens High Error(PAGE 40-433) ENG L03 system
Failure code [CA3318] KDOC Outlet Temp Electrical
CA3318 Sens In Range Error(PAGE 40-437) ENG L03 system
Failure code [CA3319] KDPF Outlet Temp Electrical
CA3319 Sens High Error(PAGE 40-442) ENG L03 system
Failure code [CA3321] KDPF Outlet Temp Electrical
CA3321 Sens Low Error(PAGE 40-446) ENG L03 system
Failure code [CA3322] KDPF Outlet Temp Electrical
CA3322 Sens In Range Error(PAGE 40-449) ENG L03 system
Failure code [CA3419] Mass Air Flow Sensor Electrical
CA3419 Sup Volt High Error(PAGE 40-454) ENG L03 system
Failure code [CA3421] Mass Air Flow Sensor Electrical
CA3421 Sup Volt Low Error(PAGE 40-456) ENG L03 system
Failure code [D150KA] Disconnection of Electrical
D150KA Emerg. Steering Relay(PAGE 40-458) WRK L03 system

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Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [D150KB] Ground Fault of Electrical
D150KB Emerg. Steering Relay(PAGE 40-460) WRK L03 system
Failure code [D150KY] Hot Short of Electrical
D150KY Emergency Steering Relay(PAGE 40-462) WRK L03 system
Failure code [D160KA] Disconnection of Electrical
D160KA Backup Lamp Relay Output(PAGE 40-464) TM L01 system
Failure code [D160KB] Ground Fault of Electrical
D160KB Backup Lamp Relay Output(PAGE 40-466) TM L01 system
Failure code [D160KY] Hot Short of Backup Electrical
D160KY Lamp Relay Output(PAGE 40-468) TM L01 system
Failure code [D191KA] Disconnection of Electrical
D191KA Neutral Output Relay(PAGE 40-470) TM L03 system
Failure code [D191KB] Ground Fault of Electrical
D191KB Neutral Output Relay(PAGE 40-472) TM L03 system
Failure code [D191KY] Hot Short of Neutral Electrical
D191KY Output Relay(PAGE 40-474) TM L03 system
Failure code [D192KA] Disconnection of Electrical
D192KA ECSS Solenoid(PAGE 40-476) TM L01 system
Failure code [D192KB] Ground Fault of ECSS Electrical
D192KB Solenoid(PAGE 40-478) TM L01 system
Failure code [D192KY] Hot Short of ECSS Electrical
D192KY Solenoid(PAGE 40-479) TM L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-480) MON L03 system
Failure code [D1E6KA] Disconnection of Electrical
D1E6KA Parking Brake Relay(PAGE 40-482) TM L03 system
Failure code [D1E6KB] Ground Fault of Electrical
D1E6KB Parking Brake Relay(PAGE 40-484) TM L03 system
Failure code [D1E6KY] Hot Short of Parking Electrical
D1E6KY Brake Relay(PAGE 40-486) TM L03 system
Failure code [D5ZHKA] Failure of Key SW C Electrical
D5ZHKA Signal(PAGE 40-488) TM L01 system
Failure code [D5ZHKB] Key SW C Signal Electrical
D5ZHKB Short Circuit(PAGE 40-490) TM L01 system
Failure code [D5ZHKZ] Failure of Key SW C Electrical
D5ZHKZ Signal(PAGE 40-492) WRK L01 system
Failure code [D5ZHL6] Disconnection of Key Electrical
D5ZHL6 SW C(PAGE 40-494) MON L01 system
Failure code [D811MC] KOMTRAX Error Electrical
D811MC (PAGE 40-496) KOMTRAX –
system
Failure code [D862KA] GPS Antenna Open Electrical
D862KA Circuit(PAGE 40-497) KOMTRAX –
system
Failure code [D8ALKA] Operating Lamp Open Electrical
D8ALKA Circuit (KOMTRAX)(PAGE 40-498) KOMTRAX –
system
Failure code [D8ALKB] Operating Lamp Short Electrical
D8ALKB Circuit (KOMTRAX)(PAGE 40-500) KOMTRAX –
system
Failure code [D8AQK4] CAN2 Discon Electrical
D8AQK4 (KOMTRAX) 2(PAGE 40-502) MON L03 system
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR (KOMTRAX)(PAGE 40-503) MON –
system
Failure code [DAF0KT] Abnormality of Non- Electrical
DAF0KT volatile Memory (MON)(PAGE 40-505) MON L03 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB Abnormality(PAGE 40-506) MON –
system
Failure code [DAF0MC] Monitor Error(PAGE Electrical
DAF0MC 40-507) MON –
system

WA470-7 40-125
40 Troubleshooting
General information on troubleshooting

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [DAF3KK] Controller Power Electrical
DAF3KK Source Low (MON)(PAGE 40-508) MON –
system
Failure code [DAF8KB] Camera Power Supply Electrical
DAF8KB Short Circuit(PAGE 40-510) MON L03 system
Failure code [DAFDKB] Monitor 12V Power Electrical
DAFDKB Output Short Circuit(PAGE 40-511) MON L01 system
Failure code [DAFGMC] GPS Module Error Electrical
DAFGMC (PAGE 40-513) KOMTRAX –
system
Failure code [DAFLKA] Operating Lamp Open Electrical
DAFLKA Circuit (MON)(PAGE 40-514) MON –
system
Failure code [DAFLKB] Operating Lamp Short Electrical
DAFLKB Circuit (MON)(PAGE 40-516) MON –
system
Failure code [DAFQKR] CAN2 Discon Electrical
DAFQKR (Monitor)(PAGE 40-518) KOMTRAX –
system
Failure code [DAQ0KK] Controller Power Electrical
DAQ0KK Source Low (T/M)(PAGE 40-519) TM L03 system
Failure code [DAQ0KT] Abnormality of Non- Electrical
DAQ0KT volatile Memory (T/M)(PAGE 40-522) TM L01 system
Failure code [DAQ0MC] T/M Con Error(PAGE Electrical
DAQ0MC 40-523) TM –
system
Failure code [DAQ1KA] Disconnection of Key Electrical
DAQ1KA SW ACC (T/M)(PAGE 40-524) TM L03 system
Failure code [DAQ2KK] Solenoid Power Electrical
DAQ2KK Source Low (T/M)(PAGE 40-526) TM L03 system
Failure code [DAQ4KB] Ground Fault of Sol. Electrical
DAQ4KB Self-Holding Relay(PAGE 40-529) TM L01 system
Failure code [DAQ9KQ] Inconsistency of Electrical
DAQ9KQ Model Selection (T/M)(PAGE 40-531) TM L03 system
Failure code [DAQLKA] Operating Lamp Open Electrical
DAQLKA Circuit (T/M)(PAGE 40-532) TM –
system
Failure code [DAQLKB] Operating Lamp Short Electrical
DAQLKB Circuit (T/M)(PAGE 40-534) TM –
system
Failure code [DAQQKR] CAN2 Discon Electrical
DAQQKR (Transmission Con)(PAGE 40-536) MON L03 system
Failure code [DAQRKR] CAN1 Discon Electrical
DAQRKR (Transmission Con)(PAGE 40-537) MON L03 system
Failure code [DAQRMA] Inconsistency of Electrical
DAQRMA Option Selection (T/M)(PAGE 40-538) TM L03 system
Failure code [DAZ9KQ] A/C Model Selection Electrical
DAZ9KQ Abnormality(PAGE 40-539) MON –
system
Failure code [DAZQKR] CAN2 Discon (Aircon Electrical
DAZQKR ECU)(PAGE 40-540) MON L01 system
Failure code [DB2QKR] CAN2 Discon (Engine Electrical
DB2QKR Con)(PAGE 40-541) MON L03 system
Failure code [DB2RKR] CAN1 Discon (Engine Electrical
DB2RKR Con)(PAGE 40-546) MON L03 system
Failure code [DB90KK] Drop in BBC Controller Electrical
DB90KK Main Power Source(PAGE 40-551) WRK L03 system
Failure code [DB90KT] Abnormality of Non- Electrical
DB90KT volatile Memory (BBC)(PAGE 40-553) WRK L01 system
Failure code [DB90MC] BBC Error(PAGE 40- Electrical
DB90MC 554) WRK –
system
Failure code [DB91KA] Disconnection of Key Electrical
DB91KA SW ACC (BBC)(PAGE 40-555) WRK L03 system
Failure code [DB92KK] Solenoid Power Electrical
DB92KK Source Low (BBC)(PAGE 40-557) WRK L03 system

40-126 WA470-7
40 Troubleshooting
General information on troubleshooting

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [DB95KX] Failure of 5 V Power Electrical
DB95KX Source 1(PAGE 40-559) WRK L03 system
Failure code [DB96KX] Failure of 5 V Power Electrical
DB96KX Source 2(PAGE 40-561) WRK L03 system
Failure code [DB99KQ] Inconsistency of Electrical
DB99KQ Model Selection (BBC)(PAGE 40-563) WRK L03 system
Failure code [DB9LKA] Operating Lamp Open Electrical
DB9LKA Circuit (BBC)(PAGE 40-564) WRK –
system
Failure code [DB9LKB] Operating Lamp Short Electrical
DB9LKB Circuit (BBC)(PAGE 40-566) WRK –
system
Failure code [DB9QKR] CAN2 Discon (Bucket Electrical
DB9QKR Boom Con)(PAGE 40-568) MON L03 system
Failure code [DB9RKR] CAN1 Discon (Bucket Electrical
DB9RKR Boom Con)(PAGE 40-569) MON L03 system
Failure code [DB9RMA] Inconsistency of Electrical
DB9RMA Option Selection (BBC)(PAGE 40-570) WRK L03 system
Failure code [DBE5KX] Failure of 5V Power Electrical
DBE5KX Source(PAGE 40-571) TM L01 system
Failure code [DBE6KX] Failure of 24 V Power Electrical
DBE6KX Source(PAGE 40-573) TM L01 system
Failure code [DD1ALD] Ground Fault of Electrical
DD1ALD Remote Positioner Set SW(PAGE 40-575) WRK L01 system
Failure code [DDAAL6] Discon of Engine Electrical
DDAAL6 Shutdown Secondary Switch(PAGE 40-577) MON L03 system
Failure code [DDB6L4] Neutral Signal Electrical
DDB6L4 Malfunction(PAGE 40-579) TM L03 system
Failure code [DDD1LD] Failure of Bucket Electrical
DDD1LD Positioner Set Switch(PAGE 40-582) WRK L01 system
Failure code [DDK3KA] FNR SW Input Signal Electrical
DDK3KA Disconnection(PAGE 40-584) TM L03 system
Failure code [DDK3KB] FNR SW Input Signal Electrical
DDK3KB Short Circuit(PAGE 40-587) TM L03 system
Failure code [DDK6KA] FNR Lever Input Electrical
DDK6KA Signal Disconnection(PAGE 40-589) TM L03 system
Failure code [DDK6KB] FNR Lever Input Electrical
DDK6KB Signal Short Circuit(PAGE 40-592) TM L03 system
Failure code [DDNRKY] Hot Short of Work Electrical
DDNRKY Equipment Lock SW(PAGE 40-594) WRK L01 system
Failure code [DDT0L4] Failure of Shift Mode Electrical
DDT0L4 Select SW(PAGE 40-596) TM L01 system
Failure code [DDT4LD] Ground Fault of T/M Electrical
DDT4LD Cut Off Set SW Signal(PAGE 40-598) TM L01 system
Failure code [DDT9LD] Ground Fault of T/M Electrical
DDT9LD Cut Off SW Signal(PAGE 40-600) TM L01 system
Failure code [DDW9LD] Ground Fault of Electrical
DDW9LD Kickdown Switch(PAGE 40-602) TM L01 system
Failure code [DDWLLD] Ground Fault of T/M Electrical
DDWLLD Shift Hold SW(PAGE 40-604) TM L01 system
Failure code [DF10KA] Disconnection of Shift Electrical
DF10KA Lever Input(PAGE 40-606) TM L03 system
Failure code [DF10KB] Ground Fault of Shift Electrical
DF10KB Lever Input(PAGE 40-608) TM L03 system
Failure code [DGF1KA] Disconnection of T/M Electrical
DGF1KA Oil Temp. Sensor(PAGE 40-611) TM L01 system
Failure code [DGF1KB] Ground Fault of T/M Electrical
DGF1KB Oil Temp. Sensor(PAGE 40-613) TM L01 system

WA470-7 40-127
40 Troubleshooting
General information on troubleshooting

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [DGH2KX] Out of Range of HYD Electrical
DGH2KX Oil Temp. Sensor(PAGE 40-615) TM L01 system
Failure code [DGR2KB] Ground Fault of Brake Electrical
DGR2KB Oil Temp. Sensor(PAGE 40-617) MON L01 system
Failure code [DGR2KZ] Failure of Brake Oil Electrical
DGR2KZ Temp. Sensor(PAGE 40-618) MON L01 system
Failure code [DGT1KA] Disconnection of T/C Electrical
DGT1KA Oil Temp. Sensor(PAGE 40-620) TM L01 system
Failure code [DGT1KB] Ground Fault of T/C Electrical
DGT1KB Oil Temp. Sensor(PAGE 40-623) TM L01 system
Failure code [DH21KA] Failure of Loader Electrical
DH21KA Pump Press. Sensor(PAGE 40-625) WRK L01 system
Failure code [DH21KB] Loader Pump Press. Electrical
DH21KB Sensor Short Circuit(PAGE 40-627) WRK L01 system
Failure code [DHA4KA] Failure of Air Cleaner Electrical
DHA4KA Sensor Circuit(PAGE 40-629) MON L01 system
Failure code [DHPCKX] Out of Range of Electrical
DHPCKX Boom Bottom Press. Sensor(PAGE 40-631) WRK L01 system
Failure code [DHPDKX] Out of Range of Electrical
DHPDKX Boom Head Press. Sensor(PAGE 40-633) WRK L01 system
Failure code [DHT1KX] Out of Range of T/M Electrical
DHT1KX Cut Off Press. Sensor(PAGE 40-635) TM L01 system
Failure code [DHT5KX] Out of Range of T/C Electrical
DHT5KX Input Pressure Sensor(PAGE 40-637) TM L01 system
Failure code [DHT7KX] Out of Range of T/C Electrical
DHT7KX Output Pressure Sensor(PAGE 40-639) TM L01 system
Failure code [DHT8KA] Failure of Steering Electrical
DHT8KA Pump Press. Sensor(PAGE 40-641) WRK L01 system
Failure code [DHT8KB] Steering Pump Press. Electrical
DHT8KB Sensor Short Circuit(PAGE 40-643) WRK L01 system
Failure code [DHT8ZG] Steering Oil Pressure Mechanical
DHT8ZG Low(PAGE 40-645) WRK L03 system
Failure code [DHUDKA] Failure of Emrg. Electrical
DHUDKA Steering Press. Sensor(PAGE 40-646) WRK L01 system
Failure code [DHUDKB] Emrg. Steering Press. Electrical
DHUDKB S. Short Circuit(PAGE 40-648) WRK L01 system
Failure code [DJF1KA] Disconnection of Fuel Electrical
DJF1KA Level Sensor(PAGE 40-650) MON L01 system
Failure code [DK55KA] Failure of FNR Lever Electrical
DK55KA Potentio(PAGE 40-652) TM L01 system
Failure code [DK55KY] Hot Short of FNR Electrical
DK55KY Lever Potentio Circuit(PAGE 40-655) TM L01 system
Failure code [DK55L5] Failure of FNR Lever Electrical
DK55L5 Potentio(PAGE 40-657) TM L01 system
Failure code [DK59KA] Failure of Boom Lever Electrical
DK59KA Potentio (Main)(PAGE 40-658) WRK L03 system
Failure code [DK59KY] Hot Short of Boom Electrical
DK59KY Lever Potentio (Main)(PAGE 40-661) WRK L03 system
Failure code [DK59L8] Boom Lever Potentio Electrical
DK59L8 (Main & Sub) Disagree(PAGE 40-664) WRK L03 system
Failure code [DK5AKA] Failure of Boom Lever Electrical
DK5AKA Potentio (Sub)(PAGE 40-668) WRK L03 system
Failure code [DK5AKY] Hot Short of Boom Electrical
DK5AKY Lever Potentio (Sub)(PAGE 40-671) WRK L03 system
Failure code [DK5BKA] Failure of Bucket Electrical
DK5BKA Lever Potentio (Main)(PAGE 40-674) WRK L03 system

40-128 WA470-7
40 Troubleshooting
General information on troubleshooting

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [DK5BKY] Hot Short of Bucket Electrical
DK5BKY Lever Potentio (Main)(PAGE 40-677) WRK L03 system
Failure code [DK5BL8] Bucket Lever Potentio Electrical
DK5BL8 (Main&Sub) Disagree(PAGE 40-680) WRK L03 system
Failure code [DK5CKA] Failure of Bucket Electrical
DK5CKA Lever Potentio (Sub)(PAGE 40-684) WRK L03 system
Failure code [DK5CKY] Hot Short of Bucket Electrical
DK5CKY Lever Potentio (Sub)(PAGE 40-687) WRK L03 system
Failure code [DK5DKA] Failure of 3rd Lever Electrical
DK5DKA Potentio (Main)(PAGE 40-690) WRK L03 system
Failure code [DK5DKY] Hot Short of 3rd Lever Electrical
DK5DKY Potentio (Main)(PAGE 40-693) WRK L03 system
Failure code [DK5DL8] 3rd Lever Potentio Electrical
DK5DL8 (Main & Sub) Disagree(PAGE 40-695) WRK L03 system
Failure code [DK5EKA] Failure of 3rd Lever Electrical
DK5EKA Potentio (Sub)(PAGE 40-698) WRK L03 system
Failure code [DK5EKY] Hot Short of 3rd Lever Electrical
DK5EKY Potentio (Sub)(PAGE 40-701) WRK L03 system
Failure code [DKA0KA] Failure of Boom Angle Electrical
DKA0KA Sensor(PAGE 40-703) WRK L01 system
Failure code [DKA0KY] Hot Short of Boom Electrical
DKA0KY Angle Sensor Circuit(PAGE 40-705) WRK L01 system
Failure code [DKA0L0] Boom Angle Sensor Electrical
DKA0L0 Dislocation(PAGE 40-707) WRK L01 system
Failure code [DKA1KA] Failure of Bucket Electrical
DKA1KA Angle Sensor(PAGE 40-709) WRK L01 system
Failure code [DKA1KY] Hot Short of Bucket Electrical
DKA1KY Angle Sensor Circuit(PAGE 40-711) WRK L01 system
Failure code [DLF1KA] Disconnection of T/M Electrical
DLF1KA Input Speed Sensor(PAGE 40-713) TM L03 system
Failure code [DLF1LC] Failure of T/M Input Electrical
DLF1LC Speed Sensor(PAGE 40-715) TM L03 system
Failure code [DLM3KA] Disconnection of Electrical
DLM3KA Radiator Fan Speed Sensor(PAGE 40-717) TM L01 system
Failure code [DLM3LC] Failure of Radiator Electrical
DLM3LC Fan Speed Sensor(PAGE 40-719) TM L01 system
Failure code [DLT3KA] Disconnection of Electrical
DLT3KA Output Speed Sens. (Main)(PAGE 40-721) TM L03 system
Failure code [DLT3LC] Failure of Output Electrical
DLT3LC Speed Sensor (Main)(PAGE 40-723) TM L03 system
Failure code [DPQ1KR] LIN Discon (Switch Electrical
DPQ1KR Panel)(PAGE 40-725) MON L01 system
Failure code [DPQ2KR] LIN Discon (LED Unit) Electrical
DPQ2KR (PAGE 40-728) MON L01 system
Failure code [DPQ3KR] LIN Discon (Rear Electrical
DPQ3KR View Monitor)(PAGE 40-731) MON L01 system
Failure code [DSJ0KR] CAN2 Discon (Meter Electrical
DSJ0KR Unit)(PAGE 40-734) MON L01 system
Failure code [DT20KB] Ground Fault of T/M Electrical
DT20KB Cut Off Indicator(PAGE 40-736) TM L01 system
Failure code [DT22KB] Ground Fault of Work Electrical
DT22KB Equip. Lock Indic.(PAGE 40-738) WRK L01 system
Failure code [DV00KB] Ground Fault of Electrical
DV00KB Buzzer Output(PAGE 40-740) MON L01 system
Failure code [DW4PKA] Disconnection of Electrical
DW4PKA Boom EPC Solenoid (Raise)(PAGE 40-742) WRK L03 system

WA470-7 40-129
40 Troubleshooting
General information on troubleshooting

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [DW4PKB] Ground Fault of Electrical
DW4PKB Boom EPC Solenoid (Raise)(PAGE 40-744) WRK L03 system
Failure code [DW4PKY] Hot Short of Boom Electrical
DW4PKY EPC Solenoid (Raise)(PAGE 40-746) WRK L03 system
Failure code [DW4QKA] Disconnection of Electrical
DW4QKA Boom EPC Solenoid (Lower)(PAGE 40-748) WRK L03 system
Failure code [DW4QKB] Ground Fault of Electrical
DW4QKB Boom EPC Solenoid (Lower)(PAGE 40-750) WRK L03 system
Failure code [DW4QKY] Hot Short of Boom Electrical
DW4QKY EPC Solenoid (Lower)(PAGE 40-752) WRK L03 system
Failure code [DW4RKA] Disconnection of Electrical
DW4RKA Bucket EPC Sol. (Tilt)(PAGE 40-754) WRK L03 system
Failure code [DW4RKB] Ground Fault of Electrical
DW4RKB Bucket EPC Solenoid (Tilt)(PAGE 40-756) WRK L03 system
Failure code [DW4RKY] Hot Short of Bucket Electrical
DW4RKY EPC Solenoid (Tilt)(PAGE 40-758) WRK L03 system
Failure code [DW4SKA] Disconnection of Electrical
DW4SKA Bucket EPC Sol. (Dump)(PAGE 40-760) WRK L03 system
Failure code [DW4SKB] Ground Fault of Electrical
DW4SKB Bucket EPC Solenoid (Dump)(PAGE 40-762) WRK L03 system
Failure code [DW4SKY] Hot Short of Bucket Electrical
DW4SKY EPC Solenoid (Dump)(PAGE 40-764) WRK L03 system
Failure code [DW7BKA] Disconnection of Fan Electrical
DW7BKA Reverse Solenoid(PAGE 40-766) TM L01 system
Failure code [DW7BKB] Ground Fault of Electrical
DW7BKB Radiator Fan Rev. Sol.(PAGE 40-768) TM L01 system
Failure code [DW7BKY] Hot Short of Radiator Electrical
DW7BKY Fan Rev. Sol.(PAGE 40-770) TM L01 system
Failure code [DWM1KA] Disconnection of Electrical
DWM1KA Neutral Lock Solenoid(PAGE 40-771) WRK L01 system
Failure code [DWM1KB] Ground Fault of Electrical
DWM1KB Neutral Lock Solenoid(PAGE 40-773) WRK L01 system
Failure code [DWM1KY] Hot Short of Neutral Electrical
DWM1KY Lock Solenoid(PAGE 40-775) WRK L01 system
Failure code [DWN6KA] Disconnection of Electrical
DWN6KA Detent Solenoid (Boom)(PAGE 40-777) WRK L01 system
Failure code [DWN6KB] Ground Fault of Electrical
DWN6KB Detent Solenoid (Boom)(PAGE 40-779) WRK L01 system
Failure code [DWN6KY] Hot Short of Detent Electrical
DWN6KY Solenoid (Boom)(PAGE 40-781) WRK L01 system
Failure code [DWN8KA] Disconnection of Electrical
DWN8KA Detent Solenoid (Bucket)(PAGE 40-783) WRK L01 system
Failure code [DWN8KB] Ground Fault of Electrical
DWN8KB Detent Solenoid (Bucket)(PAGE 40-785) WRK L01 system
Failure code [DWN8KY] Hot Short of Detent Electrical
DWN8KY Solenoid (Bucket)(PAGE 40-787) WRK L01 system
Failure code [DX16KA] Disconnection of Rad. Electrical
DX16KA Fan Pump EPC Sol.(PAGE 40-789) TM L03 system
Failure code [DX16KB] Ground Fault of Rad. Electrical
DX16KB Fan Pump EPC Sol.(PAGE 40-791) TM L03 system
Failure code [DX16KY] Hot Short of Radiator Electrical
DX16KY Fan Pump EPC Sol.(PAGE 40-793) TM L01 system
Failure code [DXA1KA] Disconnection of Electrical
DXA1KA Loader Pump EPC Solenoid(PAGE 40-795) WRK L01 system
Failure code [DXA1KB] Ground Fault of Electrical
DXA1KB Loader Pump EPC Solenoid(PAGE 40-797) WRK L01 system

40-130 WA470-7
40 Troubleshooting
General information on troubleshooting

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [DXA1KY] Hot Short of Loader Electrical
DXA1KY Pump EPC Solenoid(PAGE 40-799) WRK L01 system
Failure code [DXANKA] Disconnection of Electrical
DXANKA Steering Pump EPC Sol.(PAGE 40-801) WRK L01 system
Failure code [DXANKB] Ground Fault of Electrical
DXANKB Steering Pump EPC Solenoid(PAGE 40-803) WRK L01 system
Failure code [DXANKY] Hot Short of Steering Electrical
DXANKY Pump EPC Solenoid(PAGE 40-805) WRK L01 system
Failure code [DXH1KA] Disconnection of Electrical
DXH1KA ECMV Solenoid (Lockup)(PAGE 40-806) TM L03 system
Failure code [DXH1KB] Ground Fault of Electrical
DXH1KB ECMV Solenoid (Lockup)(PAGE 40-808) TM L03 system
Failure code [DXH1KY] Hot Short of ECMV Electrical
DXH1KY Solenoid (Lockup)(PAGE 40-810) TM L03 system
Failure code [DXH4KA] Disconnection of Electrical
DXH4KA ECMV Solenoid (1st)(PAGE 40-812) TM L03 system
Failure code [DXH4KB] Ground Fault of Electrical
DXH4KB ECMV Solenoid (1st)(PAGE 40-814) TM L03 system
Failure code [DXH4KY] Hot Short of ECMV Electrical
DXH4KY Solenoid (1st)(PAGE 40-816) TM L03 system
Failure code [DXH5KA] Disconnection of Electrical
DXH5KA ECMV Solenoid (2nd)(PAGE 40-818) TM L03 system
Failure code [DXH5KB] Ground Fault of Electrical
DXH5KB ECMV Solenoid (2nd)(PAGE 40-820) TM L03 system
Failure code [DXH5KY] Hot Short of ECMV Electrical
DXH5KY Solenoid (2nd)(PAGE 40-822) TM L03 system
Failure code [DXH6KA] Disconnection of Electrical
DXH6KA ECMV Solenoid (3rd)(PAGE 40-824) TM L03 system
Failure code [DXH6KB] Ground Fault of Electrical
DXH6KB ECMV Solenoid (3rd)(PAGE 40-826) TM L03 system
Failure code [DXH6KY] Hot Short of ECMV Electrical
DXH6KY Solenoid (3rd)(PAGE 40-828) TM L03 system
Failure code [DXH7KA] Disconnection of Electrical
DXH7KA ECMV Solenoid (Reverse)(PAGE 40-830) TM L03 system
Failure code [DXH7KB] Ground Fault of Electrical
DXH7KB ECMV Solenoid (Reverse)(PAGE 40-832) TM L03 system
Failure code [DXH7KY] Hot Short of ECMV Electrical
DXH7KY Solenoid (Reverse)(PAGE 40-834) TM L03 system
Failure code [DXH8KA] Disconnection of Electrical
DXH8KA ECMV Solenoid (Forward)(PAGE 40-836) TM L03 system
Failure code [DXH8KB] Ground Fault of Electrical
DXH8KB ECMV Solenoid (Forward)(PAGE 40-838) TM L03 system
Failure code [DXH8KY] Hot Short of ECMV Electrical
DXH8KY Solenoid (Forward)(PAGE 40-840) TM L03 system
Failure code [DXHHKA] Disconnection of Electrical
DXHHKA ECMV Solenoid (4th)(PAGE 40-842) TM L03 system
Failure code [DXHHKB] Ground Fault of Electrical
DXHHKB ECMV Solenoid (4th)(PAGE 40-844) TM L03 system
Failure code [DXHHKY] Hot Short of ECMV Electrical
DXHHKY Solenoid (4th)(PAGE 40-846) TM L03 system
Failure code [DXHJKA] Disconnection of 3rd Electrical
DXHJKA EPC Solenoid (EXT)(PAGE 40-848) WRK L03 system
Failure code [DXHJKB] Ground Fault of 3rd Electrical
DXHJKB EPC Solenoid (EXT)(PAGE 40-850) WRK L03 system
Failure code [DXHJKY] Hot Short of 3rd EPC Electrical
DXHJKY Solenoid (EXT)(PAGE 40-852) WRK L03 system

WA470-7 40-131
40 Troubleshooting
General information on troubleshooting

Failure Action Category


Failure (Displayed on screen) Controller Remarks
code level history
Failure code [DXHKKA] Disconnection of 3rd Electrical
DXHKKA EPC Solenoid (RET)(PAGE 40-854) WRK L03 system
Failure code [DXHKKB] Ground Fault of 3rd Electrical
DXHKKB EPC Solenoid (RET)(PAGE 40-856) WRK L03 system
Failure code [DXHKKY] Hot Short of 3rd EPC Electrical
DXHKKY Solenoid (RET)(PAGE 40-858) WRK L03 system
Failure code [DY30MA] Malfunction 1 of Electrical
DY30MA Emerg. Steering Motor(PAGE 40-860) WRK L01 system
Failure code [DY30MC] Malfunction 2 of Electrical
DY30MC Emerg. Steering Motor(PAGE 40-863) WRK L03 system
Failure code [DY30ME] Emerg. Steering Mechanical
DY30ME Long-Time Activated(PAGE 40-867) WRK L02 system
Failure code [LA00L3] Failure of Fan Reverse Mechanical
LA00L3 (PAGE 40-869) TM L01 system

a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a A component in charge is a controller or the machine monitor in charge of the system check.
MON: Machine monitor
ENG: Engine controller
PT: power train controller
WE: Work equipment controller
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
a The history classification column shows in which system each failure is classified, the electrical system or
mechanical system, when it is recorded in the abnormality record.
For details, see "Troubleshooting by failure code (Display of code)".

40-132 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)

Failure code [1500L0] Double Engagement of T/M Clutches (WA380_7-1500L0-400-A-


Z0-A)

Action level Failure code Double Engagement of T/M Clutches


Failure
L04 1500L0 (Transmission controller system)
Detail of • Fill switch ON signals from impossible combination of two or more clutches are input.
failure
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position once.
• Shifts gear speed to NEUTRAL.
Problem on • Transmission can be damaged.
machine • Machine cannot travel.
• Other failure code (failure code related to clutch pressure control valve system: 15S*L1) is
Related generated together.
information • Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
Generation of failure code
1 (15S*L1) related to clutch Perform troubleshooting for generated failure code.
pressure control valve
Defective hydraulic or Clutch ECMV may malfunction. Perform troubleshooting of hydraulic
2 mechanical system of clutch and mechanical systems.
ECMV

WA470-7 40-133
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SAL1] Release Trouble of ECMV (Forward) (WA380_7-15SAL1-400-A-


Z0-A)

Action level Failure code Release Trouble of ECMV (Forward)


Failure
L03 15SAL1 (Transmission controller system)
Detail of • When controller does not drive F (forward) ECMV solenoid, ON signal is input from F
failure (forward) ECMV fill switch and F clutch is not disengaged.
• Determines that F (forward) ECMV fill switch signal is ON.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (NEUTRAL) position.
Problem on
• Machine can travel forward but cannot travel in reverse.
machine
• Output current value to F (forward) clutch ECMV solenoid can be checked with monitoring
function. (Code: 31608 "ECMV Current (Forward)")
• Input signal (ON/OFF) from F (Forward) clutch fill switch can be checked with monitoring
Related function (0: OFF, 1: ON) (Code: 02216 "F clutch").
information • First, check for mechanical trouble such as clogged oil filter of F clutch or pressure control
valve.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if clutches other than F (forward) clutch do not have
Abnormal F (forward) remaining pressure and only F (forward) clutch has remaining pressure.
1 clutch pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Turn starting switch to OFF position.
2. Disconnect connector F.SW.
3. Turn starting switch to ON position.
If failure code [15SAL1] disappears, F clutch fill switch is defective.
Defective F (forward) a If failure code [15SAL1] is still displayed, wiring harness has ground fault
2
clutch fill switch or transmission controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector F.SW, and connect T-adapter to male side.
Between F.SW (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch turned OFF)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and F.SW, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L62 (female) (12) or F.SW
circuit) Resistance (female) (1) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
Defective transmission 5. Set parking brake switch to OFF position.
4
controller 6. Depress brake pedal to prevent machine from starting.
Directional (FNR) lever
or directional selector Max. 1 V
Between L62 (12) and (FNR) switch: F (forward)
Voltage
ground Directional (FNR) lever
or directional selector 7 to 9 V
(FNR) switch: F (forward)

40-134 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to F clutch ECMV

WA470-7 40-135
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SALH] Malfunction of ECMV (Forward) (WA380_7-15SALH-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (Forward)


Failure
L01 15SALH (Transmission controller system)
Detail of • When controller drives F (forward) ECMV solenoid, ON signal is not input from F (forward)
failure ECMV fill switch.
Action of • Determines that F (forward) ECMV fill switch signal is OFF.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Directional selection may cause shifting shocks or have time lag.
machine
• This failure code may appear immediately after replacement of transmission oil.
• Output current value to F (forward) clutch ECMV solenoid can be checked with monitoring
function. (Code: 31608 "ECMV Current (Forward)")
• Input signal (ON/OFF) from F (Forward) clutch fill switch can be checked with monitoring
Related function (0: OFF, 1: ON) (Code: 02216 "F clutch").
information • First, check for mechanical trouble such as clogged oil filter of F clutch or pressure control
valve.
• Method of reproducing failure code: Start engine and set directional (FNR) lever or R.H.
directional selector (FNR) switch to F (forward).
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if F (forward) clutch pressure is not detected when
Abnormal F (forward) the F (forward) ECMV solenoid is energized.
1 clutch pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed R2 (R: 2nd)
and check that failure code [15SBLH] does not appear.
3. Turn starting switch to OFF position.
4. Interchange connections of connectors of R clutch and F clutch.
• R.PS io F.PS
Defective F (forward) • R.SW io F.SW
2 clutch fill switch 5. Start engine.
(internal open circuit) 6. While depressing brake pedal, move shift lever to gear speed R2 (R: 2nd).
a If failure code [15SBLH] appears, check clutch pressure. If clutch pressure
is normal, F clutch fill switch is defective.
a If failure code [15SBLH] does not appear, wiring harness has open circuit
or transmission controller is defective.
a After check, return connectors to their original positions.
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector F.SW and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between F.SW (female) (1) and ground 7 to 9 V
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L62 and F.SW, and connect T-adapters to each
defective contact of female side.
connector) Max. 1z
Resistance Between L62 (female) (12) and F.SW (female) (1)

40-136 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to the OFF position.
Defective transmission 5. Set parking brake switch to the OFF position.
5 6. Depress brake pedal to prevent machine from starting.
controller
Directional (FNR) lever
or directional selector Max. 1 V
(FNR) switch: F (forward)
Between L62 (12) and
Voltage Directional (FNR) lever
ground
or directional selector
(FNR) switch: Other than 7 to 9 V
F (forward)

Circuit diagram related to F clutch ECMV

WA470-7 40-137
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SBL1] Release Trouble of ECMV (Reverse) (WA380_7-15SBL1-400-A-Z0-


A)

Action level Failure code Release Trouble of ECMV (Reverse)


Failure
L03 15SBL1 (Transmission controller system)
Detail of • When controller does not drive R (reverse) clutch ECMV solenoid, ON signal is input from
failure R (reverse) ECMV fill switch and R clutch is not disengaged.
• Determines that R (reverse) clutch fill switch signal is ON.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (NEUTRAL) position.
Problem on
• Machine can travel in reverse but cannot travel forward.
machine
• Output current value to R (reverse) clutch ECMV solenoid can be checked with monitoring
function. (Code: 31606 "ECMV Current (Reverse)")
• Input signal (ON/OFF) from R (reverse) clutch fill switch can be checked with monitoring
Related function (0: OFF, 1: ON) (Code: 02216 "R Clutch").
information • First, check for mechanical trouble such as clogged oil filter of R clutch or pressure control
valve.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if clutches other than R (reverse) clutch do not have
Abnormal R (reverse) remaining pressure and only R (reverse) clutch has remaining pressure.
1 clutch pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Turn starting switch to OFF position.
2. Disconnect connector R.SW.
3. Turn starting switch to ON position.
If failure code [15SBL1] is not displayed, R clutch fill switch is defective.
Defective R (reverse) a If failure code [15SBL1] is still displayed, wiring harness has ground fault
2
clutch fill switch or transmission controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector R.SW and connect T-adapter to male side.
Between R.SW (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch turned OFF)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors R.SW and L62, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L62 (female) (2) or R.SW
circuit) Resistance (female) (1) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to the OFF position.
5. Set parking brake switch to the OFF position.
Defective transmission 6. Depress brake pedal to prevent machine from starting.
4
controller
Directional (FNR) lever
or directional selector
(FNR) switch: R Max. 1 V
Between L62 (female) (reverse)
Voltage
(2) and ground Directional (FNR) lever
or directional selector
(FNR) switch: Other than 7 to 9 V
R (reverse)

40-138 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch ECMV solenoid

WA470-7 40-139
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SBLH] Malfunction of ECMV (Reverse) (WA380_7-15SBLH-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (Reverse)


Failure
L01 15SBLH (Transmission controller system)
Detail of • When controller drives R (reverse) ECMV solenoid, ON signal is not input from R
failure (reverse) ECMV fill switch.
Action of • Determines that R (reverse) ECMV fill switch signal is OFF.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Directional selection may cause shifting shocks or have time lag.
machine
• This failure code may appear immediately after replacement of transmission oil.
• Output current value to R (reverse) clutch ECMV solenoid can be checked with monitoring
function. (Code: 31606 "ECMV Current (Reverse)")
• Input signal (ON/OFF) from R (reverse) clutch fill switch can be checked with monitoring
Related function (0: OFF, 1: ON) (Code: 02216 "R Clutch").
information • First, check for mechanical trouble such as clogged oil filter of R clutch or pressure control
valve.
• Method of reproducing failure code: Start engine and set directional (FNR) lever or R.H.
directional selector (FNR) switch to R (reverse).
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if R (reverse) clutch pressure is not detected when
Abnormal R (reverse) the R (reverse) ECMV solenoid is turned ON.
1 clutch pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Start engine.
2. While depressing brake pedal, move the shift lever to gear speed F2 (F:
2nd) and check that failure code [15SALH] does no appear.
3. Turn starting switch to OFF position.
4. Interchange connections of connectors of R clutch and F clutch.
• R.PS io F.PS
Defective R (reverse) • R.SW io F.SW
2 clutch fill switch 5. Start engine.
(internal open circuit) 6. While depressing brake pedal, move shift lever to gear speed F2 (F: 2nd).
a If failure code [15SALH] appears, check clutch pressure. If clutch pressure
is normal, R clutch fill switch is defective.
a If failure code [15SALH] does not appear, wiring harness has open circuit
or transmission controller is defective.
a After check, return connectors to their original positions.
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R.SW and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R.SW (female) (1) and ground 7 to 9 V
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L62 and R.SW, and connect T-adapters to each
defective contact of female side.
connector) Max. 1z
Resistance Between L62 (female) (2) and R.SW (female) (1)

40-140 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
5. Set parking brake switch to OFF position.
Defective transmission 6. Depress brake pedal to prevent machine from starting.
5
controller
Directional (FNR) lever
or directional selector
(FNR) switch: R Max. 1 V
Between L62 (female) (reverse)
Voltage
(2) and ground Directional (FNR) lever
or directional selector
(FNR) switch: Other than 7 to 9 V
R (reverse)

Circuit diagram related to R clutch ECMV solenoid

WA470-7 40-141
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SEL1] Release Trouble of ECMV (1st) (WA380_7-15SEL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (1st)


Failure
L03 15SEL1 (Transmission controller system)
Detail of • When controller does not drive 1st ECMV solenoid, ON signal is input from 1st clutch fill
failure switch and 1st clutch is not disengaged.
• Determines that 1st ECMV fill switch signal is ON.
• Continues to stop driving 2nd, 3rd and 4th clutch proportional solenoids.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (NEUTRAL) position.
Problem on • Machine may be able to travel in 1st gear speed but cannot travel in 2nd, 3rd, nor 4th gear
machine speed.
• Output current value to 1st clutch ECMV solenoid can be checked with monitoring
function. (Code: 31602 "ECMV Current (1st)")
• Input signal (ON/OFF) from 1st clutch fill switch can be checked with monitoring function.
Related (0: OFF, 1: ON) (Code: 02216 "1st clutch")
information • First, check for mechanical failures such as problem in 1st clutch, clogged oil filter of
pressure control valve, etc.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if clutches other than 1st clutch do not have
Abnormal 1st clutch remaining pressure and only 1st clutch has remaining pressure.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Turn starting switch to OFF position.
2. Disconnect connector 1.SW.
3. Turn starting switch to ON position.
If failure code [15SEL1] disappears, 1st clutch fill switch is defective.
Defective 1st clutch fill a If failure code [15SEL1] is still displayed, wiring harness has ground fault
2
switch or transmission controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector 1.SW, and connect T-adapter to male side.
Between 1.SW (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch turned OFF)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors 1.SW and L62, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L62 (female) (17) or 1.SW
circuit) Resistance (female) (1) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
Defective transmission 5. Set parking brake switch to OFF position.
4
controller 6. Depress brake pedal to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Between L62 (17) and Gear shift lever: 1st Max. 1 V
Voltage Gear shift lever: Other
ground 7 to 9 V
than 1st

40-142 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 1st clutch

WA470-7 40-143
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SELH] Malfunction of ECMV (1st) (WA380_7-15SELH-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (1st)


Failure
L01 15SELH (Transmission controller system)
Detail of • When controller drives 1st clutch ECMV solenoid, ON signal is not input from 1st clutch
failure ECMV fill switch.
Action of • Determines that 1st ECMV fill switch signal is ON.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Machine may not be able to travel in 1st gear speed.
machine • Shifting to 1st gear speed may cause shifting shocks or time lag.
• This failure code may appear immediately after replacement of transmission oil.
• Output current value to 1st clutch ECMV solenoid can be checked with monitoring
function. (Code: 31602 "ECMV Current (1st)")
• Input signal (ON/OFF) from 1st clutch fill switch can be checked with monitoring function.
Related (0: OFF, 1: ON) (Code: 02216 "1st clutch")
information • First, check for mechanical failures such as problem in 1st clutch, clogged oil filter of
pressure control valve, etc.
• Method of reproducing failure code: Start engine, turn manual/auto shift selector switch to
"MANUAL", move directional (FNR) lever or set R.H. directional selector (FNR) switch to
F (forward) or R (reverse) position, and set shift lever to 1st speed.
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if 1st clutch pressure is not detected when the 1st
Abnormal 1st clutch clutch ECMV solenoid is energized.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F4 (F: 4th),
and check that failure code [15SHLH] does not appear.
3. Turn starting switch to OFF position.
4. Interchange connections of connectors of 1st clutch and 4th clutch.
• 1.PS io 4.PS
• 1.SW io 4.SW
Defective 1st clutch fill 5. Start engine.
2 switch (internal open 6. While depressing brake pedal, set manual/auto shift selector switch to
circuit) "MANUAL", and move shift lever to gear speed F4 (F: 4th).
a If failure code [15SHLH] appears, check clutch pressure. If clutch pressure
is normal, 1st clutch fill switch is defective.
a If failure code [15SHLH] does not appear, wiring harness has open circuit
or transmission controller is defective.
a After check, return connectors to their original positions.
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector 1.SW, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between 1.SW (female) (1) and ground 7 to 9 V
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L62 and 1.SW, and connect T-adapters to each
defective contact of female side.
connector) Max. 1z
Resistance Between L62 (female) (17) and 1.SW (female) (1)

40-144 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to the OFF position.
Defective transmission 5. Set parking brake switch to the OFF position.
5
controller 6. Depress brake pedal to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Between L62 (17) and Gear shift lever: 1st Max. 1 V
Voltage Gear shift lever: Other
ground 7 to 9 V
than 1st

Circuit diagram related to 1st clutch ECMV

WA470-7 40-145
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SFL1] Release Trouble of ECMV (2nd) (WA380_7-15SFL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (2nd)


Failure
L03 15SFL1 (Transmission controller system)
Detail of • When controller does not drive 2nd clutch ECMV solenoid, ON signal is input from 2nd
failure clutch fill switch and 2nd clutch is not disengaged.
• Determines that 2nd clutch fill switch signal is ON.
• Continues to stop driving 2nd, 3rd and 4th clutch proportional solenoids.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
Problem on • Machine may be able to travel in 2nd gear speed but cannot travel in 1st, 3rd or 4th gear
machine speed.
• Output current value to 2nd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31603 ECMV solenoid current (2nd))
• Input signal (ON/OFF) from 2nd clutch fill switch can be checked with monitoring function.
Related (Code: 02216 2nd clutch) (0: OFF, 2: ON)
information • First, check for mechanical trouble such as clogged oil filter of 2nd clutch or pressure
control valve.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if clutches other than 2nd clutch do not have
Abnormal 2nd clutch remaining oil pressure and only 2nd clutch has remaining pressure.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Turn starting switch to OFF position.
2. Disconnect connector 2.SW.
3. Turn starting switch to ON position.
If failure code [15SFL1] disappears, 2nd clutch fill switch is defective.
Defective 2nd clutch fill a If failure code [15SFL1] is still displayed, wiring harness has ground fault
2
switch or transmission controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector 2.SW, and connect T-adapters to male side.
Between 2.SW (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch turned: OFF)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors 2.SW and L62, and connect T-adapters to either
3 female side.
(contact with ground
Between ground and L62 (female) (7) or 2.SW
circuit) Resistance (female) (1) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF.
Defective transmission 5. Set parking brake switch to OFF.
4
controller 6. Depress brake to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(FORWARD) or R (REVERSE) position.
Between L62 (female) Shift lever: 2nd Max. 1 V
Voltage Shift lever: Other than
(7) and ground 7 to 9 V
2nd

40-146 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 2nd clutch ECMV

WA470-7 40-147
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SFLH] Malfunction of ECMV (2nd) (WA380_7-15SFLH-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (2nd)


Failure
L01 15SFLH (Transmission controller system)
Detail of • When controller drives 2nd clutch ECMV solenoid, ON signal is not input from 2nd ECMV
failure fill switch.
Action of • Determines that 2nd clutch fill switch signal is OFF.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Machine may not be able to travel in 2nd gear speed.
machine • Shifting to 2nd gear speed may cause shifting shocks or time lag.
• This failure code may appear immediately after replacement of transmission oil.
• Output current value to 2nd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31603 "ECMV Current (2nd)")
• Input signal (ON/OFF) from 2nd clutch fill switch can be checked with monitoring function.
Related (0: OFF, 2: ON) (Code: 02216 "2nd clutch")
information • First, check for mechanical failures such as problem in 2nd clutch, clogged oil filter of
pressure control valve, etc.
• Method of reproducing failure code: Start engine, turn manual/auto shift selector switch to
"MANUAL", move directional (FNR) lever or set R.H. directional selector (FNR) switch to
F (forward) or R (reverse) position, and set shift lever to 2nd speed.
No. Cause Procedure, measuring location, criteria and remarks
If 2nd clutch pressure is not detected when 2nd ECMV solenoid is energized,
Abnormal 2nd clutch this failure code appears.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F3 (F: 3rd)
and check that failure code [15SGLH] does no appear.
3. Turn starting switch to OFF position.
4. Interchange connections of connectors of 2nd clutch and 3rd clutch.
• 2.PS io 3.PS
• 2.SW io 3.SW
Defective 2nd clutch fill 5. Start engine.
2 switch (internal open 6. While depressing brake pedal, set manual/auto shift selector switch to
circuit) "MANUAL", and move shift lever to gear speed F3 (F: 3rd).
a If failure code [15SGLH] appears, check clutch pressure. If clutch pressure
is normal, 2nd clutch fill switch is defective.
a If failure code [15SGLH] does not appear, wiring harness has open circuit
or transmission controller is defective.
a After check, return connectors to their original positions.
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector 2.SW, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between 2.SW (female) (1) and ground 7 to 9 V
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L62 and 2.SW, and connect T-adapters to each
defective contact of female side.
connector) Max. 1z
Resistance Between L62 (female) (7) and 2.SW (female) (1)

40-148 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
Defective transmission 5. Set parking brake switch to OFF position.
5
controller 6. Depress brake pedal to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Between L62 (female) Gear shift lever: 2nd Max. 1 V
Voltage Gear shift lever: Other
(7) and ground 7 to 9 V
than 2nd

Circuit diagram related to 2nd clutch ECMV

WA470-7 40-149
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SGL1] Release Trouble of ECMV (3rd) (WA380_7-15SGL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (3rd)


Failure
L03 15SGL1 (Transmission controller system)
Detail of • When controller does not drive 3rd clutch ECMV solenoid, ON signal is input from 3rd
failure ECMV fill switch and 3rd clutch is not disengaged.
• Determines that 3rd ECMV fill switch signal is ON.
• Continues to stop driving 1st, 2nd, and 4th clutch proportional solenoids.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (NEUTRAL) position.
Problem on • Machine may be able to travel in 3rd gear speed but cannot travel in 1st, 2nd, nor 4th gear
machine speed.
• Output current value to 3rd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31604 "ECMV Current (3rd)")
• Input signal (ON/OFF) from 3rd clutch fill switch can be checked with monitoring function.
Related (0: OFF, 1: ON) (Code: 02216 "3rd clutch")
information • First, check for mechanical failures such as problem in 3rd clutch, clogged oil filter of
pressure control valve, etc.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if clutches other than 3rd clutch do not have
Abnormal 3rd clutch remaining pressure and only 3rd clutch has remaining pressure.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Turn starting switch to OFF position.
2. Disconnect connector 3.SW.
3. Turn starting switch to ON position.
If failure code [15SGL1] disappears, 3rd clutch fill switch is defective.
Defective 1st clutch fill a If failure code [15SGL1] is still displayed, wiring harness has ground fault
2
switch or transmission controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector 3.SW, and connect T-adapter to male side.
Between 3.SW (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch turned OFF)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors 3.SW and L62, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L62 (female) (13) or 3.SW
circuit) Resistance (female) (1) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
Defective transmission 5. Set parking brake switch to OFF position.
4
controller 6. Depress brake pedal to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Between L62 (female) Gear shift lever: 3rd Max. 1 V
Voltage Gear shift lever: Other
(13) and ground 7 to 9 V
than 3rd

40-150 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd clutch ECMV solenoid

WA470-7 40-151
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SGLH] Malfunction of ECMV (3rd) (WA380_7-15SGLH-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (3rd)


Failure
L01 15SGLH (Transmission controller system)
Detail of • When controller drives 3rd clutch ECMV solenoid, ON signal is not input from 3rd clutch
failure fill switch.
Action of • Determines that 3rd clutch fill switch signal is OFF.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Machine may not be able to travel in 3rd gear speed.
machine • Shifting to 3rd gear speed may cause shifting shocks or time lag.
• This failure code may appear immediately after replacement of transmission oil.
• Output current value to 3rd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31604 "ECMV Current (3rd)")
• Input signal (ON/OFF) from 3rd clutch fill switch can be checked with monitoring function.
Related (0: OFF, 1: ON) (Code: 02216 "3rd clutch")
information • First, check for mechanical failures such as problem in 3rd clutch, clogged oil filter of
pressure control valve, etc.
• Method of reproducing failure code: Start engine, turn manual/auto shift selector switch to
"MANUAL", move directional (FNR) lever or set R.H. directional selector (FNR) switch to
F (forward) or R (reverse) position, and set shift lever to 3rd speed.
No. Cause Procedure, measuring location, criteria and remarks
If 3rd clutch pressure is not detected when 3rd ECMV solenoid is energized,
Abnormal 3rd clutch this failure code appears.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F2 (F: 2nd)
and check that failure code [15SFLH] does no appear.
3. Turn starting switch to OFF position.
4. Interchange connections of connectors of 2nd clutch and 3rd clutch.
• 2.PS io 3.PS
• 2.SW io 3.SW
Defective 3rd clutch fill 5. Start engine.
2 switch (internal open 6. While depressing brake pedal, set manual/auto shift selector switch to
circuit) "MANUAL", and move shift lever to gear speed F2 (F: 2nd).
a If failure code [15SFLH] appears, check clutch pressure. If clutch pressure
is normal, 3rd clutch fill switch is defective.
a If failure code [15SFLH] does not appear, wiring harness has open circuit
or transmission controller is defective.
a After check, return connectors to their original positions.
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector 3.SW, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between 3.SW (female) (1) and ground 7 to 9 V
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L62 and 3.SW, and connect T-adapters to each
defective contact of female side.
connector) Max. 1z
Resistance Between L62 (female) (13) and 3.SW (female) (1)

40-152 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
Defective transmission 5. Set parking brake switch to OFF position.
5
controller 6. Depress brake pedal to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Between L62 (13) and Gear shift lever: 3rd Max. 1 V
Voltage Gear shift lever: Other
ground 7 to 9 V
than 3rd

Circuit diagram related to 3rd clutch ECMV

WA470-7 40-153
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SHL1] Release Trouble of ECMV (4th) (WA380_7-15SHL1-400-A-Z0-A)

Action level Failure code Release Trouble of ECMV (4th)


Failure
L03 15SHL1 (Transmission controller system)
Detail of • When controller does not drive 4th clutch ECMV solenoid, ON signal is input from 4th
failure ECMV fill switch and 4th clutch is not disengaged.
• Determines that 4th ECMV fill switch signal is ON.
• Continues to stop driving 1st, 2nd, and 3rd clutch proportional solenoids.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (NEUTRAL) position.
Problem on • Machine may be able to travel in 4th gear speed but cannot travel in 1st, 2nd, nor 3rd gear
machine speed.
• Output current value to 4th clutch ECMV solenoid can be checked with monitoring
function. (Code: 31605 "ECMV Current (4th)")
• Input signal (ON/OFF) from 4th clutch fill switch can be checked with monitoring function.
Related (0: OFF, 1: ON) (Code: 02216 "4th clutch")
information • First, check for mechanical trouble such as clogged oil filter of 4th clutch or pressure
control valve.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
This failure code appears if clutches other than 4th clutch do not have
Abnormal 4th clutch remaining pressure and only 4th clutch has remaining pressure.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Turn starting switch to OFF position.
2. Disconnect connector 4.SW.
3. Turn starting switch to ON position.
If failure code [15SHL1] disappears, 4th clutch fill switch is defective.
Defective 4th clutch fill
switch (internal open a If failure code [15SHL1] is still displayed, wiring harness has ground fault
2
circuit) or transmission controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector 4.SW, and connect T-adapter to male side.
Between 4.SW (male) (1) and ground
Resistance Min. 1 Mz
(Fill switch turned OFF)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and 4.SW, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L62 (female) (3) or 4.SW
circuit) Resistance (female) (1) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
Defective transmission 5. Set parking brake switch to OFF position.
4
controller 6. Depress brake pedal to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Between L62 (3) and Gear shift lever: 4th Max. 1 V
Voltage Gear shift lever: Other
ground 7 to 9 V
than 4th

40-154 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 4th clutch ECMV

WA470-7 40-155
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [15SHLH] Malfunction of ECMV (4th) (WA380_7-15SHLH-400-A-Z0-A)

Action level Failure code Malfunction of ECMV (4th)


Failure
L01 15SHLH (Transmission controller system)
Detail of • When controller drives 4th clutch ECMV solenoid, ON signal is not input from 4th ECMV
failure fill switch.
Action of • Determines that 4th ECMV fill switch signal is OFF.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Machine may not be able to travel in 4th gear speed.
machine • Shifting to 4th gear speed may cause shifting shocks or time lag.
• This failure code may appear immediately after replacement of transmission oil.
• Output current value to 4th clutch ECMV solenoid can be checked with monitoring
function. (Code: 31605 "ECMV Current (4th)")
• Input signal (ON/OFF) from 4th clutch fill switch can be checked with monitoring function.
Related (0: OFF, 1: ON) (Code: 02216 "4th clutch")
information • First, check for mechanical trouble such as clogged oil filter of 4th clutch or pressure
control valve.
• Method of reproducing failure code: Start engine, turn manual/auto shift selector switch to
"MANUAL", move directional (FNR) lever or set R.H. directional selector (FNR) switch to
F (forward) or R (reverse) position, and set shift lever to 4th speed.
No. Cause Procedure, measuring location, criteria and remarks
If 4th clutch pressure is not detected when 4th ECMV solenoid is energized,
Abnormal 4th clutch this failure code appears.
1 pressure
(See troubleshooting for hydraulic and mechanical systems (H mode).)
1. Start engine.
2. While depressing brake pedal, move shift lever to gear speed F1 (F: 1st),
and check that failure code [15SELH] does not appear.
3. Turn starting switch to OFF position.
4. Interchange connections of connectors of 1st clutch and 4th clutch.
• 1.PS io 4.PS
• 1.SW io 4.SW
Defective 4th clutch fill 5. Start engine.
2 switch (internal open 6. While depressing brake pedal, set manual/auto shift selector switch to
circuit) "MANUAL", and move shift lever to gear speed F1 (F: 1st).
a If failure code [15SELH] appears, check clutch pressure. If clutch pressure
is normal, 4th clutch fill switch is defective.
a If failure code [15SELH] does not appear, wiring harness has open circuit
or transmission controller is defective.
a After check, return connectors to their original positions.
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector 4.SW, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between 4.SW (female) (1) and ground 7 to 9 V
Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L62 and 4.SW, and connect T-adapters to each
defective contact of female side.
connector) Max. 1z
Resistance Between L62 (female) (3) and 4.SW (female) (1)

40-156 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, transmission controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Start engine.
4. Set transmission cut-off switch to OFF position.
Defective transmission 5. Set parking brake switch to OFF position.
5
controller 6. Depress brake pedal to prevent machine from starting.
7. Set manual/auto shift selector switch to MANUAL.
8. Set directional (FNR) lever or R.H. directional selector (FNR) switch to F
(forward) or R (reverse) position.
Between L62 (female) Gear shift lever: 4th Max. 1 V
Voltage Gear shift lever: Other
(3) and ground 7 to 9 V
than 4th

Circuit diagram related to 4th clutch ECMV

WA470-7 40-157
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [2F00MA] Failure of Parking Brake Circuit (WA470_7-2F00MA-400-A-Z0-A)

k Be sure to chock wheels. If you perform troubleshooting with parking brake released, depress foot
brake (two persons required for this work).
Action level Failure code Failure of Parking Brake Circuit
Failure
L03 2F00MA (Machine monitor system)
• Parking brake pressure switch remains off for 20 seconds during travel (parking brake is
Detail of applied).
failure (Monitor controller does not correctly recognize that parking brake pressure switch is ON
(parking brake is released)).
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine is used as is, parking brake may be damaged.
machine
• When 24 V is applied to parking brake solenoid, parking brake is released.
• Method of reproducing failure code: Start engine and actual gear speed is other than
NEUTRAL.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
• Parking brake relay (L120) works as self-holding relay.
Related 1. When parking brake switch is operated, pin 5 and pin 6 of parking brake switch are
information connected with each other.
2. Parking brake relay is engaged and L120 works as self-holding relay.
3. When parking brake switch is set to Release position, pin 3 and pin 4 of parking brake
are connected with each other. Since L120 remains engaged, power is supplied to pin
4 of parking brake switch and then flows to L62 (6) pin of transmission controller.
4. If voltage of L62 (6) pin goes to 20 V or above, transmission controller drives parking
brake solenoid from L63 (18) pin (parking brake is released).
No. Cause Procedure, measuring location, criteria and remarks
Inappropriate operation • Check that parking brake switch is set to "Release" position.
1 of parking brake switch • Do not use parking brake while machine is travelling.
1. Turn starting switch to OFF position.
2. Interchange relay L120 with horn relay L119.
3. Start engine and drive machine.
Defective parking brake Does machine become Machine becomes Original relay L120 is
2 relay (L120) normal after parking normal. defective.
brake relay (L120) is
Machine does not Original relay L120 is
interchanged with relay
become normal. normal.
L119?
• When failure code [D1E6KA], [D1E6KB] or [D1E6KY] is displayed,
perform troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Interchange relay L133 with horn relay L119.
Defective auto-idle stop 3. Start engine and drive machine.
3 parking brake relay
L133 Does machine become Machine becomes Original relay L133 is
normal after parking normal. defective.
brake relay (L133) is Original relay L133 is
Machine does not
interchanged with relay normal.
become normal.
L119?

40-158 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Connect T-adapters to connector S_FA (male).
3. Start engine.
Parking brake switch:
Max. 1 z
Between S_FA (male) (3) Release
Defective parking brake
4 and (4) Parking brake switch:
switch Min. 1 Mz
Parking
Resistance
Parking brake switch:
Min. 1 Mz
Between S_FA (male) (5) Release
and (6) Parking brake switch:
Parking Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connector PB.SW and connect T-adapters to female side.
3. Start engine.
Defective parking brake
5 pressure switch Parking brake switch:
Max. 1 z
Between PB.SW (male) Release
Resistance (1) and (2) Parking brake switch:
Parking Min. 1 Mz
• Parking brake switch operation line
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector PB.SW, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
6 short circuit of wiring
harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the
transmission controller voltage drops to approximately 0 V during shaking, circuit is open around
this point.
Voltage Between PB.SW (female) (1) and (2) Min. 10 V
• Parking brake switch operation line
1. Turn starting switch to OFF position.
2. Disconnect connectors L62 and L63, and insert T-adapters into them.
3. Turn starting switch to ON position.
Parking
brake
20 to 30 V
switch:
Release
Voltage Between L62 (6) and L63 (18)
Parking
brake
switch: Max. 3 V
Parking
Open circuit in wiring • Parking brake pressure switch line
harness
a If no failure is found by check on cause 6, this check is not required.
7 (wire breakage or
defective contact of 1. Turn starting switch to OFF position.
connector) 2. Disconnect connectors MCM1 A and PB.SW, and connect T-adapters to
each female side.
Between MCM1 A (female) (71) and PB.SW
Max. 1 z
Resistance (female) (1)
Between PB.SW (female) (2) and ground Max. 1 z
• Parking brake solenoid line
1. Turn starting switch to OFF position.
2. Disconnect connector PB.PS and connect T-adapters to female side.
3. Turn starting switch to ON position.
Parking brake switch:
20 to 30 V
Between PB.PS (female) Release
Voltage
(1) and (2) Parking brake switch: Max. 3 V
Parking

WA470-7 40-159
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective parking brake 2. Disconnect connector PB.PS and connect T-adapters to male side.
8
solenoid Between PB.PS (male) (1) and (2) 10 to 100 z
Resistance
Between PB.PS (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapters to connector L63.
Defective transmission 3. Turn starting switch to ON position.
9
controller
Between L63 (18) and Parking brake switch:
Voltage 20 to 30 V
(31) Release
Defective parking brake
Perform testing and troubleshooting of parking brake hydraulic piping or
10 hydraulic circuit or parking brake valve.
parking brake valve
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
11 this is an internal defect, troubleshooting cannot be performed.)
controller

40-160 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake

WA470-7 40-161
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [2G42ZG] Accumulator Oil Pressure Low (Front) (WA470_7-2G42ZG-


400-A-Z0-A)

Action level Failure code Accumulator Oil Pressure Low (Front)


Failure
L03 2G42ZG (Machine monitor system)
Detail of • After engine is started, front brake accumulator pressure sensor indicates specified
failure pressure once, but then pressure switch becomes open.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Front brake accumulator pressure drops.
machine • Brakes may not work.
• Input signal (ON/OFF) from brake pressure sensor can be checked with monitoring
Related function.
information (Code: 04510 Front brake oil pressure switch signal)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Pressure drop of front Check oil pressure of front brake accumulator.
1
brake accumulator (See Testing and adjusting.)
1. Turn starting switch to OFF position.
2. Disconnect connector R52 and connect T-adapters to male side.
Front brake accumulator
pressure: Normal
Defective front brake Max. 1 z
Min. 5.88 MPa
2 pressure sensor
(internal open circuit) Between R52 (male) (1) Min. {60 kg/cm2}
Resistance and (2)
Front brake accumulator
pressure: Dropped
Max. 3.92 MPa Min. 1 Mz
Max. {40 kg/cm2}
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R52, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R52 (female) (1) and (2) Min. 10 V
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1 A, and connect T-adapters to female side.
Front brake accumulator
pressure: Normal
Open circuit or ground Max. 1 z
4 fault in wiring harness Min. 5.88 MPa
Between MCM1 A Min. {60 kg/cm2}
Resistance (female) (73) and (13) or
(17) Front brake accumulator
pressure: Dropped Min. 1 Mz
Max. 3.92 MPa
Max. {40 kg/cm2}

40-162 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors MCM1 A and R52, and connect T-adapters to each
harness female side.
5 (wire breakage or Between MCM1 A (female) (73) and R52 (female)
(1) Max. 1 z
defective contact of
connector) Between R52 (female) (2) and MCM1 A (female)
Resistance (13) Max. 1 z
Between R52 (female) (2) and MCM1 A (female)
(17) Max. 1 z
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
6 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to brake accumulator

WA470-7 40-163
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [2G43ZG] Accumulator Oil Pressure Low (Rear) (WA470_7-2G43ZG-400-


A-Z0-A)

Action level Failure code Accumulator Oil Pressure Low (Rear)


Failure
L03 2G43ZG (Machine monitor system)
Detail of • After engine is started, rear brake accumulator pressure sensor indicates specified
failure pressure once, but then pressure switch becomes open.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Rear brake accumulator pressure drops.
machine • Brakes may not work.
• Input signal (ON/OFF) from brake pressure sensor can be checked with monitoring
Related function.
information (Code: 04510 Rear brake oil pressure switch signal)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Pressure drop of rear Check oil pressure of rear brake accumulator.
1
brake accumulator (See Testing and adjusting.)
1. Turn starting switch to OFF position.
2. Disconnect connector R54 and connect T-adapters to male side.
Rear brake accumulator
pressure: Normal
Defective rear brake Max. 1 z
Min. 5.88 MPa
2 pressure sensor
(internal open circuit) Between R54 (male) (1) Min. {60 kg/cm2}
Resistance and (2)
Rear brake accumulator
pressure: Dropped
Max. 3.92 MPa Min. 1 Mz
Max. {40 kg/cm2}
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R54, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R54 (female) (1) and (1) Min. 10 V
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1 A, and connect T-adapters to female side.
Rear brake accumulator
pressure: Normal
Open circuit or ground Max. 1 z
4 fault in wiring harness Min. 5.88 MPa
Between MCM1 A Min. {60 kg/cm2}
Resistance (female) (72) and (13) or
(17) Rear brake accumulator
pressure: Dropped Min. 1 Mz
Max. 3.92 MPa
Max. {40 kg/cm2}

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No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors MCM1 A and R54, and connect T-adapters to each
harness female side.
5 (wire breakage or Between MCM1 A (female) (72) and R54 (female)
(2) Max. 1 z
defective contact of
connector) Between R54 (female) (1) and MCM1 A (female)
Resistance (13) Max. 1 z
Between R54 (female) (1) and MCM1 A (female)
(17) Max. 1 z
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
6 this is an internal defect, troubleshooting cannot be performed.)
controller

Circuit diagram related to brake accumulator

WA470-7 40-165
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879AKA] A/C Inner Sensor Open Circuit (WA380_7-879AKA-441-A-Z0-A)

See "Failure code [879AKA] A/C Inner Sensor Open Circuit" in chapter 80 of "Others".

40-166 WA470-7
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Troubleshooting by failure code (Display of code)

Failure code [879AKB] A/C Inner Sensor Short Circuit (WA380_7-879AKB-441-A-Z0-A)

See "Failure code [879AKB] A/C Inner Sensor Short Circuit" in chapter 80 of "Others".

WA470-7 40-167
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879BKA] A/C Outer Sensor Open Circuit (WA380_7-879BKA-441-A-Z0-A)

See "Failure code [879BKA] A/C Outer Sensor Open Circuit" in chapter 80 of "Others".

40-168 WA470-7
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Troubleshooting by failure code (Display of code)

Failure code [879BKB] A/C Outer Sensor Short Circuit (WA380_7-879BKB-441-A-Z0-A)

See "Failure code [879BKB] A/C Outer Sensor Short Circuit" in chapter 80 of "Others".

WA470-7 40-169
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879CKA] Ventilating Sensor Open Circuit (WA380_7-879CKA-441-A-Z0-A)

See "Failure code [879CKB] Ventilating Sensor Short Circuit" in chapter 80 of "Others".
a The ventilating sensor means the evaporator temperature sensor.

40-170 WA470-7
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Troubleshooting by failure code (Display of code)

Failure code [879CKB] Ventilating Sensor Short Circuit (WA380_7-879CKB-441-A-Z0-A)

See "Failure code [879CKB] Ventilating Sensor Short Circuit" in chapter 80 of "Others".
a The ventilating sensor means the evaporator temperature sensor.

WA470-7 40-171
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879DKZ] Sunlight Sensor Open or Short Circuit (WA380_7-879DKZ-


441-A-Z0-A)

See "Failure code [879DKZ] Sunlight Sensor Open or Short Circuit" in chapter 80 of "Others".

40-172 WA470-7
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Failure code [879EMC] Ventilation Damper Abnormality (WA380_7-879EMC-441-A-Z0-A)

See "Failure code [879EMC] Ventilation Damper Abnormality" in chapter 80 of "Others".

WA470-7 40-173
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [879FMC] Air Mix Damper Abnormality (WA380_7-879FMC-441-A-Z0-A)

See "Failure code [879FMC] Air Mix Damper Abnormality" in chapter 80 of "Others".

40-174 WA470-7
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Failure code [989A00] Engine Overrun Prevention Activated (WA380_7-989A00-400-A-


Z0-A)

Action level Failure code Engine Overrun Prevention Activated


Failure
L02 989A00 (Transmission controller system)
Detail of • Engine speed exceeds upper control limit.
failure
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
machine • Disengages lockup clutch.
monitor
Problem on
• Lockup clutch does not work.
machine
Related • Engine speed can be checked with monitoring function.(Code 01002: Engine speed)
information
No. Cause Procedure, measuring location, criteria and remarks
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
Improper method of using Method of using machine may be improper, so instruct operator on
2 how to use machine properly.
machine
If no failure is found by checks on causes 1 and 2, power train
3 Defective engine controller controller may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

WA470-7 40-175
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [989L00] Engine Controller Lock Caution 1 (WA380_7-989L00-400-A-Z0-A)

Action level Failure code Engine Controller Lock Caution 1


Failure
- 989L00 (Machine monitor system)
Detail of • Machine monitor detects engine controller lock (cause 1).
failure
Action of • None in particular.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine does not start.
machine
• When this failure code appears after replacement of monitor controller, user password
Related must be replaced with one before replacement of controller.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Replacement of monitor This trouble may result from replacement of monitor controller.
1
controller

40-176 WA470-7
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Failure code [989M00] Engine Controller Lock Caution 2 (WA380_7-989M00-400-A-Z0-A)

Action level Failure code Engine Controller Lock Caution 2


Failure
- 989M00 (Machine monitor system)
Detail of • Machine monitor detects engine controller lock (cause 2).
failure
Action of • None in particular.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine does not start.
machine
• When this failure code appears after replacement of monitor controller, user password
Related must be replaced with one before replacement of controller.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Replacement of monitor This trouble may result from replacement of monitor controller.
1
controller
If this failure code appears when monitor controller is not replaced,
2 Defective monitor controller monitor controller may be defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

WA470-7 40-177
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Troubleshooting by failure code (Display of code)

Failure code [989N00] Engine Controller Lock Caution 3 (WA380_7-989N00-400-A-Z0-A)

Action level Failure code Engine Controller Lock Caution 3


Failure
- 989N00 (Machine monitor system)
Detail of • Machine monitor detects engine controller lock (cause 3).
failure
Action of • Tries automatic restoration.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on
machine
Related • Method of reproducing failure code: Failure code is not reproduced because of automatic
information restoration.
No. Cause Procedure, measuring location, criteria and remarks
If this failure code appears repeatedly, engine controller may be
1 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot be
performed.)

40-178 WA470-7
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Failure code [A1U0N3] HC Desorb Request 1 (HM300_3-A1U0N3-400-A-Z0-A)

Action level Failure code HC Desorb Request 1


Failure
L01 A1U0N3 (Engine controller system)
Detail of • Unburned fuel remains in KDPF because engine has been run at low idle or low load for a
failure long time.
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)

k Since temperature of KDPF and KDOC becomes 500 °C or higher, take care not to
get burn injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
Related difference between these temperatures is approx. 10 °C. (KDOC inlet temperature >
information KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationery regeneration) is performed due to the
guidance of monitor displaying failure code A1U0N3 or A1U0N4, fuel dosing is disabled.
Accordingly, each temperature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to
approx. 250 to 400 °C.
• When active regeneration (manual stationary regeneration) except above is in progress,
KDOC inlet temperature is approx. 250 to 400 °C, and KDOC outlet temperature and
KDPF outlet temperature are approx. 450 to 550 °C.
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.

WA470-7 40-179
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Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Performing manual stationery 1. Perform manual stationary regeneration by following the instructions
regeneration on the monitor.
1
If this failure code is cleared after regeneration is performed, repair is
regeneration (to dry KDPF)
complete.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
2 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is also displayed,
3 temperature sensor perform troubleshooting for [CA3313], [CA3314] or [CA3315] first.
1. Turn starting switch to ON position.
4 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

a Turn the starting switch ON and make sure that this failure code is not displayed.

40-180 WA470-7
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Failure code [A1U0N4] HC Desorb Request 2 (HM300_3-A1U0N4-400-A-Z0-A)

Action level Failure code HC Desorb Request 2


Failure
L03 A1U0N4 (Engine controller system)
Detail of • Unburned fuel remains in KDPF because engine has been run at low idle or low load for a
failure long time.
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)

k Since the temperature of the KDPF and KDOC will become higher than 500 °C , take
care not to get burn injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301(V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 ( °C ))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401(V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 ( °C ))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201(V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 ( °C ))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
Related engine running at idle (without regenerating KDPF) are all approx. 100 to 250 °C and
information temperature differences among them are approx. 10 °C (KDOC inlet temperature >
KDOC outlet temperature> KDPF outlet temperature).
• When manual stationary regeneration is performed as an action taken for A1U0N3 or
A1U0N4, dosing fuel is not injected. Therefore, KDOC inlet, KDOC outlet, and KDPF
outlet temperatures will be around 250 to 400 °C .
• In other cases than the above, when active regeneration (manual stationary regeneration)
is in progress, the KDOC inlet temperature will be approx. 250 to 400 °C , and the KDOC
outlet temperature and KDPF outlet temperature will both be approx. 450 to 550 °C .
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Perform manual stationary regeneration by following the instructions
Performing manual stationary on the monitor.
1
regeneration (to dry KDPF) If this failure code is cleared after regeneration is performed, repair is
complete.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
2 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
3 temperature sensor troubleshooting for it.

WA470-7 40-181
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Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to ON position.
4 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

a Turn the starting switch ON and make sure that this failure code and code [A1U0N3] are not displayed.

40-182 WA470-7
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Failure code [AA10NX] Air Cleaner Clogging (WA470_7-AA10NX-400-A-Z0-A)

Action level Failure code Air Cleaner Clogging


Failure
L01 AA10NX (Machine monitor system)
Detail of • When engine is started, air cleaner clogging signal circuit is "open" (disconnected from
failure GND).
Action of • Lights up air cleaner clogging caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
• Engine does not start smoothly, does not pick-up smoothly, lacks power or exhaust gas is
Problem on black.
machine • If machine is used as it is, engine may be damaged.
• Voltage at MCM1 A (53) is GND level when air cleaner is normal and Min. 10 V when air
cleaner is clogged (circuit is open).
• Input signal (ON/OFF) from air cleaner clogging sensor can be checked with monitoring
General function.
information (Code: 04509 "Air cleaner clogging sensor")
• Method of reproducing failure code: Start engine.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
Dust indicator does not indicate red
When air cleaner is normal
1 Air cleaner clogging zone.
Dust indicator indicates red zone. Air cleaner clogging
1. Turn starting switch to OFF position.
2. Disconnect connector E45 and connect T-adapter to male side.
Defective air cleaner 3. Turn starting switch to ON position or start engine to perform
2 clogging sensor troubleshooting.
Between E45 (male) (1) Air cleaner is normal. Max. 1z
Resistance and (2)
Air cleaner is clogged. Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector E45, and connect T-adapter to female side.
circuit, hot short circuit 3. Turn starting switch to ON position.
3 of wiring harness, or a Shake the wiring harness by hand while measuring the voltage. If the
defective monitor voltage drops to approximately 0 V during shaking, circuit is open around
controller this point.
Voltage Between E45 (female) (1) and (2) 16 to 24 V
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and E45, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of Between MCM1 A (female) (53) and E45 (female)
(1) Max. 1z
connector) Resistance
Between E45 (female) (2) and each of MCM1 A
(female) (13) and (17) Max. 1z

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector E45.
Defective monitor 3. Turn starting switch to ON position or start engine to perform
5 troubleshooting.
controller
Air cleaner is normal. Max. 1 V
Voltage Between E45 (1) and (2)
Air cleaner is clogged. 16 to 24 V

WA470-7 40-183
40 Troubleshooting
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Circuit diagram related to air cleaner clogging sensor

40-184 WA470-7
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Failure code [B@BAZG] Eng Oil Press Low (WA500_7-BaBAZG-400-A-Z0-A)

Action level Failure code Engine Oil Pressure Low


Failure
L03 B@BAZG (Engine controller system)
Detail of • Engine controller determines that engine oil pressure drops abnormally because signal
failure voltage from engine oil pressure switch drops to ground level while engine is running.
Action of • Lights up engine oil pressure caution lamp in red on machine monitor.
machine • Lights up centralized warning lamp and sounds alarm buzzer.
monitor • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine is operated as it is, engine may seize up.
machine
• Engine oil pressure switch signal is input to engine controller that transmits information to
machine monitor through CAN communication system.
Related • Engine oil pressure can be checked with monitoring function (Code: 37200 Engine oil
information pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Drop of engine oil pressure Engine oil pressure may drops. Check it and remove cause of failure if
1 oil pressure is low.
(When system is normal)
If no failure is found by check on cause 1, engine oil pressure sensor
Defective engine oil pressure
2 system may be defective. Perform troubleshooting for failure code
sensor system
[CA135], [CA141]

WA470-7 40-185
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@BAZK] Eng Oil Level Low (WA470_7-BaBAZK-400-A-Z0-A)

Action level Failure code Engine Oil Level Low


Failure
L01 B@BAZK (Machine monitor system)
• When engine is stopped, engine oil level sensor circuit is open (disconnected from
ground) for 2 seconds or more.
Detail of (This error, however, is not detected for 5 minutes after the engine stops.)
failure • The failure code generated while the engine is not running remains active even after the
engine is started until the problem is solved.
Action of • Lights up the engine oil level caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine is used as it is, engine may be seized.
machine
• Input signal (ON/OFF) from engine oil level sensor can be checked with monitoring
Related function.
information (Code: 04510 Engine oil level sensor)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
• Engine oil level is normal.
1 Engine oil level is low.
a If engine oil level is low, check for oil leakage from engine before adding
oil.
1. Turn starting switch to OFF position.
2. Disconnect connector E27 and connect T-adapter to male side.
Defective engine oil
2 Engine oil level is
level switch Between E27 (male) (1) Max. 1 z
Resistance and ground normal.
Engine oil level is low. Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector E27, and connect T-adapter to female side.
circuit, hot short circuit 3. Turn starting switch to ON position.
3 of wiring harness, or a Shake the wiring harness by hand while measuring the voltage. If the
defective monitor voltage drops to approximately 0 V during shaking, circuit is open around
controller this point.
Voltage Between E27 (female) (1) and ground 16 to 24 V

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors MCM1 A and E27, and connect T-adapters to each
defective contact of female side.
connector) Between MCM1 A (female) (69) and E27 (female)
Resistance (1) Max. 1 z

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector E27.
Defective monitor 3. Turn starting switch to ON position.
5
controller Engine oil level is
Between E27 (2) and Max. 1 V
Voltage normal.
ground
Engine oil level is low. 16 to 24 V

40-186 WA470-7
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Circuit diagram related to engine oil level sensor

WA470-7 40-187
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@BCNS] Eng Water Overheat (WA380_7-BaBCNS-400-A-Z0-A)

Action level Failure code Engine Water Overheat


Failure
L02 B@BCNS (Engine controller system)
Detail of • Engine controller determines that engine coolant overheats because signal voltage from
failure engine coolant temperature sensor drops while engine is running.
• Lights up engine coolant temperature overheat caution lamp in red on machine monitor.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine is operated as it is, engine may seize up.
machine
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function.
information (Code: 04107 Engine coolant temperature)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Overheating of engine
coolant Engine coolant may overheat. Check coolant temperature and remove
1
cause of failure if coolant overheats.
(When system is normal)
If no failure is found by check on cause 1, engine coolant temperature
Defective engine coolant
2 sensor system may be defective. Perform troubleshooting for failure
temperature sensor system
codes [CA144] and [CA145].

40-188 WA470-7
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Troubleshooting by failure code (Display of code)

Failure code [B@BCZK] Eng Water Level Low (WA470_7-BaBCZK-400-A-Z0-A)

Action level Failure code Engine Water Level Low


Failure
L01 B@BCZK (Monitor controller system)
Detail of • Radiator coolant level switch signal circuit is "open" (disconnected from ground).
failure (detected time 30 sec)
Action of • Lights up radiator coolant level caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If the machine continues to be used with a low coolant level, the engine may overheat.
machine
• Input signal (ON/OFF) from coolant level sensor can be checked by using monitoring
function.
Related (Code: 04509 Engine coolant level sensor)
information • Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
• Check if radiator coolant level is normal.
Low radiator coolant
1 a If radiator coolant level is low, check for coolant leakage from engine and
level
radiator components before adding coolant.
1. Turn starting switch to OFF position.
2. Disconnect connector R32 and connect T-adapter to male side.
Defective radiator Radiator coolant level is
2 Max. 1 z
coolant level switch Between R32 (male) (1) normal.
Resistance and ground
Radiator coolant level is
Min. 1 Mz
low.
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R32, and connect T-adapter to female side.
circuit, hot short circuit 3. Turn starting switch to ON position.
3 of wiring harness, or a Shake the wiring harness by hand while measuring the voltage. If the
defective monitor voltage drops to approximately 0 V during shaking, circuit is open around
controller this point.
Voltage Between R32 (female) (1) and (2) 16 to 24 V

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors and connect T-adapters to each female side.
defective contact of Between MCM1 A (female) (48) and R32 (female)
Max. 1 z
connector) Resistance (1)
Between R32 (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R32.
3. Turn starting switch to ON position.
Defective monitor
5 Radiator coolant level is
controller Max. 1 V
Voltage Between R32 (1) and (2) normal.
Radiator coolant level is
16 to 24V
low.

WA470-7 40-189
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to coolant level sensor

40-190 WA470-7
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Troubleshooting by failure code (Display of code)

Failure code [B@CENS] T/C Oil Temp. Overheat (WA380_7-BaCENS-400-A-Z0-A)

Action level Failure code Torque Converter Oil Temperature Overheat


Failure
L02 B@CENS (Machine monitor system)
Detail of • Overheating of the torque converter oil temperature is detected (130°C or above).
failure
• Lights up torque converter oil overheat caution lamp.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
(If oil temperature remains below 130 °C for continuous one second.)
Problem on • If machine is used as is, torque converter may be damaged.
machine
• Information from torque converter oil temperature sensor is obtained from transmission
Related controller through CAN communication.
information • Torque converter oil temperature can be checked with monitoring function.
(Monitoring code: 30100 (°C), 30101 (V))
No. Cause Procedure, measuring location, criteria and remarks
Overheating of torque
1 converter oil (when system is Torque converter oil may overheat. Check and remove cause of failure.
normal)
Defective torque converter oil
2 Perform troubleshooting for failure codes [DGT1KA] and [DGT1KB].
temperature sensor system
If no failure is found by check on cause 2 but substantial difference is
Defective transmission observe between torque converter oil temperature sensed by using
3 monitoring function (code: 30100) and actual oil temperature,
controller
transmission controller may be defective.
4 Defective monitor controller If no failure is found by above checks, monitor controller is defective.

WA470-7 40-191
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [B@HANS] HYD Oil Temp. Overheat (WA380_7-BaHANS-400-A-Z0-A)

Action level Failure code Hydraulic Oil Temperature Overheat


Failure
L02 B@HANS (Machine monitor system)
Detail of • Monitor controller determines that hydraulic oil overheats (100°C or higher for more than
failure 10 second).
• Lights up hydraulic oil temperature caution lamp.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
(If hydraulic oil temperature remains below 100 °C for continuous 10 second.)
Problem on • If machine is operated as it is, pump and cylinder seal may be damaged.
machine
• Information of hydraulic oil temperature sensor is obtained from transmission controller
Related through CAN communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Monitoring code: 04401 Hydraulic oil temperature (°C), 04404 Sensor voltage (V))
No. Cause Procedure, measuring location, criteria and remarks
Overheating of hydraulic oil
1 Hydraulic oil may overheat. Check and remove cause of failure.
(when system is normal)
Defective hydraulic oil
2 Perform troubleshooting for failure code [DGH2KX].
temperature sensor system
If no failure is found by check on cause 2 but substantial difference is
Defective transmission observed between hydraulic oil temperature sensed by using monitoring
3 function (code: 04401) and actual oil temperature, transmission
controller
controller may be defective.
4 Defective monitor controller If no failure is found by above checks, monitor controller is defective.

40-192 WA470-7
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Failure code [CA115] Eng Ne and Bkup Speed Sens Error (PC400-CA115-400-A-Z0-A)

Action level Failure code Engine Ne and Bkup Speed Sensor Error
Failure
L04 CA115 (Engine controller system)
Detail of • Abnormality is detected in signal circuits of Ne and Bkup speed sensors at the same time.
failure
Action of • Stops engine.
controller
Problem on • Engine does not start (if engine is stopped).
machine • Engine stops (if engine is running).
Related • Method of reproducing failure code: Start engine.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective Ne speed sensor
1 Perform troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Perform troubleshooting for failure code [CA778].
system
If no failure is found by above checks, engine controller is defective.
3 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-193
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA122] Chg Air Press Sensor High Error (PC400-CA122-400-A-Z0-A)

Action level Failure code Charge Air Pressure Sensor High Error
Failure
L03 CA122 (Engine controller system)
Detail of • High voltage occurs in charge (boost) pressure sensor signal circuit.
failure
• Sets charge (boost) pressure to fixed value (400 kPa {4.1 kg/cm2}) and runs engine.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Acceleration performance of engine drops.
machine • Engine output reduces.
• Signal voltage from charge (boost) pressure sensor can be checked with monitoring
function. (Code: 36501 (V))
• Boost pressure sensed by charge (boost) pressure sensor can be checked with
Related
monitoring function. (Code: 36500 (kPa))
information
• Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected, failure code [CA123] for "Low Error" is displayed
even in normal condition.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2 supply system for it first.
1. Turn starting switch to OFF position.
2. Disconnect connector PIM.
3. Turn starting switch to ON position.
If failure code changes from [CA122] to [CA123], charge (boost) pressure
sensor is defective.
Defective charge
3 (boost) pressure sensor • Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1 or PIM.
3. Turn starting switch to ON position.
Between J1 (15) and (59), or between Sensor
Voltage 0.3 to 4.7 V
PIM (3) and (2) output
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and PIM, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of a To check open circuit in GND line
connector) Resistance Between J1 (female) (59) and PIM (female) (2) Max. 1 z
1. Turn starting switch to OFF position, then perform troubleshooting.
2. Disconnect connectors J1 and PIM, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between J1 (female) (15) and (60), or between PIM
Resistance (female) (3) and (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector PIM, and connect T-adapter to female side or insert
Hot short circuit in T-adapters into connector J1.
6 wiring harness 3. Turn starting switch to ON position (with connector PIM disconnected).
Between PIM (female) (3) and (2), or between J1
Voltage Max. 1 V
(15) and (59)
Defective engine If no failure is found by above checks, engine controller is defective.
7
controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to charge pressure sensor

WA470-7 40-195
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA123] Chg Air Press Sensor Low Error (PC400-CA123-400-A-Z0-A)

Action level Failure code Charge Air Pressure Sensor Low Error
Failure
L03 CA123 (Engine controller system)
Detail of • Low voltage appears in boost pressure sensor signal circuit.
failure
• Takes it that boost pressure is at fixed value (400 kPa {4.1 kg/cm2}), and allows engine to
run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Acceleration performance of engine drops.
machine • Engine output lowers.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
using monitoring function (Code: 36501 (V)).
Related • Pressure (Boost pressure) sensed by charge pressure sensor (boost pressure sensor)
information can be checked by using monitoring function (Code: 36500 (kPa)).
• Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected, this failure code is displayed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
2 system of boost 2. Disconnect connectors PIM and connect T-adapter to female side.
pressure sensor 3. Switch: ON
Voltage Between PIM (female) (1) and (2) Power input 4.75 to 5.25
V
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and PIM and connect T-adapters to each
female side.
3 (wire breakage or Between J1 (female) (60) and PIM (female) (1) Max. 1 z
defective contact of
connector) Resistance Between J1 (female) (15) and PIM (female) (3) Max. 1 z
Between J1 (female) (59) and PIM (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PIM and connect T-adapters to either
Short circuit in wiring female side.
4
harness 3.
Between J1 (female) (15) and (59) or between PIM
Resistance (female) (3) and (2) Min. 1 Mz

Ground fault in wiring 1. Turn starting switch to OFF position, then perform troubleshooting.
harness 2. Disconnect connectors J1 and PIM and connect T-adapter to either female
5 side.
(contact with ground
Between J1 (female) (15) or PIM (female) (3) and
circuit) Resistance ground Min. 1 Mz

a If no failure is found by checks on causes 1 to 5 and check result on cause


6 is abnormal, sensor is defective.
Defective charge 1. Turn starting switch to OFF position.
6 pressure (boost 2. Insert T-adapter into connector J1 or PIM.
pressure) sensor 3. Turn starting switch to ON position.
Between J1 (15) and (59), or between Sensor 0.3 to 4.7 V
Voltage
PIM (3) and (2) output

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No. Cause Procedure, measuring location, criteria and remarks


Defective engine If no failure is found by above checks, engine controller is defective.
7
controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to boost pressure sensor

WA470-7 40-197
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA131] Throttle Sensor High Error (WA380_7-CA131-400-A-Z0-A)

Action level Failure code Throttle Sensor High Error


Failure
L03 CA131 (Engine controller system)
Detail of • High voltage appears in throttle sensor signal circuit.
failure
Action of • Sets throttle position at 0% with accelerator pedal released and at 50% with accelerator
controller pedal depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine
• Input voltage from throttle sensor can be checked with monitoring function. (Code:
03000).
Related • Accelerator pedal position sensed by throttle sensor can be checked with monitoring
information function. (Code: 31701)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
Defective throttle sensor If failure code [CA2185] is also displayed, perform troubleshooting for it
2 power supply system first.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and PD, and connect T-adapters to
Short circuit in wiring
3 either female side.
harness
Resis- Between EC3 (female) (51) and (42), or
between PD (female) (1) and (2) Min. 1 Mz
tance
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector PD and connect T-adapters to female side.
4 3. Turn starting switch to ON position.
(contact with 24 V circuit)
Voltage Between PD (female) (2) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector PD.
3. Turn starting switch to ON position.
Defective accelerator pedal
5 (throttle sensor) When accelerator
pedal is depressed 3.7 to 4.0 V
Between PD (2) and
Voltage
(3) When accelerator
pedal is released 0.5 to 0.8 V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into EC3.
3. Turn starting switch to ON position.
6 Defective engine controller 4. Operate accelerator pedal to perform troubleshooting.
Between EC3 (42) and 4.75 to 5.25
Power supply
(41) V
When accelerator
Voltage 3.7 to 4.0 V
Between EC3 (51) and pedal is depressed
(41) When accelerator 0.5 to 0.8 V
pedal is released

40-198 WA470-7
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Circuit diagram related to throttle sensor

WA470-7 40-199
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA132] Throttle Sensor Low Error (WA380_7-CA132-400-A-Z0-A)

Action level Failure code Throttle Sensor Low Error


Failure
L03 CA132 (Engine controller system)
Detail of • Low voltage appears in throttle sensor signal circuit.
failure
Action of • Sets throttle position at 0% with accelerator pedal released and at 50% with accelerator
controller pedal depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine
• Input voltage from throttle sensor can be checked with monitoring function. (Code:
03000).
Related • Accelerator pedal position sensed by throttle sensor can be checked with monitoring
information function. (Code: 31701)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
If failure code [CA2186] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
Defective throttle sensor 2. Disconnect connectors PD and PDV, and connect T-adapters to
2 power supply system each female side.
3. Turn starting switch to ON position.
Between PD (female) (1) and (3) 4.75 to 5.25 V
Voltage
Between PDV (female) (1) and (2) 4.75 to 5.25 V
1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
2. Disconnect connectors EC3, PD, and PDV, and connect T-adapters
to each female side.
a If no failure is found by check on cause 2,
this check is not required. Max. 1 Mz
Between EC3 (female) (42) and PD (female)
Open circuit in wiring harness (1)
3 (wire breakage or defective
contact of connector) a If no failure is found by check on cause 2,
Resis- this check is not required.
tance Max. 1 z
Between EC3 (female) (41) and PD (female)
(3)
Between EC3 (female) (51) and PD (female)
(2) Max. 1 z
Between EC3 (43) and PDV (female) (2) Max. 1 z
Between EC3 (52) and PDV (female) (1) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors EC3 and PD, and connect T-adapters to
either female side.
Resis- Between EC3 (female) (51) and (41), or
Min. 1 Mz
tance between PD (female) (2) and (3)
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors EC3 and PD, and connect T-adapters to
5 either female side.
(contact with ground circuit)
Resis- Between ground and EC3 (female) (51) or Min. 1 Mz
tance PD (female) (2)

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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapters into connector PD.
3. Turn starting switch to ON position.
Defective accelerator pedal
6 (throttle sensor) When accelerator
3.7 to 4.0 V
Between PD (2) and pedal is depressed
Voltage
(3) When accelerator
pedal is released 0.5 to 0.8 V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter to EC3.
3. Turn starting switch to ON position.
7 Defective engine controller 4. Operate accelerator pedal to perform troubleshooting.
Between EC3 (42)
Power supply 4.75 to 5.25 V
and (43)
When accelerator
Voltage 3.7 to 4.0 V
Between EC3 (51) pedal is depressed
and (43) When accelerator
pedal is released 0.5 to 0.8 V

Circuit diagram related to throttle sensor

WA470-7 40-201
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA135] Eng Oil Press Sensor High Error (PC400-CA135-400-A-Z0-A)

Action level Failure code Engine Oil Pressure Sensor High Error
Failure
L01 CA135 (Engine controller system)
Detail of • High voltage occurs in engine oil pressure sensor signal circuit.
failure
Action of • Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2}) and runs engine.
controller
Problem on
machine
• Signal voltage from engine oil pressure sensor can be checked with monitoring function.
(Code: 37201 (V))
Related • Engine oil pressure sensed by engine oil pressure sensor can be checked with monitoring
information function. (Code: 37200 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective power supply
system of engine oil If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
2
pressure sensor for it first.

1. Turn starting switch to OFF position.


2. Disconnect connector POIL.
3. Turn starting switch to ON position.
If failure code changes from [CA135] to [CA141] , engine oil pressure sensor
is defective.
Defective engine oil
3 pressure sensor • Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1 or POIL.
3. Turn starting switch to ON position.
Between J1 (2) and (59) or between Sensor
Voltage 0.3 to 4.7 V
POIL (3) and (2) output
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and POIL, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of a To check open circuit in GND line
connector) Resistance Between J1 (female) (59) and POIL (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and POIL, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between J1 (female) (2) and (60), or between POIL
Resistance (female) (1) and (3) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector POIL.
3. Connect T-adapter to female side of connector POIL, or insert T-adapter
Hot short circuit in
6 into connector J1.
wiring harness
4. Turn starting switch to ON position (with connector POIL disconnected).
Between J1 (2) and (59) or between POIL (female)
Voltage Max. 1 V
(3) and (2)
Defective engine If no failure is found by above checks, engine controller is defective.
7
controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Circuit diagram related to engine oil pressure sensor

WA470-7 40-203
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA141] Eng Oil Press Sensor Low Error (PC400-CA141-400-A-Z0-A)

Engine Oil Pressure Sensor Low Error


Action level Failure code Failure
(Engine controller system)
L01 CA141
Detail of • Low voltage appears in engine oil pressure sensor signal circuit.
failure
Action of • Sets engine oil pressure to fixed value (250 kPa {2.5 kg/cm2}), and allows engine to run.
controller
Problem on
machine
• Signal voltage from engine oil pressure sensor can be checked by using monitoring
function. (Code: 37201 (V))
Related • Engine oil pressure sensed by engine oil pressure sensor can be checked by using
information monitoring function. (Code: 37200 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA187] or [CA227] is displayed, perform troubleshooting
for it first.
Defective power supply 1. Turn starting switch to OFF position.
2 system of engine oil pressure 2. Disconnect connector POIL and connect T-adapter to female side.
sensor 3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between POIL (female) (1) and (2)
input V
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and POIL and connect T-adapters to each
female side.
a If power supply input in checks on cause 2
is normal, this check is not required.
Max. 1 z
Open circuit in wiring harness Between J1 (female) (60) and POIL
3 (wire breakage or defective (female) (1)
contact of connector) Resis-
a If power supply input in checks on cause 2
tance
is normal, this check is not required.
Max. 1 z
Between J1 (female) (59) and POIL
(female) (2)
Between J1 (female) (2) and POIL (female) (3)
(Sensor output) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors J1 and POIL, and connect T-adapter to either
4 harness female side.
(contact with ground circuit) Resis- Between J1 (female) (2) and ground, or
between POIL (female) (3) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and POIL, and connect T-adapter to either
5 Short circuit in wiring harness female side.
Resis- Between J1 (female) (2) and (59), or between
POIL (female) (2) and (3) Min. 1 Mz
tance

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No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 1 to 5 and check result of
Defective engine oil pressure cause 6 is abnormal, sensor is defective.
sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector J1 or POIL.
(improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Between J1 (2) and (59) or Sensor
Voltage 0.3 to 4.7 V
between POIL (3) and (2) output
If no failure is found by above checks, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine oil pressure sensor

WA470-7 40-205
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA144] Coolant Temp Sens High Error (PC400-CA144-400-A-Z0-A)

Action level Failure code Coolant Temperature Sensor High Error


Failure
L01 CA144 (Engine controller system)
Detail of • High voltage appears in engine coolant temperature sensor signal circuit.
failure
Action of • Takes it that coolant temperature is at fixed value (90°C) and allows engine to run.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function. (Code: 04105 (V))
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • This failure code appears if sensor connector is disconnected.
• Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700
z to 37 kz when coolant temperature is min. 0 °C.
Defective coolant 0°C 30 to 37 kz
2 temperature sensor
Between TWTR (male) (A) and (B) 9.3 to 10.7
25°C
Resis- kz
tance a Coolant temperature- 50°C 3.2 to 3.8 kz
Resistance characteristics 80°C 1.0 to 1.3 kz
95°C 700 to 800 z
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to female side.
Between J1 (female) (14) and (13) (Coolant
Open or short circuit in wiring
3 temperature: Min. 0 °C)
harness Resis- 700 z to 37
tance a Use Coolant temperature-Resistance kz
characteristics table for check on cause 2
as resistance criteria.
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to coolant temperature sensor

WA470-7 40-207
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA145] Coolant Temp Sens Low Error (PC400-CA145-400-A-Z0-A)

Action level Failure code Coolant Temperature Sensor Low Error


Failure
L01 CA145 (Engine controller system)
Detail of • Low voltage appears in engine coolant temperature sensor signal circuit.
failure
Action of • Takes it that coolant temperature is at fixed value (90°C) and allows engine to run.
controller
Problem on • Engine startability is poor at low temperatures.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function. (Code: 04105 (V))
• Temperature sensed by engine coolant temperature sensor can be checked with
Related monitoring function. (Code: 04107 (°C))
information • Method of reproducing failure code: Turn starting switch to ON position.
• If temperature sensor connector is disconnected, failure code [CA144] for high error is
displayed in place of this failure code.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector TWTR, and connect to socket to male side.
a Regard coolant temperature sensor as normal if its resistance is 700
z to 37 kz when coolant temperature is min. 0 °C.
0°C 30 to 37 kz
Between TWTR (male) (A) and (B) 9.3 to 10.7
Defective coolant 25°C
2 kz
temperature sensor a Coolant temperature- 50°C 3.2 to 3.8 kz
Resis- Resistance characteristics 80°C 1.0 to 1.3 kz
tance 95°C 700 to 800z
Whole
Between TWTR (male) (B) and coolant
ground tempera- Min. 1 Mz
ture range
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to female side.
Between J1 (female) (14) and (13) (Coolant
Short circuit in wiring
3 temperature: Min. 0°C)
harness Resis- 700 z to 37
tance a Use Coolant temperature-Resistance kz
characteristics table for check on cause 2
as resistance criteria.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors J1 and TWTR, and connect T-adapters to
4 harness female side of connector J1.
(contact with ground circuit) Resis- Between J1 (female) (14) and ground
Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
5 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-208 WA470-7
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Circuit diagram related to coolant temperature sensor

WA470-7 40-209
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA153] Chg Air Temp Sensor High Error (PC400-CA153-400-A-Z0-A)

Action level Failure code Charge Air Temperature Sensor High Error
Failure
L03 CA153 (Engine controller system)
Detail of • High voltage appears in boost temperature sensor signal circuit.
failure
Action of • Takes it that boost temperature is at fixed temperature (70 °C ) and allows engine to run.
controller
Problem on • Engine does not start easily at low temperatures.
machine
• Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
• Temperature sensed by boost temperature sensor can be checked with monitoring
function. (Code: 18500 (°C))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed as a T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z to 382 kz, regard
boost temperature sensor as normal.
291 to 382
-40 °C
Defective boost temperature kz
2
sensor -20 °C 85 to 109 kz
Between TIM (male) (A) and (B)
Resis- 0 °C 29 to 36 kz
tance a Boost temperature-Resistance 30 °C 7.3 to 8.8 kz
chariacteristic 60 °C 2.3 to 2.7 kz
90 °C 860 to 970 z
130 °C 280 to 320 z
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to female side.
Open or short circuit in wiring Between J1 (female) (5) and (59)
3
harness Resis- a Use Temperature-Resistance 280 z to 382
tance characteristics table for troubleshooting on kz
cause 2.
If no failure is found by above checks, engine controller is defective.
4 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to boost temperature sensor

WA470-7 40-211
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA154] Chg Air Temp Sensor Low Error (PC400-CA154-400-A-Z0-A)

Action level Failure code Charge Air Temperature Sensor Low Error
Failure
L03 CA154 (Engine controller system)
Detail of • Low voltage appears in boost temperature sensor signal circuit.
failure
• Takes it that boost temperature is at fixed temperature (70 °C ) and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine does not start easily at low temperatures.
machine • Engine output lowers.
• Signal voltage from boost temperature sensor can be checked with monitoring function.
(Code: 18501 (V))
• Temperature sensed by boost temperature sensor can be checked with monitoring
Related function. (Code: 18500 (°C))
information • Method of reproducing failure code: Turn starting switch to ON position.
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA153] for "High Error" is displayed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector TIM and connect socket to male side.
a If temperature sensor has resistance of 280 z to 382 kz, regard
boost temperature sensor as normal.
291 to 382
-40 °C
kz
Defective boost temperature -20 °C 85 to 109 kz
2 Between TIM (male) (A) and (B)
sensor 0 °C 29 to 36 kz
Resis- a Boost temperature-Resistance 30 °C 7.3 to 8.8 kz
tance chariacteristic 60 °C 2.3 to 2.7 kz
90 °C 860 to 970 z
130 °C 280 to 320 z
Between TIM (male) (B) and Whole
ground range Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector J1 and connect T-adapters to female side.
Short circuit in wiring Between J1 (female) (5) and (59)
3
harness Resis- a Use Temperature-Resistance 280 z to 382
tance characteristics table for troubleshooting on kz
cause 2.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors J1 and TIM, and connect T-adapter to the
4 harness female side of connector J1.
(contact with ground circuit) Resis- Between J1 (female) (5) and ground
Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
5 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-212 WA470-7
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Troubleshooting by failure code (Display of code)

Circuit diagram related to boost temperature sensor

WA470-7 40-213
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA187] Sensor 2 Supply Volt Low Error (HM300_3-CA187-400-A-Z0-A)

Action level Failure code Sensor 2 Supply Voltage Low Error


Failure
L03 CA187 (Engine controller system)
Detail of • Low voltage appears in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is at fixed
value (250 kPa {2.5 kg/cm2}), and allows engine to run.
• Ignores signals from ambient pressure sensor, takes it that ambient pressure is at fixed
value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Action of • Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value
controller (400 kPa {4.1 kg/cm2}), and allows engine to run.
• Ignores signals from crankcase pressure sensor, takes it that crankcase pressure is at
fixed value (0 kPa), and allows engine to run.
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective harness troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine harness is
defective.
a Other failure codes (many codes) are also displayed. They are generated
Defective sensor or because of disconnection of connector. Ignore failure codes other than
2 wiring harness [CA187].
Bkup speed sensor G
Engine oil pressure
POIL
sensor
Boost pressure sensor PIM
Connector
Ambient pressure sensor PAMB
Crankcase pressure
PCCV
sensor
Engine harness J1
Defective relevant
3 If other failure codes are also displayed, perform troubleshooting for them.
system
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to male side.
Defective engine
4 3. Turn starting switch to ON position with connector J1 disconnected.
controller
Voltage Between J1 (male) (60) and (59) 4.75 to 5.25
V

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Circuit diagram related to sensor power supply 2 (5 V) circuit

WA470-7 40-215
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA221] Ambient Press Sensor High Error (PC400-CA221-400-A-Z0-A)

Action level Failure code Ambient Pressure Sensor High Error


Failure
L03 CA221 (Engine controller system)
Detail of • High voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective ambient
2 pressure sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
supply system for it first.

1. Turn starting switch to OFF position.


2. Disconnect connector PAMB.
3. Turn starting switch to ON position.
If failure code changes from [CA221] to [CA222], sensor is defective.
Defective ambient • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1 or PAMB.
3. Turn starting switch to ON position.
Between J1 (16) and (59), or between Sensor
Voltage 0.3 to 4.7 V
PAMB (3) and (2) output
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors J1 and PAMB, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of a To check open circuit in GND line
connector) Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PAMB, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between J1 (female) (60) and (16), or between
Resistance PAMB (female) (1) and (3) Min. 1 Mz

1. Turn starting switch to OFF position.


Hot short circuit in 2. Disconnect connector PAMB, and connect T-adapter to female side.
6 wiring harness 3. Turn starting switch to ON position.
Voltage Between PAMB (female) (3) and (2) Max. 1 V
Defective engine If no failure is found by above checks, engine controller is defective.
7
controller (Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to ambient pressure sensor

WA470-7 40-217
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA222] Ambient Press Sensor Low Error (PC400-CA222-400-A-Z0-A)

Action level Failure code Ambient Pressure Sensor Low Error


Failure
L03 CA222 (Engine controller system)
Detail of • Low voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (not designed as T-adapter).
• This failure code appears if sensor connector is disconnected.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting
for it first.
Defective ambient 1. Turn starting switch to OFF position.
2 pressure sensor power 2. Disconnect connector PAMB, and connect T-adapter to female side.
supply system 3. Turn starting switch to ON position.
Power 4.75 to 5.25
Voltage Between PAMB (female) (1) and (2)
supply input V
1. Turn starting switch to OFF position.
2. Disconnect connectors PAMB and J1, and connect T-adapter to either
Short circuit in wiring
3 female side.
harness
Between J1 (female) (16) and (59), or between
Resistance PAMB (female) (3) and (2) Min. 1 Mz

Ground fault in wiring 1. Turn starting switch to OFF position.


harness 2. Disconnect connectors PAMB and J1, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and J1 (female) (16) or PAMB
circuit) Resistance (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors PAMB and J1, and connect T-adapter to female
Open circuit in wiring side of connector J1.
5 Between J1 (female) (16) and PAMB (female) (3) Max. 1 z
harness
Resistance Between J1 (female) (59) and PAMB (female) (2) Max. 1 z
Between J1 (female) (60) and PAMB (female) (1) Max. 1 z

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No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 1 to 5 and failure is found by
check on cause 6, sensor is defective.
Defective ambient 1. Turn starting switch to OFF position.
6 pressure sensor 2. Insert T-adapters into connector J1 or PAMB.
3. Turn starting switch to ON position.
Between J1 (16) and (59), or between Sensor
Voltage 0.3 to 4.7 V
PAMB (3) and (2) output
Defective engine If no failure is found by above checks, engine controller is defective.
7
controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to ambient pressure sensor

WA470-7 40-219
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA227] Sensor 2 Supply Volt High Error (PC400-CA227-400-A-Z0-A)

Action level Failure code Sensor 2 Supply Voltage High Error


Failure
L03 CA227 (Engine controller system)
Detail of • High voltage appears in sensor power supply 2 (5V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from engine oil pressure sensor, takes it that engine oil pressure is at
fixed value (250 kPa {2.5 kg/cm2}), and allows engine to run.
• Ignores signals from ambient pressure sensor, takes it that ambient pressure is at fixed
value (52.44 kPa {0.53 kg/cm2}), and allows engine to run.
Action of • Ignores signals from boost pressure sensor, takes it that boost pressure is at fixed value
controller (400 kPa {4.1 kg/cm2}), and allows engine to run.
• Ignores signals from crankcase pressure sensor, takes it that crankcase pressure is at
fixed value (0 kPa), and allows engine to run.
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective sensor power
1 Perform troubleshooting for failure code [CA187].
supply 2 circuit

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Failure code [CA234] Eng Overspeed (PC400-CA234-400-A-Z0-A)

Action level Failure code Engine Overspeed


Failure
L02 CA234 (Engine controller system)
Detail of • Engine speed is above operating range.
failure
Action of • Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem on • Engine speed fluctuates.
machine
Related • Engine speed can be checked by using monitoring function. (Code: 01002 (rpm))
information • Method of reproducing failure code: Run engine at full speed.
No. Cause Procedure, measuring location, criteria and remarks
1 Use of improper fuel Fuel used may be improper. Check it.
2 Defect in related system If another failure code is displayed, perform troubleshooting for it.
Improper use Usage of machine may be improper. Instruct operator on proper use of
3
machine.
If no problem is found by checks on causes 1 and 2, engine controller is
4 Defective engine controller defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-221
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Troubleshooting by failure code (Display of code)

Failure code [CA238] Ne Speed Sensor Supply Volt Error (PC400-CA238-400-A-Z0-A)

Action level Failure code Ne speed sensor supply voltage error


Failure
L01 CA238 (Engine controller system)
Detail of • Ne speed sensor power supply (5 V) circuit is defective.
failure
Action of • Controls engine by using signals of Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also abnormal).
machine • Stopped engine cannot be started (when Bkup(G) speed sensor is also abnormal).
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. After each troubleshooting, turn starting switch to OFF position.
If this failure code is not displayed when a sensor is disconnected,
Defective sensor or wiring sensor or engine wiring harness is defective.
2
harness
a Other failure codes are displayed, too. This is because connector is
disconnected. Ignore failure codes other than [CA238].
Sensor or harness Connector
Ne speed sensor NE
Engine wiring harness J1
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapter to male side.
3 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
Voltage Between J1 (male) (36) and (37) 4.75 to 5.25
V

Circuit diagram related to Ne speed sensor

40-222 WA470-7
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Failure code [CA239] Ne Speed Sens Supply Volt High Error (PC400-CA239-400-A-Z0-
A)

Action level Failure code Ne Speed Sensor Supply Voltage High Error
Failure
L01 CA239 (Engine controller system)
Detail of • High voltage appears in Ne speed sensor power supply (5 V) circuit.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup (G) speed sensor is also defective).
machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector NE.
3. Turn starting switch to ON position.
If this failure code is not displayed, disconnected sensor or engine wiring
2 Defective Ne speed sensor
harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].
1. Turn starting switch to OFF position.
2. Disconnect connector J1.
3. Turn starting switch to ON position.
3 Defective wiring harness If this failure code disappears, wiring harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than [CA239].
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
Voltage Between J1 (male) (36) and (37) 4.75 to 5.25
V

Circuit diagram related to Ne speed sensor

WA470-7 40-223
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA271] IMV/PCV1 Short Error (PC400-CA271-400-A-Z0-A)

Action level Failure code IMV/PCV1 Short Error


Failure
L03 CA271 (Engine controller system)
Detail of • Short circuit is detected in supply pump PCV1 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine
• Under normal conditions, pulse voltage of approx. 24 V is applied to PCV1 (1) while
Related engine is running. However, it cannnot be measured by using multimeter since it is pulse
information voltage.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connectors PCV1 and connect socket to male side.
Defective supply pump PCV1 3. Turn starting switch to ON position.
2 Resis- Between PCV1 (male) (1) and (2) 2.3 to 5.3
(internal short circuit)
tance z
Resis- Between PCV1 (male) (1) and ground
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
3 Short circuit in wiring harness
Resis- Between J2 (female) (4) and (5) (PCV1 2.3 to 5.3
tance resistance) z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV1 and connect T-adapter to
4 female side of connector J2.
(contact with ground circuit)
Resis- Between J2 (female) (5) and ground
Min. 1 Mz
tance
If no abnormality is found by above diagnosis, engine controller is
5 Defective engine controller defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to PCV1

40-224 WA470-7
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Failure code [CA272] IMV/PCV1 Open Error (PC400-CA272-400-A-Z0-A)

Action level Failure code IMV/PCV1 Open Error


Failure
L03 CA272 (Engine controller system)
Detail of • Open circuit is detected in supply pump PCV1 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV1 (1) while
engine is runing. However, it cannot be measured by using multimeter since it is pulse
Related voltage.
information • Because troubleshooting "socket" for this sensor features female connector alone, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed as a T-adapter).
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
Defective supply pump PCV1 2. Disconnect connectors PCV1 and connect socket to male side.
2
(internal open circuit) Resis- Between PCV1 (male) (1) and (2)
2.3 to 5.3 z
tance
1. Turn starting switch to OFF position.
Open or short circuit in wiring 2. Disconnect connector J2 and connect T-adapters to female side.
3
harness Resis- Between J2 (female) (4) and (5) (PCV1
resistance) 2.3 to 5.3 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors J2 and PCV1.
4 harness 3. Connect T-adapter to female side of connector J2.
(contact with ground circuit) Resis- Between J2 (female) (5) and ground
Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
5 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to PCV1

WA470-7 40-225
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA273] PCV2 Short Error (PC400-CA273-400-A-Z0-A)

Action level Failure code PCV2 Short Error


Failure
L03 CA273 (Engine controller system)
Detail of • Short circuit is detected in supply pump PCV2 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Under normal conditions, pulse voltage of approx. 24 V is applied to PCV2 (1) while
information engine is running. However, it cannot be measured by using multimeter since it is pulse
voltage.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector PCV2 and connect socket to male side.
Defective supply pump PCV2 Resis- Between PCV2 (male) (1) and (2) 2.3 to 5.3
2
(internal short circuit) tance z
Resis- Between PCV2 (male) (1) and ground
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
3 Short circuit in wiring harness
Resis- Between J2 (female) (1) and (2) (PCV2 2.3 to 5.3
tance resistance) z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV2 and connect T-adapter to
4 female side of connector J2.
(contact with ground circuit)
Resis- Between J2 (female) (2) and ground
Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
5 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to PCV2

40-226 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA274] PCV2 Open Error (PC400-CA274-400-A-Z0-A)

Action level Failure code PCV2 Open Error


Failure
L03 CA274 (Engine controller system)
Detail of • Open circuit is detected in supply pump PCV2 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Under normal conditions, pulse voltage of approximately 24 V is applied to PCV2 (1)
while engine is running. However, it cannot be measured by using multimeter since it is
Related pulse voltage.
information • Because troubleshooting "socket" for this sensor features female connector alone, it is
not connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed as a T-adapter).
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
Defective supply pump PCV2 2. Disconnect connector PCV2 and connect socket to male side.
2
(internal open circuit) Resis- Between PCV2 (male) (1) and (2) 2.3 to 5.3
tance z
1. Turn starting switch to OFF position.
Open or short circuit in wiring 2. Disconnect connector J2 and connect T-adapters to female side.
3
harness Resis- Between J2 (female) (1) and (2) (PCV2 2.3 to 5.3
tance resistance) z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J2 and PCV2.
4 3. Connect T-adapter to female side of connector J2.
(contact with ground circuit)
Resis- Between J2 (female) (2) and ground
Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
5 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to PCV2

WA470-7 40-227
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA322] Inj #1(L#1) Open/Short Error (PC400-CA322-400-A-Z0-A)

Action level Failure code Injector #1(L#1) Open/Short Error


Failure
L03 CA322 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #1 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector CN1 and connect T-adapter to male side.
2 Defective injector #1 Resis- Between CN1 (male) (1) and (2)
0.4 to 1.1 z
tance
Resis- Between CN1 (male) (1) and ground
Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to female side.
Open circuit or ground fault in Resis- Between J1 (female) (48) and (58)
3 wiring harness 0.4 to 1.1 z
tance
Resis- Between J1 (female) (48) and ground
Min. 1 Mz
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and CN1, and connect T-adapters to each
4 (wire breakage or defective female side.
contact of connector) Resis- Between J1 (female) (48) and CN1 (female)
(1) Max. 1 z
tance
Resis- Between J1 (female) (58) and CN1 (female)
(2) Max. 1 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness
5 2. Disconnect connectors J1 and CN1, and connect T-adapters to
(contact with ground circuit) either female side.
Resis- Between J1 (female) (48) or CN1 (female) (1)
and ground Min. 1 Mz
tance

40-228 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and CN1, and connect T-adapters to
female side of connector J1.
a Check by using multimeter in continuity mode.
No
6 Short circuit in wiring harness Between J1 (female) (48) and and each other continuity
pin (No sound
is heard)
Continuity
No
continuity
Between J1 (female) (58) and each other pin
(No sound
is heard)
Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them, too.
If no failure is found by above checks, engine controller is defective.
8 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #1

WA470-7 40-229
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA323] Inj #5(L#5) Open/Short Error (PC400-CA323-400-A-Z0-A)

Action level Failure code Injector #5(L#5) Open/Short Error


Failure
L03 CA323 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #5 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector CN5 and connect T-adapter to male side.
2 Defective injector #5
Resis- Between CN5 (male) (1) and (2) 0.4 to 1.1 z
tance Between CN5 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground fault in 2. Disconnect connector J1 and connect T-adapters to female side.
3 wiring harness Resis- Between J1 (female) (44) and (54) 0.4 to 1.1 z
tance Between J1 (female) (44) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and CN5, and connect T-adapter to each
4 (wire breakage or defective female side.
contact of connector) Between J1 (female) (44) and CN5 (female)
Max. 1 z
Resis- (1)
tance Between J1 (female) (54) and CN5 (female)
(2) Max. 1 z

a If no failure is found by check on cause 3, this check is not required.


1. Turn starting switch to OFF position.
Ground fault in wiring harness
5 2. Disconnect connectors J1 and CN5, and connect T-adapter to either
(contact with ground circuit) female side.
Resis- Between J1 (female) (44) or CN5 (female) (1)
and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and CN5, and connect T-adapter to the
female side of connector J1.
a Check by using multimeter in continuity mode.
No
Short circuit in wiring harness continuity
6 Between J1 (female) (44) and each other pin
(No sound
is heard)
Continuity
No
continuity
Between J1 (female) (54) and each other pin
(No sound
is heard)

40-230 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them, too.
If no failure is found by above checks, engine controller is defective.
8 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #5

WA470-7 40-231
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA324] Inj #3(L#3) Open/Short Error (PC400-CA324-400-A-Z0-A)

Action level Failure code Injector #3(L#3) Open/Short Error


Failure
L03 CA324 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #3 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector CN3 and connect T-adapter to male side.
2 Defective injector #3
Resis- Between CN3 (male) (1) and (2) 0.4 to 1.1 z
tance Between CN3 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground fault in 2. Disconnect connector J1 and connect T-adapters to female side.
3 wiring harness Resis- Between J1 (female) (46) and (56) 0.4 to 1.1 z
tance Between J1 (female) (46) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and CN3, and connect T-adapter to each
4 (wire breakage or defective female side.
contact of connector) Between J1 (female) (46) and CN3 (female)
Max. 1 z
Resis- (1)
tance Between J1 (female) (56) and CN3 (female)
(2) Max. 1 z

a If no failure is found by check on cause 3, this check is not required.


1. Turn starting switch to OFF position.
Ground fault in wiring harness
5 2. Disconnect connectors J1 and CN3, and connect T-adapter to either
(contact with ground circuit) female side.
Resis- Between J1 (female) (46) or CN3 (female) (1)
and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and CN3, and connect T-adapter to the
female side of connector J1.
a Check by using multimeter in continuity mode.
No
Short circuit in wiring harness continuity
6 Between J1 (female) (46) and each other pin
(No sound
is heard)
Continuity
No
continuity
Between J1 (female) (56) and each other pin
(No sound
is heard)

40-232 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them, too.
If no failure is found by above checks, engine controller is defective.
8 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #3

WA470-7 40-233
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA325] Inj #6(L#6) Open/Short Error (PC400-CA325-400-A-Z0-A)

Action level Failure code Injector #6(L#6) Open/Short Error


Failure
L03 CA325 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #6 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector CN6 and connect T-adapter to male side.
2 Defective injector #6
Resis- Between CN6 (male) (1) and (2) 0.4 to 1.1 z
tance Between CN6 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground fault in 2. Disconnect connector J1 and connect T-adapters to female side.
3 wiring harness Resis- Between J1 (female) (45) and (55) 0.4 to 1.1 z
tance Between J1 (female) (45) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and CN6, and connect T-adapter to each
4 (wire breakage or defective female side.
contact of connector) Between J1 (female) (45) and CN6 (female)
Max. 1 z
Resis- (1)
tance Between J1 (female) (55) and CN6 (female)
(2) Max. 1 z

a If no failure is found by check on cause 3, this check is not required.


1. Turn starting switch to OFF position.
Ground fault in wiring harness
5 2. Disconnect connectors J1 and CN6, and connect T-adapter to either
(contact with ground circuit) female side.
Resis- Between J1 (female) (45) or CN6 (female) (1)
and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and CN6, and connect T-adapter to the
female side of connector J1.
a Check by using multimeter in continuity mode.
No
Short circuit in wiring harness continuity
6 Between J1 (female) (45) and each other pin
(No sound
is heard)
Continuity
No
continuity
Between J1 (female) (55) and each other pin
(No sound
is heard)

40-234 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them, too.

If no failure is found by above checks, engine controller is defective.


8 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #6

WA470-7 40-235
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA331] Inj #2(L#2) Open/Short Error (PC400-CA331-400-A-Z0-A)

Action level Failure code Injector #2(L#2) Open/Short Error


Failure
L03 CA331 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #2 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector CN2 and connect T-adapter to male side.
2 Defective injector #2
Resis- Between CN2 (male) (1) and (2) 0.4 to 1.1 z
tance Between CN2 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground fault in 2. Disconnect connector J1 and connect T-adapters to female side.
3 wiring harness Resis- Between J1 (female) (47) and (57) 0.4 to 1.1 z
tance Between J1 (female) (47) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and CN2, and connect T-adapter to each
4 (wire breakage or defective female side.
contact of connector) Between J1 (female) (47) and CN2 (female)
Max. 1 z
Resis- (1)
tance Between J1 (female) (57) and CN2 (female)
(2) Max. 1 z

a If no failure is found by check on cause 3, this check is not required.


1. Turn starting switch to OFF position.
Ground fault in wiring harness
5 2. Disconnect connectors J1 and CN2, and connect T-adapter to either
(contact with ground circuit) female side.
Resis- Between J1 (female) (47) or CN2 (female) (1)
and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and CN2, and connect T-adapter to the
female side of connector J1.
a Check by using multimeter in continuity mode.
No
Short circuit in wiring harness continuity
6 Between J1 (female) (47) and each other pin
(No sound
is heard)
Continuity
No
continuity
Between J1 (female) (57) and each other pin
(No sound
is heard)

40-236 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them, too.
If no failure is found by above checks, engine controller is defective.
8 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #2

WA470-7 40-237
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA332] Inj #4(L#4) Open/Short Error (PC400-CA332-400-A-Z0-A)

Action level Failure code Injector #4(L#4) Open/Short Error


Failure
L03 CA332 (Engine controller system)
Detail of • Open circuit or short circuit is detected in injector #4 circuit.
failure
Action of
controller
Problem on • Engine output lowers.
machine • Engine speed does not stabilize.
• Method of reproducing failure code: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is applied to
information injector (positive) side. But it is pulse voltage and cannot be measured by using
multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector CN4 and connect T-adapter to male side.
2 Defective injector #4
Resis- Between CN4 (male) (1) and (2) 0.4 to 1.1 z
tance Between CN4 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit or ground fault in 2. Disconnect connector J1 and connect T-adapters to female side.
3 wiring harness Resis- Between J1 (female) (43) and (53) 0.4 to 1.1 z
tance Between J1 (female) (43) and ground Min. 1 Mz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and CN4, and connect T-adapter to each
4 (wire breakage or defective female side.
contact of connector) Between J1 (female) (43) and CN4 (female)
Max. 1 z
Resis- (1)
tance Between J1 (female) (53) and CN4 (female)
(2) Max. 1 z

a If no failure is found by check on cause 3, this check is not required.


1. Turn starting switch to OFF position.
Ground fault in wiring harness
5 2. Disconnect connectors J1 and CN4, and connect T-adapter to either
(contact with ground circuit) female side.
Resis- Between J1 (female) (43) or CN4 (female) (1)
and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and CN4, and connect T-adapter to the
female side of connector J1.
a Check by using multimeter in continuity mode.
No
Short circuit in wiring harness continuity
6 Between J1 (female) (43) and each other pin
(No sound
is heard)
Continuity
No
continuity
Between J1 (female) (53) and each other pin
(No sound
is heard)

40-238 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Defective other cylinder If failure codes for other injectors are displayed, perform troubleshooting
7 injectors or wiring harness for them, too.
If no failure is found by above checks, engine controller is defective.
8 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #4

WA470-7 40-239
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA343] ECM Critical Internal Failure (PC400-CA343-400-A-Z0-A)

Action level Failure code ECM Critical Internal Failure


Failure
L04 CA343 (Engine controller system)
Detail of • Engine controller has internal defect.
failure
Action of • None in particular
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine start if it is stopped.
• Power supply voltage of engine controller can be checked with moniitoring funtion.
Related (Code: 03203 Battery voltage)
information • Method of reproducing failure code: Turn starting switch to ON position
No. Cause Procedure, measuring location, criteria and remarks
Defective engine controller
1 Perform troubleshooting for failure code [CA441].
system

40-240 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA351] Injectors Drive Circuit Error (PC400-CA351-400-A-Z0-A)

Action level Failure code Injectors Drive Circuit Error


Failure
L03 CA351 (Engine controller system)
Detail of • Injector drive circuit is defective.
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
Problem on • Engine output lowers.
machine
Related • Method of reproducing failure code: Start engine.
information
No. Cause Procedure, measuring location, criteria and remarks
Check failure code (injector system failure code) that is displayed at the
1 Defect in related system
same time. If another code is displayed, perform troubleshooting for it.
Defective engine controller
2 Perform troubleshooting for failure code [CA441].
system

WA470-7 40-241
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA352] Sensor 1 Supply Volt Low Error (PC400-CA352-400-A-Z0-A)

Action level Failure code Sensor 1 Supply Voltage Low Error


Failure
L03 CA352 (Engine controller system)
Detail of • Low voltage appears in sensor power supply 1 (5 V) circuit.
failure
• Ignores signals from dosing (post-treatment injector) fuel pressure sensor, and stops
Action of KDPF regeneration control.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine
harness is defective.
Defective sensor or wiring
2 a Other failure codes (many codes) are also displayed. They are
harness
generated because of disconnection of connector. Ignore failure
codes other than [CA352].
Dosing fuel pressure sensor PDOSER connector
EGR valve lift sensor SEGR connector
Connector
KVGT position sensor SVGT connector
Engine harness J2
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
3
them.
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with connector J2 disconnected.
Voltage Between J2 (male) (30) and (47) 4.75 to 5.25
V

40-242 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to sensor power supply 1 (5 V)

WA470-7 40-243
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA356] Mass Air Flow Sensor High Error (WA500_7-CA356-400-A-Z0-A)

Action level Failure code Mass Air Flow Sensor High Error
Failure
L03 CA356 (Engine controller system)
Detail of • High frequency appears in signal circuit of mass air flow sensor.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake air temperature sensor are integrated.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective mass air flow 2. Disconnect connector E27.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to [CA357], mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector E27 and connect T-adapters to female side.
Defective sensor power
4 3. Turn starting switch to ON position.
supply system
Power Approx. 12
Voltage Between E27 (female) (2) and (3)
supply V
a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to each
5 (wire breakage or defective female side.
contact of connector)
a To check open circuit in GND line
Resis- Between J1 (female) (22) and E27 (female) (3)
Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
female side of J1.
6 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Resis- Between J1 (female) (23) and each pin other
than pin (23) Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to mass air flow sensor

WA470-7 40-245
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Troubleshooting by failure code (Display of code)

Failure code [CA357] Mass Air Flow Sensor Low Error (WA500_7-CA357-400-A-Z0-A)

Action level Failure code Mass Air Flow Sensor Low Error
Failure
L03 CA357 (Engine controller system)
Detail of • Low frequency appears in signal circuit of mass air flow sensor.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, both this failure code and failure code [CA691] are
information displayed.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective mass air flow 2. Replace mass air flow sensor.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code does not appear, original mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connectorE27, and connect T-adapters to female side.
Defective sensor power
4 3. Turn starting switch to ON position.
supply system
Power Approx. 12
Voltage Between E27 (female) (2) and (3)
supply V
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to each
female side.
a If no failure is found by check on cause 4,
Open circuit in wiring harness this check is not required. Max. 1 z
5 (wire breakage or defective Between J1 (female) (21) and E27 (female) (2)
contact of connector) Resis-
tance a If no failure is found by check on cause 4,
this check is not required. Max. 1 z
Between J1 (female) (22) and E27 (female) (3)
Between J1 (female) (23) and E27 (female) (1) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to
6 either female side.
(contact with ground circuit)
Resis- Between ground and J1 (female) (23) or E27
(female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
female side of connector J1.
7 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Resis- Between J1 (female) (23) and each pin other
than pin (23) Min. 1 Mz
tance

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No. Cause Procedure, measuring location, criteria and remarks


1. Be ready with starting switch at OFF position.
Hot short circuit in wiring 2. Disconnect connector E27, and connect T-adapters to female side.
8 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) a Ignore displayed failure codes.
Voltage Between E27 (female) (1) and (3) Max. 1 V
If no failure is found by above checks, engine controller is defective.
9 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to mass air flow sensor

WA470-7 40-247
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Failure code [CA386] Sensor 1 Supply Volt High Error (PC400-CA386-400-A-Z0-A)

Action level Failure code Sensor 1 Supply Voltage High Error


Failure
L03 CA386 (Engine controller system)
Detail of • High voltage appears in sensor power supply 1 (5 V) circuit.
failure
• Ignores signals from dosing (post-treatment injector) fuel pressure sensor, and stops
Action of KDPF regeneration control.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective sensor power
1 Perform troubleshooting for failure code [CA352].
supply 1 circuit

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Failure code [CA431] Idle Validation Sw Error (WA380_7-CA431-400-A-Z0-A)

Action level Failure code Idle Validation Switch Error


Failure
L01 CA431 (Engine controller system)
Detail of • Idle validation switch signals 1 and 2 (IVS1 and IVS2) are abnormal.
failure
Action of • Uses throttle position from throttle sensor to run engine.
controller
Problem on
machine
• Input (ON/OFF) of idle validation signal 1 can be checked with monitoring function. (Code:
18300)
Related • Input (ON/OFF) of idle validation signal 2 can be checked with monitoring function. (Code:
information 18301)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector PDV.
Defective power supply 3. Turn starting switch to ON position.
2 system
a If check result is unusual, go to check on cause 4.
Voltage Between PDV (1) and (2) 4.75 to 5.25
V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector PD.
3. Turn starting switch to ON position.
Defective accelerator pedal
3 a If check result is unusual, perform checks on causes 4 and 5 to
(internal defect) check wiring harness. If wiring harness is normal, regard accelerator
pedal as defective.
Between PD (5) and (4) See IVS1 in Fig. 1
Between PD (6) and (4) See IVS2 in Fig. 1
1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
2. Disconnect connectors PD, PDV and EC3, and connect T-adapters
to each female side.
Between EC3 (female) (19) and PD (female)
(4) Max. 1 z
Open circuit in wiring harness
Between EC3 (female) (49) and PD (female)
4 (wire breakage or defective (5) Max. 1 z
contact of connector)
Resis- Between EC3 (female) (50) and PD (female)
(6) Max. 1 z
tance
Between EC3 (female) (52) and PDV
(female) (1) Max. 1 z
Between EC3 (female) (43) and PDV
(female) (2) Max. 1 z
1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
2. Disconnect connectors PD and EC3, and connect T-adapters to
female side of EC3.
5 Short circuit in wiring harness
Between EC3 (female) (49) and each pin
Min. 1 Mz
Resis- other than pin (49)
tance Between EC3 (female) (50) and each pin Min. 1 Mz
other than pin (50)

WA470-7 40-249
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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
2. Insert T-adapters into connector EC3.
Defective transmission 3. Set battery disconnect switch to ON position.
6 controller (internal defect) 4. Turn starting switch to ON position.
Between EC3 (42) and (41) 4.75 to 5.25
Voltage V
Between EC3 (52) and (43) 4.75 to 5.25
V
If no failure is found by above checks, engine controller is defective.
• Reference
1. Turn starting switch to OFF position.
Defective engine controller
7 2. Insert T-adapters into connector EC3.
(internal defect)
3. Turn starting switch to ON position.
Between EC3 (49) and (19) See IVS1 in Fig. 1
Between EC3 (50) and (19) See IVS2 in Fig. 1

Circuit diagram related to idle validation

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Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage : Output voltage: (pin 2 of connector PD and pin 51 of connector EC3)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF

WA470-7 40-251
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA432] Idle Validation Process Error (WA380_7-CA432-400-A-Z0-A)

Action level Failure code Idle Validation Process Error


Failure
L03 CA432 (Engine controller system)
Detail of • Idle validation switch signal does not match with (but contradicts) signal of throttle sensor.
failure
1. When idle validation switch signal indicates that accelerator pedal is OFF but throttle
sensor signal indicates that accelerator pedal is ON: Controls throttle position to 0 %
while idle validation signal is indicating that accelerator pedal is OFF, and to 50 % while
Action of
idle validation signal is indicating that accelerator pedal is ON.
controller
2. When idle validation switch signal indicates that accelerator pedal is ON but throttle
sensor signal indicates that accelerator pedal is OFF: Controls throttle position to 0 %.
(Fix engine speed to low idle.)
• Engine speed does not increase from low idle speed.
Problem on • Centralized warning lamp lights up and alarm buzzer sounds (according to command
machine from machine monitor).
• Input (ON/OFF) of idle validation signal 1 can be checked with monitoring function. (Code:
18300)
• Input (ON/OFF) of idle validation signal 2 can be checked with monitoring function. (Code:
Related 18301)
information • Input voltage from throttle sensor can be checked with monitoring function. (Code: 03000)
• Accelerator pedal position sensed by throttle sensor can be checked with monitoring
function. (Code: 31701)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
For idle validation switch signal error, perform troubleshooting for failure code [CA431].
1
(For throttle sensor error, perform checks on causes 2 and after)
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector PD.
Defective power supply 3. Turn starting switch to ON position.
2 system
a If check result is unusual, go to check on cause 4.
Voltage Between PD (1) and (3) 4.75 to 5.25
V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector PD.
3. Turn starting switch to ON position.
Defective accelerator pedal
3 a If check result is unusual, perform checks on causes 4 and 5 to
(internal defect)
check wiring harness. If wiring harness is normal, regard accelerator
pedal as defective.
Between PD (2) and (3) See output voltage in Fig. 1
1. Turn starting switch to OFF position.
2. Disconnect connectors PD and EC3, and connect T-adapters to each
female side.
Open circuit in wiring harness Between EC3 (female) (42) and PD (female)
(1) Max. 1 z
4 (wire breakage or defective
contact of connector) Resis- Between EC3 (female) (51) and PD (female)
(2) Max. 1 z
tance
Between EC3 (female) (41) and PD (female)
(3) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors PD and EC3, and connect T-adapters to
5 Short circuit in wiring harness female side of EC3.
Resis- Between EC3 (female) (9) and each pin other
than pin (9) Min. 1 Mz
tance

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No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, engine controller is defective.
• Reference
1. Turn starting switch to OFF position.
Defective engine controller
6 2. Insert T-adapters into connector EC3.
(internal defect)
3. Turn starting switch to ON position.
See output voltage in Fig. 1 on next
Between EC3 (51) and (41)
page.

Circuit diagram related to idle validation

WA470-7 40-253
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Troubleshooting by failure code (Display of code)

Fig. 1
Pedal stroke: Stroke of accelerator pedal
Output voltage : Output voltage: (pin 2 of connector PD and pin 51 of connector EC3)
IVS1: Signal voltage of idle validation switch 1
IVS2: Signal voltage of idle validation switch 2
Switch gap: Zone where both signals of IVS1 and IVS2 are OFF

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Failure code [CA441] Battery Voltage Low Error (WA470_7-CA441-400-A-Z0-A)

Action level Failure code Battery Voltage Low Error


Failure
L04 CA441 (Engine controller system)
Detail of • Low voltage appears in engine controller power supply circuit.
failure
Action of • Takes it that power supply voltage is at fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
• Power supply voltage of engine controller can be checked with monitoring function.
(Code: 03203 Battery voltage)
• Method of reproducing failure code: Turn starting switch to ON position
Related
• Since T-adapter is not provided for alternator connector, operating voltage cannot be
information
measured.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
Loose or corroded
1 Battery terminal may be loose or corroded. Check it directly.
battery terminal
1. Turn starting switch to OFF position.
Loose terminal or partial
2 open circuit at terminal Check terminals of alternator, battery relay, ground terminals (R50, E14A,
E14B, and E09), etc.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective harness troubleshooting", and check it.
3 2. Turn starting switch to ON position.
connector
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position, then perform troubleshooting.
4 Lowered battery voltage 2. Measure voltage while cranking engine.
Voltage Between battery terminals (+) and (-). 20 to 30 V
1. Turn starting switch to OFF position.
5 Defective alternator 2. Start engine. (Engine speed: Middle or faster)
Voltage Between terminal E02 and ground 26 to 30.5 V
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Insert T-adapters into connector EC3.
Defective engine 3. Set battery disconnect switch to ON position.
6
controller 4. Measure voltage with starting switch at OFF position and when starting
engine.
Between EC3 (1) and (21) 20 to 30 V
Between EC3 (2) and (22) 20 to 30 V
Voltage
Between EC3 (11) and (31) 20 to 30 V
Between EC3 (12) and (32) 20 to 30 V

WA470-7 40-255
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Troubleshooting by failure code (Display of code)

Circuit diagram related to engine controller power supply

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Failure code [CA442] Battery Voltage High Error (WA500_7-CA442-400-A-Z0-A)

Action level Failure code Battery Voltage High Error


Failure
L04 CA442 (Engine controller system)
Detail of • High voltage (approx. 36 V or higher) appears in controller power supply circuit.
failure
Action of • Takes it that power supply voltage is at fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart if it is stopped.
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03203 Battery voltage)
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply
1 Perform troubleshooting for failure code [CA441].
system of engine controller

WA470-7 40-257
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA449] Rail Press Very High Error (PC400-CA449-400-A-Z0-A)

Action level Failure code Rail Pressure Very High Error


Failure
L03 CA449 (Engine controller system)
Detail of • High voltage (exceeding the preset limit) occurs in common rail pressure sensor circuit.
failure
Action of • Limits engine output and allows engine to run (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective common rail
1 Perform troubleshooting for failure code [CA553].
pressure sensor system

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Failure code [CA451] Rail Press Sensor High Error (PC400-CA451-400-A-Z0-A)

Action level Failure code Rail Pressure Sensor High Error


Failure
L03 CA451 (Engine controller system)
Detail of • High voltage appears in signal circuit of common rail pressure sensor.
failure
Action of • Limits engine output and allows engine to run (limits common rail pressure).
controller
Problem on • Engine output decreases.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• This failure code appears if common rail pressure sensor connector is disconnected.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
a If failure code [CA515] or [CA516] is also displayed, perform
troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1) and
Voltage supply 4.75 to 5.25
(3) V
input
1. Turn starting switch to OFF position.
2. Disconnect connectors PFUEL and J2, and connect T-adapters to
each female side of connectors.
a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Open circuit in wiring harness Between J2 (female) (31) and PFUEL
3 (wire breakage or defective (female) (1)
contact of connector)
Resistance a If power supply input is normal in check on
cause 2, this check is not required. Max. 1 z
Between J2 (female) (21) and PFUEL
(female) (3)
Between J2 (female) (55) and PFUEL
(female) (2) (sensor output) Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connectors PFUEL and J2.
4 Short circuit in wiring harness 3. Connect T-adapter to female side of J2.
Min. 1 Mz
Resistance Between J2 (female) (55) and (31)

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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector PFUEL, and insert T-adapter to connector J2.
3. Turn starting switch to ON position (with connector PFUEL
Hot short circuit in wiring disconnected).
5
harness
a Pin (55) of connector J2 is connected to 5 V circuit via resistor inside
engine controller.
Voltage Between J2 (55) and (21) Approx. 5 V
a If no failure is found by checks on causes 1 to 5 and if failure is
Defective common rail found by check on cause 6, sensor is defective.
pressure sensor 1. Turn starting switch to OFF position.
6 2. Insert T-adapters into connector J2.
(improper input voltage to
engine controller) 3. Turn starting switch to ON position.
Sensor
Voltage Between J2 (55) and (21)
output 0.2 to 4.6 V
If no failure is found by above checks, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to common rail pressure sensor

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Failure code [CA452] Rail Press Sensor Low Error (PC400-CA452-400-A-Z0-A)

Action level Failure code Rail Pressure Sensor Low Error


Failure
L03 CA452 (Engine controller system)
Detail of • Low voltage occurs in signal circuit of common rail pressure sensor.
failure
Action of • Limits engine output and allows engine to run (limits common rail pressure).
controller
Problem on • Engine output reduces.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
• Common rail pressure sensed by common rail pressure sensor can be checked with
Related monitoring function. (Code: 36400 (MPa))
information • Method of reproducing failure code: Turn starting switch to ON position.
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code is not displayed, wiring harness connector is
defective.
a If this failure code is displayed, perform following checks.
a If failure code [CA515] or [CA516] is also displayed, perform
troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective common rail 2. Disconnect connector PFUEL, and connect T-adapter to female side
2 pressure sensor power supply of connector.
system 3. Turn starting switch to ON position.
Power
Between PFUEL (female) (1)
Voltage supply 4.75 to 5.25 V
and (3)
input
1. Turn starting switch to OFF position.
2. Disconnect connector PFUEL.
3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451], sensor is defective.
Defective common rail • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PFUEL or J2.
3. Turn starting switch to ON position.
Between PFUEL (2) and (3), or Sensor
Voltage 0.2 to 4.6 V
between J2 (55) and (21) output
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PAMB, and connect T-adapters to
Open circuit in wiring harness each female side of connectors.
4 (wire breakage or defective
contact of connector) a Open circuit of 5 V circuit
Between J2 (female) (31) and PFUEL
Resistance (female) (1) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
5 either female side.
(contact with ground circuit)
Between ground and PFUEL (female) (2) or Min. 1 Mz
Resistance J2 (female) (55)

WA470-7 40-261
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Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
6 Short circuit in wiring harness either female side.
Between PFUEL (female) (2) and (3) or
Resistance between J2 (female) (55) and (21) Min. 1 Mz
If no failure is found by above checks, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to common rail pressure sensor

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Failure code [CA515] Rail Press Sens Sup Volt High Error (PC400-CA515-400-A-Z0-A)

Action level Failure code Rail Pressure Sensor Supply Voltage High Error
Failure
L03 CA515 (Engine controller system)
Detail of • High voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and allows engine to run.
controller • Limits the common rail pressure.
Problem on • Engine output lowers.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector PFUEL.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J2.
3. Turn starting switch to ON position.
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Hot short circuit in wiring
2. Disconnect connector PFUEL, and connect T-adapter to female side
4 harness
of connector.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between PFUEL (female) (1) and (3) 4.75 to 5.25
V
1. Turn starting switch to OFF position.
2. Disconnect connector J2, and connect T-adapter to male side.
5 Defective engine controller 3. Turn starting switch to ON position.
Voltage Between J2 (male) (31) and (21) 4.7 to 5.25
V

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Circuit diagram related to common rail pressure sensor

40-264 WA470-7
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Troubleshooting by failure code (Display of code)

Failure code [CA516] Rail Press Sens Sup Volt Low Error (PC400-CA516-400-A-Z0-A)

Action level Failure code Rail Pressure Sensor Supply Voltage Low Error
Failure
L03 CA516 (Engine controller system)
Detail of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
Action of • Limits engine output and allows engine to run.
controller • Limits the common rail pressure.
Problem on • Engine output lowers.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector PFUEL.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect)
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J2.
3. Turn starting switch to ON position.
Defective wiring harness If this failure code does not appear, wiring harness may be defective.
3
Perform following troubleshooting.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring harness
4 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
(contact with ground circuit) female side of either connector.
Resis- Between ground and J2 (female) (31) or
PFUEL (female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
5 Short circuit in wiring harness 2. Disconnect connectors J2 and PFUEL, and connect T-adapter to
female side of either connector.
Resis- Between J2 (female) (21) and (31), or
between PFUEL (female) (1) and (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2, and connect T-adapter to male side.
6 Defective engine controller 3. Turn starting switch to ON position.
Voltage Between J2 (male) (31) and (21) 4.7 to 5.25
V

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Circuit diagram related to common rail pressure sensor

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Failure code [CA553] Rail Press High Error (PC400-CA553-400-A-Z0-A)

Action level Failure code Rail Pressure High Error


Failure
L01 CA553 (Engine controller system)
Detail of • High voltage (above the limit) appears and continued 15 or more seconds in signal circuit
failure of common rail pressure sensor.
Action of • None in particular
controller
Problem on • Engine output decreases.
machine
• Signal voltage from common rail pressure sensor can be checked with monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
2 Improper fuel Fuel used may be improper. Check it (the viscosity is high).
Defective electric system of Electrical system of common rail pressure sensor may be defective.
3 common rail pressure sensor Perform troubleshooting for failure codes [CA451] and [CA452].
Defective mechanical system
4 of common rail pressure Common rail pressure sensor may have mechanical failure. Check it.
sensor
The overflow valve may has a damaged spring, worn seat, or ball
5 Defective overflow valve clogging trouble. Check it.
6 Clogging of overflow piping Check overflow piping for clogging.
7 Defective pressure limiter The pressure limiter may have a mechanical failure. Check it.

WA470-7 40-267
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Troubleshooting by failure code (Display of code)

Failure code [CA555] Crankcase Press High Error 1 (PC400-CA555-400-A-Z0-A)

Action level Failure code Crankcase Press High Error 1


Failure
L01 CA555 (Engine controller system)
Detail of • High pressure error of crankcase pressure is detected.
failure
Action of • None in particular.
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
defective

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Failure code [CA556] Crankcase Press High Error 2 (PC400-CA556-400-A-Z0-A)

Action level Failure code Crankcase Pressure High Error 2


Failure
L03 CA556 (Engine controller system)
Detail of • Crankcase pressure high error (level 2) has occurred.
failure
Action of • Limits engine output and allows engine to run.
controller
Problem on • Engine output lowers.
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • The pressure sensed by the crankcase pressure sensor can be checked by using
information monitoring function. (Code: 48400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1 Clogged KCCV filter Replace KCCV filter with a new one.
When this failure code is not cleared after KCCV filter is replaced and
Blocked KCCV gas piping emulsion is found inside KCCV, KCCV blowby gas piping may be
2
blocked with emulsified matter. Perform troubleshooting for coolant
leaks.
Crankcase pressure sensor Crankcase pressure sensor system may be defective. Perform
3 troubleshooting for failure codes [CA1843] and [CA1844].
defective
When the error is not cleared after the KCCV filter is replaced and
crankcase pressure high error 2 occurs in a short time, the engine may
4 Blow-by gas increases
be seized or the turbocharger may be defective. Carry out
troubleshooting for the mechanical system.

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Failure code [CA559] Rail Press Low Error (WA470_7-CA559-400-A-Z0-A)

Action level Failure code Rail Pressure Low Error


Failure
L01 CA559 (Engine controller system)
Detail of • Supply pump pressure is very low (level 1).
failure
Action of
controller
Problem on • Engine output reduces.
machine
• Common rail pressure sensed by common rail pressure sensor can be checked with
General monitoring function. (Code: 36400 (MPa))
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective relevant
1 If another failure code is displayed, perform troubleshooting for it first.
system
2 Improper fuel Improper fuel may be used, so check fuel.
a For details of troubleshooting, see Note 1.
a For check of fuel pressure in low-pressure circuit, see Testing and
Defective low-pressure adjusting, "Testing fuel pressure".
3
circuit devices Fuel pressure in low-pressure circuit 0.15 to 0.3 MPa
(with engine running at high idle or under load {1.5 to 3.0 kg/cm2}
equivalent to rated load)
Clogged fuel filter or
4 a For details of troubleshooting, see Note 2.
strainer
Defective electrical Electrical system of supply pump PCV may be defective. Perform
5 system of supply pump troubleshooting for failure codes [CA271], [CA272], [CA273], and [CA274].
PCV
Defective common rail Common rail pressure sensor may be defective. Check wiring harness for
6 pressure sensor damage.
a For check of leakage from pressure limiter, see Testing and adjusting,
"Testing fuel return rate and leakage".
Defective pressure
7 Leakage from pressure limiter
limiter
(Engine operation equivalent to rated operation Max. 10 cc/min
(with load by torque converter stall))
a For check of limit return rate (spill) from injector, see Testing and adjusting,
"Testing fuel return rate and leakage".
Engine speed at rated operation (with
Limit return rate (spill) from injector
load by torque converter stall)
8 Defective injector 1,600 rpm 960 cc/min
1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
Defective supply pump If no failure is found by checks on causes 1 to 8, supply pump may be
9
defective.
<How to use check sheet>
Perform above troubleshooting and fill in check results on attached "Check sheet for fuel pressure low error".
Note 1: Check low-pressure fuel circuit parts for following items.
1. Remaining quantity of fuel
2. Clogging of fuel tank breather
3. Looking and wear of fuel feed pump and clogging of filter
4. Leakage from or clogging of low-pressure fuel piping
5. Malfunction of bypass valve and installation of wrong part (See Fig. 1)
6. Clogging of fuel filter

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7. Fuel in oil pan (fuel leakage inside cylinder head cover)


Figure 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through the nut hole.
• Fuel inlet joint (3): Gauze filter is seen through both holes.

Note 2: Check, clean, and replace filters and strainers according to following procedure.
1. Gauze filter: Disassemble and check gauze filter. If clogged, clean it.
2. Upstream filter of gauze filter: If gauze filter is clogged, clean upstream filter, as well.
3. Fuel filter: If trouble is not solved by performing above steps 1) and 2), replace fuel filter.
Check sheet for fuel pressure low error
Model Work No.
Machine serial No. # Date of check / /
Engine SAA6D125E-6 Service meter h
Engine serial No. # Worker's name
No good
Good

A. Visual check

1 Fuel leakage to outside


2 Clogging of fuel tank breather

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No good
Good
B. Inspection with machine monitor
(02 = Abnormality record; 01 = Monitoring; 09 = Cylinder cutout mode operation)

3 Check of failure code / / / /


Check of monitoring information
Standard

No good
Good
value Measured
Code Item displayed Testing conditions ISO unit (Reference value
value)
Low idle r/min 800 (+50 / -0)
High idle r/min 2,170 (± 50)
01002 Engine speed Torque converter stall
r/min 1,710 (± 50)
(E-mode)
Torque converter stall
r/min 1,785 (± 50)
(P-mode)
Low idle % 0
31701 Throttle opening
High idle % 100
4 Last fuel injection
18600 quantity command Torque converter stall mg/st - - -
(in weight)
Last common rail
36200 Torque converter stall MPa -
pressure command
Common rail
36400 Torque converter stall MPa -
pressure
Low idle CA - - -
Last injection timing High idle - - -
36300 CA
command
Torque converter stall CA - - -

36500 Charge pressure Torque converter stall kPa - - -


Engine coolant
04107 Low idle °C - - -
temperature
14200 Fuel temperature Low idle °C - - -
Check result of cylinder cutout mode operation (engine speed)
Standard
No good
Good

value Measured
Function Cutout cylinder Testing conditions ISO unit (Reference value
value)
No. 1 cylinder Low idle r/min - - -
5 No. 2 cylinder Low idle r/min - - -
Set
cylinder No. 3 cylinder Low idle r/min - - -
to be cut
out by No. 4 cylinder Low idle r/min - - -
cylinder.
No. 5 cylinder Low idle r/min - - -
No. 6 cylinder Low idle r/min - - -

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Standard

No good
Good
C. Check of fuel circuit value Measured
Testing conditions Unit
pressure (Reference value
value)
High idle or under load
Fuel pressure in low- equivalent to rated MPa {kg/ 0.15 to 0.3
6 pressure circuit operation (load by torque cm2} {1.5 to 3.0}
converter stall)

No good
Good
D. Check of strainers and filters

7 Visual check of strainer

8 Visual check of gauze filter

9 Visual check of fuel filter

10 Visual check of bypass valve

Standard

No good
Good
E. Check of leakage and value Measured
Testing conditions Unit
return rate (Reference value
value)
Engine operation
Leakage from pressure equivalent to rated
11 operation (with load by cc/min Max. 10
limiter
torque converter stall)
Torque converter stall at
1,600 rpm cc/min 960
Torque converter stall at
cc/min 1,020
1,700 rpm
Torque converter stall at Speed:
12 Return rate from injector 1,800 rpm cc/min 1,080
Return rate:
Torque converter stall at
cc/min 1,140
1,900 rpm
Torque converter stall at
cc/min 1,200
2,000 rpm

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Failure code [CA595] Turbo Speed High Error 2 (PC400-CA595-400-A-Z0-A)

Action level Failure code Turbocharger Speed High Error 2


Failure
L01 CA595 (Engine controller system)
Detail of • Turbocharger runs at abnormally high speed.
failure
Action of • Takes it that turbocharger is at fixed value of 130,000 (rpm), and allows engine to run.
controller
Problem on
machine
• Turbocharger speed sensed by turbocharger speed sensor can be checked with
Related monitoring function. (Code: 48100 (rpm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Increased turbocharger
1 Turbocharger speed may increase abnormally high. Check it.
speed
2 Defective turbocharger Turbocharger may be defective. Check it.
If no failure is found by check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
3
sensor [CA687].

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Failure code [CA687] Turbo Speed Low Error (PC400-CA687-400-A-Z0-A)

Action level Failure code Turbocharger Speed Low Error


Failure
L01 CA687 (Engine controller system)
Detail of • Turbocharger rotates at abnormally low speed.
failure
Action of • Takes it that turbocharger is at fixed value of 130,000 (rpm), and allows engine to run.
controller
Problem on
machine
• Turbocharger speed sensed by turbocharger speed sensor can be checked with
Related monitoring function. (Code: 48100 (rpm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1 Defective turbocharger Turbocharger may be defective. Check it.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
2 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective sensor power If failure code [CA283] is also displayed, perform troubleshooting for it
3 supply system first.
1. Turn starting switch to OFF position.
Defective turbocharger speed 2. Disconnect connector VGT REV. and connect T-adapter to female
4 sensor side of connector.
(internal defect) Resis- Between VGT REV. (female) (1) and (2) 600 to 1600
tance z
Open or short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector J2 and connect T-adapters to female side.
5 (short circuit, wire breakage
or defective contact of Resis- Between J2 (female) (32) and (33) 600 to 1600
connector) tance z
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and VGT REV. and connect T-adapter to
Ground fault in wiring harness either female side.
6 Resis- Between ground and J2 (female) (32) or VGT
(contact with ground circuit) REV. (female) (1) Min. 1 Mz
tance
Resis- Between ground and J2 (female) (33) or VGT
REV. (female) (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Short circuit in wiring harness 2. Disconnect connectors J2 and VGT REV. and connect T-adapter to
7 either female side.
(contact with ground circuit)
Resis- Between J2 (female) (32) and (33), or
between VGT REV. (female) (1) and (2) Min. 1 Mz
tance
Defective installation of Turbocharger speed sensor may be installed incorrectly (loose fitting) or
8 sensor or defective speed speed sensor parts (internal parts of KVGT) may be defective (due to
sensing part thermal deformation). Check them.
If no failure is found by above checks, engine controller is defective.
9 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to turbocharger speed sensor

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Failure code [CA689] Eng Ne Speed Sensor Error (PC400-CA689-400-A-Z0-A)

Action level Failure code Engine Ne Speed Sensor Error


Failure
L01 CA689 (Engine controller system)
Detail of • Engine Ne speed sensor signal is abnormal.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
Problem on • Running engine stops (when Bkup speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Bkup speed sensor is also defective).
• Method of reproducing failure code: Start engine.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• The speed sensor detects holes drilled through the flywheel and calculates the engine
speed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective Ne speed sensor If failure code [CA238] is also displayed, perform troubleshooting for it
2 power supply system first.
Breakage or improper
Engine Ne speed sensor may be broken or installed improperly
3 installation (loosened) of
(loosened). Check it.
engine Ne speed sensor
1. Turn starting switch to OFF position.
2. Disconnect connector NE, and connect T-adapter to female side.
Defective Ne speed sensor 3. Turn starting switch to ON position.
4 power supply input Power
Voltage Between NE (female) (1) and (2) supply 4.75 to 5.25
input V

1. Turn starting switch to OFF position.


2. Disconnect connectors J1 and NE, and connect T-adapter to each
female side.
If no failure is found by check on cause 4, this
Open circuit in wiring harness check is not required. Max. 1 z
5 (wire breakage or defective Between J1 (female) (36) and NE (female) (1)
contact of connector) Resis- If no failure is found by check on cause 4, this
tance check is not required. Max. 1 z
Between J1 (female) (37) and NE (female) (2)
Between J1 (female) (26) and NE (female) (3) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and NE, and connect T-adapter to either
female side.
6 Short circuit in wiring harness Between J1 (female) (36) and (26), or
Min. 1 Mz
Resis- between NE (female) (1) and (3)
tance Between J1 (female) (37) and (26), or
between NE (female) (2) and (3) Min. 1 Mz

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors J1 and NE, and connect T-adapter to either
7 harness female side.
(contact with ground circuit) Resis- Between ground and J1 (female) (26) or NE Min. 1 Mz
tance (female) (3)

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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector NE, and connect T-adapter to female side.
8 3. Turn starting switch to ON position.
harness
Voltage Between NE (female) (3) and ground Max. 1 V
If no failure is found by above checks, engine Ne speed sensor may be
Defective engine Ne speed defective. (Since this is an internal defect, troubleshooting cannot be
9
sensor performed.)
If no failure is found by above checks, engine controller is defective.
10 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine Ne speed sensor

• The Ne speed sensor detects area (A) where holes (H) are not drilled through flywheel (1), and the engine
controller calculates the engine speed and signal phase.

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Failure code [CA691] Intake Air Temp Sens High Error (WA500_7-CA691-400-A-Z0-A)

Action level Failure code Intake Air Temperature Sensor High Error
Failure
L01 CA691 (Engine controller system)
Detail of • High voltage appears in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake air temperature is at fixed value (25 °C) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake air temperature sensor are integrated.
• Signal voltage from intake air temperature sensor can be checked with monitoring
function. (Code: 18401 (V))
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
information function. (Code: 18400 (°C))
• If sensor connector is disconnected, this failure code is displayed together with failure
code [CA357].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27 and connect T-adapters to male side.
-30°C 25 to 28 kz
Defective intake air Between E27 (male) (3) and (4) 0°C 5.5 to 6.1 kz
2 temperature sensor 25°C 1.9 to 2.1 kz
(internal defect) Resis- a Intake air temperature-
tance Resistance characteristics 40°C 1.1 to 1.2 kz
100°C 180 to 185 z
Between E27 (male) (3) and Whole
ground (sensor body) range Min. 1 Mz

1. Turn starting switch to OFF position.


Open or short circuit in wiring
2. Disconnect connector J1 and connect T-adapters to female side.
harness
Resis- Between J1 (female) (6) and (22) 180 z to 28
3 (short circuit, wire breakage tance kz
or defective contact of
connector) a Use Intake air temperature-Resistance characteristics table for
check on cause 2 as resistance criteria.
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector E27.
harness 3. Insert T-adapters into connector J1, or connect T-adapters to female
4
side of connector E27.
(contact with 24 V circuit)
Between J1 (6) and (22) or between E27
Voltage Max. 5.25 V
(female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
female side of connector J1.
5 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Resis- Between J1 (female) (6) and each pin other
than pin (6) Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
6 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to intake air temperature sensor

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Failure code [CA692] Intake Air Temp Sens Low Error (WA500_7-CA692-400-A-Z0-A)

Action level Failure code Intake Air Temperature Sensor Low Error
Failure
L01 CA692 (Engine controller system)
Detail of • Low voltage appears in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake air temperature is at fixed value (25 °C) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake air temperature sensor are integrated.
• Signal voltage from intake air temperature sensor can be checked with monitoring
Related function. (Code: 18401 (V))
information • Temperature sensed by intake air temperature sensor can be checked with monitoring
function. (Code: 18400 (°C))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27.
3. Turn starting switch to ON position.
If this failure code changes to failure code [CA691], intake air
temperature sensor is defective.
• Reference
Defective intake air 1. Turn starting switch to OFF position.
2 temperature sensor 2. Disconnect connector E27 and connect T-adapters to male side.
(internal defect) -30°C 25 to 28 kz
Between E27 (male) (3) and (4) 0°C 5.5 to 6.1 kz
25°C 1.9 to 2.1 kz
Resis- a Intake air temperature-
tance Resistance characteristics 40°C 1.1 to 1.2 kz
100°C 180 to 185 z
Between E27 (male) (3) and Whole
ground (sensor body) range Min. 1 Mz

1. Turn starting switch to OFF position.


Open or short circuit in wiring
2. Disconnect connector J1 and connect T-adapters to female side.
harness
Resis- Between J1 (female) (6) and (22) 180 z to 28
3 (short circuit, wire breakage tance kz
or defective contact of
connector) a Use Intake air temperature-Resistance characteristics table for
check on cause 2 as resistance criteria.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to
4 either female side.
(contact with ground circuit)
Resis- Between ground and J1 (female) (6) or E27
(female) (4) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
female side of connector J1.
5 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Resis- Between J1 (female) (6) and each pin other
than pin (6) Min. 1 Mz
tance
If no failure is found by above checks, engine controller is defective.
6 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Circuit diagram related to intake air temperature sensor

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Troubleshooting by failure code (Display of code)

Failure code [CA697] ECM Internal Temp Sensor High Error (PC400-CA697-400-A-Z0-
A)

Action level Failure code ECM Internal Temperature Sensor High Error
Failure
L01 CA697 (Engine controller system)
Detail of • High voltage appears in engine controller internal temperature sensor signal circuit.
failure
Action of • None in particular.
controller
Problem on
machine
• Temperature sensed by engine controller internal temperature sensor can be checked by
Related using monitoring function (Code: 18900(°C)).
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1 Improper usage of controller Check if the controller has been used in high temperature environments.
If no failure is found by above checks, engine controller is defective.
2 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Troubleshooting by failure code (Display of code)

Failure code [CA698] ECM Int Temp Sensor Low Error (PC400-CA698-400-A-Z0-A)

Action level Failure code ECM Internal Temperature Sensor Low Error
Failure
L01 CA698 (Engine controller system)
Detail of • Low voltage appears in engine controller internal temperature sensor signal circuit.
failure
Action of • None in particular.
controller
Problem on
machine

• Temperature sensed by engine controller internal temperature sensor can be checked by


Related using monitoring function (Code: 18900(°C)).
information • Method of reproducing failure code: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks


1 Improper usage of controller Check if the controller has been used in low temperature environments.
If no failure is found by above checks, engine controller is defective.
2 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

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Failure code [CA731] Eng Bkup Speed Sens Phase Error (PC400-CA731-400-A-Z0-A)

Action level Failure code Engine Bkup Speed Sensor Phase Error
Failure
L01 CA731 (Engine controller system)
• Engine controller receives signals from engine Bkup sensor, and detects a signal phase
Detail of error.
failure (The signal is out of phase when compared with signals sent from Ne speed sensor.)
Action of • Controls engine by using signals from engine Ne speed sensor.
controller
Problem on • Running engine stops (when Ne speed sensor is also defective).
machine • Stopped engine cannot be restarted (when Ne speed sensor is also defective).
• Method of reproducing failure code: Start engine.
Related
information a The fuel supply pump must also be replaced during replacement of Bkup speed sensor.
(See Disassembly and assembly, "Removal and installation of fuel supply pump".)
No. Cause Procedure, measuring location, criteria and remarks
Defective engine Ne speed Engine Ne speed sensor may be defective. Perform troubleshooting for
1 failure code [CA689].
sensor circuit
Defective engine Bkup speed Engine Bkup speed sensor may be defective. Perform troubleshooting
2 for failure code [CA778].
sensor circuit

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Failure code [CA778] Eng Bkup Speed Sensor Error (PC400-CA778-400-A-Z0-A)

Action level Failure code Engine Bkup Speed Sensor Error


Failure
L01 CA778 (Engine controller system)
Detail of • Abnormality occurred in engine Bkup speed sensor circuit.
failure
Action of • Controls engine by using signals of Ne speed sensor.
controller
Problem on • Running engine stops (when Ne speed sensor is also defective).
machine • Stopped engine cannot be started (when Ne speed sensor is also defective).
• Method of reproducing failure code: Start engine.
a If engine Bkup speed sensor needs to be replaced, fuel supply pump must be
replaced as a unit.
Related (See "Disassembly and assembly", "Removal and installation of fuel supply pump".)
information • Since inside of speed sensor is not composed of coil but electronic circuit, speed sensor
cannot be determined to be normal by measuring its resistance by using multimeter .
• Since speed sensor output is 5 V pulse voltage during normal operation, it cannot be
measured by using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform
2 supply system troubleshooting for it first.
Damage or improper
Engine Bkup speed (G) sensor may be damaged or improperly installed
3 installation (loose) of engine
(loose). Check it.
Bkup speed (G) sensor
1. Turn starting switch to OFF position.
Defective resistor (G-RES) 2. Disconnect connector G-RES and connect T-adapter to male side.
4
Resis- Between G-RES (male) (1) and (2)
620 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector G and connect T-adapter to female side.
Defective engine Bkup speed
5 3. Turn starting switch to ON position.
sensor power supply input
Power 4.75 to 5.25
Voltage Between G (female) (1) and (2)
supply V
1. Turn starting switch to OFF position.
Open or short circuit in wiring 2. Disconnect connectors J1 and G, and connect T-adapter to the
6 harness (resistor RES line) female side of connector J1.
Resis- Between J1 (female) (9) and (60)
620 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1, G, and G-RES, and connect T-adapters
to each female side.
a If power supply voltage in checks on
Open circuit in wiring harness cause 5 is normal, this check is not Max. 1 z
required.
7 (wire breakage or defective Between J1 (female) (60) and G (female) (1)
contact of connector) Resis-
tance a If power supply voltage in checks on
cause 5 is normal, this check is not Max. 1 z
required.
Between J1 (female) (59) and G (female) (2)
Between J1 (female) (9) and G (female) (3) Max. 1 z

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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors J1, G, and G-RES, and connect T-adapter to
female side of J1 or G.
8 Short circuit in wiring harness Between J1 (female) (60) and (9), or between
Min. 1 Mz
Resis- G (female) (1) and (3)
tance Between J1 (female) (59) and (9), or between
G (female) (2) and (3) Min. 1 Mz

1. Turn starting switch to OFF position.


Ground fault in wiring harness 2. Disconnect connectors J1 and G and connect T-adapter to either
9 female side.
(contact with ground circuit)
Resis- Between J1 (female) (9) or G (female) (3) and
ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors G and G-RES, and connect T-adapter to
Hot short circuit in wiring female side of G.
10
harness 3. Turn starting switch to ON position.
Voltage Between G (female) (3) and ground Max. 1 V
If no problem is found by above checks, engine Bkup speed sensor may
Defective engine Bkup speed be defective.
11
sensor
(Since this is an internal defect, troubleshooting cannot be performed.)
If no abnormality is found by above diagnosis, engine controller is
12 Defective engine controller defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to engine Bkup speed sensor

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Failure code [CA1117] Persistent Data Lost Error (PC400-CA1117-400-A-Z0-A)

Action level Failure code Persistent Data Lost Error


Failure
L04 CA1117 (Engine controller system)
Detail of
• Internal defect occurred in controller.
failure
Action of • None in particular.
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start if it is stopped.
machine • Engine controller cannot store internal data correctly.
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Since the engine controller internal data (KDPF related, etc.) may be lost, appropriate
information actions must be taken after the system recovers from the error.
No. Cause Procedure, measuring location, criteria and remarks
Since the power supply circuit may be defective, carry out
1 Defective power supply circuit
troubleshooting for failure code [CA441].
Improper operation of battery Battery disconnect switch may have been operated improperly.
2
disconnect switch
Actions to be
taken after See "How to perform regeneration for service" section.
recovery from
error

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Failure code [CA1664] KDOC Malfunction (WA470_7-CA1664-400-A-Z0-A)

Action level Failure code KDOC Malfunction


Failure
L03 CA1664 (Engine controller system)
• During KDPF regeneration, KDOC inlet temperature sensor and KDOC outlet
Detail of temperature sensor indicate similar values (temperature difference is approximately within
failure 10°C).
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
Problem on • Reduced engine output.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
General • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
information engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
repair.

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A. Identification of cause and repair


No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
1 temperature sensor troubleshooting for [CA3313], [CA3314], or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is displayed, perform
2 temperature sensor troubleshooting for [CA3316], [CA3317], or [CA3318].

Defective wiring 1. See descriptions of wiring harness and connectors in "c: Electrical
3 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and repair as needed.
1. Turn starting switch to ON position.
2. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
outlet temperature sensor, and note signal voltages from respective
temperature sensors in initial condition (see Related information).
3. Turn starting switch to OFF position.
4. Disconnect either connector TEMP1 or TEMP2.
Short circuit in wiring 5. Turn starting switch to ON position.
4 6. Monitor signal voltages from KDOC inlet temperature sensor and KDOC
harness
outlet temperature sensor, and note second signal voltages from
respective temperature sensors (see Related information).
If second signal voltages sensed by KDOC inlet temperature sensor and
KDOC outlet temperature sensor do not change notably (almost same as first
signal voltages), check wiring harness for short circuit (troubleshooting for
failure codes [CA3313] and [CA3316]).

5 Defective KDOC 1. Check that KDPF is installed to exhaust system.


2. Check that KDOC is installed to KDPF.
B. Machine operation for clearing failure code
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle for approximately 1 minute.
3. Use monitoring function to display KDOC inlet temperature.
4. Run engine at high idle (approximately 2,170 rpm with no load) for 15 minutes.
(KDOC inlet temperature must be higher than 250°C.)
If failure code is cleared after steps 1 to 4 are implemented, repair work is complete.
a To make the engine speed approximately 2,200 rpm, release the parking brake while running the engine
at high idle.
a When service tool "INSITE" is available, you can clear every failure code by executing “Reset All Faults“
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
6 engine controller is defective.
controller

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Circuit diagram related to KDOC temperature sensor

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Troubleshooting by failure code (Display of code)

Failure code [CA1691] Regeneration Ineffective (PC400-CA1691-400-A-Z0-A)

Action level Failure code Regeneration Ineffective


Failure
L03 CA1691 (Engine controller system)
• KDOC efficiency (catalyst action) is degraded. (Soot trapped in KCSF does not burn
Detail of sufficiently because the KDOC outlet temperature does not rise enough. During
failure regeneration, KDOC inlet temperature is normally approximately 250 to 400°C, and
KDOC outlet temperature is normally approximately 450 to 550°C.)
• Closes EGR valve and open KVGT fully.
Action of • Limits engine output and allows engine to run.
controller • Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C)
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration (normal) is in progress, KDOC inlet temperature is
approximately 250 to 400°C, and KDOC outlet temperature and KDPF outlet temperature
are approximately 450 to 550°C.
Related • When manual stationary regeneration without injecting dosing fuel (KDOC drying) is in
information progress, KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature are all approximately 250 to 400°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
1. Start the engine.
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then perform "Manual Stationary Regeneration (manual stationary
regeneration will be completed in approximately 40 minutes).
a Failure code [CA2637] may be displayed at the same time, however, perform
troubleshooting for this failure code [CA1691].
• Method of reproducing failure code:
When KDOC is changed, there is no need to check completion of repair.
When KDOC is not changed, start engine and turn manual stationary regeneration switch
ON. (See cause 6.)

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No. Cause Procedure, measuring location, criteria and remarks


• If there is a significant difference between KDOC outlet temperature
Defective KDOC outlet and KDOC inlet temperature and KDPF outlet temperature when
1 temperature sensor KDPF is completely cool or engine running at idle (not regenerating),
replace KDOC outlet temperature sensor.
1. Rapidly accelerate engine from low idle to high idle 2 times, and then
keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
2 Unusual exhaust gas color
clogged in a short time".
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
a Dry KDOC.
1. Turn starting switch to ON position.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, note temperature values from each
Defective KDOC sensor with KDPF under initial condition and during manual
3 stationary regeneration, and check that KDOC outlet temperature
(KDOC drying)
sensor is normal. (See "Related information".)
3. Perform manual stationary regeneration. (See "Related
information".)
a Since this is for drying KDOC, dosing fuel is not injected during
regeneration.

k Perform after KDPF and KDOC are sufficiently cooled.

1. Remove KDPF.
Defective KDOC 2. Remove KDOC.
4 (dirty or cracked or damaged 3. Blow air from KDOC outlet side to clean ceramic surfaces inside
KDOC surface) KDOC.
4. Check ceramic inside KDOC for cracks.
If cracks are found in KDOC, KDOC is defective (replace KDOC).
a Perform the following regardless whether KDOC is replaced or not.
1. Install KDOC and KDPF.
2. Turn starting switch to ON position.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
a When reset after KDOC change is performed, failure codes
5 Reset after KDOC change [CA1691] and [CA2637] will not be displayed. At that time, remedy of
not injecting dosing fuel when the failure code is displayed is
released.
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
manual stationary regeneration.

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No. Cause Procedure, measuring location, criteria and remarks


a Perform this troubleshooting when KDOC is not changed.
1. Turn starting switch to ON position.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, note temperature values from each
sensor with KDPF under initial condition and during manual
stationary regeneration, and check that KDOC outlet temperature
sensor is normal. (See "Related information".)
Defective KDOC 3. Perform manual stationary regeneration. (See "Related
information".)
6 (degraded KDOC catalyst 4. Turn starting switch to OFF position.
action) 5. Start engine and perform manual stationary regeneration again.
(Check whether failure code [CA2637] is displayed or not.)
a Check that failure code is not displayed and finish troubleshooting.
a If failure code [CA2637] is displayed after manual stationary
regeneration is completed, KDOC is defective (catalyst action of
KDOC is degraded. Change KDOC).
a When KDOC is changed, perform troubleshooting for cause 5 again.

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Failure code [CA1695] Sensor 5 Supply Volt High Error (WA500_7-CA1695-400-A-Z0-A)

Action level Failure code Sensor 5 Supply Voltage High Error


Failure
L03 CA1695 (Engine controller system)
Detail of • High voltage appears in 5 V power supply for KDPF delta pressure sensor and KDPF
failure outlet pressure sensor.
• Takes it that KDPF outlet pressure sensor is at fixed value (0 kPa {0 kg/cm 2 }) and allows
engine to run.
• Takes it that KDPF delta pressure value is at estimated value and allows engine to run
Action of (uses delta pressure of 0 kPa in some cases).
controller • Closes EGR valve and open KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective KDPF delta 2. Disconnect connector E25.
pressure (outlet pressure) 3. Turn starting switch to ON position.
2 sensor a Ignore displayed failure codes other than this code.
(internal defect) If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
Short circuit in wiring
3 female side of EC3.
harness
Resis- Between EC3 (female) (52) and each pin
other than pin (52) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Insert T-adapters into connector EC3, or connect T-adapters to
4 Defective engine controller female side of connector E25.
4. Turn starting switch to ON position.
Between EC3 (52) and (43) or between E25
Voltage 4.75 to 5.25 V
(female) (4) and (1)

Circuit diagram related to sensor power supply 5 circuit

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Failure code [CA1696] Sensor 5 Supply Volt Low Error (WA500_7-CA1696-400-A-Z0-A)

Action level Failure code Sensor 5 Supply Voltage Low Error


Failure
L03 CA1696 (Engine controller system)
Detail of • Low voltage appears in 5 V power supply circuit for KDPF delta pressure sensor and
failure KDPF outlet pressure sensor.
• Takes it that KDPF outlet pressure sensor value is at fixed value (0 kPa{0 kg/cm 2 }) and
allows engine to run.
• Takes it that KDPF delta pressure sensor value is at estimated value and allows engine to
Action of run (uses delta pressure of 0 kPa in some cases).
controller • Closes EGR valve and open KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective KDPF delta 2. Disconnect connector E25.
pressure (outlet pressure) 3. Turn starting switch to ON position.
2 sensor a Ignore displayed failure codes other than this code.
(internal defect) If this failure code is not displayed, KDPF delta pressure (outlet
pressure) sensor is defective.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors EC3 and E25, and connect T-adapters to
3 harness either female side.
(contact with ground circuit) Resis- Between ground and EC3 (female) (52) or
E25 (female) (4) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
Short circuit in wiring
4 female side of EC3.
harness
Resis- Between EC3 (female) (52) and each pin
other than pin (52) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Insert T-adapters into connector EC3, or connect T-adapters to
5 Defective engine controller female side of connector E25.
4. Turn starting switch to ON position.
Between EC3 (52) and (43) or between E25
Voltage 4.75 to 5.25 V
(female) (4) and (1)

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Circuit diagram related to sensor power supply 5 circuit

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Failure code [CA1843] Crankcase Press Sens High Error (HM300_3-CA1843-400-A-Z0-A)

Action level Failure code Crankcase Pressure Sensor High Error


Failure
L01 CA1843 (Engine controller system)
Detail of • High voltage occurs in signal circuit of crankcase pressure sensor.
failure
Action of • Sets crankcase pressure to fixed value (approximately 0 kPa) and runs engine.
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code is not displayed, wiring harness connector is
defective.
a If this failure code is displayed, perform following checks.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform
2 supply system troubleshooting for [CA187] or [CA227] first.
1. Turn starting switch to OFF position.
2. Disconnect connector PCCV.
3. Turn starting switch to ON position.
If failure code [CA1843] changes to [CA1844], crankcase pressure
Defective crankcase sensor is defective.
3 pressure sensor • Reference
(internal defect) 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector PCCV.
3. Turn starting switch to ON position.
Between PCCV (female) (3) and Sensor
Voltage 0.3 to 4.7 V
(2) output
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PCCV, and connect T-adapters to
Open circuit in wiring harness each female side.
4 (wire breakage or defective
contact of connector) a To check open circuit in GND line
Resis- Between J1 (female) (59) and PCCV (female)
(2) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PCCV, and connect T-adapter to
5 Short circuit in wiring harness either female side.
Resis- Between J1 (female) (3) and (60), or between
PCCV (female) (1) and (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector PCCV and connect T-adapter to female side.
6 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) Max. 1 V
Voltage Between PCCV (female) (3) and (2)

40-298 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector J1.
3. Turn starting switch to ON position.
Sensor
Voltage Between J1 (3) and (59) 0.3 to 4.7 V
output

Circuit diagram related to crankcase pressure sensor

WA470-7 40-299
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1844] Crankcase Press Sens Low Error (HM300_3-CA1844-400-A-Z0-A)

Action level Failure code Crankcase Pressure Sensor Low Error


Failure
L01 CA1844 (Engine controller system)
Detail of • Low voltage appears in signal circuit of crankcase pressure sensor.
failure
Action of • Takes it that crankcase pressure is at fixed value (approximately 0 kPa), and allows
controller engine to run.
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA187] or [CA227] is displayed, perform troubleshooting
for [CA187] or [CA227] first.
1. Turn starting switch to OFF position.
Defective sensor power 2. Disconnect connector PCCV and connect T-adapters to female
2 supply system side.
3. Turn starting switch to ON position.
Between PCCV (female) (1) and Power 4.75 to 5.25
Voltage
(2) supply V
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PCCV and connect T-adapters to
each female side.
a If any failure is found in wiring harness, disconnect connector
BREAK OUT and check further to determine which is defective,
engine harness or chassis harness.

Open circuit in wiring harness a If no failure is found by check on cause 2,


Resis- this check is not required.
3 (wire breakage or defective Max. 1 z
tance Between J1 (female) (60) and PCCV
contact of connector)
(female) (1)
a If no failure is found by check on cause 2,
Resis- this check is not required.
Max. 1 z
tance Between J1 (female) (59) and PCCV
(female) (2)
Resis- Between J1 (female) (3) and PCCV (female)
(3) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PCCV and connect T-adapters to
either female side.
Ground fault in wiring harness a If any failure is found in wiring harness, disconnect connector
4
(contact with ground circuit) BREAK OUT and check further to determine which is defective,
engine harness or chassis harness.
Resis- Between ground and J1 (female) (3) or PCCV Min. 1 Mz
tance (female) (3)

40-300 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and PCCV and connect T-adapters to
5 Short circuit in wiring harness either female side.
Resis- Between J1 (female) (3) and (59), or between
PCCV (female) (2) and (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Defective crankcase pressure 2. Insert T-adapters into connector PCCV.
6 sensor 3. Turn starting switch to ON position.
(internal defect) Sensor
Voltage Between PCCV (3) and (2) 0.3 to 4.7 V
output
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1.
3. Turn starting switch to ON position.
Sensor
Voltage Between J1 (3) and (59) 0.3 to 4.7 V
output

Circuit diagram related to crankcase pressure sensor

WA470-7 40-301
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1879] KDPF Delta P Sensor High Error (WA500_7-CA1879-400-A-Z0-A)

Action level Failure code KDPF Delta Pressure Sensor High Error
Failure
L03 CA1879 (Engine controller system)
Detail of • High voltage appears in signal circuit of KDPF delta pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
Action of run engine.)
controller • Closes EGR valve and KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine

k Since KDPF is heated to 500°C or above, take care not to get burn injury.

• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1695] is not displayed but failure code [CA3133] is on screen, GND
Related circuit probably has open circuit (defective contact of connector).
information • Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
Defective KDPF delta If failure code changes to [CA1881], KDPF delta pressure sensor is
3 pressure sensor defective.
a If this failure code remains displayed, wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and E25, and connect T-adapters to
4 each female side.
(wire breakage or defective
contact of connector) a To check open circuit in GND line
Resis- Between EC3 (female) (43) and E25 (female)
(1) Max. 1 z
tance

40-302 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
female side of EC3.
Short circuit in wiring
5 a Check by using multimeter in continuity mode.
harness
No continuity
Between EC3 (female) (55) and each pin
Continuity (No sound is
other than pin (55)
heard)
1. Turn starting switch to ON position.
6 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to KDPF delta pressure sensor

WA470-7 40-303
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1881] KDPF Delta P Sensor Low Error (WA500_7-CA1881-400-A-Z0-A)

Action level Failure code KDPF Delta Pressure Sensor Low Error
Failure
L03 CA1881 (Engine controller system)
Detail of • Low voltage appears in signal circuit of KDPF delta pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
Action of run engine.)
controller • Closes EGR valve and open KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine

k Since KDPF is heated to 500°C or above, take care not to get burn injury.

• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1696] is not displayed but failure code [CA3134] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
Related contact of connector).
information • This failure code appears if sensor connector is disconnected.
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25
V
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
each female side.
a If no failure is found by check on cause 2,
this check is not required. Max. 1 z
Open circuit in wiring harness Between EC3 (female) (43) and E25 (female)
3 (wire breakage or defective (1)
contact of connector) Resis-
a If no failure is found by check on cause 2,
tance
this check is not required. Max. 1 z
Between EC3 (female) (52) and E25 (female)
(4)
Between EC3 (female) (55) and E25 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors EC3 and E25, and connect T-adapters to
4 harness either female side.
(contact with ground circuit) Resis- Between ground and EC3 (female) (55) or
E25 (female) (2) Min. 1 Mz
tance

40-304 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
female side of EC3.
5 Short circuit in wiring harness a Check by using multimeter in continuity mode.
No continuity
Between EC3 (female) (55) and each pin
Continuity (No sound is
other than pin (55)
heard)
1. Turn starting switch to OFF position.
Defective KDPF delta 2. Insert T-adapters into connector E25.
6 pressure sensor 3. Turn starting switch to ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
1. Turn starting switch to ON position.
7 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to KDPF delta pressure sensor

WA470-7 40-305
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1883] KDPF Delta P Sens In Range Error (WA500_7-CA1883-400-A-Z0-A)

Action level Failure code KDPF Delta Pressure Sensor In Range Error
Failure
L03 CA1883 (Engine controller system)
Detail of • Signal voltage from KDPF delta pressure sensor is out of range. (Signal voltage from
failure sensor is within operating range.)
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
run engine.)
Action of • Closes EGR valve and open KVGT fully.
controller • Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
a You can cancel above measures by "turning starting switch to OFF position and then to
ON position" after failure code is generated.
Problem on • Engine output decreases.
machine

k Since KDPF is heated to 500°C or above, take care not to get burn injury.

• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
Related function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Oil temperature sensed by torque converter oil temperature sensor can be checked with
monitoring function. (Code: 30100 T/C oil temperature)
a Use "Short-circuit connector: 799T-601-4611".
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and fixing
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after fixing trouble.
A. Identification of cause and fixing
No. Cause Procedure, measuring location, criteria and remarks
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power supply 1. Turn starting switch to OFF position.
1 system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. See descriptions of wiring harness and connectors in "c: Electrical
2 Defective harness connector equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it and fix trouble as
needed.

40-306 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
If failure code [CA1881] is not displayed, wiring harness or engine
controller is defective.
a Perform check on cause 2 again.
a Ignore other displayed failure codes.

Defective wiring harness or 1. Turn starting switch to OFF position.


3 engine controller 2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (2) of
connector E25).
3. Turn starting switch to ON position.
If failure code [CA1879] is not displayed, wiring harness or engine
controller is defective.
a Perform check on cause 2 again.
a Ignore other displayed failure codes.
Defective KDPF delta a If failure codes [CA1881] and [CA1879] are displayed in check on
4 pressure sensor cause 3, KDPF delta pressure sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
each female side.
a If no failure is found by check on cause 1,
this check is not required. Max. 1 z
Open circuit in wiring harness Between EC3 (female) (43) and E25
5 (wire breakage or defective (female) (1)
contact of connector) Resis-
a If no failure is found by check on cause 1,
tance
this check is not required. Max. 1 z
Between EC3 (female) (52) and E25
(female) (4)
Between EC3 (female) (55) and E25
(female) (2) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring harness 2. Disconnect connectors EC3 and E25, and connect T-adapters to
6 either female side.
(contact with ground circuit)
Resis- Between ground and EC3 (female) (55) or
Min. 1 Mz
tance E25 (female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
female side of EC3.
7 Short circuit in wiring harness a Check by using multimeter in continuity mode.
No continuity
Continu- Between EC3 (female) (55) and each pin
ity other than pin (55) (No sound is
heard)

WA470-7 40-307
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1.Remove KDPF delta pressure sensor tube.
2.Clean KDPF delta pressure sensor tube to clear clogging.
3.Check KDPF delta pressure sensor tube for cracks and damage.
4.Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Defective KDPF delta
8 • Reference
pressure sensor tube
How to check KDPF delta pressure sensor tube for clogging
1. Turn starting switch to ON position.
2. Monitor delta pressure sensed by KDPF delta pressure sensor on
monitoring screen of machine monitor.
Code 47100 (kPa) 0 ± 3 (kPa)
B. Machine operation for clearing failure code

k Place machine on a flat ground, turn parking brake switch to ON position, and chock wheels.

1. Turn starting switch to ON position and leave it in that position for 1 minute. (In order to allow engine
controller to determine drift of voltage when starting switch is turned to ON position.)
2. Turn starting switch from OFF position to ON position.
3. Start engine and run it at low idle for approximately 1 minute.
4. After warm-up operation, perform <torque converter stall operation> as described below.
<Torque converter stall operation>
5. Set transmission cut-off switch to "OFF" position and depress left brake pedal securely.
6. Set torque converter lockup switch (if equipped) to "OFF" position.
7. Set transmission shift mode selector switch to "MANUAL".
8. While keeping directional lever or directional selector switch in "N" (NEUTRAL) position, set gear shift
lever or gear shift switch to "4th" gear speed.
9. Release parking brake.
10.While depressing brake pedal, set directional lever or directional selector switch to "F (forward)" or "R
(reverse)" position.

k Keep brake pedal firmly depressed.


11.Depress accelerator pedal gradually to stall torque converter with engine running at high idle.
a Take care that torque converter oil temperature does not exceed 120°C.
a If failure code still remains displayed, repeat above steps 2 to 11 three times.
• If failure code disappears, repair is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
No. Cause Procedure, measuring location, criteria and remarks
If this failure code appears again after above procedures are
9 Defective engine controller implemented, engine controller is defective.

Circuit diagram related to KDPF delta pressure sensor

40-308 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1921] KDPF Soot Load High Error 1 (PC400-CA1921-400-A-Z0-A)

Action level Failure code KDPF Soot Load High Error 1


Failure
L03 CA1921 (Engine controller system)
• Soot accumulation of KDPF reaches level 6 or 7. As much soot is accumulated in KCSF,
Detail of the user is requested to perform "Manual Stationary Regeneration" immediately.
failure (If soot accumulation reaches level 8, KDPF must be replaced.)
• Closes EGR valve and open KVGT fully.
Action of • Limits engine output and allows engine to run.
controller • Disables automatic regeneration but allows manual stationary regeneration.
Problem on • Engine output decreases.
machine

k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
Related • Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
information function. (Code: 47100 (kPa))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.

WA470-7 40-309
40 Troubleshooting
Troubleshooting by failure code (Display of code)

a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: approximately 40 minutes to 1 hour
• If soot accumulation is level 5: approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: approximately 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that leads to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
a If failure code [CA1922] has been displayed originally, it changes to [CA1921] during
troubleshooting process of [CA1922]. In such case, refer to failure code [CA1922].
• Method of reproducing failure code: Turn starting switch to the ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Check if the regeneration stop button is pressed down from the
machine monitor.
a If the regeneration stop button is pressed down, release it.
2. Start the engine.
3. Make sure that machine is in safe condition.
4. Perform manual stationary regeneration from user mode.
a When the manual stationary regeneration is finished correctly, the
Excessive KDPF (KCSF) repair is completed.
1
soot accumulation level
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922] or [CA2639] is displayed after manual
stationary regeneration is completed, proceed to checks on
cause 2.
a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".

2 Unusual exhaust gas color a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
1. Rapidly accelerate engine from low idle to high idle 2 times, and then
keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
clogged in a short time".

40-310 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
a Check that no failure code appears.
a When you finish the check of the exhaust gas color, release
"Regeneration Disable".

WA470-7 40-311
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1922] KDPF Soot Load High Error 2 (PC400-CA1922-400-A-Z0-A)

Action level Failure code KDPF Soot Load High Error 2


Failure
L04 CA1922 (Engine controller system)
• Soot accumulation in KDPF is very high, and machine must be stopped and performed
Detail of maintenance immediately.
failure • Soot accumulation reaches level 8 (KDPF is completely clogged with soot).
• Closes EGR valve and open KVGT fully.
Action of • Limits engine output and allows engine to run.
controller • Disables the automatic regeneration and the manual stationary regeneration.
Problem on • Engine output decreases.
machine

k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
Related • Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
information function. (Code: 47100 (kPa))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approximately 250 to 400°C, and KDOC outlet temperature and KDPF
outlet temperature are approximately 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.

40-312 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: approximately 40 minutes to 1 hour
• If soot accumulation is level 5: approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: approximately 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that lead to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
• Procedure of performing the manual stationary regeneration from the "Regeneration for
Service".
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from the "Regeneration for Service".
1. Start the engine.
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"Regeneration for Service", and then perform the "Manual Stationary Regeneration".
a Resetting after KDPF cleaning
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Cleaning" (reset after KDPF cleaning).
a Resetting after KDPF change
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Change" (resetting after KDPF change).
a When KCSF in KDPF is changed, always perform resetting procedures for KDPF cleaning
and KDPF change, and then perform the "Manual Stationary Regeneration" from the
"Regeneration for Service" to eliminate moisture from KCSF.
• Method of reproducing failure code: Turn starting switch to the ON position.

WA470-7 40-313
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Check if the regeneration stop button is pressed down from the
Increase of soot machine monitor.
1 accumulation due to a If the regeneration stop button is pressed down, release it.
"Regeneration Disable"
a After releasing the "Regeneration Disable", proceed to checks on
causes 2 and after.
• Check the abnormality record.
1. Turn starting switch to the ON position.
2. From the machine monitor, displays the abnormality record screen
and check the history of failure codes CA2639, CA1921 and
CA1922.
Interval between failure code CA2639 and CA1921
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
and
Interval between failure code CA1921 and CA1922
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
[When above conditions are satisfied]
a As much soot is accumulated, KDPF regeneration can not be
performed.
1. Replace the KCSF or the KDPF.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
Defective KDPF (KCSF)
2 procedure after KDPF cleaning, and perform the reset after KDPF
(change KCSF) cleaning again.
3. Reset the KDPF after its change (see "Related information").
4. Perform checks on causes 4 to 7 (When KDPF is changed, this is not
needed.)
5. Start the engine.
6. Make sure that machine is in safe condition.
7. Perform regeneration for service.
a When the manual stationary regeneration is finished correctly, the
repair is completed.
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
[When above conditions are not satisfied]
(When the actual soot accumulation is less than the displayed value)
Proceed to checks on cause 3 and after.

40-314 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a When the actual soot accumulation is less than the displayed value
on the machine monitor
1. Proceed to checks on cause 4 to 7.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
procedure after KDPF cleaning, and perform the reset after KDPF
cleaning again.
3. Start the engine.
4. Make sure that machine is in safe condition.
Defective KDPF (KCSF) 5. Perform manual stationary regeneration from user mode.
3 (abnormal condition of soot
accumulation) a When the manual stationary regeneration is finished correctly, the
repair is completed.
a If failure code [CA1922] is displayed again within 1 hour after
starting the manual stationary regeneration, perform Step 2 and 3
again.
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
4 temperature sensor troubleshooting for [CA3313], [CA3314], or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is displayed, perform
5 temperature sensor troubleshooting for [CA3316], [CA3317], or [CA3318].
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform
6 temperature sensor troubleshooting for [CA3316], [CA3321] or [CA3322].
1. Turn starting switch to the ON position.
2. Monitor differential pressure sensed by KDPF differential pressure
sensor on monitoring screen of machine monitor.
Code 47,100 (kPa) 0 ± 3 (kPa)
a If the differential pressure is outside of the above range, perform the
Defective KDPF differential following.
7 pressure sensor
1. Remove KDPF differential pressure sensor tube.
(including sensor tubes) 2. Clean KDPF differential pressure sensor tube to clear clogging.
a If the KDPF differential pressure sensor tube is not clogged,
perform the following.
3. Perform for "Short circuit in wiring harness" of failure code [CA1881]
or [CA1883]. (If no short circuit occurs, replace the KDPF differential
pressure sensor.)

WA470-7 40-315
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
1. Rapidly accelerate engine from low idle to high idle 2 times, and then
8 Unusual exhaust gas color keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
clogged in a short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
a When you finish the check of the exhaust gas color, release
"Regeneration Disable".

a Check that no failure code appears.

40-316 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1923] Dosing Fuel Valve 1 High Error (PC400-CA1923-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve 1 High Error


Failure
L03 CA1923 (Engine controller system)
Detail of Abnormal low voltage (or high circuit resistance) has occurred in dosing fuel solenoid valve 1
failure (shut-off valve).
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If failure code [CA2732] is also displayed, the ground (GND) leads may be open.
• This failure code appears if sensor connector is disconnected.
• See failure code [CA1925].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective dosing fuel 2. Disconnect connector SOV1, and connect T-adapter to male side of
2 solenoid valve 1 (shut-off connector.
valve) Resis- Between SOV1 (male) (2) and (1)
4 to 6 z
tance
1. Turn starting switch to OFF position.
Open or short circuit in wiring 2. Disconnect connector J2 and connect T-adapters to female side.
3
harness Resis- Between J2 (female) (9) and (18)
4 to 6 z
tance a The resistance is the same as above.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV1, and connect T-adapter to each
Open circuit in wiring harness female side of connectors.
4 (wire breakage or defective a To check open circuit in GND line
contact of connector)
Between J2 (female) (9) and SOV1 (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (18) and SOV1 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connectors J2 and SOV1, and connect T-adapter to
female side of connector J2.

5 Short circuit in wiring harness a Check by using multimeter in continuity mode.


No
Between J2 (female) (9) and each pin other continuity
Continuity
than pin (9) (No sound
is heard)
1. Start engine and run it at low idle for 1 minute.
a If another failure code is displayed, perform troubleshooting for it.
6 Defective engine controller
If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

WA470-7 40-317
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to dosing fuel solenoid valve

40-318 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1924] Dosing Fuel Valve 1 Low Error (PC400-CA1924-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve 1 Low Error


Failure
L03 CA1924 (Engine controller system)
Detail of Abnormal high voltage (or low circuit resistance) has occurred in dosing fuel solenoid valve 1
failure (shut-off valve).
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If sensor connector is disconnected, failure code [CA1923] appears.
• See failure code [CA1925].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective fuel doser solenoid 2. Disconnect connector SOV1, and connect T-adapter to male side of
valve 1 connector.
2 Between SOV1 (male) (2) and (1) 4 to 6 z
(shut-off valve) Resis-
Between SOV1 (male) (1) and ground (SOV
tance Min. 1 Mz
body)
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring
3 Between J2 (female) (9) and (18)
harness Resis-
a The resistance is the same as that of shut- 4 to 6 z
tance
off valve.
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness 2. Disconnect connectors J2 and SOV1, and connect T-adapter to
(contact with ground circuit) female side of either connector.
Resis- Between ground and J2 (female) (9) or SOV1
(female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV1, and connect T-adapter to
female side of connector J2.
a Check by using multimeter in continuity mode.
5 Short circuit in wiring harness
No
continuity
Between J2 (female) (9) and each pin other
Continuity (No sound
than pin (9)
is heard)

WA470-7 40-319
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If failure code [CA2265] or [CA2266] is also displayed, perform
troubleshooting for [CA2265] or [CA2266] first.
1. Turn starting switch to OFF position.
2. Loosen the joint bolt (JB) of fuel tube.
Defective electric fuel feed 3. Tilt the switch for the fuel feed pump to ON position while starting
6 pump switch is in OFF position.
(Be careful since fuel may spurt out.)
When completing the check, turn the starting switch to ON position or
tilt the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB), the electric fuel feed pump is
defective.
Defective dosing fuel
7 solenoid valve 1 (shut-off Replace dosing fuel solenoid valve 1 (shut-off valve).
valve)
1. Start engine and run it at low idle for 1 minute.
a If another failure code is displayed, perform troubleshooting for it.
8 Defective engine controller
If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to dosing fuel solenoid valve

40-320 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel doser

A: From electric fuel pump


B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
JB: Fuel tube joint bolt
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve) connector
SOV2: Dosing fuel solenoid valve 2 (drain valve) connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor

WA470-7 40-321
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1925] Dosing Fuel Valve 1 In Range Error (PC400-CA1925-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve 1 In Range Error


Failure
L03 CA1925 (Engine controller system)
Dosing fuel solenoid valve 1 does not operate normally. (The valve at fuel inlet is half open
Detail of although it must be fully closed. Therefore, the dosing fuel pressure does not drop
failure sufficiently.)
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.

• In this failure code, the dosing fuel valve 1 (shut-off valve) is determined defective from
the fuel pressure change caused by the operation of solenoid valve.
• Therefore, the pressure check by fuel pressure sensor is required.
• When the starting switch is turned to ON position, the fuel pressure is checked by the
engine controller.
Related • Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
information (Code: 47600 (V))
• Pressure detected by dosing fuel pressure sensor can be checked with monitoring
function. (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Method of reproducing failure code: Start the engine (and observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1927] or [CA1928] is also displayed, perform
troubleshooting for [CA1927] or [CA1928] first.
1. Turn starting switch to OFF position.
Defective dosing fuel 2. Disconnect fuel supply line (2) from fuel doser (1).
2 pressure sensor 3. Turn starting switch to ON position.
If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective (see "Related information").
a The dosing fuel pressure must be equal to the ambient pressure.
1. Turn starting switch to OFF position.
2. Disconnect fuel supply line (2) from fuel doser (1).
3. Disconnect connector SOV1.
4. Connect the disconnected SOV1 connector to a new SOV connector
socket.
Defective dosing fuel shut-off a If connector SOV1 is open, failure code [CA1923] is displayed
3
valve and the pressure test (which checks the fuel dosing system) is
not carried out. Also, the electric fuel pump is not driven.
5. Turn starting switch to ON position.
6. Start engine.
If fuel leaks from the fuel connector of fuel supply line (2), dosing fuel
solenoid valve 1 (shut-off valve) (3) is defective.

40-322 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Start engine and run it for 3 minute.
2. If this failure code appears, perform procedure for <How to clear
Defective engine controller failure code> in "Related information".
4
If this failure code is still displayed and no failure is found by above
checks, engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to fuel doser

A: From electric fuel pump


B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel valve 1 (shut-off valve) connector
SOV2: Dosing fuel valve 2 (drain valve) connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor

WA470-7 40-323
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1927] Dosing Fuel Press Sens High Error (PC400-CA1927-400-A-Z0-A)

Action level Failure code Dosing Fuel Pressure Sensor High Error
Failure
L01 CA1927 (Engine controller system)
Detail of • Signal voltage from doser fuel pressure sensor indicates a value higher than the
failure threshold.
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since the temperature of the exhaust connector and KDPF will become higher than
500 °C , take care not to get burn injury.

Related • Signal voltage from the doser fuel pressure sensor can be checked by using monitoring
information function. (Code: 47600(V))
• The pressure sensed by the doser fuel pressure sensor can be checked by using
monitoring function. (Code: 47601 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position (observe for one
minute) (since this is L01, check on the abnormality record screen).
No. Cause Procedure, measuring location, criteria and remarks
1. Perform checks referring to harness and connecter related
descriptions in "c: Electrical equipment" of "Checks before
Defective wiring harness troubleshooting" in "General information on troubleshooting".
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA352] or [CA386] is displayed, perform troubleshooting
for it first.
1. Turn starting switch to OFF position.
Doser fuel pressure sensor
2 power supply error 2. Disconnect connector PDOSER and connect T-adapter to female
side.
3. Turn starting switch to ON position.
Voltage Between PDOSER (female) (1) and (2) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector PDOSER.
3. Turn starting switch to ON position.
Defective doser fuel pressure If failure code changes from [CA1927] to [CA1928], doser fuel pressure
3
sensor sensor is defective.
• Carry out troubleshooting for cause 1 again.
• If failure code [CA1927] does not changes to [CA1928], the wiring
harness or engine controller is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
Open circuit in wiring each female side.
harness a To check for open circuit in GND line
4
(wire breakage or defective
contact of connector) a If no failure is found by check on cause 2,
Resis- this check is not required. Max. 1 z
tance Between J2 (female) (47) and PDOSER
(female) (2)

40-324 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PDOSER and connect T-adapter to
female side of connector J2.
Short circuit in wiring
5 a Check by using multimeter in continuity mode.
harness
No continuity
Continuity Between J2 (female) (36) and each other pin (No sound is
heard)
1. Start the engine and run at low idle for one minute.
6 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to doser fuel pressure sensor

WA470-7 40-325
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1928] Dosing Fuel Press Sens Low Error (PC400-CA1928-400-A-Z0-A)

Action level Failure code Dosing Fuel Pressure Sensor Low Error
Failure
L01 CA1928 (Engine controller system)
Detail of • Signal voltage from doser fuel pressure sensor indicates a value lower than the threshold.
failure
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since the temperature of the exhaust connector and KDPF will become higher than
500 °C , take care not to get burn injury.

• Signal voltage from the doser fuel pressure sensor can be checked by using monitoring
Related function. (Code: 47600(V))
information • The pressure sensed by the doser fuel pressure sensor can be checked by using
monitoring function. (Code: 47601 (kPa))
• This failure code is displayed if the sensor connector is disconnected.
• Method of reproducing failure code: Turn starting switch to ON position (observe for one
minute) (since this is L01, check on the abnormality record screen).
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA352] or [CA386] is displayed, perform troubleshooting
for it first.
Doser fuel pressure sensor 1. Turn starting switch to OFF position.
2 2. Disconnect connector PDOSER and connect T-adapter to female
power supply error
side.
3. Turn starting switch to ON position.
Voltage Between PDOSER (female) (1) and (2) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
Defective doser fuel pressure 2. Disconnect connector PDOSER.
3 3. Turn starting switch to ON position.
sensor
Voltage Between PDOSER (3) and (2) 0.5 to 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PDOSER, and connect T-adapters to
each female side.
a If no failure is found by check on cause 2,
Open circuit in wiring this check is not required. Max. 1 z
harness Between J2 (female) (30) and PDOSER
4 (female) (1)
(wire breakage or defective
contact of connector) Resis-
a If no failure is found by check on cause 2,
tance
this check is not required. Max. 1 z
Between J2 (female) (47) and PDOSER
(female) (2)
Between J2 (female) (36) and PDOSER
(female) (3) Max. 1 z

40-326 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and PDOSER and connect T-adapter to
female side of connector J2.
Short circuit in wiring
5 a Check by using multimeter in continuity mode.
harness
No continuity
Continuity Between J2 (female) (36) and each other pin (No sound is
heard)
1. Start the engine and run at low idle for one minute.
6 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to doser fuel pressure sensor

WA470-7 40-327
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1942] Crankcase Press Sens In Range Error (PC400-CA1942-400-A-


Z0-A)

Action level Failure code Crankcase Pressure Sensor In Range Error


Failure
L01 CA1942 (Engine controller system)
Detail of • Output value from crankcase pressure sensor is out of normal range.
failure
Action of • None in particular
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401 (V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
information (Code: 48400 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective crankcase pressure Crankcase pressure sensor system may be defective. Perform
1 troubleshooting for failure codes [CA1843] and [CA1844].
sensor
2 Clogged KCCV filter Replace KCCV filter.
If error condition is not cleared after KCCV filter is replaced and
3 Blocked KCCV gas piping emulsion is found inside KCCV, emulsion may block KCCV blowby gas
piping. Perform troubleshooting for leakage of coolant.
If error condition is not cleared after KCCV filter is replaced and failure
code of crankcase pressure high error 2 is generated in short times,
4 Increase of blowby gas
engine may be seized or turbocharger may be defective. Perform
troubleshooting for mechanical system.

40-328 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA1963] Dosing Fuel Valve 1 Servo Error (PC400-CA1963-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve 1 Servo Error


Failure
L03 CA1963 (Engine controller system)
Detail of • Although dosing fuel solenoid valve 1 (shut-off valve) is ON, the pressure detected by
failure dosing fuel pressure sensor is below the threshold.
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.

• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
Related • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
information function. (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Method of reproducing failure code: Start the engine (and observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
Defective dosing fuel
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
2 solenoid valve 1 (shut-off
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)
Defective dosing fuel If failure code [CA2732] or [CA2733] is also displayed, perform
3 solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
4 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
If failure code [CA559] is also displayed, perform troubleshooting for
5 Defective fuel supply pump
[CA559] first.
If failure code [CA2265] or [CA2266] is also displayed, perform
troubleshooting for [CA2265] or [CA2266] first.
1. Turn starting switch to OFF position.
2. Loosen the joint bolt (JB) of fuel tube.
Defective electric fuel feed 3. Tilt the switch for the fuel feed pump to ON position while starting
6 pump switch is in OFF position.
(Be careful since fuel may spurt out.)
When completing the check, turn the starting switch to ON position or
tilt the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB), the electric fuel feed pump is
defective.
7 Clogging of fuel filter Check fuel filter for clogging.

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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect fuel supply line (2) from fuel doser (1).
Defective dosing fuel 3. Turn starting switch to ON position.
8 pressure sensor If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective (see "Related information").
a The dosing fuel pressure must be equal to the ambient pressure.
Defective dosing fuel
9 solenoid valve 1 (shut-off Replace dosing fuel solenoid valve 1 (shut-off valve).
valve)

Circuit diagram related to fuel doser

A: From electric fuel pump


B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
JB: Fuel tube joint bolt
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve) connector
SOV2: Dosing fuel solenoid valve 2 (drain valve) connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor

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Failure code [CA1977] Fuel Doser Open/Short Error (PC400-CA1977-400-A-Z0-A)

Action level Failure code Fuel Doser Open/Short Error


Failure
L03 CA1977 (Engine controller system)
Detail of • The fuel doser circuit is short-circuited or opened.
failure
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500 °C or above, take care not to
get burn injury.

• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
Related (Code: 47600 (V))
information • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
function. (Code: 47601 (kPa))
• This failure code appears if sensor connector is disconnected.
• Method of reproducing failure code: Turn starting switch to ON position (observe for 1
minute).
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector DOSER, and connect T-adapter to male side
of connector.
2 Defective fuel doser (injector)
Between DOSER (male) (1) and (2) 0.5 to 2 z
Resis-
Between DOSER (male) (1) and ground (fuel
tance Min. 1 Mz
doser body)
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring Between J2 (female) (50) and (60)
3
harness Resis-
a The resistance is the same as fuel doser 0.5 to 2 z
tance
(injector).
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J2 and DOSER, and connect T-adapters to
4 (wire breakage or defective each female side.
contact of connector) Between J2 (female) (50) and DOSER (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (60) and DOSER (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors J2 and DOSER, and connect T-adapters to
5 harness either female side.
(contact with ground circuit) Resis- Between J2 (female) (50) or DOSER (female) Min. 1 Mz
tance (1) and ground (frame)

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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and DOSER, and connect T-adapter to
female side of connector J2.
6 Short circuit in wiring harness
a Check by using multimeter in continuity mode.
Between J2 (female) (50) and each No continuity (no sound
Continuity
pin other than pin (50) is heard)
1. Start engine and run it at low idle for 1 minute.
7 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to fuel doser (injector)

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Failure code [CA1993] KDPF Delta Pressure Low Error (WA500_7-CA1993-400-A-Z0-A)

Action level Failure code KDPF Delta Pressure Low Error


Failure
L03 CA1993 (Engine controller system)
Detail of • Signal voltage from KDPF delta pressure sensor is lower than threshold value.
failure
• Closes EGR valve and open KVGT fully.
• Limits engine output and allows engine to run.
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measure by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
Problem on • Engine output decreases.
machine

k Since KDPF is heated to 500°C or above, take care not to get burn injury.

• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101 (V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
Related function. (Code: 47300 (°C))
information • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and repair
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after repair trouble.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF delta If failure code [CA1879], [CA1881], or [CA1883] is displayed, perform
1 pressure sensor troubleshooting for [CA1879], [CA1881], or [CA1883] first.
1. Turn starting switch to OFF position once, and then turn it to ON
position.
2. Check whether failure codes other than [CA1993] are generated.
3. Start engine and accelerate it suddenly from low idle to full speed 2
times, then run it at high idle for 5 seconds. During above operation,
check exhaust gas color at exhaust pipe when engine accelerates
suddenly and runs at high idle.
2 KCSF abnormality 1
4. If black smoke is exhausted from exhaust pipe in above step 3,
KCSF is abnormal. Check whether KCSF is installed. If yes, check
KCSF for damage and contamination by foreign substances, and fix
trouble as needed.
a If black smoke is not exhausted, proceed to checks on causes 3 and
after.

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Perform following checks.


1. Check whether KDPF delta pressure sensor tube is installed.
2. Check whether KDPF delta pressure sensor tube is connected
Defective KDPF delta correctly.
3 pressure sensor tube 3. Remove KDPF delta pressure sensor tube and check it for clogging,
cracks, and damage.
4. Check both ends of KDPF delta pressure sensor tube for loose
connection.
B. Machine operation for clearing failure code

k Place machine on a level ground and set parking brake lever to LOCK position.

1. Turn starting switch to OFF position.


2. Turn starting switch from OFF position to ON position.
3. Start engine and run it at low idle (with no load) for approximately 1 minute.
4. Run engine at high idle and perform hydraulic relief of work equipment for continuous 1 minute.
• If failure code disappears after implementing steps 1 to 4, repair work is complete.
• If failure code still remains displayed, repeat above steps 5 and after.
5. Turn starting switch from OFF position to ON position.
6. Start engine and run it at low idle (with no load) for approximately 1 minute.
7. Perform torque converter stall operation for approximately continuous 40 seconds with throttle position at
100% (see troubleshooting for failure code [CA1883]).
a Take care not to overheat torque converter oil.
• If failure code disappears, repair is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
No. Cause Procedure, measuring location, criteria and remarks
If this failure code is still displayed after above procedures are
implemented, remove KDPF and remove KCSF, and check filter for
4 KCSF abnormality 2 damage or foreign material in it. After fixing trouble, implement above "B.
Machine operation for clearing failure code".
If this failure code appears again after above procedures are
5 Defective engine controller implemented, engine controller is defective.

Circuit diagram related to KDPF delta pressure sensor

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Failure code [CA2185] Throt Sensor Sup Volt High Error (WA380_7-CA2185-400-A-Z0-A)

Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
L03 CA2185 (Engine controller system)
Detail of • High voltage (5.25 V or higher) appears in throttle sensor power supply circuit.
failure
Action of • Sets throttle position at 0% with accelerator pedal released and at 50 % with accelerator
controller pedal depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector PD and turn starting switch to ON position.
Defective throttle sensor If this failure code disappears, throttle sensor is defective.
2 (accelerator pedal)
a Other failure codes are also displayed. They are generated because
of disconnection of connector. Ignore failure codes other than
[CA2185].
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and PD, and connect T-adapters to
female side of EC3.
3 Short circuit in wiring harness Between EC3 (female) (42) and each pin
Min. 1 Mz
Resis- other than pin (42)
tance Between EC3 (female) (42) and EC3
(female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector PD and connect T-adapters to female side.
Hot short circuit in wiring
4 3. Turn starting switch to ON position.
harness
Voltage Between PD (female) (1) and ground 4.75 to 5.25
V
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and connect T-adapters to female side.
5 Defective engine controller 3. Turn starting switch to ON position.
Voltage Between EC3 (42) and (41) 4.75 to 5.25
V

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Circuit diagram related to throttle sensor

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Failure code [CA2186] Throt Sensor Sup Volt Low Error (WA380_7-CA2186-400-A-Z0-A)

Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
L03 CA2186 (Engine controller system)
Detail of • Low voltage appears in throttle sensor power supply circuit.
failure
Action of • Sets throttle position at 0% with accelerator pedal released and at 50 % with accelerator
controller pedal depressed, and allows engine to run.
Problem on • Engine does not run at full throttle.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General information
on troubleshooting", and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector PD and turn starting switch to ON position.
Defective throttle sensor If this failure code disappears, throttle sensor is defective.
2 (accelerator pedal)
a Other failure codes are also displayed. They are generated because
of disconnection of connector. Ignore failure codes other than
[CA2186].
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors EC3 and PD, and connect T-adapters to
3 harness either female side.
(contact with ground circuit) Resis- Between ground and EC3 (female) (42) or
PD (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and PD, and connect T-adapters to
4 Short circuit in wiring harness female side of EC3.
Resis- Between EC3 (female) (42) and each pin
other than pin (42) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and connect T-adapters to male side.
5 Defective engine controller 3. Turn starting switch to ON position with wiring harness
disconnected.
Voltage Between EC3 (42) and (41) 4.75 to 5.25 V

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Circuit diagram related to throttle sensor

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Failure code [CA2249] Rail Press Very Low Error (PC400-CA2249-400-A-Z0-A)

Action level Failure code Rail Pressure Very Low Error


Failure
L03 CA2249 (Engine controller system)
Detail of • Supply pump does not feed fuel (level 2).
failure
Action of • Limits engine output (limits common rail pressure) and allows engine to run.
controller
Problem on • Engine output lowers.
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
function. (Code: 36401 (V))
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error

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Failure code [CA2265] Fuel Feed Pump Open Error (WA470_7-CA2265-400-A-Z0-A)

Action level Failure code Fuel Feed Pump Open Error


Failure
L01 CA2265 (Engine controller system)
Detail of • Fuel feed pump drive signal circuit is open (when controller drives pump time switch).
failure
Action of • None in particular
controller
Problem on • KDPF regeneration does not work.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
General
information a Since this failure code has action level of L01, check whether this failure code is currently
active on abnormality record screen.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following troubleshooting.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and E28, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between EC3 (female) (14) and E28 (female) (5) Max. 1 z
connector) Resistance
Between E28 (female) (10) and ground Max. 1 z
If no failure is found by above checks, engine controller or time switch is
defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
Defective engine 1. Turn starting switch to OFF position.
3 controller or defective 2. Insert T-adapter into EC3.
time switch 3. Turn starting switch to ON position.
Between EC3 (14) and When time switch
(21) operates Max. 1 V
Voltage
Between EC3 (14) and
When time switch stops 20 to 30 V
(21)

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Circuit diagram related to fuel feed pump

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Troubleshooting by failure code (Display of code)

Failure code [CA2266] Fuel Feed Pump Short Error (WA470_7-CA2266-400-A-Z0-A)

Action level Failure code Fuel Feed Pump Short Error


Failure
L01 CA2266 (Engine controller system)
Detail of • Fuel feed pump drive signal circuit shorts (when controller drives pump time switch).
failure
Action of • None in particular
controller
Problem on • Engine output reduces.
machine • KDPF regeneration does not work.
• Method of reproducing failure code: Turn starting switch to ON position.
General
information a Since this failure code has action level of L01, check whether this failure code is currently
active on abnormality record screen.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following troubleshooting.
1. Turn starting switch to OFF position.
2. Disconnect connector E29.
Defective electric fuel 3. Turn starting switch to ON position.
2 feed pump If this failure code [CA2266] disappears, electric fuel feed pump is defective.
a Ignore failure codes other than this code, which are generated due to
disconnection of connector.
1. Turn starting switch to OFF position.
2. Disconnect connector E28.
Defective pump time 3. Turn starting switch to ON position.
3
switch If this failure code [CA2266] disappears, pump time switch is defective.
a Ignore failure codes other than this code, which are generated due to
disconnection of connector.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and E28, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and EC3 (female) (14) or E28
circuit) Resistance (female) (5) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors EGC3, EPP, and EFP, and connect T-adapters to
Short circuit in wiring female side of EC3 and E29.
5
harness Between EC3 (female) (14) and each of (21), (22),
Min. 1 Mz
Resistance (31), and (32)
Between E29 (female) (1) and (2) Min. 1 Mz
If no failure is found by above checks, engine controller or time switch is
defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
Defective engine 1. Turn starting switch to OFF position.
6 controller or defective 2. Insert T-adapter into EC3.
time switch 3. Turn starting switch to ON position.
Between EC3 (14) and When time switch
(21) operates Max. 1 V
Voltage
Between EC3 (14) and
When time switch stops 20 to 30 V
(21)

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Circuit diagram related to fuel feed pump

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Failure code [CA2271] EGR Valve Pos Sens High Error (PC400-CA2271-400-A-Z0-A)

Action level Failure code EGR Valve Position Sensor High Error
Failure
L03 CA2271 (Engine controller system)
Detail of • High voltage appears in EGR valve lift sensor signal circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18100 (mm))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
information monitoring function. (Code: 18101 (V))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective sensor power If failure code [CA352] or [CA386] is also displayed, perform
2 supply system troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective EGR valve lift 2. Disconnect connector SEGR.
3 sensor 3. Turn starting switch to ON position (with connector SEGR
(internal defect) disconnected).
If failure code changes from [CA2271] to [CA2272], sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SEGR, and connect T-adapters to
Open circuit in wiring harness each female side.
4 (wire breakage or defective
contact of connector) a To check for open circuit in GND line
Resis- Between J2 (female) (47) and SEGR (female)
(2) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SEGR, and connect T-adapter to
Short circuit in wiring harness either female side.
5
Between J2 (female) (30) and (59), between
Resis- SEGR (female) (1) and (3), or between SEGR
Min. 1 Mz
tance (female) (1) and (4)
1. Turn starting switch to OFF position.
Hot short circuit in harness 2. Disconnect connector SEGR and connect T-adapter to female side.
6 3. Turn starting switch to ON position (with connector SEGR
(contact with 24 V circuit) disconnected).
Voltage Between SEGR (female) (3) or (4) and (2) Max. 1 V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J2.
3. Turn starting switch to ON position.
Voltage Between J2 (59) and (47) 1.0 to 4.0
V

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Circuit diagram related to EGR valve lift sensor

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Troubleshooting by failure code (Display of code)

Failure code [CA2272] EGR Valve Pos Sens Low Error (PC400-CA2272-400-A-Z0-A)

Action level Failure code EGR Valve Position Sensor Low Error
Failure
L03 CA2272 (Engine controller system)
Detail of • Low voltage appears in EGR valve lift sensor signal circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal voltage from EGR valve lift sensor can be checked by using monitoring function.
(Code: 18101 (V))
Related • EGR valve position (mm) sensed by EGR valve lift sensor can be checked by using
information monitoring function. (Code: 18100 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA352] or [CA386] is also displayed, perform
troubleshooting for it first.

Defective sensor power 1. Turn starting switch to OFF position.


2 supply system 2. Disconnect connector SEGR and connect T-adapter to female side.
3. Turn starting switch to ON position.
Between SEGR (female) (1) and Power 4.75 to 5.25
Voltage
(2) supply V
1. Turn starting switch to OFF position.
2. Disconnect connectors SEGR and J2, and connect T-adapters to
each female side.
a If power supply voltage in check on cause
2 is normal, this check is not required.
Open circuit in wiring Max. 1 z
harness Between J2 (female) (30) and SEGR
3 (female) (1)
(wire breakage or defective
contact of connector) Resis-
a If power supply voltage in check on cause
tance
2 is normal, this check is not required.
Max. 1 z
Between J2 (female) (47) and SEGR
(female) (2)
Between J2 (female) (59) and SEGR (female)
(3), (4) (sensor output) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors J2 and SEGR, and connect T-adapter to
4 harness either female side.
(contact with ground circuit) Resis- Between J2 (female) (59) and ground, or
between SEGR (female) (3) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SEGR, and connect T-adapter to
Short circuit in wiring
5 either female side.
harness
Resis- Between J2 (female) (59) and (47), or between
SEGR (female) (2) and (3) Min. 1 Mz
tance

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Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 1 to 5 and check result of
cause 6 is abnormal, sensor is defective.
Defective EGR valve lift 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector J2 or SEGR.
sensor
3. Turn starting switch to ON position.
Between J2 (59) and (47), or between SEGR
Voltage 1.0 to 4.0 V
(3) and (2)
If no failure is found by above checks, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to EGR valve lift sensor

WA470-7 40-347
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2349] EGR Valve Solenoid Open Error (PC400-CA2349-400-A-Z0-A)

Action level Failure code EGR Valve Solenoid Open Error


Failure
L03 CA2349 (Engine controller system)
Detail of • Open circuit is in EGR valve solenoid drive circuit .
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal current to the EGR valve solenoid can be checked with monitoring function. (Code:
Related 48600 (mA))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male
2 side.
(internal open circuit)
Resis- Between EGR-SOL (male) (1) and (2)
5 to 10 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring a If resistance is above 1 Mz, wiring harness has open circuit. If
3
harness resistance is below 1z, wiring harness has short circuit.
Resis- Between J2 (female) (6) and (16)
5 to 10 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J2 and EGR-SOL, and connect T-adapters to
4 (wire breakage or defective each female side.
contact of connector) Between J2 (female) (6) and EGR-SOL
Max. 1 z
Resis- (female) (1)
tance Between J2 (female) (16) and EGR-SOL
(female) (2) Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connector EGR-SOL and connect T-adapter to male
Hot short circuit in harness side.
5 3. Turn starting switch to ON position (with connector EGR-SOL
(contact with 24 V circuit)
disconnected).
Voltage Between EGR-SOL (female) (1) and (2) Max. 3 V
If no abnormality is found by above diagnosis, engine controller is
6 Defective engine controller defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

40-348 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to EGR valve solenoid

WA470-7 40-349
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2353] EGR Valve Solenoid Short Error (PC400-CA2353-400-A-Z0-A)

Action level Failure code EGR Valve Solenoid Short Error


Failure
L03 CA2353 (Engine controller system)
Detail of
• Short circuit is in EGR valve solenoid drive circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal current to the EGR valve solenoid can be checked with monitoring function. (Code:
Related 48600 (mA))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male
2 side.
(internal open circuit)
Resis- Between EGR-SOL (male) (1) and (2) 5 to 10 z
tance Between EGR-SOL (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapter to male side.
Open or short circuit in wiring a If resistance is above 1 Mz, wiring harness has open circuit. If
3
harness resistance is below 1z, wiring harness has short circuit.
Resis- Between J2 (female) (6) and (16)
5 to 10 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and EGR-SOL, and connect T-adapter to
4 Short circuit in wiring harness either female side.
Resis- Between J2 (female) (6) and (16), or between
EGR-SOL (female) (1) and (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J2 and EGR-SOL.
5
(contact with ground circuit) Resis- Between J2 (female) (6) or EGR-SOL (female)
(1) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector EGR-SOL and connect T-adapter to male
Hot short circuit in harness side.
6 3. Turn starting switch to ON position (with connector EGR-SOL
(contact with 24 V circuit)
disconnected).
Voltage Between EGR-SOL (female) (1) and (2) Max. 3 V
If no abnormality is found in the above, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-350 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to EGR valve solenoid

WA470-7 40-351
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2357] EGR Valve Servo Error (PC400-CA2357-400-A-Z0-A)

Action level Failure code EGR Valve Servo Error


Failure
L03 CA2357 (Engine controller system)
Detail of • EGR valve servo error occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
• Limits engine output and allows engine to run.
Action of • Does not supply current to EGR valve (closes EGR valve).
controller • Fully open KVGT.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Related Position (mm))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
a For testing of EGR valve drive pressure, see .Testing and adjusting,
Insufficient EGR valve drive "Testing EGR valve and KVGT drive oil pressure".
2 pressure
If EGR valve drive pressure is abnormal, perform checks on causes 3
and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
3 system (main circuit) If engine oil pressure is abnormal, perform troubleshooting (S mode) for
mechanical system. (S-12 Oil pressure lowers.)
Defective oil pump for EGR Oil pump or relief valve for EGR valve circuit may be defective. Check
4
valve them.
Defective hydraulic piping for Hydraulic piping of EGR valve circuit may be defective. Check it.
5
EGR valve
Defective return hydraulic
6 Return hydraulic piping for EGR valve circuit may be defective. Check it.
piping for EGR valve
7 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If no failure is found by checks on causes 1 to 8, engine controller is
9 Defective engine controller defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

40-352 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2381] KVGT Pos Sens High Error (PC400-CA2381-400-A-Z0-A)

Action level Failure code KVGT Position Sensor High Error


Failure
L03 CA2381 (Engine controller system)
Detail of • High voltage appears in KVGT position sensor signal circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position (mm) sensed by KVGT position sensor can be checked with monitoring function.
information (Code: 48700 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective sensor power If failure code [CA1695] or [CA1696] is displayed, perform
2 supply system troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective KVGT position 2. Disconnect connector SVGT.
3 sensor 3. Turn starting switch to ON position (with connector SVGT
(internal defect) disconnected).
If failure code changes from [CA2381] to [CA2382], sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SVGT, and connect T-adapters to
Open circuit in wiring harness each female side.
4 (wire breakage or defective
contact of connector) a To check open circuit in GND line
Resis- Between J2 (female) (47) and SVGT (female)
(B) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SVGT, and connect T-adapters to
5 Short circuit in wiring harness either female side.
Resis- Between J2 (female) (38) and (30), or between
SVGT (female) (A) and (C) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in harness 2. Disconnect connector SVGT and connect T-adapters to female side.
6 3. Turn starting switch to ON position (with connector SVGT
(contact with 24 V circuit) disconnected).
Voltage Between SVGT (female) (C) and (B) Max. 1 V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J2.
3. Turn starting switch to ON position.
Voltage Between J2 (38) and (47) 1.0 to 4.0
V

WA470-7 40-353
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KVGT position sensor

40-354 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2382] KVGT Pos Sens Low Error (PC400-CA2382-400-A-Z0-A)

Action level Failure code KVGT Position Sensor Low Error


Failure
L03 CA2382 (Engine controller system)
Detail of • Low voltage appears in KVGT position sensor signal circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position (mm) sensed by KVGT position sensor can be checked with monitoring function.
information (Code: 48700 (mm))
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
If failure code [CA352] or [CA386] is also displayed, perform
troubleshooting for it first.

Defective sensor power 1. Turn starting switch to OFF position.


2 supply system 2. Disconnect connector SVGT and connect T-adapters to female side.
3. Turn starting switch to ON position.
Between SVGT (female) (A) and Power 4.75 to 5.25
Voltage
(B) supply V
1. Turn starting switch to OFF position.
2. Disconnect connectors SVGT2 and J, and connect T-adapters to
each female side.
a If power supply voltage in check on cause
2 is normal, this check is not required.
Max. 1 z
Open circuit in wiring harness Between J2 (female) (30) and SVGT
3 (wire breakage or defective (female) (A)
contact of connector) Resis-
a If power supply voltage in check on cause
tance
2 is normal, this check is not required.
Max. 1 z
Between J2 (female) (47) and SVGT
(female) (B)
Between J2 (female) (38) and SVGT (female)
(C) (Sensor output) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors J2 and SVGT, and connect T-adapter to
4 harness either female side.
(contact with ground circuit) Resis- Between J2 (female) (38) and ground, or
between SVGT (female) (C) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SVGT, and connect T-adapter to
5 Short circuit in wiring harness either female side.
Resis- Between ENG (female) (38) and (47), or
between SVGT (female) (B) and (C) Min. 1 Mz
tance

WA470-7 40-355
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 1 to 5 and check result of
cause 6 is abnormal, sensor is defective.
Defective KVGT position 1. Turn starting switch to OFF position.
6 2. Insert T-adapter into connector J2 or SVGT.
sensor
3. Turn starting switch to ON position.
Between J2 (38) and (47), or between SVGT
Voltage 1.0 to 4.0 V
(C) and (B)
If no failure is found by above checks, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to KVGT solenoid

40-356 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2383] KVGT Solenoid Open Error (PC400-CA2383-400-A-Z0-A)

Action level Failure code KVGT Solenoid Open Error


Failure
L03 CA2383 (Engine controller system)
Detail of • Open circuit occurs in KVGT solenoid drive circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
Related (mA))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code is not displayed, wiring harness connector is
defective.
a If this failure code is displayed, perform following checks.
1. Turn starting switch to OFF position.
Defective KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapter to male
2 side.
(internal open circuit)
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapter to female side.
Open or short circuit in wiring a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z
3
harness or below, harness has short circuit.
Resis- Between J2 (female) (10) and (20)
5 to 10 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors J2 and VGT-SOL, and connect T-adapters to
4 (wire breakage or defective each female side.
contact of connector) Between J2 (female) (10) and VGT-SOL
Max. 1 z
Resis- (female) (1)
tance Between J2 (female) (20) and VGT-SOL
(female) (2) Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connector VGT-SOL and connect T-adapter to female
Hot short circuit in wiring side.
5 3. Turn starting switch to ON position (with connector VGT-SOL
harness
disconnected).
Voltage Between VGT-SOL (female) (1) and (2) Max. 3 V
If no failure is found by above checks, engine controller is defective.
6 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-357
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KVGT solenoid

40-358 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2386] KVGT Solenoid Short Error (PC400-CA2386-400-A-Z0-A)

Action level Failure code KVGT Solenoid Short Error


Failure
L03 CA2386 (Engine controller system)
Detail of
• Short circuit is detected in KVGT solenoid drive circuit.
failure
• Limits engine output and allows engine to run.
Action of • Closes EGR valve and opens KVGT fully.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48600
Related (mA))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
1. Turn starting switch to OFF position.
2. Disconnect connector VGT-SOL and connect T-adapters to male
KVGT solenoid defective
2 side.
(internal short circuit)
Resis- Between VGT-SOL (male) (1) and (2) 5 to 10 z
tance Between VGT-SOL (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring a If resistance is above 1 Mz, wiring harness has open circuit. If
3
harness resistance is below 1z, wiring harness has short circuit.
Resis- Between J2 (female) (10) and (20)
5 to 10 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and VGT-SOL, and connect T-adapter to
4 Short circuit in wiring harness either female side.
Resis- Between J2 (female) (10) and (20), or between
VGT-SOL (female) (1) and (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J2 and VGT-SOL, and connect T-adapters to
5 each female side.
(contact with ground circuit)
Resis- Between J2 (female) (10) or VGT-SOL (female)
(1) and ground Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector VGT-SOL and connect T-adapter to female
Hot short circuit in harness side.
6 3. Turn starting switch to ON position (with connector VGT-SOL
(contact with 24 V circuit)
disconnected).
Voltage Between VGT-SOL (female) (1) and (2) Max. 1 V
If no abnormality is found in the above, engine controller is defective.
7 Defective engine controller
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-359
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KVGT solenoid

40-360 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2387] KVGT Servo Error (PC400-CA2387-400-A-Z0-A)

Action level Failure code KVGT servo error


Failure
L03 CA2387 (Engine controller system)
Detail of • KVGT servo error has occurred.
failure (Response from KVGT position sensor differs from KVGT opening command.)
• Closes EGR valve and opens KVGT fully.
Action of • Limits engine output and allows engine to run.
controller • Stops KDPF regeneration control.
Problem on • Engine output lowers.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defect in related system If another failure code is indicated, carry out troubleshooting for it.
For testing of KVGT drive pressure, see Testing and adjusting, "Testing
KVGT drive oil pressure EGR valve and KVGT oil pressure".
2
abnormal
a If the KVGT drive pressure is abnormal, check causes 3 and 4.
For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
3 system
(main circuit) a If engine oil pressure is not normal, perform troubleshooting (S
mode) for mechanical system. (S-12 Oil pressure lowers.)
4 Defective oil pump for KVGT Oil pump or relief valve for KVGT circuit may be defective. Check them.
Defective oil supply pipe for Oil supply pipe for the KVGT circuit may be defective. Check it.
5
KVGT
Defective oil return pipe for Oil return pipe for KVGT circuit may be defective. Check it.
6
KVGT
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged
7 Defective KVGT after performing regeneration for service, KVGT is defective.
(Since the time required for manual stationary regeneration depends on
the accumulated soot level, see failure code CA2639. )
Defective KVGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
8
sensor
9 Defective engine controller If no failure is found by above checks, engine controller is defective.

WA470-7 40-361
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2555] Grid Htr Relay Volt Low Error (WA470_7-CA2555-400-A-Z0-A)

Action level Failure code Grid Heater Relay Voltage Low Error
Failure
L01 CA2555 (Engine controller system)
Detail of • Open circuit is in preheat relay drive circuit (primary circuit).
failure
Action of • None in particular
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to the ON position (Engine
General coolant temperature: Max. -5 °C).
information • Troubleshooting of this failure code covers circuits from engine controller to primary circuit
(coil) of preheat relay L125.
• For troubleshooting of secondary circuit of heater relay and preheat relay L125, see E-2 in
E-mode troubleshooting.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following troubleshooting.
1. Turn starting switch to OFF position.
Defective preheat
2 2. Disconnect relay L125 and connect T-adapter to male side.
relay L125
Resistance Between L125 (male) (1) and (2) 200 to 400 z
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connectors EC3 and connect T-adapter to female side.
3 wiring harness Between EC3 (female) (4) and ground
Resistance 200 to 400 z
a To measure coil resistance of relay L125
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector EC3 and relay L125, and connect T-adapters to each
4
harness female side.
Between EC3 (female) (4) and L125 (female) (1) Max. 1 z
Resistance
Between L125 (female) (2) and ground Max. 1 z
Defective engine If no failure is found by above checks, engine controller is defective.
5
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-362 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to intake air heater relay

WA470-7 40-363
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2556] Grid Htr Relay Volt High Error (WA470_7-CA2556-400-A-Z0-A)

Action level Failure code Grid Heater Relay Voltage High Error
Failure
L01 CA2556 (Engine controller system)
Detail of • Short circuit is in preheat relay drive circuit (primary circuit).
failure
Action of • None in particular
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
• Method of reproducing failure code: Turn starting switch to the ON position (Engine coolant
General temperature: Max. -5 °C).
information • Troubleshooting of this failure code covers circuits from engine controller to primary circuit
(coil) of preheat relay L125.
• For troubleshooting of secondary circuit of heater relay and preheat relay L125, see E-2 in
E-mode troubleshooting.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following troubleshooting.
1. Turn starting switch to OFF position.
Defective preheat
2 2. Disconnect relay L125 and connect T-adapter to male side.
relay L125
Resistance Between L125 (male) (1) and (2) 200 to 400 z
1. Turn starting switch to OFF position.
2. Disconnect connector EC3 and relay L125, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and EC3 (female) (4) or L125
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector EC3 and relay L125, and connect T-adapter to
female side of EC3.
Short circuit in wiring
4
harness a Check by using multimeter in continuity mode.
Between EC3 (female) (4) and each No continuity
Continuity
pin other than pin (4) (No sound is heard)
Defective engine If no failure is found by above checks, engine controller is defective.
5
controller (Since this is an internal defect, troubleshooting cannot be performed.)

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40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to intake air heater relay

WA470-7 40-365
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2637] KDOC Face Plugging (PC400-CA2637-400-A-Z0-A)

Action level Failure code KDOC Face Plugging


Failure
L01 CA2637 (Engine controller system)
• KDOC face is plugged.
1. The KDOC surface is contaminated due to the operating conditions, and the catalytic
Detail of efficiency has dropped (clean the DOC).
failure 2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or
dropped efficiency due to damage (Replace KDOC with a new or used one.)
Action of • Stops fuel dosing.
controller
Problem on • None in particular
machine

k Since temperature of the turbocharger exhaust connector, KDOC and KDPF


exceeds 500 °C, take care not to get burn injury.

a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
Related 1. Start the engine.
information 2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"02 Regeneration for service", and then perform the "Manual Stationary
Regeneration".
• If the KDOC efficiency is still low, this failure code [CA2637] may be displayed repeatedly
and failure code [CA1691] indicating the poor regeneration may be displayed.
<How to clear failure code>
• Start the engine and perform the warm-up operation, then operate the machine under
normal conditions for approximately 3 hours.
(If the exhaust gas temperature is high, this operation time can be reduced.)
No. Cause Procedure, measuring location, criteria and remarks
1 Defective KVGT If failure code [CA238*] is displayed, troubleshoot for it first.
If failure code [CA227*], [CA23**] or others is displayed, troubleshoot for
2 Defective EGR valve
it first.
1. Remove turbocharger exhaust connector.
Defective turbocharger 2. Check for oil or fuel inside turbocharger exhaust connector.
3
exhaust connector • If contaminated, troubleshoot for failure codes [CA227*], [CA23**],
etc., relating to the EGR valve and KVGT.
Defective exhaust connector Check exhaust system between turbocharger and KDPF for damage of
4 and ducts connected to the connector and ducts, and for loose connection.
KDPF
1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when running the engine at
high idle, troubleshoot for "S-9 KDPF gets clogged in a short time".
5 Unusual exhaust gas color
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.

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No. Cause Procedure, measuring location, criteria and remarks


1. Remove KDPF.
2. Remove KDOC.
• Check KDOC for cracks (replace KDOC if cracks are found).
• Check whether more than 50% of KDOC inlet surface is plugged with
6 Defective KDOC soot or not.
(KDOC cleaning)
a When KDOC is replaced, perform check on cause 7. And when
cleaning of KDOC is done, perform checks on causes 7 and 8.
1. Install KDOC and KDPF.
2. Turn starting switch to ON position.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
7 Reset after KDOC change
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
manual stationary regeneration.
1. Perform manual stationary regeneration from Regeneration for
Service.
2. Turn starting switch to OFF position.
3. Repeat the "Regeneration for service" (to check the repair
Performing manual stationery completion).
8 regeneration
a If failure code [CA2637] is displayed after you have completed the
"Regeneration for Service", the KDOC efficiency has dropped.
Replace the KDOC and perform reset after KDOC change (see
Cause 7).

a Operate the machine approximately 3 hours and check that this failure code is not displayed.

WA470-7 40-367
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2639] Manual Stationary Regeneration Request (HM300_3-


CA2639-400-A-Z0-A)

Action level Failure code Manual Stationary Regeneration Request


Failure
L01 CA2639 (Engine controller system)
Manual stationary regeneration request prompts operator to "forcibly" perform stationary
Detail of regeneration, which is more effective to remove soot, because soot accumulation in the
failure KCSF of KDPF has exceeded level for automatic regeneration.
• Soot accumulation reaches level 4 or 5.
Action of
• Normal control
controller
Problem on • None in particular
machine

k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.

a If manual stationary regeneration is started when KDOC inlet temperature is below


approximately 250°C, fuel dosing will be disabled, so actually regeneration will not start.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
Related • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
information engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
difference between these temperatures is approx. 10°C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet
temperature are approx. 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• How to perform stationary manual regeneration
1. Start the engine.
2. Make sure that machine is in safe condition.
3. From the service menu of the machine monitor, display the "Diagnostic Tests" screen,
open "Regeneration for service", and perform the "Manual Stationary Regeneration".
a While the regeneration for service is in progress, the “monitoring” screen is displayed by
performing the switch operation: keep pressing “r” on the left bottom of the switch panel
and sequentially press numeral input switch [1], [2] and [3] in order.
(For detail, see Testing and adjusting “Regeneration for service ” . )

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a Time required for manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: Approx. 40 minutes to 1 hour
• If soot accumulation is level 5: Approx. 1 to 2 hours
• If soot accumulation is level 6 or 7: Approx. 1 to 3 hours
Related • If soot accumulation is level 8: The manual stationary regeneration can not be performed.
information
a If this failure code is still displayed after several hours have passed after manual
stationary regeneration, perform following troubleshooting procedures.
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Check if the regeneration stop button is pressed down from the
machine monitor.
If the regeneration stop button is pressed down, release it.
2. Turn starting switch to the ON position.
Increase of soot 3. Make sure that machine is in safe condition.
1 accumulation due to 4. Start the engine, and perform the manual stationary regeneration
"Regeneration Disable" from user mode.
a When the manual stationary regeneration is finished correctly, the
repair is completed.
a If the regeneration does not complete within 3 hours, proceed to
checks on cause 2 and after.
• If there is a significant difference between KDOC inlet temperature
Defective KDOC inlet and KDOC outlet temperature when KDPF is completely cool or
2 temperature sensor engine running at idle (not regenerating), replace KDOC inlet
temperature sensor.
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged after
3 Defective KVGT performing regeneration for service, KVGT is defective.
(The time required for manual stationary regeneration depends on the
accumulated soot level. See related information.)
Defective KDPF (KDOC, 1. Perform the troubleshooting "S-22 Active regeneration takes time" of
4 KCSF) S mode.
a If failure code [CA2639] is displayed after the manual stationary
regeneration is completed, perform the following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for 5 seconds.
5 Unusual exhaust gas color • If excessive black smoke is exhausted when accelerating engine or
running it at high idle, troubleshoot for "S-9 KDPF gets clogged in a
short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
a Check that no failure code appears.
a When you finish the check of the exhaust gas color, release
"Regeneration Disable".

WA470-7 40-369
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to ON position.
6 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

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Failure code [CA2732] Dosing Fuel Valve 2 High Error (PC400-CA2732-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve 2 High Error


Failure
L03 CA2732 (Engine controller system)
Detail of Abnormal low voltage (or high circuit resistance) has occurred in dosing fuel solenoid valve 2
failure (drain valve).
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If failure code [CA1923] is also displayed, the ground (GND) leads may be open.
• This failure code appears if sensor connector is disconnected.
• See failure code [CA1963].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
Defective dosing fuel 2. Disconnect connector SOV2, and connect T-adapter to male side of
2 solenoid valve 2 (drain valve) connector.
Resis- Between SOV2 (male) (2) and (1)
4 to 6 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring Between J2 (female) (8) and (18)
3
harness Resis-
a The resistance is the same as that of 4 to 6 z
tance
dosing fuel solenoid valve 2.
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV2, and connect T-adapter to each
Open circuit in wiring harness female side of connectors.
4 (wire breakage or defective a To check open circuit in GND line
contact of connector)
Between J2 (female) (8) and SOV2 (female)
Max. 1 z
Resis- (1)
tance Between J2 (female) (18) and SOV2 (female)
(2) Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connectors J2 and SOV2, and connect T-adapter to
female side of connector J2.
a Check by using multimeter in continuity mode.
5 Short circuit in wiring harness
No
continuity
Between J2 (female) (8) and each pin other
Continuity (No sound
than pin (8)
is heard)

WA470-7 40-371
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Start engine and run it at low idle for 1 minute.
a If another failure code is displayed, perform troubleshooting for it.
6 Defective engine controller
If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to dosing fuel solenoid valve

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Failure code [CA2733] Dosing Fuel Valve 2 Low Error (PC400-CA2733-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve 2 Low Error


Failure
L03 CA2733 (Engine controller system)
Detail of Abnormal high voltage (or low circuit resistance) has occurred in dosing fuel solenoid valve 2
failure (drain valve).
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • If sensor connector is disconnected, failure code [CA2732] is displayed.
• See failure code [CA1963].
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector SOV2, and connect T-adapter to male side of
Defective dosing fuel connector.
2 solenoid valve 2 (drain valve) Between SOV2 (male) (2) and (1) 4 to 6 z
Resis-
Between SOV2 (male) (1) and ground (dosing
tance Min. 1 Mz
fuel valve 2 body)
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and connect T-adapters to female side.
Open or short circuit in wiring Between J2 (female) (8) and (18)
3
harness Resis-
a The resistance is the same as that of 4 to 6 z
tance
dosing fuel solenoid valve 2.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors J2 and SOV2, and connect T-adapter to
4 harness female side of either connector.
(contact with ground circuit) Resis- Between ground (frame) and J2 (female) (8) or
SOV2 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J2 and SOV2, and connect T-adapter to
female side of connector J2.

5 Short circuit in wiring harness a Check by using multimeter in continuity mode.


No
Between J2 (female) (8) and each pin other continuity
Continuity
than pin (8) (No sound
is heard)
1. Start engine and run it at low idle for 1 minute.
a If another failure code is displayed, perform troubleshooting for it.
6 Defective engine controller
If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

WA470-7 40-373
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to dosing fuel solenoid valve

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Troubleshooting by failure code (Display of code)

Failure code [CA2741] Dosing Fuel Valve Swap Error (PC400-CA2741-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve Swap Error


Failure
L03 CA2741 (Engine controller system)
Detail of • Dosing fuel solenoid valve 1 (shut-off valve) and dosing fuel solenoid valve 2 (drain valve)
failure are connected reversely.
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.
Related
information • Method of reproducing failure code: Turn starting switch to ON position
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
Reverse connection of wiring
1 1. Check connectors SOV1 and SOV2.
harness

Circuit diagram related to dosing fuel solenoid valve

A: From electric fuel pump


B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve) connector
SOV2: Dosing fuel solenoid valve 2 (drain valve) connector

WA470-7 40-375
40 Troubleshooting
Troubleshooting by failure code (Display of code)

1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor

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Failure code [CA2765] Inj Trim Data Error (PC400-CA2765-400-A-Z0-A)

Action level Failure code Injector Trim Data Error


Failure
L01 CA2765 (Engine controller system)
Detail of • Injector trim data input to to the engine controller is not correct.
failure
Action of
controller
Problem on • Since the engine controller can not know the production variance of each injector, the
machine exhaust gas purification will be degraded.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks

1 Injector trim data mismatch a When replacing injectors, see chapter 30 Testing and adjusting,
"Injector trim".

WA470-7 40-377
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA2878] Dosing Fuel Valve 2 Servo Error (PC400-CA2878-400-A-Z0-A)

Action level Failure code Dosing Fuel Valve 2 Servo Error


Failure
L03 CA2878 (Engine controller system)
• When fuel pressure is checked immediately after engine startup, the ON/OFF command
of dosing fuel solenoid valve 2 (SOV2 drain valve) does not match with the expected
value of fuel pressure detected by dosing fuel pressure sensor.
Detail of
1. When Open SOV1 Valve and Close SOV2 Valve commands are given, the dosing fuel
failure
pressure detected by dosing fuel pressure sensor does not increase sufficiently.
2. When Close SOV1 Valve and Open SOV2 Valve commands are given, the dosing fuel
pressure detected by dosing fuel pressure sensor does not decrease sufficiently.
Action of • Stops KDPF regeneration control.
controller
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.

• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
Related • Pressure detected by dosing fuel pressure sensor can be checked with monitoring
information function. (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Method of reproducing failure code: Start the engine (observe for 3 minutes).
<How to clear failure code>
Turn starting switch ON from OFF position to start engine. If failure code is disappeared after
running engine at low idol for approx. 3 minutes, repair is completed.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
2 Defective fuel system For above check, see Testing and adjusting, "Measuring fuel pressure".
Defective dosing fuel
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
3 solenoid valve 1 (shut-off
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)
Defective dosing fuel If failure code [CA2732] or [CA2733] is also displayed, perform
4 solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
5 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
1. Turn starting switch to OFF position.
2. Disconnect connector SOV2, and connect T-adapter to female side
Hot short circuit in wiring of connector.
6
harness 3. Turn starting switch to ON position.
Voltage Between SOV2 (female) (1) and (2) Max. 4.7 V

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No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors SOV1 and SOV2.
3. Replace dosing fuel solenoid valve 1 with dosing fuel solenoid valve
2.
Defective dosing fuel solenoid
7 a Do not replace the SOV1 and SOV2 connectors.
valve 2 (drain valve)
4. Turn starting switch to ON position.
If this failure code changes to [CA1963], the previous dosing fuel
solenoid valve 2 (drain valve) is defective.
a If this failure code appears, perform following checks.
8 Clogging of fuel return tube Disconnect the fuel return tube and check it for clogging.
Defective fuel shut-off valve Disconnect the fuel system tube and check the fuel connector of fuel
9 shut-off valve manifold for clogging.
manifold
1. Turn starting switch to OFF position.
2. Disconnect fuel supply line (2) from fuel doser (1).
3. Turn starting switch to ON position.
Defective dosing fuel pressure 4. See "Related information",and display dosing fuel pressure and
10 ambient pressure at the same time.
sensor
If the dosing fuel pressure is clearly different from ambient pressure,
the dosing fuel pressure sensor is defective.
a The dosing fuel pressure must be equal to the ambient pressure.

Circuit diagram related to dosing fuel solenoid valve

WA470-7 40-379
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Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel doser

A: From electric fuel pump


B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve) connector
SOV2: Dosing fuel solenoid valve 2 (drain valve) connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor

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Failure code [CA2881] Dosing Fuel Pressure Low Error 1 (WA470_7-CA2881-400-A-Z0-A)

Action level Failure code Dosing fuel pressure low error 1


Failure
L03 CA2881 (Engine controller system)
Detail of Pressure detected by dosing fuel pressure sensor during dosing is below the threshold value
failure (the fuel pressure is low).
• Stops KDPF regeneration control.
Action of • You can cancel above measure by "turning starting switch to OFF position once, then
controller turning starting switch to ON position" after failure code is generated.
Problem on • Automatic regeneration is disabled.
machine • Manual stationary regeneration is disabled.

k Since exhaust connector and KDPF are heated to 500°C or above, take care not to
get burn injury.

• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
General • Pressure sensed by dosing fuel pressure sensor can be checked with monitoring function.
information (Code: 47601 (kPa))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
Defective wiring troubleshooting", and check it.
1 2. Turn starting switch to ON position.
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.
Defective dosing fuel
If failure code [CA1923] or [CA1924] or [CA1925] is also displayed, perform
2 solenoid valve 1 (shut-
troubleshooting for [CA1923] or [CA1924] or [CA1925] first.
off valve)
Defective dosing fuel
If failure code [CA2732] is also displayed, perform troubleshooting for
3 solenoid valve 2 (drain
[CA2732] first.
valve)
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
4 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
Defective fuel supply If failure code [CA559] is also displayed, perform troubleshooting for [CA559]
5 pump first.

WA470-7 40-381
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Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If failure code [CA2265] or [CA2266] is also displayed, perform
troubleshooting for [CA2265] or [CA2266] first.
1. Turn starting switch to OFF position.
2. Loosen the joint bolt (JB) of fuel tube.
Defective electric fuel 3. Tilt the switch for the fuel feed pump to ON position while starting switch is
6 feed pump in OFF position.
(Be careful since fuel may spurt out.)
When completing the check, turn the starting switch to ON position or tilt
the switch for the fuel feed pump to OFF position.
If fuel is not fed from the joint bolt (JB) of fuel tube, fuel feed pump is
defective.
1. Turn starting switch to OFF position. 
2. Disconnect connector SOV2, and connect T-adapter to female side of
Hot short circuit in
7 connector.
wiring harness
3. Turn starting switch to ON position.
Voltage Between SOV2 (female) (1) and (2) Max. 4.7 V
8 Clogging of fuel filter Check fuel filter for clogging.
9 Defective fuel system For above check, see Testing and adjusting, "Testing fuel pressure".
Clogging of fuel supply
10 tube or leakage from Check the fuel supply tube and its joint bolt (JB).
connector
Defective fuel shut-off Disconnect the fuel system tube and check the fuel connector of fuel shut-off
11 valve manifold for clogging.
valve manifold
1. Turn starting switch to OFF position. 
2. Disconnect fuel supply line (2) from fuel doser (1).
Defective dosing fuel 3. Turn starting switch to ON position.
12 pressure sensor If the dosing fuel pressure is clearly different from ambient pressure, the
dosing fuel pressure sensor is defective (see "Related information").
a The dosing fuel pressure must be equal to the ambient pressure.
Defective dosing fuel
13 solenoid valve 2 (drain Replace dosing fuel solenoid valve 2 (drain valve).
valve)
B. Machine operation for clearing failure code
1. Turn starting switch from OFF position to ON position.
2. Start engine and increase the engine speed from low idle (with no load) to high idle (with no load). After
engine speed reaches to high idle speed (approximately 2,170 rpm with no load), decrease it to low idle
speed.
a Automatic regeneration is started after performing the preceding procedure, then engine speed is
maintained at low idle speed (approximately 1,000 rpm).
a If automatic regeneration is started and fuel pressure of fuel doser increases properly, the failure code
is cleared.
a If automatic regeneration is not started(*), perform following steps.
3. Turn starting switch to OFF position.
4. Disconnect either connector R93 from mass air flow sensor or TEMP1, TEMP2, or TEMP3 from
temperature sensor consolidating box. (You may disconnect all of them.)
5. Turn starting switch to ON position and wait until soot accumulation level becomes "3" on machine
monitor (approximately 7 minutes).
a At this time, the next failure codes appear, however, ignore them because they are open circuit errors
caused by disconnecting the connectors.
• When disconnecting connector R93 from mass air flow sensor: [CA357], [CA691]
• When disconnecting connector TEMP1 from temperature sensor: [CA3314]
• When disconnecting connector TEMP2 from temperature sensor: [CA3317]
• When disconnecting connector TEMP3 from temperature sensor: [CA3319]
• When disconnecting all the connectors: [CA3314], [CA3317], [CA3319]

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40 Troubleshooting
Troubleshooting by failure code (Display of code)

a Failure codes [CA3313], [CA3316], and [CA3321] may remain in the abnormality record on rare
occasions.
6. Turn starting switch to OFF position.
7. Connect the disconnected sensor connectors.
8. If automatic regeneration is started and fuel pressure of fuel doser increases properly by performing the
preceding operations 1 and 2, the failure code is cleared.
*: When automatic regeneration is not started
In the following cases, automatic regeneration may not be started after performing the preceding operations
1 and 2. At that time, perform the operations 3 to 8.
• When "Regeneration Disable" is set from machine monitor.
• When failure code [CA2881] appears during regeneration for service.
• When failure code [CA2881] appears during automatic regeneration or manual stationary regeneration of
user mode, and also machine is operated for long period at heavy load (under high exhaust temperature)
after the regeneration.

Circuit diagram related to dosing fuel solenoid valve

WA470-7 40-383
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel doser

A: From fuel feed pump


B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
JB: Fuel tube joint bolt
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve)
connector
SOV2: Dosing fuel solenoid valve 2 (drain valve)
connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor

40-384 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to mass air flow sensor

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-385
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3133] KDPF Outlet Press Sens High Error (WA500_7-CA3133-400-A-Z0-
A)

Action level Failure code KDPF Outlet Pressure Sensor High Error
Failure
L03 CA3133 (Engine controller system)
Detail of • High voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value (gauge pressure) and allows
Action of engine to run.
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on • None in particular
machine

k Since KDPF is heated to 500°C or above, take care not to get burn injury.

• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, GND
Related circuit probably has open circuit (defective contact of connector).
information • Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47001 (V))
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47000 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
Defective KDPF outlet If this failure code changes to [CA3134], KDPF outlet pressure sensor is
3 pressure sensor defective.
a If this failure code remains displayed, wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and E25, and connect T-adapters to
4 each female side.
(wire breakage or defective
contact of connector) a To check open circuit in GND line
Resis- Between EC3 (female) (43) and E25 (female)
(1) Max. 1 z
tance

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40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
female side of EC3.
Short circuit in wiring
5 a Check by using multimeter in continuity mode.
harness
No continuity
Between EC3 (female) (58) and each pin
Continuity (No sound is
other than pin (58)
heard)
1. Turn starting switch to ON position.
6 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to KDPF outlet pressure sensor

WA470-7 40-387
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3134] KDPF Outlet Press Sens Low Error (WA500_7-CA3134-400-A-Z0-
A)

Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
L03 CA3134 (Engine controller system)
Detail of • Low voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on • None in particular
machine

k Since KDPF is heated to 500°C or above, take care not to get burn injury.

• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
Related contact of connector).
information • This failure code appears if sensor connector is disconnected.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47001 (V))
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47000 (kPa))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power 1. Turn starting switch to OFF position.
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
each female side.
a If no failure is found by check on cause 2,
Open circuit in wiring this check is not required. Max. 1 z
harness Between EC3 (female) (43) and E25
3 (female) (1)
(wire breakage or defective
contact of connector) Resis-
a If no failure is found by check on cause 2,
tance
this check is not required. Max. 1 z
Between EC3 (female) (52) and E25
(female) (4)
Between EC3 (female) (58) and E25
(female) (3) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors EC3 and E25, and connect T-adapter to
4 harness either female side.
(contact with ground circuit) Resis- Between ground and EC3 (female) (58) or
E25 (female) (3) Min. 1 Mz
tance

40-388 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
female side of EC3.
5 Short circuit in wiring harness a Check by using multimeter in continuity mode.
No continuity
Between EC3 (female) (58) and each pin
Continuity (No sound is
other than pin (58)
heard)
1. Turn starting switch to OFF position.
Defective KDPF outlet 2. Insert T-adapters into connector E25.
6 pressure sensor 3. Turn starting switch to ON position.
Voltage Between E25 (3) and (1) 0.5 to 4.5 V
1. Turn starting switch to ON position.
7 Defective engine controller If this failure code appears and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)

Circuit diagram related to KDPF outlet pressure sensor

WA470-7 40-389
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3135] KDPF Outlet Press Sens In Range Error (WA500_7-CA3135-
400-A-Z0-A)

Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
L03 CA3135 (Engine controller system)
Detail of • Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage is within operating range.)
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on • None in particular
machine

k Since KDPF is heated to 500°C or above, take care not to get burn injury.

• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47001 (V))
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
function. (Code: 47000 (kPa))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
Related function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
a Use "Short-circuit connector: 799T-601-4670" (its wiring is not identical with that of "Short-
circuit connector: 799T-601-4611).
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and repair
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after repair trouble.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
If failure code [CA1695] or [CA1696] is also displayed, perform
troubleshooting for [CA1695] or [CA1696] first.
Defective sensor power supply 1. Turn starting switch to OFF position.
1 system 2. Disconnect connector E25 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
1. See descriptions of wiring harness and connectors in "c: Electrical
2 Defective harness connector equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it and fix trouble as
needed.

40-390 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
If failure code [CA3134] is not displayed, wiring harness or engine
controller is defective.
a Perform check on cause 2 again.
a Ignore other displayed failure codes.

Defective wiring harness or 1. Turn starting switch to OFF position.


3 engine controller 2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (3) of
connector E25).
3. Turn starting switch to ON position.
If failure code [CA3133] is not displayed, wiring harness or engine
controller is defective.
a Perform check on cause 2 again.
a Ignore other displayed failure codes.
Defective KDPF outlet a If failure codes [CA3134] and [CA3133] are displayed in check on
4 pressure sensor cause 3, KDPF outlet pressure sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
each female side.
a If no failure is found by check on cause 1,
this check is not required. Max. 1 z
Open circuit in wiring harness Between EC3 (female) (43) and E25
5 (wire breakage or defective (female) (1)
contact of connector) Resis-
a If no failure is found by check on cause 1,
tance
this check is not required. Max. 1 z
Between EC3 (female) (52) and E25
(female) (4)
Between EC3 (female) (58) and E25
(female) (3) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring harness 2. Disconnect connectors EC3 and E25, and connect T-adapters to
6 either female side.
(contact with ground circuit)
Resis- Between ground and EC3 (female) (58) or
Min. 1 Mz
tance E25 (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E25, and connect T-adapters to
female side of EC3.
7 Short circuit in wiring harness a Check by using multimeter in continuity mode.
No continuity
Continu- Between EC3 (female) (58) and each pin
ity other than pin (58) (No sound is
heard)

WA470-7 40-391
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1.Remove KDPF delta pressure sensor tube.
2.Clean KDPF delta pressure sensor tube to clear clogging.
3.Check KDPF delta pressure sensor tube for cracks and damage.
4.Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Defective KDPF delta
8 • Reference
pressure sensor tube
How to check KDPF delta pressure sensor tube for clogging
1. Turn starting switch to ON position.
2. Monitor outlet pressure sensed by KDPF outlet pressure sensor on
monitoring screen of machine monitor.
Code 47000 (kPa) 0 ± 3 (kPa)
B. Machine operation for clearing failure code

k Place machine on a level ground and set parking brake lever to LOCK position.

1. Turn starting switch to OFF position.


2. Turn starting switch from OFF position to ON position.
3. Start engine and run it at low idle (with no load) for approximately 1 minute.
4. Run engine at high idle and perform hydraulic relief of work equipment for continuous 1 minute.
• If failure code disappears after implementing steps 1 to 4, repair work is complete.
• If failure code still remains displayed, repeat above steps 5 and after.
5. Turn starting switch from OFF position to ON position.
6. Start engine and run it at low idle (with no load) for approximately 1 minute.
7. Perform torque converter stall operation for approximately continuous 40 seconds with throttle position at
100% (see troubleshooting for failure code [CA1883]).
a Take care not to overheat torque converter oil.
• If failure code disappears, repair is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
No. Cause Procedure, measuring location, criteria and remarks
If this failure code appears again after above procedures are
9 Defective engine controller implemented, engine controller is defective.

Circuit diagram related to KDPF outlet pressure sensor

40-392 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3167] Fuel Doser Degradation (D155-CA3167-400-A-Z0-A)

Action level Failure code Fuel Doser Degradation


Failure
― CA3167 (Engine controller system)
Detail of • Fuel doser is deteriorated.
failure • The injection port of fuel doser is clogged.
Action of None in particular
controller
Problem on • It takes time to perform automatic regeneration. (KDOC outlet temperature does not rise
machine easily and it takes much time to burn the soot.)

k Since exhaust connector and KDPF are heated to 500 °C or above, take care not to
get burn injury.

• Signal voltage from dosing fuel pressure sensor can be checked with monitoring function.
(Code: 47600 (V))
• Pressure sensed by dosing fuel pressure sensor can be checked with monitoring function.
Related (Code: 47601 (kPa))
information • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
• For the cleaning method of the fuel doser, see Chapter 30 Testing and adjusting
"Procedures for cleaning fuel doser".
• Since this failure code has no action level, it is not displayed in the user screen of the
machine monitor. It is displayed in the service screen of the machine monitor and
KOMTRAX.
When this failure code appears, perform troubleshooting according to following work flow.
A: Identification of cause
O
B: Fuel doser memory reset
a When this failure code is displayed, the fuel doser injection amount is corrected. After
repair trouble, it is necessary to reset the corrected information of fuel doser injection
amount. Be sure to perform the fuel doser memory reset after repair.
a If it is not performed, there is a danger that KCSF may be damaged.
You can cancel above measure by "turning starting switch to the OFF position" once, then
Machine "turning starting switch to the ON position" after failure code is generated.
operation for
clearing a In the following cases, this failure code does not disappear by simply "turning starting
failure code switch to ON position from OFF position". It disappears after performing the next
automatic regeneration.
1. After this failure code is displayed, any other failure code related to fuel doser is displayed
before "turning starting switch to the OFF position" is performed.
2. After this failure code is displayed, "B. Fuel doser memory reset" is performed before
"turning starting switch to the OFF position" is performed.
3. After this failure code is displayed, the automatic regeneration is performed before
"turning starting switch to the OFF position" is performed.
a When service tool "INSITE" is available, you can clear every failure code by executing
"Reset All Faults" command.
For how to use "INSITE", see "INSITE" operation manual.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
1 Defective harness connector equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it and fix trouble as
needed.
Defective dosing fuel If failure code [CA1927] or [CA1928] is also displayed, perform
2 pressure sensor troubleshooting for [CA1927] or [CA1928] first.
Defective dosing fuel
If failure code [CA1923], [CA1924] or [CA1925] is also displayed,
3 solenoid valve 1 (shut-off
perform troubleshooting for [CA1923], [CA1924] or [CA1925] first.
valve)

WA470-7 40-393
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Defective dosing fuel If failure code [CA2732] or [CA2733] is also displayed, perform
4 solenoid valve 2 (drain valve) troubleshooting for [CA2732] or [CA2733] first.
If failure code [CA1977] is displayed, perform troubleshooting for
5 Defective fuel doser system
[CA1977] first.
Defective fuel doser solenoid If failure code [CA1963], [CA2878] or [CA2881] is also displayed,
6 perform troubleshooting for [CA1963], [CA2878] or [CA2881] first.
valve
1. Turn starting switch to OFF position.
Clogged fuel doser injection 2. Remove fuel doser (1) from exhaust connector.
7 port 3. Clean fuel doser.
a For the cleaning method of the fuel doser, see "Related information".
1. Turn starting switch to the OFF position.
2. Remove fuel doser (1) from exhaust connector.
3. Install replacement fuel doser to exhaust connector.
a This is for prevention of exhaust gas leakage from fuel doser
8 Defective fuel doser mounting hole.
4. Turn starting switch to ON position.
5. Perform the "Regeneration Disable".
6. Start engine.
7. Run engine at low idle and wait 2 minutes.
If fuel leaks from the tip end of fuel doser (1), fuel doser is defective.
If this failure code appears again after above procedures are performed,
doser fuel block is clogged with some foreign materials, etc. In this case,
9 Defective fuel doser system replace the doser fuel block itself.
After replacing, perform "B: Fuel doser memory reset (as follows)".
If this failure code appears again after above procedures are performed,
10 Defective engine controller engine controller is defective.
B: Fuel doser memory reset
How to perform "Fuel doser memory reset"
1. Turn starting switch to the ON position. (Do not start the engine.)
2. From the service menu of the machine monitor, display the "KDPF Memory Reset" and perform "04 Fuel
Doser Cleaning".

40-394 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel doser

A: From fuel feed pump


B: Fuel return
C: To fuel supply pump
D: From cooling plate of engine controller
PDOSER: Dosing fuel pressure sensor connector
SOV1: Dosing fuel solenoid valve 1 (shut-off valve)
connector
SOV2: Dosing fuel solenoid valve 2 (drain valve)
connector
1. Fuel doser
2. Fuel supply line
3. Dosing fuel solenoid valve 1 (shut-off valve)
4. Dosing fuel solenoid valve 2 (drain valve)
5. Dosing fuel pressure sensor

WA470-7 40-395
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3251] KDOC Inlet Temp High Error (WA470_7-CA3251-400-A-Z0-A)

Action level Failure code KDOC Inlet Temperature High Error


Failure
L03 CA3251 (Engine controller system)
Detail of • KDOC inlet temperature remains at high level.
failure
• Closes EGR valve and opens KVGT fully.
Action of • Limits engine output and allows engine to run.
controller • You can cancel above measure by "turning starting switch to the OFF position once, then
turning starting switch to the ON position" after failure code is generated.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is also displayed, perform
1 temperature sensor troubleshooting for [CA3313], [CA3314] or [CA3315] first.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
2 troubleshooting for [CA1925] or [CA1963] first.
solenoid valve 1
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
3
harness connector troubleshooting", and check it and repair as needed.

40-396 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position. 
2. Disconnect connectors EC3 and TEMP1 (KDOC inlet temperature
sensor), and connect T-adapter to female side of EC3.
Short circuit in wiring
4
harness a Check by using multimeter in continuity mode.
Between EC3 (female) (45) and each No continuity
Continuity
pin other than pin (45) (No sound is heard)
1. Turn starting switch to ON position.
2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
Defective KDOC inlet 5. Monitor temperature from each sensor.
5 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater, regard
that temperature sensor as defective.
a If none of temperature sensor values changes more than 24°C, problem is
not in sensor system. Perform checks on causes 6 and after.
a If another failure code appears with engine running at idle, perform
troubleshooting for it first.
Malfunction of intake Check intake system hoses, clamps, and tubes for damage and loosening.
6 system Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
7 Defective injector
Testing and adjusting, “Handling cylinder cutout mode operation“).
1. Remove turbocharger exhaust connector. 
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Oil leak into fuel.
8 turbocharger exhaust • If oil or fuel is found, visually check for oil leaks from EGR valve and
connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
Oil leak into exhaust in.
9 connector and ducts • Wipe off oil or fuel if found.
leading to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.
B. Machine operation for clearing failure code
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle for approximately 15 minute.
If failure code is cleared, repair is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
10 engine controller is defective.
controller

WA470-7 40-397
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

40-398 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3253] KDOC Temp Error - Non Regeneration (WA470_7-CA3253-400-


A-Z0-A)

Action level Failure code KDOC Temperature Error - Non Regeneration


Failure
L03 CA3253 (Engine controller system)
Detail of • KDOC outlet temperature remains at high level when active regeneration is not
failure performed.
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measure by "turning starting switch to the OFF position once, then
turning starting switch to ON position" after failure code is generated.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47201 (V))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Since cylinders other than disabled cylinder increase their fuel injection to compensate
for torque drop, exhaust temperature may rise and KDOC inlet temperature high error
may be generated.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute or more before turning starting switch
to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.

WA470-7 40-399
40 Troubleshooting
Troubleshooting by failure code (Display of code)

A. Identification of cause and repair


No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC inlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure code
1 temperature sensor [CA3251] (causes related to sensor and wiring harness).
Defective KDOC outlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure code
2 temperature sensor [CA3254] (causes related to sensor and wiring harness).
1. Remove KDPF.
2. Remove KDOC.
• Check KDOC for cracks (replace KDOC if cracks are found).
a When KDOC of KDPF is replaced, perform reset procedure for KDOC
3 Defective KDOC change and then finish troubleshooting without performing manual
stationary regeneration (see check on cause 7 of failure code [CA2637]).
• Check whether more than 50% of KDOC inlet surface is plugged with soot
or not.
(KDOC cleaning)
B. Machine operation for clearing failure code
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 15 minute.
• If failure code is cleared, repair is complete.
If failure code is not cleared, perform following steps.
a If failure code is not cleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 4 and 5 are required to satisfy temperature
requirements.
• KDOC inlet temperature X 200°C
• KDOC outlet temperature X 200°C
3. Use monitoring function to display KDOC inlet and outlet temperatures.
4. Run engine at high idle (approximately 2,170 rpm with no load) for 3 minutes.
• If failure code is cleared, repair is complete.
If failure code is not cleared, perform following steps.
5. Run engine at full speed and perform hydraulic relief of work equipment for 1 minute.
• If failure code is cleared, repair is complete.
• If failure code is not cleared because of low ambient temperature (at -20°C level), perform step 6 and
after.
6. Turn starting switch to OFF position.
7. Disconnect connector E26 and install dummy temperature sensor to wiring harness side.
8. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
9. Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
• If failure code is cleared, repair is complete.
10.Turn starting switch to OFF position.
11.Remove dummy temperature sensor to restore connector connection.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
4 engine controller is defective.
controller

40-400 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-401
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3254] KDOC Outlet Temp High Error 1 (WA470_7-CA3254-400-A-Z0-A)

Action level Failure code KDOC Outlet Temperature High Error 1


Failure
L01 CA3254 (Engine controller system)
Detail of • KDOC outlet temperature remains at high level.
failure
Action of • None in particular
controller
Problem on • None in particular
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
2 troubleshooting for [CA1925] or [CA1963] first.
solenoid valve 1
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
3
harness connector troubleshooting", and check it and repair as needed.

40-402 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and TEMP2 (KDOC outlet temperature
sensor), and connect T-adapter to female side of EC3.
Short circuit in wiring
4
harness a Check by using multimeter in continuity mode.
Between EC3 (female) (48) and each No continuity
Continuity
pin other than pin (48) (No sound is heard)
1. Turn starting switch to ON position.
2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
Defective KDOC outlet 5. Monitor temperature from each sensor.
5 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater, regard
that temperature sensor as defective.
a If none of temperature sensor values changes more than 24°C, problem is
not in sensor system. Perform checks on causes 5 and after.
a If another failure code appears with engine running at idle, perform
troubleshooting for it first.
Malfunction of intake Check intake system hoses, clamps, and tubes for damage and loosening.
6 system Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
7 Defective injector
Testing and adjusting, "Handling of cylinder cutout mode operation).
1. Remove turbocharger exhaust connector. 
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Oil leak into fuel.
8 turbocharger exhaust • If oil or fuel is found, visually check for oil leaks from EGR valve and
connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
Oil leak into exhaust in.
9 connector and ducts • Wipe off oil or fuel if found.
leading to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.
1. Remove KDPF.
2. Remove KDOC.
• Check KDOC for cracks (replace KDOC if cracks are found).
a When KDOC of KDPF is replaced, perform reset procedure for KDOC
10 Defective KDOC change and then finish troubleshooting without performing manual
stationary regeneration (see check on cause 7 of failure code [CA2637]).
• Check whether more than 50% of KDOC inlet surface is plugged with soot
or not.
(KDOC cleaning)

WA470-7 40-403
40 Troubleshooting
Troubleshooting by failure code (Display of code)

B. Machine operation for clearing failure code


No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle for approximately 1 minute.
3. Perform regeneration for service.
4. End regeneration for service.
(Perform regeneration for service for 15 minutes minimum from its start.)
If failure code is cleared when regeneration for service is ended, repair is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
11 engine controller is defective.
controller

Circuit diagram related to KDOC and KDPF temperature sensors

40-404 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3255] KDPF Temp Error - Non Regeneration (WA470_7-CA3255-400-


A-Z0-A)

Action level Failure code KDPF Temperature Error - Non Regeneration


Failure
L03 CA3255 (Engine controller system)
Detail of • KDPF outlet temperature remains at high level when active regeneration is not performed.
failure
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
General function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute or more before turning starting switch
to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.

WA470-7 40-405
40 Troubleshooting
Troubleshooting by failure code (Display of code)

A. Identification of cause and repair


No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed, perform
1 temperature sensor troubleshooting for [CA3319], [CA3321] or [CA3322] first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring
2 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and repair as needed.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and TEMP3 (KDPF outlet temperature
Short circuit in wiring sensor), and connect T-adapter to female side of EC3.
3
harness a Check by using multimeter in continuity mode.
Between EC3 (female) (54) and each No continuity (no sound
Continuity
pin other than pin (54) is heard)
1. Turn starting switch to ON position.
2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
Defective KDPF outlet
4 5. Monitor temperature from each sensor.
temperature sensor
If temperature of any temperature sensor fluctuates 24°C or greater, regard
that temperature sensor as defective.
• If none of temperature sensor values changes more than 24°C, problem is
not in sensor system. Perform checks on causes 5 and after.
• If another failure code appears with engine running at idle, perform
troubleshooting for it first.
Malfunction of intake Check intake system hoses, clamps, and tubes for damage and loosening.
5 system Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
6 Defective injector
Testing and adjusting, "Handling of cylinder cutout mode operation).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Oil leak into fuel.
7 turbocharger exhaust • If oil or fuel is found, visually check for oil leaks from EGR valve and
connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
Oil leak into exhaust in.
8 connector and ducts • Wipe off oil or fuel if found.
leading to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.

40-406 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

B. Machine operation for clearing failure code


No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position and hold it there for 1 minute.
• If failure code is cleared, repair is complete.
If failure code is not cleared, perform following steps.
2. Start engine and run it at low idle (with no load) for approximately 15 minute.
• If failure code is cleared, repair is complete.
If failure code is not cleared, perform following steps.
a If failure code is not cleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 3 and 4 are required to satisfy temperature
requirements.
• KDOC outlet temperature X 200°C
• KDPF outlet temperature X 200°C
3. Use monitoring function to display KDOC outlet and KDPF outlet temperatures.
4. Run engine at high idle (approximately 2,170 rpm with no load) for 3 minutes.
• If failure code is cleared, repair is complete.
• If failure code is not cleared because of low ambient temperature (at -20°C level), perform step 5 and
after.
5. Turn starting switch to OFF position.
6. Disconnect connector E26 and install dummy temperature sensor to wiring harness side.
7. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
8. Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
• If failure code is cleared, repair is complete.
9. Turn starting switch to OFF position.
10.Remove dummy temperature sensor to restore connector connection.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
9 engine controller is defective.
controller

WA470-7 40-407
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

40-408 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3256] KDPF Outlet Temp High Error 1 (WA470_7-CA3256-400-A-Z0-A)

Action level Failure code KDPF Outlet Temperature High Error 1


Failure
L01 CA3256 (Engine controller system)
Detail of • KDPF outlet temperature remains at high level.
failure
Action of • None in particular
controller
Problem on • None in particular
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately100 to 250°C, and
difference between these temperatures is approximately 10°C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing B. Machine operation for clearing failure code
failure code
a This failure code is not cleared by simply turning starting switch to ON position from OFF
position after repair. You must perform machine operation for clearing failure code after
completing repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed, perform
1 temperature sensor troubleshooting for [CA3319], [CA3321] or [CA3322] first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
2
harness connector troubleshooting", and check it and repair as needed.

WA470-7 40-409
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and TEMP3 (KDPF outlet temperature
sensor), and connect T-adapter to female side of EC3.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between EC3 (female) (54) and each pin other than No continuity
pin (54) (No sound is heard)
1. Turn starting switch to ON position.
2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
Defective KDPF outlet 5. Monitor temperature from each sensor.
4 temperature sensor
If temperature of any temperature sensor fluctuates 24°C or greater, regard
that temperature sensor as defective.
• If none of temperature sensor values changes more than 24°C, problem is
not in sensor system. Perform checks on causes 5 and after.
• If another failure code appears with engine running at idle, perform
troubleshooting for it first.
Malfunction of intake Check intake system hoses, clamps, and tubes for damage and loosening.
5 system Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
6 Defective injector
Testing and adjusting, "Handling of cylinder cutout mode operation).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Oil leak into fuel.
7 turbocharger exhaust • If oil or fuel is found, visually check for oil leaks from EGR valve and
connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
Oil leak into exhaust in.
8 connector and ducts • Wipe off oil or fuel if found.
leading to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.
B. Machine operation for clearing failure code
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 1 minute.
3. Perform regeneration for service.
4. End regeneration for service.
(Perform regeneration for service for 15 minutes minimum from its start.)
If failure code is cleared when regeneration for service is ended, repair is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
9 engine controller is defective.
controller

40-410 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-411
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3311] KDOC Outlet Temp High Error 2 (WA470_7-CA3311-400-A-Z0-A)

Action level Failure code KDOC Outlet Temperature High Error 2


Failure
L03 CA3311 (Engine controller system)
Detail of • KDOC outlet temperature remains extremely high relative to KDOC inlet temperature.
failure
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
General • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
information function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing C. Machine operation for confirming completion of repair
failure code
a This failure code is cleared when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring
2 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and repair as needed.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and TEMP2 (KDOC outlet temperature
sensor), and connect T-adapter to female side of EC3.
Short circuit in wiring
3 a Check by using multimeter in continuity mode.
harness
No continuity
Between EC3 (female) (48) and each
Continuity (No sound is heard)
pin other than pin (48)

40-412 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to ON position.
2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
Defective KDOC outlet 5. Monitor temperature from each sensor.
4 temperature sensor
If temperature of any temperature sensor fluctuates 24°C or greater, regard
that temperature sensor as defective.
• If none of temperature sensor values changes more than 24°C, problem is
not in sensor system. Perform checks on causes 5 and after.
• If another failure code appears with engine running at idle, perform
troubleshooting for it first.
Malfunction of intake Check intake system hoses, clamps, and tubes for damage and loosening.
5 system Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
6 Defective injector
Testing and adjusting, "Handling of cylinder cutout mode operation).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Oil leak into fuel.
7 turbocharger exhaust • If oil or fuel is found, visually check for oil leaks from EGR valve and
connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
Oil leak into exhaust in.
8 connector and ducts • Wipe off oil or fuel if found.
leading to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.
C. Machine operation for confirming completion of repair
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
a Failure code is cleared once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
2. Start engine and run it at low idle (with no load) for approximately 2 minute.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3316] KDOC Outlet Temp Sens Low Error
• [CA3317] KDOC Outlet Temp Sens High Error
Defective engine If this failure code appears again after above procedures are implemented,
9 engine controller is defective.
controller

WA470-7 40-413
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

40-414 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3312] KDPF Outlet Temp High Error 2 (WA470_7-CA3312-400-A-Z0-A)

Action level Failure code KDPF Outlet Temperature High Error 2


Failure
L03 CA3312 (Engine controller system)
Detail of • KDPF outlet temperature remains at very high level.
failure
• Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approximately 100 to 250°C,
and difference between these temperatures is approximately 10°C. (KDOC inlet
temperature > KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
Machine
operation for O
clearing C. Machine operation for confirming completion of repair
failure code
a This failure code is cleared when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed, perform
1 temperature sensor troubleshooting for [CA3319], [CA3321] or [CA3322] first.
Defective fuel doser If failure code [CA1925] or [CA1963] is also displayed, perform
2 troubleshooting for [CA1925] or [CA1963] first.
solenoid valve 1
See descriptions of wiring harness and connectors in "c: Electrical equipment"
Defective wiring in "Checks before troubleshooting" of "General information on
3
harness connector troubleshooting", and check it and repair as needed.

WA470-7 40-415
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and TEMP3 (KDPF outlet temperature
sensor), and connect T-adapter to female side of EC3.
Short circuit in wiring
4
harness a Check by using multimeter in continuity mode.
Between EC3 (female) (54) and each No continuity
Continuity
pin other than pin (54) (No sound is heard)
1. Turn starting switch to ON position.
2. Use monitoring function to display signal voltages and temperatures from
KDOC inlet temperature sensor, KDOC outlet temperature sensor, and
KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
Defective KDPF outlet 5. Monitor temperature from each sensor.
5 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater, regard
that temperature sensor as defective.
a If none of temperature sensor values fluctuates more than 24°C, problem
is not in sensor system. Perform checks on causes 5 and after.
a If another failure code appears with engine running at idle, perform
troubleshooting for it first.
Malfunction of intake Check intake system hoses, clamps, and tubes for damage and loosening.
6 system Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
7 Defective injector
Testing and adjusting, "Handling of cylinder cutout mode operation).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Oil leak into fuel.
8 turbocharger exhaust • If oil or fuel is found, visually check for oil leaks from EGR valve and
connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel leaking
Oil leak into exhaust in.
9 connector and ducts • Wipe off oil or fuel if found.
leading to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and clean or
replace it as necessary.
C. Machine operation for confirming completion of repair
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
a Failure code is cleared once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
2. Start engine and run it at low idle (with no load) for approximately 2 minute.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3319] KDPF Outlet Temp Sens Low Error
• CA3321] KDPF Outlet Temp Sens High Error
Defective engine If this failure code appears again after above procedures are implemented,
10 engine controller is defective.
controller

40-416 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-417
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3313] KDOC Inlet Temp Sensor Low Error (WA470_7-CA3313-400-A-Z0-
A)

Action level Failure code KDOC Inlet Temperature Sensor Low Error
Failure
L03 CA3313 (Engine controller system)
Detail of • Low voltage appears in KDOC inlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDOC
Action of inlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3314] for "High Error" appears.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.

40-418 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect TEMP1 (KDOC inlet temperature sensor).
3. Turn starting switch to ON position.
If this failure code changes to [CA3314], KDOC inlet temperature sensor is
defective.
a If this failure code still remains displayed, wiring harness or engine
controller is defective.
• Reference
1. Turn starting switch to OFF position.
Defective KDOC inlet 2. Disconnect connector TEMP1, and connect T-adapter to female side.
2 temperature sensor
-10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP1 (female) (1) and (2) 50°C
kz
a Temperature-Resistance 3.2 to 4.5
Resistance 100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Between TEMP1 (female) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP1, and connect T-adapter to female
(contact with ground side of EC3 or male side of TEMP1.
circuit)
3
(including wiring Between ground and EC3 (female) (45) or TEMP1
harness in KDPF Resistance (male) (1) Min. 1 Mz
temperature sensor
consolidating box)
Short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP1, and connect T-adapter to female
side of EC3.
4 (including wiring
harness in KDPF a Check by using multimeter in continuity mode.
temperature sensor Between EC3 (female) (45) and each No continuity
consolidating box) Continuity
pin other than pin (45) (No sound is heard)
a If no failure is found by checks on causes 3 and 4, this check is not
required.
1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
Defective KDPF
5 temperature sensor a If no failure is found by check on cause 3, this
consolidating box check is not required. Min. 1 Mz
Between E26 (male) (3) and ground
Resistance
a If no failure is found by check on cause 4, this
check is not required. Min. 1 Mz
Between E26 (male) (3) and each pin other than
pin (3)
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
6 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (45) or E26 Min. 1 Mz
Resistance (female) (3)

WA470-7 40-419
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
7
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (45) and each No continuity
Continuity
pin other than pin (45) (No sound is heard)
1. Turn starting switch to ON position.
2. If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
8
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

Circuit diagram related to KDOC and KDPF temperature sensors

40-420 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3314] KDOC Inlet Temp Sens High Error (WA470_7-CA3314-400-A-Z0-A)

Action level Failure code KDOC Inlet Temperature Sensor High Error
Failure
L03 CA3314 (Engine controller system)
Detail of • High voltage appears in KDOC inlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDOC
Action of inlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47200 (°C))
information • This failure code appears if sensor connector is disconnected.
• If failure codes [CA3317] and [CA3319] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.

WA470-7 40-421
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector TEMP1 (KDOC inlet temperature sensor) and
connect T-adapter to male side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box by using
jumper cable.
a Connect ground line to signal line
4. Turn starting switch to ON position.
If this failure code changes to [CA3313] , KDOC inlet temperature sensor is
defective.
a If this failure code remains displayed, wiring harness or engine controller is
Defective KDOC inlet defective.
2 temperature sensor • Reference
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP1, and connect T-adapter to female side.
-10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP1 (female) (1) and (2) 50°C
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors EC3 and connect T-adapter to female side.
(including wiring Between EC3 (45) and (19)
3
harness in KDPF 64 z to 65
temperature sensor Resistance a Use above Temperature-Resistance
kz
consolidating box) characteristics as resistance criteria.
Open circuit in wiring
a If no failure is found by check on cause 3, this check is not required.
harness
1. Turn starting switch to OFF position.
(wire breakage or
2. Disconnect connectors EC3 and TEMP1, and connect T-adapters to
defective contact of
female side of EC3 and male side of TEMP1.
4 connector)
Between EC3 (female) (45) and TEMP1 (male) (1) Max. 1 z
(including wiring
harness in KDPF Resistance
temperature sensor Between EC3 (female) (19) and TEMP1 (male) (2) Max. 1 z
consolidating box)
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors EC3 and TEMP1, and connect T-adapter to female
harness side of J3.
5 (including wiring
harness in KDPF a Check by using multimeter in continuity mode.
temperature sensor No continuity
Between J3 (female) (45) and each
consolidating box) Continuity (No sound is heard)
pin other than pin (45)

40-422 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 3 to 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP1.
a If no failure is found by check on cause 3 or 4,
Defective KDPF this check is not required. Max. 1 z
6 temperature sensor Between E26 (male) (2) and TEMP1 (male) (2)
consolidating box
a If no failure is found by check on cause 3 or 4,
this check is not required. Max. 1 z
Resistance
Between E26 (male) (3) and TEMP1 (male) (1)
a If no failure is found by check on cause 5, this
check is not required. Min. 1 Mz
Between E26 (male) (3) and each pin other than
pin (3)

Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (45) and E26 (female) (3) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
8
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (45) and each No continuity
Continuity
pin other than pin (45) (No sound is heard)
1. Turn starting switch to ON position.
2. If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
9
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

WA470-7 40-423
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

40-424 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3315] KDOC Inlet Temp Sens In Range Error (WA470_7-CA3315-400-
A-Z0-A)

Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
L03 CA3315 (Engine controller system)
• Difference between temperature sensed by KDOC inlet temperature sensor and that by
Detail of KDOC outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDOC
Action of inlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
General • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait one minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for
1 temperature sensor it first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
2
harness connector troubleshooting", and check it and repair as needed.

WA470-7 40-425
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect TEMP1 (KDOC inlet temperature sensor).
3. Turn starting switch to ON position.
If failure code [CA3314] is not displayed, wiring harness or engine controller is
defective.
a Perform check on cause 2 again.
Defective wiring 1. Turn starting switch to OFF position.
3 harness or engine 2. Disconnect connector TEMP1 and connect T-adapter to male side.
controller 3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box by using
jumper cable.
a Connect ground line to signal line
4. Turn starting switch to ON position.
If failure code [CA3313] is not displayed, wiring harness or engine controller is
defective.
a Perform check on cause 2 again.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP1, and connect T-adapters to
(wire breakage or female side of EC3 and male side of TEMP1.
defective contact of Between EC3 (female) (45) and TEMP1 (male) (1) Max. 1 z
4 connector)
(including wiring
Resistance
harness in KDPF Between EC3 (female) (19) and TEMP1 (male) (2) Max. 1 z
temperature sensor
consolidating box)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP1, and connect T-adapter to female
(contact with ground side of EC3 or male side of TEMP1.
circuit)
5
(including wiring Between ground and EC3 (female) (45) or TEMP1
harness in KDPF Resistance (male) (1) Min. 1 Mz
temperature sensor
consolidating box)
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors EC3 and TEMP1, and connect T-adapter to female
harness side of EC3.
(including wiring
6 a Check by using multimeter in continuity mode.
harness in KDPF
temperature sensor No continuity
Between EC3 (female) (45) and each
consolidating box) Continuity (No sound is heard)
pin other than pin (45)

40-426 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP1.
a If no failure is found by check on cause 4, this
check is not required. Max. 1 z
Between E26 (male) (2) and TEMP1 (male) (2)
Defective KDPF a If no failure is found by check on cause 4, this
7 temperature sensor check is not required. Max. 1 z
consolidating box Between E26 (male) (3) and TEMP1 (male) (1)
Resistance
a If no failure is found by check on cause 5, this
check is not required. Min. 1 Mz
Between E26 (male) (3) and ground
a If no failure is found by check on cause 6, this
check is not required. Min. 1 Mz
Between E26 (male) (3) and each pin other than
pin (3)

Open circuit in wiring a If no failure is found by check on cause 4, this check is not required.
harness 1. Turn starting switch to OFF position.
8 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (45) and E26 (female) (3) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
9 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (45) or E26
Resistance (female) (3) Min. 1 Mz

a If no failure is found by check on cause 6, this check is not required.


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
10
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (45) and each No continuity
Continuity
pin other than pin (45) (No sound is heard)
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors EC3 and connect T-adapter to female side.
(including wiring Between EC3 (45) and (19)
11 64 z to 65
harness in KDPF
temperature sensor Resistance a Use Temperature-Resistance characteristics kz
consolidating box) shown below as resistance criteria.

WA470-7 40-427
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a When failure codes [CA3314] and [CA3313] are displayed in check on
cause 3 and no failure is found by checks on causes 2 and 4 to 10, and if
failure is found by check on cause 11, KDOC inlet temperature sensor is
defective.
• Reference
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP1, and connect T-adapter to female side.
Defective KDOC inlet -10°C 33 to 65 kz
12 temperature sensor
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP1 (female) (1) and (2) 50°C
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
B. Machine operation for clearing failure code
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 1 minute.
3. Run engine at full speed and perform hydraulic relief of work equipment for 25 minute.
If failure code is cleared, repair is complete.
• If the ambient temperature is below 0°C, repeat above steps 4 and after.
4. Turn starting switch to OFF position.
5. Disconnect connector E26 and install dummy temperature sensor to wiring harness side.
6. Turn starting switch from OFF position to ON position.
7. Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
8. Start engine and run it at low idle (with no load) for approximately 1 minute.
9. Run engine at high idle (approximately 2,170 rpm with no load) for 25 minutes.
If failure code is cleared after implementing steps 1 to 9, repair work is complete.
10.Turn starting switch to OFF position.
11.Remove dummy temperature sensor to restore connector connection.
a Soot accumulation reaches level 3 when this failure code is being displayed. Controller takes this
measure intentionally to reduce soot accumulation and it is not failure.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
13 engine controller is defective.
controller

40-428 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-429
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3316] KDOC Outlet Temp Sens Low Error (WA470_7-CA3316-400-A-Z0-
A)

Action level Failure code KDOC Outlet Temperature Sensor Low Error
Failure
L03 CA3316 (Engine controller system)
Detail of • Low voltage appears in KDOC outlet temperature sensor circuit.
failure
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor as well, controller sets KDOC
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3317] for "High Error" appears.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.

40-430 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position. 
2. Disconnect TEMP2 (KDOC outlet temperature sensor).
3. Turn starting switch to ON position.
If this failure code changes to [CA3317] , KDOC outlet temperature sensor is
defective.
a If this failure code remains displayed, wiring harness or engine controller is
defective.
• Reference
1. Turn starting switch to OFF position. 
Defective KDOC outlet 2. Disconnect connector TEMP2 and connect T-adapter to female side.
2 temperature sensor -10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP2 (female) (1) and (2) 50°C
kz
a Temperature-Resistance 3.2 to 4.5
Resistance 100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Between TEMP2 (female) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position. 
harness 2. Disconnect connectors EC3 and TEMP2, and connect T-adapter to female
(contact with ground side of EC3 or male side of TEMP2.
circuit)
3
(including wiring Between ground and EC3 (female) (48) or TEMP2
harness in KDPF Resistance (male) (1) Min. 1 Mz
temperature sensor
consolidating box)
Short circuit in wiring 1. Turn starting switch to OFF position. 
harness 2. Disconnect connectors EC3 and TEMP2, and connect T-adapter to female
side of EC3.
(including wiring
4
harness in KDPF a Check by using multimeter in continuity mode.
temperature sensor Between EC3 (female) (48) and each No continuity
consolidating box) Continuity
pin other than pin (48) (No sound is heard)
a If no failure is found by checks on causes 3 and 4, this check is not
required.
1. Turn starting switch to OFF position. 
2. Disconnect connector E26 and connect T-adapter to male side. 
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
Defective KDPF
5 temperature sensor a If no failure is found by check on cause 3, this
consolidating box check is not required.  Min. 1 Mz
Between E26 (male) (1) and ground
Resistance
a If no failure is found by check on cause 4, this
check is not required.  Min. 1 Mz
Between E26 (male) (1) and each pin other than
pin (1) 
a If no failure is found by check on cause 3, this check is not required. 
Ground fault in wiring
1. Turn starting switch to OFF position. 
harness
6 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (48) or E26 Min. 1 Mz
Resistance (female) (1)

WA470-7 40-431
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
7
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (48) and each No continuity
Continuity
pin other than pin (48) (No sound is heard)
1. Turn starting switch to ON position.
If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
8
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

Circuit diagram related to KDOC and KDPF temperature sensors

40-432 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3317] KDOC Outlet Temp Sens High Error (WA470_7-CA3317-400-A-Z0-
A)

Action level Failure code KDOC Outlet Temperature Sensor High Error
Failure
L03 CA3317 (Engine controller system)
Detail of • High voltage appears in KDOC outlet temperature sensor circuit.
failure
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor as well, controller sets KDOC
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47200 (°C))
information • This failure code appears if sensor connector is disconnected.
• If failure codes [CA3314] and [CA3319] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.

WA470-7 40-433
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect KDOC outlet temperature sensor (connector TEMP2) and
connect T-adapter to female side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box by using
jumper cable.
a Connect ground line to signal line
4. Turn starting switch to ON position.
If this failure code changes to [CA3316], KDOC outlet temperature sensor is
defective.
a If this failure code remains displayed, wiring harness or engine controller is
Defective KDOC outlet defective.
2 temperature sensor • Reference
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP2 and connect T-adapter to female side.
-10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP2 (female) (1) and (2) 50°C
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors EC3 and connect T-adapter to female side.
(including wiring Between EC3 (48) and (19)
3
harness in KDPF 64 z to 65
temperature sensor Resistance a Use above Temperature-Resistance
kz
consolidating box) characteristics as resistance criteria.
Open circuit in wiring
a If no failure is found by check on cause 3, this check is not required.
harness
1. Turn starting switch to OFF position.
(wire breakage or
2. Disconnect connectors EC3 and TEMP2, and connect T-adapters to
defective contact of
female side of EC3 and male side of TEMP2.
4 connector)
Between EC3 (female) (48) and TEMP2 (male) (1) Max. 1 z
(including wiring
harness in KDPF Resistance
temperature sensor Between EC3 (female) (19) and TEMP2 (male) (2) Max. 1 z
consolidating box)
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors EC3 and TEMP2, and connect T-adapter to female
harness side of EC3.
5 (including wiring
harness in KDPF a Check by using multimeter in continuity mode.
temperature sensor No continuity
Between EC3 (female) (48) and each
consolidating box) Continuity (No sound is heard)
pin other than pin (48)

40-434 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 3 to 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP2.
a If no failure is found by check on cause 3 or 4,
Defective KDPF this check is not required. Max. 1 z
6 temperature sensor Between E26 (male) (2) and TEMP2 (male) (2)
consolidating box
a If no failure is found by check on cause 3 or 4,
this check is not required. Max. 1 z
Resistance
Between E26 (male) (1) and TEMP2 (male) (1)
a If no failure is found by check on cause 5, this
check is not required. Min. 1 Mz
Between E26 (male) (1) and each pin other than
pin (1)

Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (48) and E26 (female) (1) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
8
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (48) and each No continuity
Continuity
pin other than pin (48) (No sound is heard)
1. Turn starting switch to ON position.
If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
9
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

WA470-7 40-435
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

40-436 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3318] KDOC Outlet Temp Sens In Range Error (WA470_7-CA3318-
400-A-Z0-A)

Action level Failure code KDOC Outlet Temperature Sensor In Range Error
Failure
L03 CA3318 (Engine controller system)
• Difference between temperature sensed by KDOC outlet temperature sensor and that by
Detail of KDOC inlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor as well, controller sets KDOC
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
General • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform troubleshooting for
1 temperature sensor it first.

Defective wiring 1. See descriptions of wiring harness and connectors in "c: Electrical
2 equipment" in "Checks before troubleshooting" of "General information on
harness connector
troubleshooting", and check it and repair as needed.

WA470-7 40-437
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect TEMP2 (KDOC outlet temperature sensor).
3. Turn starting switch to ON position.
If failure code [CA3317] is not displayed, wiring harness or engine controller is
defective.
a Perform check on cause 2 again.
Defective wiring 1. Turn starting switch to OFF position.
3 harness or engine 2. Disconnect connector TEMP2 and connect T-adapter to male side.
controller 3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box by using
jumper cable.
a Connect ground line to signal line
4. Turn starting switch to ON position.
If failure code [CA3316] is not displayed, wiring harness or engine controller is
defective.
a Perform check on cause 2 again.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP2, and connect T-adapters to
(wire breakage or female side of EC3 and male side of TEMP2.
defective contact of Between EC3 (female) (48) and TEMP2 (male) (1) Max. 1 z
4 connector)
(including wiring
Resistance
harness in KDPF Between EC3 (female) (19) and TEMP2 (male) (2) Max. 1 z
temperature sensor
consolidating box)
Ground fault in wiring 1. Turn starting switch to OFF position. 
harness 2. Disconnect connectors EC3 and TEMP2, and connect T-adapter to female
(contact with ground side of EC3 or male side of TEMP2.
circuit)
5
(including wiring Between ground and EC3 (female) (48) or TEMP2
harness in KDPF Resistance (male) (1) Min. 1 Mz
temperature sensor
consolidating box)
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors EC3 and TEMP2, and connect T-adapter to female
harness side of EC3.
(including wiring
6 a Check by using multimeter in continuity mode.
harness in KDPF
temperature sensor No continuity
Between EC3 (female) (48) and each
consolidating box) Continuity (No sound is heard)
pin other than pin (48)

40-438 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP2.
a If no failure is found by check on cause 4, this
check is not required. Max. 1 z
Between E26 (male) (2) and TEMP2 (male) (2)
Defective KDPF a If no failure is found by check on cause 4, this
7 temperature sensor check is not required. Max. 1 z
consolidating box Between E26 (male) (1) and TEMP2 (male) (1)
Resistance
a If no failure is found by check on cause 5, this
check is not required. Min. 1 Mz
Between E26 (male) (1) and ground
a If no failure is found by check on cause 6, this
check is not required. Min. 1 Mz
Between E26 (male) (1) and each pin other than
pin (1)

Open circuit in wiring a If no failure is found by check on cause 4, this check is not required.
harness 1. Turn starting switch to OFF position.
8 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (48) and E26 (female) (1) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
9 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (48) or E26
Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 6, this check is not required.


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
10
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (48) and each No continuity
Continuity
pin other than pin (48) (No sound is heard)
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors EC3 and connect T-adapter to female side.
(including wiring Between EC3 (48) and (19)
11 64 z to 65
harness in KDPF
temperature sensor Resistance a Use Temperature-Resistance characteristics kz
consolidating box) shown in the following resistance criteria.

WA470-7 40-439
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a When failure codes [CA3317] and [CA3316] are displayed in check on
cause 3 and no failure is found by checks on causes 2 and 4 to 10, and if
failure is found by check on cause 11, KDOC outlet temperature sensor is
defective.
• Reference
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP2 and connect T-adapter to female side.
Defective KDOC outlet -10°C 33 to 65 kz
12 temperature sensor
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP2 (female) (1) and (2) 50°C
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
B. Machine operation for clearing failure code
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 1 minute.
3. Run engine at full speed and perform hydraulic relief of work equipment for 25 minute.
If failure code is cleared, repair is complete.
• If the ambient temperature is below 0°C, repeat above steps 4 and after.
4. Turn starting switch to OFF position.
5. Disconnect connector E26 and install dummy temperature sensor to wiring harness side.
6. Turn starting switch from OFF position to ON position.
7. Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
8. Start engine and run it at low idle (with no load) for approximately 1 minute.
9. Run engine at high idle (approximately 2,170 rpm with no load) for 25 minutes.
If failure code is cleared after implementing steps 1 to 9, repair is complete.
10.Turn starting switch to OFF position.
11.Remove dummy temperature sensor to restore connector connection.
a Soot accumulation reaches level 3 when this failure code is being displayed. Controller takes this
measure intentionally to reduce soot accumulation and it is not failure.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
13 engine controller is defective.
controller

40-440 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-441
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3319] KDPF Outlet Temp Sens High Error (WA470_7-CA3319-400-A-Z0-
A)

Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
L03 CA3319 (Engine controller system)
Detail of • High voltage appears in KDPF outlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDPF
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
General function. (Code: 47200 (°C))
information • This failure code appears if sensor connector is disconnected.
• If failure codes [CA3314] and [CA3317] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.

40-442 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect KDPF outlet temperature sensor (connector TEMP3) and
connect T-adapter to female side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box by using
jumper cable.
a Connect ground line to signal line
4. Turn starting switch to ON position.
If this failure code changes to [CA3321], KDPF outlet temperature sensor is
defective.
a If this failure code remains displayed, wiring harness or engine controller is
Defective KDPF outlet defective.
2 temperature sensor • Reference
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP3, and connect T-adapter to female side.
-10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP3 (female) (1) and (2) 50°C
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Open or short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors EC3 and connect T-adapter to female side.
(including wiring Between EC3 (54) and (19)
3
harness in KDPF 64 z to 65
temperature sensor Resistance a Use above Temperature-Resistance
kz
consolidating box) characteristics as resistance criteria.
Open circuit in wiring
a If no failure is found by check on cause 3, this check is not required.
harness
1. Turn starting switch to OFF position.
(wire breakage or
2. Disconnect connectors EC3 and TEMP3, and connect T-adapters to
defective contact of
female side of EC3 and male side of TEMP3.
4 connector)
Between EC3 (female) (54) and TEMP3 (male) (1) Max. 1 z
(including wiring
harness in KDPF Resistance
temperature sensor Between EC3 (female) (19) and TEMP3 (male) (2) Max. 1 z
consolidating box)
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors EC3 and TEMP3, and connect T-adapter to female
harness side of EC3.
5 (including wiring
harness in KDPF a Check by using multimeter in continuity mode.
temperature sensor No continuity
Between EC3 (female) (54) and each
consolidating box) Continuity (No sound is heard)
pin other than pin (54)

WA470-7 40-443
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 3 to 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP3.
a If no failure is found by check on cause 3 or 4,
Defective KDPF this check is not required. Max. 1 z
6 temperature sensor Between E26 (male) (2) and TEMP3 (male) (2)
consolidating box
a If no failure is found by check on cause 3 or 4,
this check is not required. Max. 1 z
Resistance
Between E26 (male) (4) and TEMP3 (male) (1)
a If no failure is found by check on cause 5, this
check is not required. Min. 1 Mz
Between E26 (male) (4) and each pin other than
pin (4)

Open circuit in wiring a If no failure is found by check on cause 3 or 4, this check is not required.
harness 1. Turn starting switch to OFF position.
7 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (54) and E26 (female) (4) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
8
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (54) and each No continuity
Continuity
pin other than pin (54) (No sound is heard)
1. Turn starting switch to ON position.
If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
9
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

40-444 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-445
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3321] KDPF Outlet Temp Sens Low Error (WA470_7-CA3321-400-A-Z0-A)

Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
L03 CA3321 (Engine controller system)
Detail of • Low voltage appears in KDPF outlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDPF
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47201 (V))
General • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47200 (°C))
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3319] for "High Error" appears.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• Method of reproducing failure code: Turn starting switch to ON position.
<How to clear failure code>
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
a Soot accumulation reaches level 3 when this failure code is being displayed. This may
cause automatic regeneration to be started after this failure code is cleared. Controller
takes this measure intentionally to reduce soot accumulation and it is not failure.
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General information on
troubleshooting", and check it.
Defective wiring 2. Turn starting switch to ON position.
1
harness connector
If this failure code is not displayed, wiring harness connector is defective.
a If this failure code is displayed, perform following checks.

40-446 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect TEMP3 (KDPF outlet temperature sensor).
3. Turn starting switch to ON position.
If this failure code changes to [CA3319], KDPF outlet temperature sensor is
defective.
a If this failure code remains displayed, wiring harness or engine controller is
defective.
• Reference
1. Turn starting switch to OFF position.
Defective KDPF outlet 2. Disconnect connector TEMP3, and connect T-adapter to female side.
2 temperature sensor
-10°C 33 to 65 kz
0°C 25 to 47 kz
7.8 to 12.2
Between TEMP3 (female) (1) and (2) 50°C
kz
a Temperature-Resistance 3.2 to 4.5
Resistance 100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
Between TEMP3 (female) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP3, and connect T-adapters to
(contact with ground female side of EC3 and male side of TEMP3.
circuit)
3
(including wiring Between ground and EC3 (female) (54) or TEMP3
harness in KDPF Resistance (male) (1) Min. 1 Mz
temperature sensor
consolidating box)
Short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP3, and connect T-adapter to female
side of EC3.
4 (including wiring
harness in KDPF a Check by using multimeter in continuity mode.
temperature sensor Between EC3 (female) (54) and each No continuity
consolidating box) Continuity
pin other than pin (54) (No sound is heard)
a If no failure is found by checks on causes 3 and 4, this check is not
required.
1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
Defective KDPF
5 temperature sensor a If no failure is found by check on cause 3, this
consolidating box check is not required. Min. 1 Mz
Between E26 (male) (4) and ground
Resistance
a If no failure is found by check on cause 4, this
check is not required. Min. 1 Mz
Between E26 (male) (4) and each pin other than
pin (4)
a If no failure is found by check on cause 3, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
6 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (54) or E26 Min. 1 Mz
Resistance (female) (4)

WA470-7 40-447
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 4, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female
Short circuit in wiring side of EC3.
7
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (54) and each No continuity
Continuity
pin other than pin (54) (No sound is heard)
1. Turn starting switch to ON position.
2. If this failure code appears, perform procedure for <How to clear failure
Defective engine code> in "Related information".
8
controller If this failure code is still displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect, troubleshooting
cannot be performed.)

Circuit diagram related to KDOC and KDPF temperature sensors

40-448 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3322] KDPF Outlet Temp Sens In Range Error (WA470_7-CA3322-
400-A-Z0-A)

Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
L03 CA3322 (Engine controller system)
Detail of • Temperature sensed by KDPF outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor as well, controller sets KDPF
Action of outlet temperature to default value (250°C) and runs engine.)
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output reduces.
machine

k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.

• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301 (V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47401 (V))
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
function. (Code: 47400 (°C))
General • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet temperature sensor connector label
"TEMP3" are shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF assembly".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait one minute and more before turning starting
switch to ON position again.
• When this failure code appears, perform troubleshooting according to the following work
flow.
A. Identification of cause and repair
O
Machine
operation for B. Machine operation for clearing failure code
clearing a This failure code is not cleared by simply turning starting switch to ON position from OFF
failure code position after repair. You must perform machine operation for clearing failure code after
completing repair.
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
A. Identification of cause and repair
No. Cause Procedure, measuring location, criteria and remarks
Defective KDPF outlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for it
1 temperature sensor first.
1. See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring equipment" in "Checks before troubleshooting" of "General information on
2
harness connector troubleshooting", and check it.

WA470-7 40-449
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect TEMP3 (KDPF outlet temperature sensor).
3. Turn starting switch to ON position.
If failure code [CA3319] is not displayed, wiring harness or engine controller is
defective.
a Perform check on cause 2 again.
Defective wiring 1. Turn starting switch to OFF position.
3 harness or engine 2. Disconnect TEMP3 and connect T-adapter to female side.
controller 3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box by using
jumper cable.
a Connect ground line to signal line
4. Turn starting switch to ON position.
If failure code [CA3321] is not displayed, wiring harness or engine controller is
defective.
a Perform check on cause 2 again.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors EC3 and TEMP3, and connect T-adapters to female
(wire breakage or side of EC3 and male side of TEMP3.
defective contact of Between EC3 (female) (54) and TEMP3 (male) (1) Max. 1 z
4 connector)
(including wiring
Resistance
harness in KDPF Between EC3 (female) (19) and TEMP3 (male) (2) Max. 1 z
temperature sensor
consolidating box)
Ground fault in wiring 1. Turn starting switch to OFF position. 
harness 2. Disconnect connectors EC3 and TEMP3, and connect T-adapter to female
(contact with ground side of EC3 or male side of TEMP3.
circuit)
5
(including wiring Between ground and EC3 (female) (54) or TEMP3
harness in KDPF Resistance (male) (1) Min. 1 Mz
temperature sensor
consolidating box)
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors EC3 and TEMP3, and connect T-adapter to female
harness side of EC3.
(including wiring
6 a Check by using multimeter in continuity mode.
harness in KDPF
temperature sensor No continuity
Between EC3 (female) (54) and each
consolidating box) Continuity (No sound is heard)
pin other than pin (54)

40-450 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect T-
adapter to male side of TEMP3.
a If no failure is found by check on cause 4, this
check is not required. Max. 1 z
Between E26 (male) (2) and TEMP3 (male) (2)
Defective KDPF a If no failure is found by check on cause 4, this
7 temperature sensor check is not required. Max. 1 z
consolidating box Between E26 (male) (4) and TEMP3 (male) (1)
Resistance
a If no failure is found by check on cause 5, this
check is not required. Min. 1 Mz
Between E26 (male) (4) and ground
a If no failure is found by check on cause 6, this
check is not required. Min. 1 Mz
Between E26 (male) (4) and each pin other than pin
(4)

Open circuit in wiring a If no failure is found by check on cause 4, this check is not required.
harness 1. Turn starting switch to OFF position.
8 (wire breakage or 2. Disconnect connectors EC3 and E26, and connect T-adapters to each
defective contact of female side.
connector) Between EC3 (female) (54) and E26 (female) (4) Max. 1 z
Resistance
Between EC3 (female) (19) and E26 (female) (2) Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
9 2. Disconnect connectors EC3 and E26, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and EC3 (female) (54) or E26
Resistance (female) (4) Min. 1 Mz

a If no failure is found by check on cause 6, this check is not required.


1. Turn starting switch to OFF position.
2. Disconnect connectors EC3 and E26, and connect T-adapter to female side
Short circuit in wiring of EC3.
10
harness
a Check by using multimeter in continuity mode.
Between EC3 (female) (54) and each No continuity
Continuity
pin other than pin (54) (No sound is heard)
Open or short circuit 1. Turn starting switch to OFF position.
in wiring harness 2. Disconnect connectors EC3 and connect T-adapter to female side.
(including wiring Between EC3 (54) and (19)
11 64 z to 65
harness in KDPF
temperature sensor Resistance a Use Temperature-Resistance characteristics kz
consolidating box) shown in the following resistance criteria.

WA470-7 40-451
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a When failure codes [CA3319] and [CA3321] are displayed in check on
cause 3 and no failure is found by checks on causes 2 and 4 to 10, if failure
is found by check on cause 11, KDOC inlet temperature sensor is defective.
• Reference
1. Turn starting switch to OFF position.
2. Disconnect connector TEMP3, and connect T-adapter to female side.
Defective KDPF outlet -10°C 33 to 65 kz
12 temperature sensor 0°C 25 to 47 kz
7.8 to 12.2
Between TEMP3 (female) (1) and (2) 50°C
kz
Resistance a Temperature-Resistance 3.2 to 4.5
100°C
characteristics kz
200 to 240
400°C
z
700°C 64 to 69 z
B. Machine operation for clearing failure code
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 1 minute.
3. Run engine at full speed and perform hydraulic relief of work equipment for 25 minute.
If failure code is cleared, repair is complete.
• If the ambient temperature is below 0°C, repeat above steps 4 and after.
4. Turn starting switch to OFF position.
5. Disconnect connector E26 and install dummy temperature sensor to wiring harness side.
6. Turn starting switch from OFF position to ON position.
7. Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
8. Start engine and run it at low idle (with no load) for approximately 1 minute.
9. Run engine at high idle (approximately 2,170 rpm with no load) for 25 minutes.
If failure code is cleared after implementing steps 1 to 9, repair is complete.
10.Turn starting switch to OFF position.
11.Remove dummy temperature sensor to restore connector connection.
a Soot accumulation reaches level 3 when this failure code is being displayed. Controller takes this
measure intentionally to reduce soot accumulation and it is not failure.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
Defective engine If this failure code appears again after above procedures are implemented,
13 engine controller is defective.
controller

40-452 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to KDOC and KDPF temperature sensors

WA470-7 40-453
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error (WA500_7-
CA3419-400-A-Z0-A)

Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
L03 CA3419 (Engine controller system)
Detail of • High voltage appears in mass air flow sensor power supply (12 V) circuit.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27.
3. Turn starting switch to ON position.
Defective mass air flow
2 sensor (internal defect) If this failure code does not appear, mass air flow sensor is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J1.
3. Turn starting switch to ON position.
3 Defective wiring harness If this failure code does not appear, wiring harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to male side.
3. Turn starting switch to ON position.
4 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

40-454 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to mass air flow sensor

WA470-7 40-455
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error (WA500_7-
CA3421-400-A-Z0-A)

Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
L03 CA3421 (Engine controller system)
Detail of • Low voltage appears in mass air flow sensor power supply (12 V) circuit.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
controller • Closes EGR valve and opens KVGT fully.
• Limits engine output and allows engine to run.
• Stops KDPF regeneration control.
Problem on • Engine output decreases.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
information on troubleshooting", and check it.
1 Defective harness connector 2. Turn starting switch to ON position.
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
1. Turn starting switch to OFF position.
2. Disconnect connector E27.
3. Turn starting switch to ON position.
Defective mass air flow
2 sensor (internal defect) If this failure code does not appear, mass air flow sensor is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
2. Disconnect connector J1.
3. Turn starting switch to ON position.
Defective wiring harness or
3 If this failure code does not appear, wiring harness is defective.
connector
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
codes other than this code.
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors J1 and E27, and connect T-adapters to
4 either female side.
(contact with ground circuit)
Resis- Between ground and J1 (female) (21) or E27
(female) (2) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors J1 and E27, and connect T-adapters to
5 Short circuit in wiring harness either female side.
Resis- Between J1 (female) (21) and (22), or between
E27 (female) (2) and (3) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Disconnect connector J1 and connect T-adapters to male side.
3. Turn starting switch to ON position.
6 Defective engine controller Approx. 12
Voltage Between J1 (male) (21) and (22)
V
If no failure is found by above checks, engine controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)

40-456 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to mass air flow sensor

WA470-7 40-457
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D150KA] Disconnection of Emerg. Steering Relay (WA470_7-


D150KA-400-A-Z0-A)

Action level Failure code Disconnection of Emergency Steering Relay


Failure
L03 D150KA (Work equipment controller system)
Detail of • When controller drives primary circuit (coil) of emergency steering relay (L126), no current
failure flows through circuit.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Automatic emergency steering does not work.
machine • Emergency steering self-check ends abnormally.
• Method of reproducing failure code: Turn starting switch to ON position.
• When starting switch is turned to ON position, controller drives emergency steering relay
to diagnose emergency steering motor.
Related • This failure code indicates failure on primary side (coil side) of emergency steering relay,
information but not on secondary side (contact side).
• Output condition (ON/OFF) to emergency steering relay can be checked with monitoring
function. (Code: 03708 BBC Output 2, Emerg. Steering Relay)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective emergency 2. Disconnect connector L126 and connect T-adapter to male side.
1 steering relay L126 200 to 400
Resistance Between L126 (male) (1) and (2)
z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L72 and L126, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between L72 (female) (8) and L126 (female) (1) Max. 1 z
connector) Resistance
Between L126 (female) (2) and ground Max. 1 z
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed).

40-458 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering relay

WA470-7 40-459
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D150KB] Ground Fault of Emerg. Steering Relay (WA470_7-D150KB-


400-A-Z0-A)

Action level Failure code Ground Fault of Emergency Steering Relay


Failure
L03 D150KB (Work equipment controller system)
Detail of • When controller drives primary circuit (coil) of emergency steering relay (L126), large
failure current flows.
• Stops driving emergency steering relay (L126).
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Automatic emergency steering does not work.
machine • Emergency steering self-check ends abnormally.
• Method of reproducing failure code: Turn starting switch to ON position.
• When starting switch is turned to ON position, controller drives emergency steering relay
to diagnose emergency steering motor.
Related • This failure code indicates failure on primary side (coil side) of emergency steering relay,
information but not on secondary side (contact side).
• Output condition (ON/OFF) to emergency steering relay can be checked with monitoring
function. (Code: 03708 BBC Output 2, Emerg. Steering Relay)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L126 and connect T-adapter to male side.
Defective emergency
1 steering relay (L126) 200 to 400
Between L126 (male) (1) and (2)
Resistance z
Between L126 (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L72 and L126, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L72 (female) (8) or L126
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


Short circuit in wiring 2. Disconnect connectors L72 and L126, and connect T-adapter to female
3
harness side of L126.
Resistance Between L126 (female) (1) and (2) Min. 1 Mz
Defective work If no failure is found by above checks, work equipment controller is defective.
4 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-460 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering relay

WA470-7 40-461
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D150KY] Hot Short of Emergency Steering Relay (WA470_7-D150KY-


400-A-Z0-A)

Action level Failure code Hot Short of Emergency Steering Relay


Failure
L03 D150KY (Work equipment controller system)
Detail of • When controller does not drive primary circuit (coil) of emergency steering relay (L126),
failure current flows through circuit.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Emergency steering continues on working.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• When starting switch is turned to ON position, controller drives emergency steering relay
to diagnose emergency steering motor.
Related • This failure code indicates failure on primary side (coil side) of emergency steering relay,
information but not on secondary side (contact side).
• Output condition (ON/OFF) to emergency steering relay can be checked with monitoring
function. (Code: 03708 BBC Output 2, Emerg. Steering Relay)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective emergency 2. Disconnect connector L126 and connect T-adapter to male side.
1 steering relay L126 200 to 400
Resistance Between L126 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Insert T-adapters into connector L126.
2 wiring harness 3. Turn starting switch to ON position and check after 1 minute.
Voltage Between L126 (1) and (2) Max 4.5 V
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed).

40-462 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering relay

WA470-7 40-463
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D160KA] Disconnection of Backup Lamp Relay


Output (WA470_7-D160KA-400-A-Z0-A)
Action level Failure code Disconnection of Backup Lamp Relay Output
Failure
L01 D160KA (Transmission controller system)
Detail of • When controller drives primary circuit (coil side) of backup lamp relay, no current flows
failure through circuit.
• Stops driving primary circuit (coil side) of backup lamp relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Backup lamp does not light up.
machine • Backup buzzer does not sound.
• Output signal (ON/OFF) to backup lamp relay can be checked with monitoring function.
(Code: 03705 Backup Lamp Relay)
Related • This failure code indicates failure on primary circuit (coil side) of backup lamp relay, but
information not on secondary circuit (contact side).
• Method of reproducing failure code:Turn starting switch to ON position and operate
directional (FNR) lever to R (reverse).
No. Cause Procedure, measuring location, criteria and remarks

Defective backup lamp 1. Turn starting switch to OFF position.


relay (L117) (internal 2. Disconnect connector L117 and connect T-adapter to male side.
1
short circuit) 200 to 400
Resistance Between L117 (male) (1) and (2)
z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and L117, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between L62 (female) (19) and L117 (female) (1) Max. 1 z
connector) Resistance
Between L117 (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Turn starting switch to ON position.
Defective transmission Directional (FNR) lever:
3
controller R (reverse) 20 to 30 V
Between L62 (female)
Voltage
(19) and ground Directional (FNR) lever:
Max 4.5 V
Other than R (reverse)

40-464 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to backup lamp relay

WA470-7 40-465
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D160KB] Ground Fault of Backup Lamp Relay


Output (WA470_7-D160KB-400-A-Z0-A)
Action level Failure code Ground Fault of Backup Lamp Relay Output
Failure
L01 D160KB (Transmission controller system)
Detail of • When controller drives primary circuit (coil side) of backup lamp relay, no abnormal
failure current flows through circuit.
• Stops driving primary circuit (coil side) of backup lamp relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Backup lamp does not light up.
machine • Backup buzzer does not sound.
• Output signal (ON/OFF) to backup lamp relay can be checked with monitoring function.
(Code: 03705 Backup Lamp Relay)
Related • This failure code indicates failure on primary circuit (coil side) of backup lamp relay, but
information not on secondary circuit (contact side).
• Method of reproducing failure code: Turn starting switch to ON position and operate
directional (FNR) lever to R (reverse).
No. Cause Procedure, measuring location, criteria and remarks

Defective backup lamp 1. Turn starting switch to OFF position.


relay (L117) (internal 2. Disconnect connector L117 and connect T-adapter to male side.
1
short circuit) 200 to 400
Resistance Between L117 (male) (1) and (2)
z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and L117, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L62 (female) (8) or L117
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L62.
3. Turn starting switch to ON position.
Defective transmission Directional (FNR) lever:R
3
controller (reverse) 20 to 30 V
Between L62 (female)
Voltage
(19) and ground Directional (FNR) lever:
Max 4.5 V
Other than R (reverse)

40-466 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to backup lamp relay

WA470-7 40-467
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D160KY] Hot Short of Backup Lamp Relay Output (WA470_7-
D160KY-400-A-Z0-A)

Action level Failure code Hot Short of Backup Lamp Relay Output
Failure
L01 D160KY (Transmission controller system)
Detail of • When controller does not drive primary circuit (coil side) of backup lamp relay, current
failure flows through circuit.
• Stops driving primary circuit (coil side) of backup lamp relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Backup lamp continues to light up.
machine • Backup alarm buzzer continues to sound.
• Output signal (ON/OFF) to backup lamp relay can be checked with monitoring function.
(Code: 03705 Backup Lamp Relay)
Related • This failure code indicates failure on primary circuit (coil side) of backup lamp relay, but
information not on secondary circuit (contact side).
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks

Defective backup lamp 1. Turn starting switch to OFF position.


relay (L117) (internal 2. Disconnect connector L117, and connect T-adapters to female side.
1
short circuit) 200 to 400
Resistance Between L117 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L117, and connect T-adapters to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between L117 (female) (1) and ground Max 4.5 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Turn starting switch to ON position.
Defective transmission Directional (R) lever: R
3
controller (reverse) 20 to 30 V
Between L62 (female)
Voltage
(19) and ground Directional (R) lever:
Max 4.5 V
Other than R (reverse)

40-468 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to backup lamp relay

WA470-7 40-469
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D191KA] Disconnection of Neutral Output Relay (WA470_7-D191KA-


400-A-Z0-A)

Action level Failure code Disconnection of Neutral Output Relay


Failure
L03 D191KA (Transmission controller system)
Detail of • When controller drives primary circuit (coil side) of neutral safety relay, no current flows
failure through circuit.
• Stops driving primary circuit (coil side) of neutral safety relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Engine does not start.
machine
• Output signal to primary circuit (coil side) of neutral safety relay can be checked with
monitoring function. (Code: 03705 Neutral Safety Relay)
Related • Method of reproducing failure code:Turn starting switch to ON position and operate
information directional lever to N (neutral).
• This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but
not on secondary circuit (contact side).
No. Cause Procedure, measuring location, criteria and remarks

Defective neutral safety 1. Turn starting switch to OFF position.


relay (internal open or 2. Disconnect connector L116 and connect T-adapter to male side.
1
short circuit) 200 to 400
Resistance Between L116 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connectors D11 and D12, and connect T-adapters to diode.
Defective diode a Measure it with diode range of multimeter.
2 (internal open or short Between D11 (male) (1) (+) and (2) (-) No continuity
circuit) Between D11 (male) (2) (+) and (1) (-) Continuity
Continuity
Between D12 (male) (1) (+) and (2) (-) No continuity
Between D12 (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and D12, and connect T-adapters to each
female side.
Open or short circuit in a If resistance is 1 Mz or higher, wiring harness has open circuit.
3 wiring harness
Between L63 (female) (8) and D12 (female) (2) Max. 1 z
Resistance a Coil resistance of relay 200 to 400
Between D12 (female) (1) and ground z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors D11 and L116, and connect T-adapters to each
defective contact of female side.
connector) Between L116 (female) (1) and D12 (female) (1) Max. 1 z
Resistance
Between L116 (female) (2) and ground Max. 1 z
If no failure is found by above checks, transmission controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
5 4. Move directional lever to perform troubleshooting.
controller
Directional lever: N
(neutral) 20 to 30 V
Between L63 (female)
Voltage
(8) and ground Directional lever: Other
than N (neutral) Max. 4.5 V

40-470 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to neutral safety relay

WA470-7 40-471
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D191KB] Ground Fault of Neutral Output Relay (WA470_7-D191KB-400-


A-Z0-A)

Action level Failure code Ground Fault of Neutral Output Relay


Failure
L03 D191KB (Transmission controller system)
Detail of • When controller drives primary circuit (coil side) of neutral safety relay, abnormal current
failure flows through circuit.
• Stops driving primary circuit (coil side) of neutral safety relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Engine does not start.
machine
• Output signal to primary circuit (coil side) of neutral safety relay can be checked with
monitoring function. (Code: 03705 Neutral Safety Relay)
Related • Method of reproducing failure code: Turn starting switch to ON position and operate
information directional lever to N (neutral).
• This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but
not on secondary circuit (contact side).
No. Cause Procedure, measuring location, criteria and remarks

Defective neutral safety 1. Turn starting switch to OFF position.


relay (internal open or 2. Disconnect connector L116 and connect T-adapter to male side.
1
short circuit) 200 to 400
Resistance Between L116 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connectors D11 and D12, and connect T-adapters to diode.
Defective diode a Measure it with diode range of multimeter.
2 (internal open or short Between D11 (male) (1) (+) and (2) (-) No continuity
circuit) Between D11 (male) (2) (+) and (1) (-) Continuity
Continuity
Between D12 (male) (1) (+) and (2) (-) No continuity
Between D12 (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and D12, and connect T-adapters to each
female side.
Open or short circuit in a If resistance is 1 Mz or higher, wiring harness has open circuit.
3 wiring harness
Between L63 (female) (8) and D12 (female) (2) Max. 1 z
Resistance a Coil resistance of relay 200 to 400
Between D12 (female) (1) and ground z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors D11, L116, D11, and D12, and connect T-adapters
harness to each female side.
4 Between ground and L116 (female) (1) or D12
(contact with ground (female) (1) Min. 1 Mz
circuit) Resistance
Between ground and D12 (female) (2) or L63
(female) (8) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
5 4. Move directional lever to perform troubleshooting.
controller
Directional lever: N
(neutral) 20 to 30 V
Between L63 (female)
Voltage
(8) and ground Directional lever: Other
than N (neutral) Max. 4.5 V

40-472 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to neutral safety relay

WA470-7 40-473
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D191KY] Hot Short of Neutral Output Relay (WA470_7-D191KY-400-A-Z0-A)

Action level Failure code Hot Short of Neutral Output Relay


Failure
L03 D191KY (Transmission controller system)
Detail of • When controller does not drive primary circuit (coil) of neutral safety relay, current flows
failure through circuit.
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Engine is allowed to start even when gear shift lever or directional selector (FNR) switch
machine is in a position other that N (neutral).
• Output signal to primary circuit (coil side) of neutral safety relay can be checked with
monitoring function. (Code: 03705 Neutral Safety Relay)
Related • Method of reproducing failure code: Turn starting switch to ON position and move
information directional lever to N (neutral).
• This failure code indicates failure on primary circuit (coil side) of neutral safety relay, but
not on secondary circuit (contact side).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective neutral safety 2. Disconnect connector L116 and connect T-adapter to male side.
1 relay 200 to 400
Resistance Between connector L116 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connector D12 and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness 4. Move directional lever to position other than N (neutral).
Between D12 (female) (1) and ground Max. 4.5 V
Voltage
Between D12 (female) (2) and ground Max. 4.5 V
If no failure is found by above checks, power train controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
3 4. Move directional lever to perform troubleshooting.
controller
Directional lever: N
(neutral) 20 to 30 V
Between L63 (female)
Voltage
(8) and ground Directional lever: Other
than N (neutral) Max. 4.5 V

40-474 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to neutral safety relay

WA470-7 40-475
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D192KA] Disconnection of ECSS Solenoid (WA470_7-D192KA-400-A-Z0-A)

Action level Failure code Disconnection of ECSS Solenoid


Failure
L01 D192KA (Transmission controller system)
Detail of • When controller drives electronically controlled suspension system (ECCS) solenoid, no
failure current flows through circuit.
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • ECCS (electronically controlled suspension system) does not work.
machine
• Output signal (ON/OFF) to ECCS (electronically controlled suspension system) solenoid
can be checked with monitoring function.
(Code: 03705 E.C.C.S. Solenoid)
Related • This troubleshooting is applicable only to machines with ECCS (electronically controlled
information suspension system) specification.
• Method of reproducing failure code: Turn starting switch to ON position, set ECCS switch
to ON, and drive machine at gear speed other than "1st".
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector F20 and connect T-adapter to male side.
1 Defective ECCS solenoid Between F20 (male) (1) and (2) 35 to 45 z
Resis-
Between ground and each of F20 (male) (1)
tance Min. 1 Mz
and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector F20, and connect T-adapter to female side.
Open circuit, short circuit, 3. Turn starting switch to ON position.
ground fault, hot short circuit
2
of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If
transmission controller the voltage drops to approximately 0 V during shaking, circuit is
open around this point.
Voltage Between F20 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in wiring 2. Disconnect connector L63, and connect T-adapter to female side.
3
harness
a Coil resistance of solenoid
Resis- Between L63 (female) (15) and (13)
35 to 45 z
tance
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors L63 and F20, and connect T-adapters to
4 (wire breakage or defective each female side.
contact of connector) Between L63 (female) (15) and F20 (female)
Max. 1 z
Resis- (1)
tance Between L63 (female) (13) and F20 (female)
(2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed).

40-476 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to electronically controlled suspension system (ECCS) solenoid

WA470-7 40-477
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D192KB] Ground Fault of ECSS Solenoid (WA470_7-D192KB-400-A-Z0-A)

Action level Failure code Ground Fault of ECSS Solenoid


Failure
L01 D192KB (Transmission controller system)
Detail of • When controller drives electronically controlled suspension system (ECCS) solenoid,
failure abnormal current flows through circuit.
• Stops driving ECCS (electronically controlled suspension system) solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • ECCS (electronically controlled suspension system) does not work.
machine • Wiring harness or controller may be burnt out.
• Output signal (ON/OFF) to ECCS (electronically controlled suspension system) solenoid
can be checked with monitoring function.
(Code: 03705 E.C.C.S. Solenoid)
Related • This troubleshooting is applicable only to machines with ECCS (electronically controlled
information suspension system) specification.
• Method of reproducing failure code: Turn starting switch to ON position, set ECCS switch
to ON, and drive machine at gear speed other than "1st".
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective ECCS 2. Disconnect connector F20 and connect T-adapter to male side.
1
solenoid Between F20 (male) (1) and (2) 35 to 45 z
Resistance
Between ground and each of F20 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L63, and connect T-adapter to female side.
2 wiring harness a Coil resistance of solenoid
Resistance Between L63 (female) (15) and ground 35 to 45 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and F20, and connect T-adapter to either
3 female side.
(contact with ground
Between L63 (female) (15) and F20 (female) (1), or
circuit) Resistance ground and L63 (female) (15) or F20 (female) (1) Min. 1 Mz
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).

Circuit diagram related to electronically controlled suspension system (ECCS) solenoid

40-478 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D192KY] Hot Short of ECSS Solenoid (WA470_7-D192KY-400-A-Z0-A)

Action level Failure code Hot Short of ECSS Solenoid


Failure
L01 D192KY (Transmission controller system)
Detail of • When controller drives electronically controlled suspension system (ECCS) solenoid,
failure abnormal voltage appears at circuit.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • ECCS (electronically controlled suspension system) remains actuated.
machine
• Output signal (ON/OFF) to ECCS (electronically controlled suspension system) solenoid
can be checked with monitoring function.
Related (Code: 03705 E.C.C.S. Solenoid)
information • This troubleshooting is applicable only to machines with ECCS (electronically controlled
suspension system) specification.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective ECCS 2. Disconnect connector F20 and connect T-adapter to male side.
1
solenoid Between F20 (male) (1) and (2) 35 to 45 z
Resistance
Between ground and each of F20 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L63, and connect T-adapter to female side.
2 wiring harness a Coil resistance of solenoid
Resistance Between L63 (female) (15) and (13) 35 to 45 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F20, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between F20 (female) (1) and (2) Max 1 V
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).

Circuit diagram related to electronically controlled suspension system (ECCS) solenoid

WA470-7 40-479
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D19JKZ] Personal Code Relay Abnormality (WA470_7-D19JKZ-400-A-Z0-A)

Action level Failure code Personal Code Relay Abnormality


Failure
L03 D19JKZ (Machine monitor system)
• When driving primary circuit (coil) of personal code relay, no current flows or excessive
Detail of current flows through circuit.
failure • When controller does not drive primary circuit (coil) of personal code relay, current flows
through circuit.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
• When cause of failure is open circuit, engine is allowed to start even if engine start lock is
Problem on activated.
machine • When cause of failure is ground fault, engine does not start.
• Output signal (ON/OFF) to personal code relay can be checked with monitoring function.
Related (Code: 04700)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-5 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 4.)
1
box 2
1. Turn starting switch to OFF position.
Defective personal 2. Disconnect connector L113 and connect T-adapter to male side.
2 code relay L113 250 to 350
Resistance Between connector L113 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors MCM1 A , L113, and L112, and connect T-
harness adapters to each female side.
3. Remove fuse-5 in fuse box 2.
3 (wire breakage or Between MCM1 A (female) (19) and L113 (female)
defective contact of (2) Max. 1 z
connector) Resistance L113 (female) (1) and L112 (female) (3)
Max. 1 z
Between fuse-5 in fuse box 2 and L112 (female) (5) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 A, L113, and L63, and connect T-adapter to
Ground fault in wiring female side of MCM1 A or L113.
harness 3. Remove fuse-5 in fuse box 2.
4
(contact with ground Between ground and MCM1 A (female) (19) or
L113 (female) (2) Min. 1 Mz
circuit)
Resistance
Between ground and fuse-5 in fuse box 2 or L112
(female) (5) Min. 1 Mz

Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed).
controller

40-480 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to personal code relay

WA470-7 40-481
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1E6KA] Disconnection of Parking Brake Relay (WA470_7-D1E6KA-


400-A-Z0-A)

Action level Failure code Disconnection of Parking Brake Relay


Failure
L03 D1E6KA (Transmission controller system)
Detail of • When controller drives primary circuit (coil) of auto idle stop parking brake relay, no
failure current flows through circuit.
• Stops driving auto idle stop parking brake relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • When auto idle stop function is actuated, parking brake is not applied automatically.
machine
• This failure code indicates failure on primary circuit (coil side) of auto idle stop parking
brake relay, but not on secondary circuit (contact side).
Related • Output signal (ON/OFF) to auto idle stop parking brake relay can be checked with
information monitoring function. (Code: 03706 Parking Brake Relay)
• Method of reproducing failure code: Actuate auto idle stop function.
No. Cause Procedure, measuring location, criteria and remarks

Defective auto idle stop 1. Turn starting switch to OFF position.


parking brake relay 2. Disconnect connector L133 and connect T-adapter to male side.
1
(L133) 200 to 400
Resistance Between connector L133 (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connector L63, and connect T-adapter to female side.
Open or short circuit in
2 wiring harness a Relay coil resistance
200 to 400
Resistance Between L63 (female) (18) and ground
z
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L63 and L133, and connect T-adapters to each
3
harness female side.
Between L63 (female) (18) and L133 (female) (1) Max. 1 z
Resistance
Between L133 (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector L63.
3. Turn starting switch to ON position.
Defective transmission Between Auto idle stop: After engine is stopped 20 to 30 V
4
controller L63
Voltage (female) Auto idle stop: Before engine is
(18) and stopped Max 4.5 V
ground

40-482 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake relay

WA470-7 40-483
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1E6KB] Ground Fault of Parking Brake Relay (WA470_7-D1E6KB-400-


A-Z0-A)

Action level Failure code Ground Fault of Parking Brake Relay


Failure
L03 D1E6KB (Transmission controller system)
Detail of • When controller drives primary circuit (coil) of auto idle stop parking brake relay, abnormal
failure current flows through circuit.
• Stops driving auto idle stop parking brake relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • When auto idle stop function is actuated, parking brake is not applied automatically.
machine
• This failure code indicates failure on primary circuit (coil side) of auto idle stop parking
brake relay, but not on secondary circuit (contact side).
Related • Output signal (ON/OFF) to auto idle stop parking brake relay can be checked with
information monitoring function. (Code: 03706 Parking Brake Relay)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective auto idle stop 2. Disconnect connector L133 and connect T-adapter to male side.
1 parking brake relay 200 to 400
(L133) Between L133 (male) (1) and (2)
Resistance z
Between L133 (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and L133, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (18) or L133
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L63 and L133, and connect T-adapter to either
Short circuit in wiring
3 female side.
harness
Between L63 (female) (18) and (31), or between
Resistance L133 (female) (1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Connect T-adapter to connector L63.
3. Turn starting switch to ON position.
Defective transmission Between Auto idle stop: After engine is stopped 20 to 30 V
4
controller L63
Voltage (female) Auto idle stop: Before engine is
(18) and stopped Max 4.5 V
ground

40-484 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake relay

WA470-7 40-485
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D1E6KY] Hot Short of Parking Brake Relay (WA470_7-D1E6KY-400-A-Z0-A)

Action level Failure code Hot Short of Parking Brake Relay


Failure
L03 D1E6KY (Transmission controller system)
Detail of • When controller does not drive primary circuit (coil) of auto idle stop parking brake relay,
failure current flows through circuit.
• Stops driving auto idle stop parking brake relay.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Parking brake remains applied.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective auto idle stop 2. Disconnect connector L133 and connect T-adapter to male side.
1 parking brake relay 200 to 400
(L133) Between L133 (male) (1) and (2)
Resistance z
Between L133 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L133, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between L133 (female) (1) and ground Max. 4.5 V
1. Turn starting switch to OFF position.
2. Connect T-adapter to connector L63.
3. Turn starting switch to ON position.
Defective transmission Between Auto idle stop: After engine is stopped 20 to 30 V
3
controller L63
Voltage (female) Auto idle stop: Before engine is
(18) and stopped Max 4.5 V
ground

40-486 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake relay

WA470-7 40-487
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D5ZHKA] Failure of Key SW C Signal (WA470_7-D5ZHKA-400-A-Z0-A)

Action level Failure code Failure of Key Switch C Signal


Failure
L01 D5ZHKA (Transmission controller system)
Detail of • An open circuit or ground fault of terminal-C line (The engine speed is 500 rpm or higher,
failure and the starting switch terminal-C signal is not entered.)
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Engine startability is poor.
machine
• Input condition (ON/OFF) to the transmission controller from terminal C of starting switch
can be checked with monitoring function (Code: 02214 Starter Status).
• When the engine is rotating, the terminal-C signal line may not be grounded.
Related • When the engine is rotating, terminal C of starting switch may be turned ON (the starting
information switch is normal).
• If fuse No. 1 in fuse box 2 is blown, the machine monitor does not light up.
• Method of reproducing failure code: Turn the starting switch to the START position.
No. Cause Procedure, measuring location, criteria and remarks
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors S40, L116, and L62, and connect T-adapters to
1 (wire breakage or each female side.
defective contact of Between S40 (female) (3) and L116 (female) (3) Max. 1 z
connector) Resistance
Between L116 (female) (5) and L62 (female) (16) Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Connect T-adapters to connectors L62 and L116.
2
(contact with ground
circuit) Resistance Between L116 (5) or L62 (16) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Be ready with starting switch OFF, then troubleshoot by switching to ON,
Defective transmission OFF and START positions.
3
controller
Starting switch: START 20 to 30 V
Between L62 (16) and
Voltage Starting switch: OFF and
ground Max 1 V
ON

40-488 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to terminal-C signal circuit

WA470-7 40-489
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D5ZHKB] Key SW C Signal Short Circuit (WA470_7-D5ZHKB-400-A-Z0-A)

Action level Failure code Key Switch C Signal Short Circuit


Failure
L01 D5ZHKB (Transmission controller system)
Detail of • A hot short in terminal-C line (The engine speed is 500 rpm or higher, and the starting
failure switch terminal-C signal is entered.)
Action of • Engine start-up assistance control function has stopped.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine startability is poor.
machine
• Input condition (ON/OFF) to the transmission controller from terminal C of starting switch
Related can be checked with monitoring function (Code: 02214 Starter Status).
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective starting 2. Disconnect connector S40 and connect T-adapter to male side.
switch 3. Troubleshoot by turning starting switch to ON, OFF and START positions.
1
(internal open circuit) Starting switch: START Max. 1 z
Between S40 (male) (1)
Resistance and (3) Starting switch: OFF and
Min. 1 Mz
ON
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Insert T-adapters into connectors L116 and L62.
2 3. Start the engine and troubleshoot during engine running.
(contact with 24V
Between L116 (3) and ground Max 1 V
circuit) Voltage
Between L116 (5) or L62 (16) and ground Max 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Be ready with starting switch OFF, then troubleshoot by switching to ON,
Defective transmission OFF and START positions.
3
controller
Starting switch: START 20 to 30 V
Between L62 (16) and
Voltage Starting switch: OFF and
ground Max 1 V
ON

40-490 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to terminal-C signal circuit

WA470-7 40-491
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D5ZHKZ] Failure of Key SW C Signal (WA470_7-D5ZHKZ-400-A-Z0-A)

Action level Failure code Failure of Key Switch C Signal


Failure
L01 D5ZHKZ (Work equipment controller system)
• An open circuit of terminal-C line (The engine speed is 500 rpm or higher, and the starting
Detail of switch terminal-C signal is not entered.)
failure • A short circuit of power supply line of terminal C-line (The engine speed is 500 rpm or
higher, and the starting switch terminal-C signal is continued for 30 seconds or longer.)
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • The engine starts rotating immediately when the starting key is turned to ON position (due
machine to short circuit to the power supply line).
• Input condition (ON/OFF) to the work equipment controller from terminal C of starting
switch can be checked with monitoring function (Code: 02217).
Related • When the engine is rotating, the terminal-C signal line may not be grounded.
information • When the engine is rotating, terminal C of starting switch may be turned ON.
• If fuse No. 1 in fuse box 2 is blown, the machine monitor does not light up.
• Method of reproducing failure code: Turn the starting switch to the START position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective starting 2. Disconnect connector S40.
switch 3. Troubleshoot by turning starting switch to ON, OFF and START positions.
1
(internal open circuit) Starting switch: START Max. 1 z
Between S40 (male) (1)
Resistance and (3) Starting switch: OFF and
Min. 1 Mz
ON
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L116, L73 and S40, and insert T-adapters into
2 (wire breakage or each female side.
defective contact of Between S40 (female) (3) and L116 (female) (3) Max. 1 z
connector) Resistance
Between L116 (female) (5) and L73 (female) (10) Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L116 and L73.
Hot short circuit in 3. Start the engine and troubleshoot during engine running.
3 wiring harness
Between L116 (3) and ground Max 1 V
Voltage
Between L116 (5) or L73 (10) and ground Max 1 V
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
Defective work 1. Turn starting switch to OFF position.
4 equipment controller 2. Insert T-adapter into connector L73.
3. Troubleshoot by turning starting switch to ON, OFF and START positions.
Between L73 (female) (10) and START 20 to 30 V
Voltage
ground OFF, ON Max 1 V

40-492 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to terminal-C signal circuit

WA470-7 40-493
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D5ZHL6] Disconnection of Key SW C (WA470_7-D5ZHL6-400-A-Z0-A)

Action level Failure code Disconnection of Key Switch C


Failure
L01 D5ZHL6 (Machine monitor system)
Detail of • While engine speed is 500 rpm or higher and R signal voltage of alternator exceeds 8 V,
failure key switch C terminal signal received by monitor controller remains "OFF".
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • None in particular
machine
• Method of reproducing failure code: Start engine.
Related • Input condition (ON/OFF) to machine monitor from starting switch terminal C can be
information checked with monitoring function (Code: 04508 Engine Starter).
No. Cause Procedure, measuring location, criteria and remarks
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and S40, and insert T-adapters into each
1 (wire breakage or female side.
defective contact of Between S40 (female) (3) and MCM1 A (female)
connector) Resistance (11) Max. 1 z
If no failure is found by above checks, monitor controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed).
• Reference
Defective monitor 1. Turn starting switch to OFF position.
2
controller 2. Disconnect connector MCM1 A, and connect T-adapter to female side.
3. Turn starting switch to START position.
Voltage Between MCM1 A (female) (11) and ground 20 to 30 V

40-494 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to key switch C terminal

WA470-7 40-495
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D811MC] KOMTRAX Error (WA380_7-D811MC-400-A-Z0-A)

Action level Failure code KOMTRAX Error


Failure
― D811MC (KOMTRAX system)
Detail of • KOMTRAX terminal does not operate properly.
failure
Action of
KOMTRAX terminal resets CPU of KOMTRAX and restarts.
controller
Problem on • KOMTRAX system does not work properly.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
KOMTRAX terminal is defective.
1 Defective KOMTRAX terminal
(Since this is an internal defect, troubleshooting cannot be performed.)

40-496 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D862KA] GPS Antenna Open Circuit (WA380_7-D862KA-400-A-Z0-A)

Action level Failure code GPS Antenna Open Circuit


Failure
― D862KA (KOMTRAX system)
Detail of • GPS module detects open circuit in GPS antenna circuit.
failure
Action of • None in particular.
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on • GPS positioning system does not work.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective GPS antenna or GPS antenna may be defective, or antenna cable may have open or
1 short circuit, or poor contact at terminal area (A).
antenna cable

Figure of structure

WA470-7 40-497
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) (WA470_7-


D8ALKA-400-A-Z0-A)

Action level Failure code Operating Lamp Open Circuit (KOMTRAX)


Failure
- D8ALKA (KOMTRAX system)
• KOMTRAX terminal determines that output circuit to system operating lamp is open
Detail of because voltage of output circuit remains at approximately 5 V or below for approx. 3
failure seconds after starting switch is turned to ON position, during which KOMTRAX terminal
does not drive system operating lamp.
• It does not output for system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX terminal memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-4 in fuse If fuse is blown, circuit probably has ground fault.
1
box 2
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors L80A and R61, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between L80A (female) (15) and R61 (female) (2) Max. 1 z
connector) Resistance Between R61 (female) (1) and battery relay
terminal (R01) Max. 1 z

Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective.


3
terminal (Since this is an internal defect, troubleshooting cannot be performed.)

40-498 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-499
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) (WA470_7-


D8ALKB-400-A-Z0-A)

Action level Failure code Operating Lamp Short Circuit (KOMTRAX)


Failure
- D8ALKB (KOMTRAX system)
• KOMTRAX terminal determines that output circuit to system operating lamp shorts
Detail of because voltage of output circuit does not become Low level while KOMTRAX terminal
failure drives system operating lamp.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine KOMTRAX terminal memory.
• Stops driving system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
No. Cause Procedure, measuring location, criteria and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
Short circuit in wiring 3.Remove fuse-4 in fuse box 2.
1 4.Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
harness
connect T-adapter to female side of R61.
Resistance Between R61 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Remove fuse-4 in fuse box 2.
Hot short circuit in
2 4. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
wiring harness
connect T-adapter to female side of R61.
5. Turn battery disconnect switch to ON position.
Voltage Between R61 (female) (2) and ground Max 1 V
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective.
3
terminal (Since this is an internal defect, troubleshooting cannot be performed.)

40-500 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-501
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8AQK4] CAN2 Discon (KOMTRAX) 2 (WA380_7-D8AQK4-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (KOMTRAX) 2


Failure
L03 D8AQK4 (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize KOMTRAX terminal over CAN communication-2
failure line (KOMNET/c).
Action of • Does not update communication information.
controller
Problem on • Engine does not start.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• For CAN communication error over CAN communication-2 line, monitor controller can
generate six failure codes; [D8AQKR], [DAQQKR], [DAZQKR], [DB2QKR], [DB9QKR],
and [DSJ0KR]. When all of these six failure codes are displayed simultaneously on
screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
communication line). In this case, check whether air conditioner is operated (ON/OFF and
Related air flow adjustment) from air conditioner operation screen since air conditioner is also
information controlled over CAN communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective CAN-2 Perform troubleshooting for [D8AQKR].
1
communication line

40-502 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [D8AQKR] CAN2 Discon (KOMTRAX) (WA470_7-D8AQKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (KOMTRAX)


Failure
- D8AQKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize KOMTRAX terminal over CAN communication-2
failure line (KOMNET/c).
Action of
machine • None
monitor
Problem on • None in particular
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• For CAN communication error over CAN communication-2 line, monitor controller can
generate six failure codes; [D8AQK4], [DAQQKR], [DAZQKR], [DB2QKR], [DB9QKR],
and [DSJ0KR]. When all of these six failure codes are displayed simultaneously on
screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
communication line). In this case, check whether air conditioner is operated (ON/OFF and
General air flow adjustment) from air conditioner operation screen since air conditioner is also
information controlled over CAN communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective fuse-3 in fuse
1 2. Remove fuse-3 in fuse box 2.
box 2
If fuse is blown, circuit probably has ground fault.
Defective power supply Perform troubleshooting for “E-58” of E-mode troubleshooting.
2
to KOMTRAX terminal
Defective CAN2 Perform checks on causes 4 to 9 in troubleshooting for failure code
3 communication system [DB2QKR].
Defective KOMTRAX If no failure is found by above checks, KOMTRAX terminal is defective.
4
terminal (Since this is an internal defect, troubleshooting cannot be performed.)
Defective monitor If no failure is found by above checks, monitor controller is defective.
5
controller (Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-503
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to power supply system

40-504 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF0KT] Abnormality of Non-volatile Memory (MON) (WA380_7-


DAF0KT-400-A-Z0-A)

Action level Failure code Abnormality of Non-volatile Memory (Monitor)


Failure
L03 DAF0KT (Machine monitor system)
Detail of • Data is not written to or read from non-volatile memory of monitor controller.
failure
Action of
controller
Problem on • Reading of service meter and odometer and other set values are changed.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Monitor controller is defective.
1 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-505
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF0MB] Monitor ROM Abnormality (WA380_7-DAF0MB-400-A-Z0-A)

Action level Failure code Monitor ROM Abnormality


Failure
― DAF0MB (Machine monitor system)
Detail of • Program of monitor controller is rewritten (program error).
failure
Action of
controller
Problem on • Data displayed on machine monitor are unreliable.
machine • Machine monitor cannot exchange data with controllers normally.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective monitor Monitor controller is defective.
1
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-506 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF0MC] Monitor Error (WA380_7-DAF0MC-400-A-Z0-A)

Action level Failure code Monitor Error


Failure
― DAF0MC (Machine monitor system)
Detail of
• Monitor controller malfunctions.
failure
Action of
controller
Problem on • Data displayed on machine monitor are unreliable.
machine • Machine monitor cannot exchange data with controllers normally.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Monitor controller is defective.
1 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-507
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF3KK] Controller Power Source Low (MON) (WA470_7-DAF3KK-400-


A-Z0-A)

Action level Failure code Controller Power Source Low (Monitor)


Failure
― DAF3KK (Machine monitor system)
Detail of • Continuous power supply voltage of monitor controller is below 18 V.
failure
Action of • Inhibits writing to memory.
controller • If cause of failure disappears, machine becomes normal by itself.
• In some cases, monitor screen displays nothing.
Problem on
• Since writing to non-volatile memory is inhibited, reliability of data displayed on screen
machine
lowers.
• Machine monitor does not display this failure code.
Related • As T-adapter for monitor controller connector is "socket-type box", operating voltage
information cannot be measured at monitor controller connector.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow If slow-blow fuse is blown, circuit may have ground fault. (See check on cause
1 fuses (R02) and (R03) 4.)
Defective fuse-3 in fuse If fuse is blown, circuit may have ground fault. (See check on cause 4.)
2
box 2
1. Turn starting switch to OFF position.
2. Set battery disconnect switch to OFF position.
3. Disconnect connector MCM1 A, and connect T-adapters to female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between MCM1 A (female) (1) and (2) 20 to 30 V
Voltage
Between MCM1 A (female) (4) and (3) 20 to 30 V
Open circuit in wiring
harness 1. Turn starting switch to OFF position.
3 (wire breakage or a If fuse-3 in fuse box 2 or slow-blow fuse (R02) is blown, replace it.
defective contact of 2. Set battery disconnect switch to OFF position.
connector) 3. Disconnect connector MCM1 A, and connect T-adapters to female side.
Between battery relay terminal R01 and each of
MCM1 A (female) (1) and (4) Max. 1 z

Resistance a Loosened or rusted ground terminal ground


terminal R22 Max. 1 z
Between ground and each of MCM1 A (female) (2)
and (3)
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect fuse-3 in fuse box 2 and connector MCM1 A, and connect T-
harness adapters to female side.
4
(contact with ground Between ground and fuse-3 in fuse box 2, or
circuit) Resistance between ground and each of MCM1 A (female) (1) Min. 1 Mz
and (4)
Defective monitor If no failure is found in above checks, monitor controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed.)
controller

40-508 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to monitor controller power supply

WA470-7 40-509
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAF8KB] Camera Power Supply Short Circuit (WA380_7-DAF8KB-400-A-


Z0-A)

Action level Failure code Camera Power Supply Short Circuit


Failure
L03 DAF8KB (Machine monitor system)
Detail of • When rear view monitor does not supply power for camera, supply voltage (rated voltage:
failure 8 V) is 10 V or more.
• Stops supplying power for rearview camera.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Camera image is not displayed on rear view monitor screen.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective rearview camera 2. Disconnect rearview camera connector G06, and turn starting switch
1 to ON position.
(internal short circuit)
Perform procedure for reproducing failure code. If this failure code
disappear, rearview camera has internal defect.
1. Turn starting switch to OFF position.
2. Disconnect connector RVM2 and connect T-adapters to male side.
2 Defective rear view monitor 3. Turn starting switch to ON position.
Voltage Between RVM2 (male) (1) and ground 6 to 10 V
1. Turn starting switch to OFF position.
2. Disconnect camera connector G06 and connect T-adapters to
female side.
Hot short circuit in wiring 3. Turn starting switch to ON position.
3
harness (Disconnect rearview camera and check that rearview camera is normal
in advance.)
Voltage Between G06 (female) (1) and (2) Max. 10 V

Circuit diagram related to camera power supply

40-510 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFDKB] Monitor 12V Power Output Short Circuit (WA380_7-
DAFDKB-400-A-Z0-A)

Action level Failure code Monitor 12V Power Output Short Circuit
Failure
L01 DAFDKB (Machine monitor system)
Detail of • When starting switch is turned to ON position, 12 V power supply voltage is 8 V or below,
failure or 14 V or above.
• Stops supplying 12 V power (stops until starting switch is turned to OFF position).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Switch panel cannot be operated.
Problem on • LED unit does not light up or lights up incorrectly.
machine • If engine start lock is enabled, engine cannot be started because password cannot be
entered.
• If failure code [DAF3KK] (Controller Power Source Low (MON)) is generated, perform
Related troubleshooting for it first.
information • Method of reproducing failure code: Turn starting switch to OFF position, and then to ON
position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors MCM1 B, MDM2, and MOM1, and connect
1 T-adapters to either female side.
(contact with ground circuit)
Resis- Between ground and MCM1 B (female) (107),
MDM2 (female) (1), or MOM1 (female) (1) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector MCM1 B, and connect T-adapters to female
2 harness side.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between MCM1 B (female) (107) and (99) Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1 B, and connect T-adapters to male
side.
3 Defective monitor controller
3. Turn starting switch to ON position.
Voltage Between MCM1 B (male) (107) and (99) 9.3 to 14.1
V

WA470-7 40-511
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to monitor controller 12 V power supply

40-512 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFGMC] GPS Module Error (WA380_7-DAFGMC-400-A-Z0-A)

Action level Failure code GPS Module Error


Failure
― DAFGMC (KOMTRAX system)
Detail of
• KOMTRAX terminal can not communicate with GPS module in serial communication..
failure
Action of • None in particular.
machine • If cause of failure disappears, machine becomes normal by itself.
monitor
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (at least 50
information seconds after starting switch is turned to ON position).
No. Cause Procedure, measuring location, criteria and remarks
GPS module in KOMTRAX terminal may be defective.
1 Defective KOMTRAX terminal
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-513
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFLKA] Operating Lamp Open Circuit (MON) (WA470_7-DAFLKA-400-


A-Z0-A)

Action level Failure code Operating Lamp Open Circuit (Monitor)


Failure
― DAFLKA (Machine monitor system)
• Monitor controller determines that output circuit to system operating lamp is open
Detail of because voltage of output circuit remains at approximately 5 V or below for approx. 3
failure seconds after starting switch is turned to ON position, during which monitor controller
does not drive system operating lamp.
• Do not turn system operating lamp output ON.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• While system operating lamp lights up, battery disconnect switch must not be set to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine monitor controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although monitor controller is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is set to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at Low level.
• Since no controller drives system operating lamp for approx. 3 seconds after starting
switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-4 in fuse If fuse is blown, circuit probably has ground fault.
1
box 2
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Set battery disconnect switch to OFF position.
harness 3. Disconnect connectors MCM1 A and R61, and connect T-adapters to each
female side.
2 (wire breakage or Between MCM1 A (female) (57) and R61 (female)
defective contact of (2) Max. 1 z
connector) Resistance
Between R61 (female) (1) and battery relay
terminal (R01) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Set battery disconnect switch to OFF position.
harness 3. Remove fuse-4 in fuse box 2.
3 4. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
(contact with ground connect T-adapters to female side of MCM1 A.
circuit)
Between MCM1 A (female) (57) and ground Min. 1 Mz
Resistance
Between R61 (female) (1) and ground Min. 1 Mz
Defective monitor If no failure is found by above checks, monitor controller is defective.
4
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-514 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-515
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFLKB] Operating Lamp Short Circuit (MON) (WA470_7-DAFLKB-400-


A-Z0-A)

Action level Failure code Operating Lamp Short Circuit (Monitor)


Failure
― DAFLKB (Machine monitor system)
• Monitor controller determines that output circuit to system operating lamp shorts because
Detail of voltage of output circuit does not become Low level while monitor controller drives system
failure operating lamp.
• Stops driving system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• While system operating lamp lights up, battery disconnect switch must not be set to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine monitor controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Although monitor controller is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is set to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at Low level.
No. Cause Procedure, measuring location, criteria and remarks
1.Turn starting switch to OFF position.
2.Set battery disconnect switch to OFF position.
Short circuit in wiring 3.Remove fuse-4 in fuse box 2.
1 4.Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
harness
connect T-adapters to female side of R61.
Resistance Between R61 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Set battery disconnect switch to OFF position.
3. Remove fuse-4 in fuse box 2.
Hot short circuit in
2 4. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
wiring harness
connect T-adapters to female side of R61.
5. Set battery disconnect switch to ON position.
Voltage Between R61 (female) (2) and ground Max. 1 V
Defective monitor If no failure is found by above checks, monitor controller is defective.
3
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-516 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-517
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAFQKR] CAN2 Discon (Monitor) (WA380_7-DAFQKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Monitor)


Failure
― DAFQKR (KOMTRAX system)
Detail of • KOMTRAX terminal does not recognize monitor controller over CAN communication-2
failure line (KOMNET/c).
Action of • None in particular.
controller
Problem on • KOMTRAX system may not function normally.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Failure code is transmitted to and displayed on machine monitor over CAN
communication line. Accordingly, if CAN communication with machine monitor fails,
Related failure code [DAFQKR] is not displayed on machine monitor and it can be observed only
information through KOMTRAX system.
• Since each controller and monitor controller are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply to Perform troubleshooting for failure code [DAF3KK].
1
monitor controller
Perform checks on causes 4 and after in troubleshooting for failure
2 Defective CAN communication code [DB2QKR]

40-518 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ0KK] Controller Power Source Low (T/M) (WA470_7-DAQ0KK-400-A-


Z0-A)

Action level Failure code Controller Power Source Low (Transmission)


Failure
L03 DAQ0KK (Transmission controller system)
• Continuous power supply voltage (power supply directly connected to battery) of
Detail of transmission controller drops.
failure • Continuous power supply voltage (power supply directly connected to battery) is 18 V or
below while engine speed is 500 rpm or above.
• Cannot detect input signals properly.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of • Stops driving all devices other than fan pump relay (comes into neutral state).
controller • Even if cause of failure disappears, machine does not become normal until directional
(reverse) lever or directional selector (reverse) switch is set to N (neutral) position.
• Machine cannot travel (transmission is left in NEUTRAL).
Problem on • Fan runs at its maximum speed and may be damaged.
machine • Fan rotating in reverse changes its direction to normal.
Related • If fuse-5 in fuse box 2 is blown, failure codes [DAQQKR] and [DAQRKR] are displayed.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
a Check battery voltage and specific gravity of battery electrolyte.
1 Defective battery Voltage Battery voltage Min. 24 V
Specific
Specific gravity of battery electrolyte Min. 1.26
gravity
Defective slow-blow If slow-blow fuse (R02) is blown, circuit may have ground fault, etc. (See
2 fuse (R02) check on cause 4.)
Defective fuse-5 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 4.)
3
box 2
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L63, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
a If voltage appears between battery (+) terminal and ground but not
between ground and each of L63 (female) (1) and (11), wiring harness or
fuse has open circuit.
Open circuit in wiring Between battery (-) terminal and ground 20 to 30 V
harness Voltage Between ground and each of L63 (female) (1) and
4 (wire breakage or (11) 20 to 30 V
defective contact of
connector) a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L63, and connect T-adapter to female side.
Between ground and each of L63 (female) (21),
(31), (32), and (33) Max. 1 z
Resistance
Between battery (+) terminal and each of L63 Max. 1 z
(female) (1) and (11)

WA470-7 40-519
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If slow-blow fuse is blown, replace it in advance.
Ground fault in wiring 1.Turn the battery disconnect switch to OFF position.
harness 2.Turn starting switch to OFF position.
5 3.Remove all fuses in fuse box 2.
(contact with ground
circuit) 4.Disconnect connector L63, and connect T-adapter to female side.
Between battery (-) terminal and ground Min. 1 Mz
Resistance
Between ground and L63 (female) (1) or (11) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L63.
Defective transmission 4. Turn battery disconnect switch to ON position.
6 5. Turn starting switch to ON position.
controller
Between L63 (1) and each of (21), (31), (32), and
Voltage (33), and between L63 (11) and each of (21), (31), 20 to 30 V
(32), and (33)

40-520 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to power supply of transmission controller

WA470-7 40-521
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ0KT] Abnormality of Non-volatile Memory (T/M) (WA380_7-


DAQ0KT-400-A-Z0-A)

Action level Failure code Abnormality of Non-volatile Memory (Transmission)


Failure
L01 DAQ0KT (Transmission controller system)
• Non-volatile memory (ROM) in transmission controller is abnormal.
Detail of • When starting switch is turned to OFF position, end processing is not completed
failure successfully.
Action of • Reset internal adjustment values and option setting to default values.
controller
Problem on • Machine control parameters change and transmission shifting shock increases in some
machine cases.
• Perform initial setting and initial adjustment similar to those required when transmission is
Related replaced.
information (See Testing and adjusting, "Setting and adjustment of devices".)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Since this is an internal defect, troubleshooting cannot be performed.
Defective transmission
1 (If noticeable failure symptom does not appear, you may use that
controller
transmission controller.)

40-522 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ0MC] T/M Con Error (WA380_7-DAQ0MC-400-A-Z0-A)

Action level Failure code Transmission Controller Error


Failure
― DAQ0MC (Transmission controller system)
Detail of • Controller exhibits unusual behavior (unexpected behavior).
failure
Action of
• Resets controller CPU and restarts it.
controller
Problem on • Machine returns to same initial condition as that when starting switch is turned to ON
machine position.
Related • None in particular.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective transmission Since this is an internal defect, troubleshooting cannot be performed.
1
controller

WA470-7 40-523
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ1KA] Disconnection of Key SW ACC (T/M) (WA470_7-DAQ1KA-400-


A-Z0-A)

Action level Failure code Disconnection of Key Switch ACC (Transmission)


Failure
L03 DAQ1KA (Transmission controller system)
Detail of • While engine is running, key switch ACC signal is not entered in transmission controller.
failure
Action of • None in particular
controller
• Machine travels normally although lockup clutch is not engaged until engine is stopped.
Problem on • If ACC signal lines of both work equipment controller and engine controller have open
machine circuit, machine comes into the same state as when engine shutdown secondary switch is
operated.
• If fuse No. 1 or No. 15 in fuse box 2 is blown, nothing is displayed on machine monitor.
Related • When the engine is rotating, power is supplied other than the line between terminal ACC
information of starting switch and transmission controller.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector L63, and connect T-adapter to female side.
4.Turn battery disconnect switch to ON position.
5.Turn starting switch to ON position.
Open circuit in wiring Between L63 (female) (14) and (21) 20 to 30 V
harness Voltage
Between L63 (female) (24) and (31) 20 to 30 V
1 (wire breakage or
defective contact of a If no failure is found by above checks, this check is not required.
connector) 1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connectors L63 and S40, and connect T-adapters to each
female side.
Between L63 (female) (14) and S40 (female) (4) Max. 1 z
Resistance
Between L63 (female) (24) and S40 (female) (4) Max. 1 z
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Insert T-adapter into connector L63.
Defective transmission 4.Turn battery disconnect switch to ON position.
2
controller 5.Turn starting switch to ON position.
Between L63 (14) and (21) 20 to 30 V
Voltage
Between L63 (24) and (31) 20 to 30 V

40-524 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to ACC signal

WA470-7 40-525
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ2KK] Solenoid Power Source Low (T/M) (WA470_7-DAQ2KK-400-A-Z0-


A)

Action level Failure code Solenoid Power Source Low (Transmission)


Failure
L03 DAQ2KK (Transmission controller system)
• 24 V solenoid power supply voltage (appears at transmission controller pins 2, 12, and
22) is 18 V or lower, while controller power supply (continuous power supply voltage from
Detail of battery) is normal.
failure • Detection conditions: Continuous power supply (battery direct power supply) is 20 V or
above and solenoid power supply is 18 V or below. Terminal-C input is OFF.
• Does not generate failure codes that can be falsely generated due to drop in 24 V
solenoid power supply voltage.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until directional
lever or directional selector switch is set to N (neutral) position.
Problem on • Machine cannot travel (transmission is left in NEUTRAL).
machine • Fan rotating in reverse changes its direction to normal.
• If failure code [DAQ4KB] (Ground Fault of Sol. Self-Holding Relay) is also displayed,
Related perform troubleshooting for it first.
information • If fuse No. 2 in fuse box 1 is blown, failure codes [DF10KA] and [DDK6A] are displayed.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow
1 fuse FL (R05 and If slow blow fuse is blown, circuit probably has ground fault.
R06A)
Defective fuse 2 in fuse If fuse is blown, circuit probably has ground fault.
2
box 1
1. Turn starting switch to OFF position.
2. Disconnect connector L112 and connect T-adapter to male side.
Between L112 (male) (1) and (2) 290 ± 30 z
Resistance
Between L112 (male) (3) and (6) Max. 1 z
Defective fan pump
1. Turn starting switch to OFF position.
3 (power supply holding)
2. Replace fan pump relay L112 with other normal relay.
relay
Check if machine Machine becomes Original relay (L112) is
becomes normal when normal. defective.
fan pump (power supply
holding) relay (L112) is Machine does not Original relay (L112) is
replaced. become normal. normal.

1. Turn starting switch to OFF position.


2. Turn the battery disconnect switch to OFF position.
Open circuit in wiring 3. Disconnect connectors L112 and L63, and insert T-adapters into each
harness female side.
4 Between battery relay terminal R07 and L63
(wire breakage or Max. 1 z
(female) (2), (12) and (22)
defective contact of
connector) Resistance a Coil resistance of fan pump (self-holding) relay
290 ± 30 z
Between L63 (female) (4) and ground
Between ground and each of L63 (21) and (31) Max. 1 z
a If slow-blow fuse is blown, replace it in advance.
1. Turn the battery disconnect switch to OFF position.
Ground fault in wiring 2. Turn starting switch to OFF position.
harness 3. Remove all fuses in fuse box 1.
5 4. Remove slow blow fuse R04.
(contact with ground
circuit) 5. Disconnect connector L63, and connect T-adapter to female side.
Between battery relay terminal (R07) and ground Min. 1 Mz
Resistance
Between ground and L63 (female) (2), (12), or (22) Min. 1 Mz

40-526 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Insert T-adapter into connector L63.
4.Turn battery disconnect switch to ON position.
Defective transmission 5.Turn starting switch to ON position.
6
controller Between L63 (2) and (21) 20 to 30 V
Between L63 (12) and (31) 20 to 30 V
Voltage
Between L63 (22) and (33), and between L63 (32)
and (33) 20 to 30 V

WA470-7 40-527
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to power supply of transmission controller

40-528 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ4KB] Ground Fault of Sol. Self-Holding Relay (WA470_7-


DAQ4KB-400-A-Z0-A)

Action level Failure code Ground Fault of Solenoid Self-Holding Relay (TM)
Failure
L03 DAQ4KB (Transmission controller system)
• Excessive current flows when the output to primary circuit (coil) of fan pump (solenoid
Detail of self-holding) relay is turned ON. When controller drives primary circuit (coil) of fan pump
failure (solenoid self-holding) relay, large current flows.
• Stops driving fan pump (solenoid self-holding) relay circuit.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • The radiator fan cannot be rotated reversely.
machine (If rotating reversely, it is changed to the normal rotation.)
• Output signal of fan pump (solenoid self-holding) relay can be checked with monitoring
function (Code: 03900).
Related • This failure code detects failure in primary (coil) circuit of fan pump (solenoid self-holding)
information relay. It does not detect failure in secondary (contact) circuit.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan pump 1. Turn starting switch to OFF position.
1 (solenoid self-holding) 2. Disconnect connector L112 and connect T-adapter to male side.
relay (L112) Resistance Between connector L112 (male) (1) and (2) 290 ± 30 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and L112, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (4) or L112
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L63 and L112, and connect T-adapter to either
Short circuit in wiring
3 female side.
harness
Between L63 (female) (4) and (21), or between
Resistance L112 (female) (1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Defective transmission 2. Insert T-adapters into connector L63.
4 3. Turn starting switch to ON position.
controller
Voltage Between L63 (female) (4) and ground 20 to 30 V

WA470-7 40-529
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fan pump (transmission solenoid self-holding) relay

40-530 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQ9KQ] Inconsistency of Model Selection (T/M) (WA380_7-


DAQ9KQ-400-A-Z0-A)

Action level Failure code Inconsistency of Model Selection (Transmission)


Failure
L03 DAQ9KQ (Transmission controller system)
Detail of • Model selection information sent from machine monitor differs from that stored in
failure transmission controller.
• Continues to operate taking it that machine model is same as that before generation of
Action of this failure code.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Does not generates failure codes that can be falsely detected due to this error.
Problem on • Driving machine may damage transmission.
machine
• Part number of transmission controller can be checked with monitoring function.
(Code: 20414)
Related • Model selection of machine monitor can be checked with monitoring function.
information (Code: 00205)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
False model may be selected in machine monitor. When replacing
False model selection of machine monitor, be sure to perform setting of model selection by
1 using adjustment function in service mode of machine monitor.
machine monitor
(See, Testing and adjustment, "Special functions of machine monitor".)
Transmission controller of Check part number of transmission controller. If it is wrong, install
2 false part number proper transmission controller.
If no failure is found by above checks, machine monitor or transmission
Defective machine monitor or controller is defective. (Since this is an internal defect, troubleshooting
3
transmission controller cannot be performed).

WA470-7 40-531
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQLKA] Operating Lamp Open Circuit (T/M) (WA470_7-DAQLKA-400-A-


Z0-A)

Action level Failure code Operating Lamp Open Circuit (Transmission)


Failure
- DAQLKA (Transmission controller system)
Transmission controller determines that output circuit to system operating lamp is open
Detail of because voltage of output circuit remains at approximately 5V or below for approx 3 seconds
failure after starting switch is turned to ON position, during which transmission controller does not
drive system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
position.
Problem on • System operating lamp may not light up while controller is performing end processing
machine a While controller is performing end processing, if battery disconnect switch is set to "OFF"
position, fan stops suddenly and may be damaged. In addition, initial learning data are not
saved resulting in increased shifting shocks.
• Although transmission controller is not able to light system operating lamp, no trouble will
result unless battery disconnect switch is turned to OFF position.
Related • When system operating lamp is lit up, output circuit voltage is at low level.
information • Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-4 in fuse If fuse is blown, circuit probably has ground fault.
1
box 2
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors L61 and L63, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between battery relay terminal (R01) and R61
Max. 1 z
connector) Resistance (female) (1)
Between L61 (female) (2) and L63 (female) (34) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Remove fuse-4 in fuse box 2.
3 4. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
(contact with ground connect T-adapter to female side of L63.
circuit)
Between L63 (female) (34) and ground Min. 1 Mz
Resistance
Between R61 (female) (1) and ground Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-532 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-533
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQLKB] Operating Lamp Short Circuit (T/M) (WA470_7-DAQLKB-400-A-


Z0-A)

Action level Failure code Operating Lamp Short Circuit (Transmission)


Failure
- DAQLKB (Transmission controller system)
• Transmission controller determines that output circuit to system operating lamp shorts
Detail of because voltage of output circuit does not become Low level while transmission controller
failure drives system operating lamp.
• Stops driving system operating lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• When controller drives system operating lamp, large current may flow through circuit
causing burnout of controller.
Problem on • System operating lamp may not light up while controller is performing end processing
machine a While controller is performing end processing, if battery disconnect switch is set to OFF
position, fan stops suddenly and may be damaged. In addition, initial learning data are not
saved resulting in increased shifting shocks.
• Although transmission controller is not able to light system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When system operating lamp is lit up, output circuit voltage is at low level.
No. Cause Procedure, measuring location, criteria and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
Short circuit in wiring 3.Remove fuse-4 in fuse box 2.
1 4.Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
harness
connect T-adapter to female side of R61.
Resistance Between R61 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Hot short circuit in 3. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
2 wiring harness connect T-adapter to female side of L63.
4. Turn battery disconnect switch to ON position.
Voltage Between L63 (female) (34) and ground Max 1 V
Defective transmission If no failure is found by above checks, transmission controller is defective.
3 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-534 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-535
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQQKR] CAN2 Discon (Transmission Con) (WA380_7-DAQQKR-400-A-


Z0-A)

Action level Failure code CAN2 Disconnection (Transmission Controller)


Failure
L03 DAQQKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize transmission controller over CAN communication-2
failure line (KOMNET/c).
• Does not update communication information.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
• Failure codes to be generated by transmission controller are not displayed.
Problem on • Fan rotation direction cannot be reverse.
machine • Adjustment function is unavailable.
• Monitoring data for which transmission controller is responsible are not updated.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• For CAN communication error over CAN communication-2 line, monitor controller can
generate six failure codes; [D8AQKR], [DAQQKR], , [DAZQKR], [DB2QKR], [DB9QKR],
and [DSJ0KR]. When all of these six failure codes are displayed simultaneously on
screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
communication line). In this case, check whether air conditioner is operated (ON/OFF and
Related air flow adjustment) from air conditioner operation screen since air conditioner is also
information controlled over CAN communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply to Perform troubleshooting for failure code [DAQ0KK].
1
transmission controller
Defective CAN-2 Perform checks on causes 4 to 9 in troubleshooting for failure code
2 [DB2QKR].
communication line
If no failure is found by above checks, transmission controller is
Defective transmission defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
4 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-536 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQRKR] CAN1 Discon (Transmission Con) (WA500_7-DAQRKR-400-A-


Z0-A)

Action level Failure code CAN1 Disconnection (Transmission Controller)


Failure
L03 DAQRKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize transmission controller over CAN communication-1
failure line (KOMNET/r).
• Hides pointer of torque converter oil temperature gauge and hydraulic oil temperature
gauge from screen.
• Changes display of speedometer to "00".
Action of • Machine monitor leaves data of CAN communication from transmission controller as the
controller value just before this failure occurs.
• Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
• Information to be obtained from transmission controller is not displayed and special
Problem on functions that need information do not work. Or received data are not updated.
machine • Pointer of torque converter oil temperature gauge and hydraulic oil temperature gauge
disappears from screen.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• For CAN communication error over CAN communication-1 line, monitor controller can
generate two other failure codes; [DB2RKR] and [DB9RKR]. When these two failure
codes are also displayed on screen, ground fault, short circuit, or hot short circuit may
Related occur in wiring harness (CAN communication line).
information • CAN1 terminating resistor on operator's cab side is located in machine monitor and that
on engine side is connector "B_RES" (connector B_RES is not located on CAN
communication-1 line (KOMNET/r) but is connected to it via connector "J2").
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply
1 to transmission Perform troubleshooting for [DAQ0KK].
controller
Defective CAN-1 Perform checks on causes 2 to 9 in troubleshooting for failure code
2 [DB2RKR].
communication line
Defective transmission If no failure is found by above checks, transmission controller is defective.
3
controller (Since this is an internal defect, troubleshooting cannot be performed.)
Defective monitor If no failure is found by above checks, monitor controller is defective.
4
controller (Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-537
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAQRMA] Inconsistency of Option Selection (T/M) (WA380_7-


DAQRMA-400-A-Z0-A)

Action level Failure code Inconsistency of Option Selection (Transmission)


Failure
L03 DAQRMA (Transmission controller system)
Detail of • When starting switch is turned to ON position, option setting information sent from monitor
failure controller differs from that stored in transmission controller.
Action of • Uses option setting stored in it to control machine.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • Machine does not operates according to option setting.
machine
• Perform initial setting and initial adjustment similar to those required when transmission is
Related replaced.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Option setting of machine monitor is probably incorrect. Perform
Improper option setting of
1 correct setting referring to Testing and adjustment, "Special functions of
machine monitor
machine monitor".
Monitor controller may be defective. (Since this is an internal defect,
2 Defective monitor controller troubleshooting cannot be performed.)
If no failures is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

40-538 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAZ9KQ] A/C Model Selection Abnormality (WA380_7-DAZ9KQ-400-A-Z0-A)

Action level Failure code Air Conditioner Model Selection Abnormality


Failure
- DAZ9KQ (Machine monitor system)
• Machine model in machine monitor program differs from that in air conditioner controller
Detail of program.
failure (Replaced machine monitor or air conditioner controller has wrong part number.)
Action of
controller
Problem on • Air conditioner does not work normally.
machine
• Model code in machine monitor program can be checked with monitoring function.
(Code: 00205 “Model selection (MON)“)
• Air conditioner controller data (machine model and series) can be checked with
monitoring function. (Code: 55201) (Air conditioner control data must be 30 (indicating
Related wheel loader.)
information • Air conditioner control data (machine model and series) of machine monitor can be
checked with monitoring function. (Code: 55200) (Air conditioner control data must be 30
(indicating wheel loader.)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective machine Defective machine monitor
1
monitor (Wrong machine model is programmed.)
Defective air conditioner Defective air conditioner controller
2
controller (Wrong machine model is programmed.)

WA470-7 40-539
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DAZQKR] CAN2 Discon (Aircon ECU) (WA380_7-DAZQKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Air Conditioner ECU)


Failure
L01 DAZQKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize air conditioner controller over CAN communication-
failure 2 line (KOMNET/c).
Action of • Holds information at time of occurrence of failure.
controller • If cause of failure disappears, machine becomes normal by itself.
• Failure codes to be generate by air conditioner controller are not displayed.
Problem on • Monitoring data for which air conditioner controller is responsible are not updated.
machine • Air conditioner cannot be operated (air does not blow out).
• Display of air conditioner operation screen of machine monitor is not correct.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• For CAN communication error over CAN communication-2 line, monitor controller can
generate six failure codes; [D8AQKR], [DAQQKR], [DAZQKR], [DB2QKR], [DB9QKR],
and [DSJ0KR]. When all of these six failure codes are displayed simultaneously on
Related screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
information communication line).
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
a If fuse-15 in fuse box2 is blown, machine monitor displays nothing..
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply to air a Perform troubleshooting shown in Chapter 80 "Troubleshooting of
1
conditioner controller power supply system".
Defective CAN-2 Perform checks on causes 4 to 9 in troubleshooting for failure code
2 [DB2QKR].
communication line
If no failure is found by above checks, air conditioner controller is
Defective air conditioner defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
4 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-540 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB2QKR] CAN2 Discon (Engine Con) (WA470_7-DB2QKR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Engine Controller)


Failure
L03 DB2QKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize engine controller over CAN communication-2 line
failure (KOMNET/c).
• Does not update communication information.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
• Failure codes to be generate by engine controller are not displayed.
Problem on • Monitoring data for which engine controller is responsible are not updated.
machine • Manual regeneration of KDPF cannot be performed.
• Cylinder cutout mode operation and no-injection cranking cannot be performed.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
• For CAN communication error over CAN communication-2 line, monitor controller can
generate six failure codes; [D8AQKR], [DAQQKR], [DAZQKR], [DB2QKR], [DB9QKR],
and [DSJ0KR]. When all of these six failure codes are displayed simultaneously on
screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
communication line). In this case, check whether air conditioner is operated (ON/OFF and
Related air flow adjustment) from air conditioner operation screen since air conditioner is also
information controlled over CAN communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
a If fuse-15 in fuse box2 is blown, machine monitor displays nothing..
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective fuse-6 in fuse
1 2. Remove fuse-6 in fuse box 2.
box 2
• When fuse is blown, engine controller may have internal short circuit.
a If fuse is not blown, this check is not required.
Defective engine 1. Turn starting switch to OFF position.
2 2. Disconnect connectors EC3 and connect T-adapters to male side.
controller
Between EC3 (male) (1) and (21) Min. 10 z
Resistance
Between EC3 (male) (11) and (31) Min. 10 z
a Check ground terminals E14A and E14B for looseness and corrosion in
advance.
1. Turn starting switch to OFF position.
Defective power supply 2. Disconnect connectors EC3 and connect T-adapters to female side.
3 to engine controller 3. Turn starting switch to ON position.
a If check result is abnormal, perform troubleshooting for [CA441].
Between EC3 (female) (1) and (2) 20 to 30 V
Voltage
Between EC3 (female) (11) and (31) 20 to 30 V
1. Turn starting switch to OFF position.
CAN terminating 2. Disconnect connector MDM 3 and CAN1, and connect T-adapters to male
resistor side.
4
(internal open or short Between CAN1 (male) (A) and (B) 120 ± 12 z
circuit) Resistance 120 ± 12 z
Between MDM3 (male) (3) and (8)

WA470-7 40-541
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• CAN communication line
a CAN terminating resistor of 120 z is also located in machine monitor. That
is, two CAN terminating resistors of 120 z are connected in parallel. When
circuit resistance is measured at connector of controller other than
machine monitor, if combined resistance is 60 z, wiring harness does not
have open circuit.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to connector at
which measurement is performed.
a If open circuit is found (resistance between two terminals is 1 z or below),
disconnect all CAN communication connectors of every controller and
check whether open circuit occurs in wiring harness or inside controller.
Open or short circuit in Approx. 120
5 wiring harness Between MDM3 (female) (3) and (8)
z
Between EC3 (female) (17) and (18) Approx. 60
z
Between MCM1 B (female) (97) and (89) Approx. 60
z
Between L72 (female) (32) and (22) Approx. 60
z
Resistance
Between L62 (female) (32) and (22) Approx. 60
z
Between AL1 (female) (4) and (6) Approx. 60
z
Between L80A (female) (10) and (11) Approx. 60
z
Between CAN1 (male) (A) and (B) Approx. 120
z
• ACC signal of starting switch (start of CAN communication is not
recognized)
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connector at which measurement is performed and insert T-
adapters into it.
3. Set battery disconnect switch to ON position, and turn starting switch to
ON position.
Between EC3 (3) and (21) 20 to 30 V
Between MCM1 A (female) (24) and (2) 20 to 30 V
Between L73 (female) (21) and each of (14) and
(24) 20 to 30 V
Voltage
Between L63 (female) (21) and each of (14) and
Open circuit in wiring (24) 20 to 30 V
harness
Between AL1 (1) and (5) 20 to 30 V
6 (wire breakage or
defective contact of Between L80B (3) and (1) 20 to 30 V
connector) a If no failure is found by check on cause 5, this check is not required.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to female side of
connector at which measurement is performed.
Between MDM3 (female) (3) and MCM1 B (female)
(97) Max. 1 z
Between MDM3 (female) (8) and MCM1 B (female)
(89) Max. 1 z
Resistance
Between MCM1 B (female) (97) and L62 (female)
(32) Max. 1 z
Between MCM1 B (female) (89) and L62 (female)
(22) Max. 1 z

40-542 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Between MCM1 B (female) (97) and EC3 (female)
(17) Max. 1 z
Between MCM1 B (female) (89) and EC3 (female)
(18) Max. 1 z
Between MCM1 B (female) (97) and L72 (female)
(32) Max. 1 z
Between MCM1 B (female) (89) and L72 (female)
(22) Max. 1 z
Between MCM1 B (female) (97) and AL1 (female)
(4) Max. 1 z
Between MCM1 B (female) (89) and AL1 (female)
(6) Max. 1 z
Between MCM1 B (female) (97) and L80A (female)
(10) Max. 1 z
Between MCM1 B (female) (89) and L80A (female)
(11) Max. 1 z
Between EC3 (female) (17) and CAN1 (female) (A) Max. 1 z
Between EC3 (female) (18) and CAN1 (female) (B) Max. 1 z
a If no failure (open circuit) is found by check on cause 5, measure
resistance at any one place in each case.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect related connectors and connect T-adapters to female side of
Ground fault in wiring connector at which measurement is performed.
7
harness Between ground and any of MDM3 (female) (3),
L62 (female) (32), L80A (female) (10), AL1 (female) Min. 1 Mz
(4), EC3 (female) (17), or L72 (female) (32)
Resistance
Between ground and any of MDM3 (female) (8),
L62 (female) (22), L80A (female) (11), AL1 (female) Min. 1 Mz
(6), EC3 (female) (18), or L72 (female) (22)
a If no failure (open circuit) is found by check on cause 5, measure voltage
at any one place in each case.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connector at which measurement is performed and insert T-
adapters into connector.
Open circuit or hot short 3. Set battery disconnect switch to ON position.
circuit in wiring harness 4. Turn starting switch to ON position.
8
(contact with 24 V a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
circuit) so regard wiring harness as normal if measure voltage is 1 to 4 V.
Between ground and any of MDM3 (female) (3),
L62 (female) (32), L80A (female) (10), AL1 (female) 1 to 4 V
(4), EC3 (female) (17), or L72 (female) (32)
Voltage
Between ground and any of MDM3 (female) (8),
L62 (female) (22), L80A (female) (11), AL1 (female) 1 to 4 V
(6), EC3 (female) (18), or L72 (female) (22)

WA470-7 40-543
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• When all of six failure codes [D8AQKR], [DAQQKR], [DAZQKR],
[DB2QKR], [DB9QKR], and [DSJ0KR] are displayed simultaneously
a To identify defective controller, repeat following steps 1. to 3. to disconnect
controllers one by one from CAN communication line .
Defective engine 1. Turn starting switch to OFF position, and set battery disconnect switch to
controller, work OFF position.
equipment controller, 2. Disconnect each CAN communication connector one by one in order
transmission controller, engine controller connector EC3, work equipment controller connector
9
air conditioner L72, transmission controller connector L62, air conditioner controller
controller, machine connector AL1, KOMTRAX terminal connector L80A, and machine
monitor (meter unit), or monitor (meter unit) connector MDM3.
KOMTRAX terminal 3. Set battery disconnect switch to ON position, turn starting switch to ON
position, then perform troubleshooting.
4. Return to step 1 to check next connector.
Has the number of displayed failure codes If YES, disconnected
decreased from six? controller is defective.
Defective engine If no failure is found by above checks, engine controller is defective.
10
controller (Since this is an internal defect, troubleshooting cannot be performed.)
Defective monitor If no failure is found by above checks, monitor controller is defective.
11
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-544 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to CAN communication-2 line

WA470-7 40-545
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB2RKR] CAN1 Discon (Engine Con) (WA470_7-DB2RKR-400-A-Z0-A)

Action level Failure code CAN1 Disconnection (Engine Controller)


Failure
L03 DB2RKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize engine controller over CAN communication-1 line
failure (KOMNET/r).
• Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
Action of • Hides pointer of engine coolant temperature gauge from screen.
controller • Moves pointer of engine speed meter to zero point.
• Machine monitor leaves CAN communication data from engine controller as the value just
before this failure occurs.
• Information to be obtained from engine controller is not displayed and special functions
that need information do not work. Or received data are not updated.
Problem on • Engine cannot be controlled.
machine • Engine speed and coolant temperature cannot be detected.
• Pointer of engine coolant temperature gauge disappears.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller may be defective (cause 1).
• For CAN communication error over CAN communication-1 line, monitor controller can
generate failure codes [DAQRKR], [DB2RKR], and [DB9RKR].
Related • CAN1 terminating resistor on operator's cab side is located in machine monitor and that
information on engine side is connector “B_RES“ (connector B_RES is not located on CAN
communication-1 line (KOMNET/r) but is connected to it via connector "ECM J2").
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective engine Perform checks on causes 1 to 3 in troubleshooting for failure code
1 controller system [DB2QKR].
1. Turn starting switch to OFF position.
Defective CAN 2. Disconnect connector MCM1 B and C23, and connect T-adapters to male
terminating resistor side.
2
(internal open or short Between C23 (male) (A) and (B) 120 ± 12 z
circuit) Resistance 120 ± 12 z
Between MCM1 B (male) (105) and (112)

40-546 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• CAN communication line
a CAN terminating resistor of 120 z is also located in monitor controller.
That is, two CAN terminating resistors of 120 z are connected in parallel.
When circuit resistance is measured at connector of controller other than
monitor controller, if combined resistance is 60 z, wiring harness does not
have open circuit.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors MCM1 B, L62, L72, ECM J1, ECM J2, and B_RES
one by one, and connect T-adapters to each female side.
a If open circuit is found (resistance between two terminals is 1 z or below),
Open or short circuit in disconnect all CAN communication connectors of every controller and
3 wiring harness check whether open circuit occurs in wiring harness or inside controller.
Between MCM1 B (female) (113) and (105) Approx. 120
z
Between L72 (female) (33) and (23) Approx. 60
z
Between L62 (female) (33) and (23) Approx. 60
z
Resistance Between B_RES (male) (A) and (B) Approx. 120
z
Between ECM J1 (female) (8) and (18) Approx. 120
z
Approx. 120
Between ECM J2 (female) (24) and (25) z

WA470-7 40-547
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• ACC signal of starting switch (start of CAN communication is not
recognized)
1. Turn starting switch to OFF position, and disconnect battery ground cable.
2. Disconnect connectors MCM1 A, L63, and EC3, and insert T-adapters.
3. Set battery disconnect switch to ON position, and turn starting switch to
ON position.
Between MCM1 A (female) (4) and each of (24)
and (43) 20 to 30 V
Between EC3 (3) and (21) 20 to 30 V
Voltage Between L73 (female) (21) and each of (14) and
(24) 20 to 30 V
Between L63 (female) (21) and each of (14) and
(24) 20 to 30 V

a If no failure is found by check on cause 3, this check is not required.


Open circuit in wiring 1. Turn starting switch to OFF position, and set battery disconnect switch to
harness OFF position.
2. Disconnect connectors MCM1 B, L62, ECM J1, ECM J2, and B_RES, and
4 (wire breakage or
connect T-adapters to each female side.
defective contact of
connector) Between MCM1 B (female) (113) and L62 (female)
(33) Max. 1 z
Between MCM1 B (female) (105) and L62 (female)
(23) Max. 1 z
Between MCM1 B (female) (113) and L72 (female)
(33) Max. 1 z
Between MCM1 B (female) (105) and L72 (female)
(23) Max. 1 z
Resistance
Between MCM1 B (female) (113) and ECM J1
(female) (8) Max. 1 z
Between MCM1 B (female) (105) and ECM J1
(female) (18) Max. 1 z
Between ECM J2 (female) (24) and B_RES
(female) (A) Max. 1 z
Between ECM J2 (female) (25) and B_RES
(female) (B) Max. 1 z

1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect connectors MCM1 B, L72, L62, ECM J1, ECM J2, and C23,
and connect T-adapters to each female side.
Between ground and any of L72 (female) (33), L62
Ground fault in wiring (female) (33), MCM1 B (female) (113), MCM1 B Min. 1 Mz
harness (female) (112), and ECM J1 (female) (8)
5
(contact with ground Between ground and ECM J2 (female) (24) or C23
circuit) (female) (A) Min. 1 Mz
Resistance
Between ground and any of L72 (female) (23), L62
(female) (23), MCM1 B (female) (105), and ECM J1 Min. 1 Mz
(female) (18)
Between ground and either of ECM J2 (female) Min. 1 Mz
(25) and B_RES (female) (B)

40-548 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure (open circuit) is found by check on cause 3, measure voltage
at any one place in each case.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
2. Disconnect any of connectors MCM1 B, L72, L62, and B_RES, and
connect T-adapters to female side.
3. Set battery disconnect switch to ON position.
Open circuit or hot short 4. Turn starting switch to ON position.
6 circuit in wiring harness a Measurement is not performed at connector ECM J1, ECM J2, or MCM1
B.
a Voltage of CAN H and CAN L is 2.5 ± 1 V including during communication,
so regard wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and any of L72 (female) (33), L62
(female) (33) and B_RES (female) (A) 1 to 4 V
Voltage
Between ground and any of L72 (female) (22), L62
(female) (22) and B_RES (female) (B) 1 to 4 V
• If failure code [DAQRKR] is also displayed
a Disconnect transmission controller and engine controller one by one from
CAM communication line to determine which controller is defective.
1. Turn starting switch to OFF position, and set battery disconnect switch to
Defective transmission OFF position.
7 2. Disconnect transmission controller connector L62.
controller
3. Set battery disconnect switch to ON position, and turn starting switch to
ON position.
Does either of failure codes [DAQRKR] and
[DB2RKR] for CAN1 communication error If YES, transmission
disappear? controller is defective.
• When failure code [DB9RKR] is also displayed
a Disconnect work equipment controller and engine controller one by one
from CAM communication line to determine which controller is defective.
1. Turn starting switch to OFF position, and set battery disconnect switch to
Defective work OFF position.
8 equipment controller 2. Disconnect work equipment controller connector L72.
3. Set battery disconnect switch to ON position, and turn starting switch to
ON position.
Does either of failure codes [DB2RKR] and
[DB9RKR] for CAN1 communication error If YES, work equipment
disappear? controller is defective.
• When failure codes[DAQRKR] and [DB9RKR] are also displayed
a Disconnect work equipment controller, transmission controller, and engine
controller one by one from CAM communication line to determine which
controller is defective.
1. Turn starting switch to OFF position, and set battery disconnect switch to
Defective engine OFF position.
9
controller 2. Disconnect engine controller connector ECM J1.
3. Set battery disconnect switch to ON position, and turn starting switch to
ON position.
Does any of failure codes [DAQRKR], [DB2RKR], If YES, engine controller
and [DB9RKR] for CAN1 communication error is defective.
disappear?
Defective engine If no failure is found by above checks, engine controller is defective.
10
controller (Since this is an internal defect, troubleshooting cannot be performed.)
Defective monitor If no failure is found by above checks, monitor controller is defective.
11
controller (Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-549
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to CAN communication-1 line

40-550 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB90KK] Drop in BBC Controller Main Power Source (WA470_7-
DB90KK-400-A-Z0-A)

Action level Failure code Drop in Bucket Boom Controller Controller Main Power Source
Failure
L03 DB90KK (Work equipment controller system)
• Continuous power supply (power supply directly connected to battery) voltage of work
Detail of equipment controller drops.
failure • Continuous power supply (battery direct power supply) voltage is 18 V or less.
• Cannot detect input signals properly.
• Correct the settings so that any failure code, other than this failure code, is not displayed
when the continuous power supply (power supply directly connected to battery) voltage is
Action of 18 V or less for 0.02 second.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until work
equipment lever is set to NEUTRAL position.
Problem on • Since an input signal cannot be detected correctly, normal operation cannot be
machine performed.
Related • If fuse-5 in fuse box 2 is blown, failure codes [DAQQKR] and [DAQRKR] are displayed.
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a Check battery voltage and specific gravity of battery electrolyte.
1 Defective battery Voltage Battery voltage Min. 24 V
Specific
Specific gravity of battery electrolyte Min. 1.26
gravity
Defective slow-blow If slow-blow fuse (R02) is blown, circuit may have ground fault, etc. (See
2 fuse (R02) check on cause 5.)
Defective fuse 3 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 5.)
3
box 2
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L73, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
a If voltage appears between battery (+) terminal and ground but not
between ground and each of L73 (1) and (11), wiring harness or fuse has
open circuit.
Open circuit in wiring Between battery (-) terminal and ground 20 to 30 V
harness Voltage Between ground and each of L73 (female) (1) and
4 (wire breakage or (11) 20 to 30 V
defective contact of
connector) a If no failure is found by above checks, this check is not required.
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector L73, and connect T-adapter to female side.
Between ground and each of L73 (female) (21),
(31), (32), and (33) Max. 1 z
Resistance
Between battery (+) terminal and each of L73 (1)
and (11) Max. 1 z

a If slow-blow fuse or fuse is blown, replace it in advance.


Ground fault in wiring 1.Turn the battery disconnect switch to OFF position.
harness 2.Turn starting switch to OFF position.
5 3.Remove all fuses in fuse box 2.
(contact with ground
circuit) 4.Disconnect connector L73, and connect T-adapter to female side of L73.
Between battery (-) terminal and ground Min. 1 Mz
Resistance
Between ground and L73 (female) (1) or (11) Min. 1 Mz

WA470-7 40-551
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L73.
Defective work 4. Turn battery disconnect switch to ON position.
6 equipment controller 5. Turn starting switch to ON position.
Between L73 (1) and each of (21), (31), (32), and
Voltage (33), and between L73 (11) and each of (21), (31), 20 to 30 V
(32), and (33)

Circuit diagram related to work equipment controller power supply

40-552 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB90KT] Abnormality of Non-volatile Memory (BBC) (WA380_7-


DB90KT-400-A-Z0-A)

Action level Failure code Abnormality of Non-volatile Memory (Bucket Boom


Failure Controller)
L01 DB90KT
(Work equipment controller system)
Detail of • The non-volatile memory in the controller has failed.
failure
• Controls option settings and internal adjustment values with the default value.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • An incorrect error detection may occur.
machine • The machine performance drops as abnormal data is used for control.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective work equipment Since this is an internal defect, troubleshooting cannot be performed.
1
controller Replace the work equipment controller.

WA470-7 40-553
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB90MC] BBC Error (WA380_7-DB90MC-400-A-Z0-A)

Action level Failure code Bucket Boom Controller Error


Failure
— DB90MC (Work equipment controller system)
Detail of • Malfunction of work equipment controller (unexpected behavior).
failure
Action of • Resets the CPU of work equipment controller, and restarts it.
controller
Problem on • The system does not operate normally.
machine • Machine returns to the initial status as when the starting switch is turned ON.
Related • Method of reproducing failure code: Turn starting switch ON.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective work equipment The work equipment controller is defective.
1
controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-554 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB91KA] Disconnection of Key SW ACC (BBC) (WA470_7-DB91KA-400-


A-Z0-A)

Action level Failure code Disconnection of Key Switch ACC (Bucket Boom Controller)
Failure
L03 DB91KA (Work equipment controller system)
Detail of • While engine is running, key switch ACC signal is not entered in work equipment
failure controller.
Action of • None in particular
controller
• Work equipment does not operate.
Problem on • If ACC signal lines of both transmission controller and engine controller have open circuit,
machine machine comes into the same state as when engine shutdown secondary switch is
operated.
• If fuse No. 1 or No. 15 in fuse box 2 is blown, nothing is displayed on machine monitor.
Related • When the engine is rotating, power is supplied other than the line between terminal ACC
information of starting switch and work equipment controller.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L73, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Open circuit in wiring Between L73 (female) (14) and (21) 20 to 30 V
harness Voltage
Between L73 (female) (24) and (31) 20 to 30 V
1 (wire breakage or
defective contact of a If no failure is found by above checks, this check is not required.
connector) 1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connectors L73 and S40, and connect T-adapters to each
female side.
Between L73 (female) (14) and S40 (female) (4) Max. 1 z
Resistance
Between L73 (female) (24) and S40 (female) (4) Max. 1 z
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L73.
Defective work 4. Turn battery disconnect switch to ON position.
2 equipment controller 5. Turn starting switch to ON position.
Between L73 (14) and (21) 20 to 30 V
Voltage
Between L73 (24) and (31) 20 to 30 V

WA470-7 40-555
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to ACC signal

40-556 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB92KK] Solenoid Power Source Low (BBC) (WA470_7-DB92KK-400-A-


Z0-A)

Action level Failure code Solenoid Power Source Low (Bucket Boom Controller)
Failure
L03 DB92KK (Work equipment controller system)
• 24V solenoid power supply voltage (appears at work equipment controller pins 2, 12, and
22) is 18 V or lower, while controller power supply (continuous power supply voltage from
Detail of battery) is normal.
failure • Detection conditions: Continuous power supply voltage (continuous power supply voltage
from battery) is Min. 20 V and solenoid power supply is Max. 18 V.
• Stops driving solenoids (stops driving all solenoids if solenoid power supply voltage drops
below 18 V).
• Does not allow failure codes to be displayed, that can be falsely generated due to drop in
Action of 24 V solenoid power supply voltage.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until work
equipment lever is set to NEUTRAL position.
Problem on • Work equipment does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow
1 fuse FL (R05 and If slow blow fuse is blown, circuit probably has ground fault.
R06A)
Defective fuse-5 in fuse If fuse is blown, circuit probably has ground fault.
2
box 1
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector L73, and connect T-adapter to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a If voltage appears between terminal R07 of battery relay and the ground,
but not between ground and each of L73 (2), (12) and (22), the wiring
Open circuit in wiring harness may be broken or the fuse may be blown.
harness Between battery relay terminal R07 and ground 20 to 30 V
3 (wire breakage or Voltage Between ground and each of L73 (female) (2), (12)
and (22) 20 to 30 V
defective contact of
connector)
a If no failure is found by above checks, this check is not required.
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
3.Disconnect connector L73, and connect T-adapter to female side.
Between ground and each of L73 (female) (21),
(31), (32), and (33) Max. 1 z
Resistance
Between battery (+) terminal and each of L73
(female) (2), (12), and (22) Max. 1 z

a If slow-blow fuse or fuse is blown, replace it in advance.


1.Turn the battery disconnect switch to OFF position.
Ground fault in wiring 2.Turn starting switch to OFF position.
harness 3.Remove all fuses in fuse box 1.
4 4.Remove slow blow fuse R05.
(contact with ground
circuit) 5.Disconnect connector L73, and connect T-adapter to female side of L73.
Between battery relay terminal (R07) and ground Min. 1 Mz
Resistance
Between ground and L73 (female) (2), (12), or (22) Min. 1 Mz

WA470-7 40-557
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector L73.
4. Turn battery disconnect switch to ON position.
Defective work 5. Turn starting switch to ON position.
5 equipment controller
Between L73 (2) and (21) 20 to 30 V
Between L73 (12) and (31) 20 to 30 V
Voltage
Between L73 (22) and (32), and between L73(22)
and (33) 20 to 30 V

Circuit diagram related to work equipment controller power supply

40-558 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB95KX] Failure of 5 V Power Source 1 (WA470_7-DB95KX-400-A-Z0-A)

Action level Failure code Failure of 5 V Power Source 1


Failure
- DB95KX (Work equipment controller system)
Detail of • Voltage of 5 V sensor power output circuit 1 is outside of normal output range of 4.7 to 5.3
failure V.
• Does not detect input signal normally because erroneous signal is input from
Action of potentiometer.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
• Pressure sensor and potentiometer signals are not input normally.
Problem on • The boom operation stops.
machine • Bucket leveler does not work.
• Komatsu SmartLoader Logic function stops.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors of the following sensors one by one and turn
starting switch ON each time.
a If this failure code goes out, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear. Ignore all
of displayed failure codes other than this one.
Defective 3. Each time troubleshooting is finished, return to step 1.
potentiometer, pressure 3rd (attachment) EPC lever potentiometer L30
1 sensor, or angle sensor Boom EPC lever potentiometer L28A
(internal open circuit) Oil pressure sensor of work equipment pump F10
Steering pump oil pressure sensor R86
Connector Emergency steering pump oil pressure sensor R37
Boom bottom pressure sensor F12
Boom head pressure sensor F13
Boom angle sensor F11
Bucket angle sensor F32
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors F10 to F13, F32, L28A, L29A, L30, and L71.
2 harness (contact with
3. Connect T-adapter to female side of connector L71.
ground circuit)
Resistance Between L71 (female) (22) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Defective work 2. Disconnect connector L71 and connect T-adapter to male side.
3 equipment controller 3. Turn starting switch to ON position.
Voltage Between L71 (male) (22) and (4) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connectors F10 to F13, F32, L28A, L29A, and L30.
Hot short circuit in
4 3. Insert T-adapter into connector L71.
wiring harness
4. Turn starting switch ON (with connector disconnected).
Voltage Between L71 (22) and ground 5.0 to 5.2 V

WA470-7 40-559
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 5V sensor power source (2 levers specification or 3 levers specification)

40-560 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB96KX] Failure of 5 V Power Source 2 (WA470_7-DB96KX-400-A-Z0-A)

Action level Failure code Failure of 5 V power source 2


Failure
- DB96KX (Work equipment controller system)
Detail of • Voltage of 5 V sensor power output circuit 2 is outside of normal output range of 4.7 to 5.3
failure V.
• Does not detect input signal normally because erroneous signal is input from
Action of potentiometer.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
• Potentiometer signals are not input normally.
Problem on
• Bucket stops operation.
machine
• Potentiometer error shown in Cause 1 occurs.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors of the following sensors one by one and turn
starting switch ON each time.
Defective potentiometer a If this failure code goes out, disconnected sensor is defective.
1
(internal short circuit)
a Since connector is disconnected, other failure codes appear. Ignore all
of displayed failure codes other than this one.
3. Each time troubleshooting is finished, return to step 1.
Connector Bucket lever potentiometer L29A
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L29A, L23, and L72.
2 3. Connect T-adapter to female side of connector L72.
(contact with ground
circuit) Resistance Between L72 (female) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Defective work 2. Disconnect connector L72, and connect T-adapter to male side.
3 equipment controller 3. Turn starting switch to ON position.
Voltage Between L72 (male) (1) and ground 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L29A and L23.
Hot short circuit in
4 3. Insert T-adapter into connector L72.
wiring harness
4. Turn starting switch ON (with connector disconnected).
Voltage Between L72 (1) and ground 5.0 to 5.2 V

WA470-7 40-561
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 5 V sensor power supply

40-562 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB99KQ] Inconsistency of Model Selection (BBC) (WA380_7-


DB99KQ-400-A-Z0-A)

Action level Failure code Inconsistency of Model Selection (Bucket Boom Controller)
Failure
L03 DB99KQ (Work equipment controller system)
Detail of • Model selection signal sent from monitor controller when starting switch is turned ON
failure differs from the model setting stored in work equipment controller.
• Continues to operate taking it that machine model is same as that before generation of
Action of this failure code.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • Work equipment may not operate normally.
machine
• Perform initial setting and initial adjustment similar to those required when the work
Related equipment controller is replaced.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
a Model setting of monitor controller is probably incorrect. After
Defective model setting by replacing the monitor controller or work equipment controller, set the
1
monitor controller model correctly. For details, see Testing and Adjusting, "Special
functions of machine monitor".
Installation of wrong work Wrong work equipment controller may be installed. Check part No. and
2 equipment controller install correct work equipment controller.
If no failure is found by above checks, work equipment controller is
Defective work equipment defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)
If no failure is found by above checks, monitor controller is defective.
4 Defective monitor controller (Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-563
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB9LKA] Operating Lamp Open Circuit (BBC) (WA470_7-DB9LKA-400-A-


Z0-A)

Action level Failure code Operating Lamp Open Circuit (Bucket Boom Controller)
Failure
- DB9LKA (Work equipment controller system)
• The work equipment controller has detected an open circuit because the output line
Detail of voltage of system operating lamp is approximately 5 V or less when the work equipment
failure controller does not output the voltage for approximately 3 seconds after the starting switch
has turned ON.
Action of • It does not output for system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine work equipment controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
• Although work equipment controller is not able to light up system operating lamp, no
Related trouble will result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after
starting switch is turned to ON position, open circuit can be detected.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-4 in fuse If fuse is blown, circuit probably has ground fault.
1
box 2
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Disconnect connectors L73 and R61, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between L73 (female) (34) and R61 (female) (2) Max. 1 z
connector) Resistance Between R61 (female) (1) and battery relay
terminal (R01) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Turn the battery disconnect switch to OFF position.
harness 3. Remove fuse-4 in fuse box 2.
3 4. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
(contact with ground connect T-adapter to female side of L73.
circuit)
Between L73 (female) (34) and ground Min. 1 Mz
Resistance
Between R61 (female) (1) and ground Min. 1 Mz
Defective work If no failure is found by above checks, work equipment controller is defective.
4 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-564 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-565
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB9LKB] Operating Lamp Short Circuit (BBC) (WA470_7-DB9LKB-400-A-


Z0-A)

Action level Failure code Operating Lamp Short Circuit (Bucket Boom Controller)
Failure
- DB9LKB (Work equipment controller system)
• Work equipment controller determines that output circuit to system operating lamp shorts
Detail of because voltage of output circuit does not become Low level while work equipment
failure controller drives system operating lamp.
Action of • Stops driving system operating lamp.
controller
• While system operating lamp is lit, battery disconnect switch must not be turned to OFF
Problem on position. Setting battery disconnect switch to OFF position may destroy data stored in
machine work equipment controller memory.
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Although work equipment controller is not able to light up system operating lamp, no
information trouble will result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
No. Cause Procedure, measuring location, criteria and remarks
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to OFF position.
Short circuit in wiring 3.Remove fuse-4 in fuse box 2.
1 4.Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
harness
connect T-adapter to female side of R61.
Resistance Between R61 (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Remove fuse-4 in fuse box 2.
Hot short circuit in
2 4. Disconnect connectors MCM1 A, L63, L80A, EC3, R61, and L73, and
wiring harness
connect T-adapter to female side of R61.
5. Turn battery disconnect switch to ON position.
Voltage Between R61 (female) (2) and ground Max 1 V
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-566 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to system operating lamp

WA470-7 40-567
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB9QKR] CAN2 Discon (Bucket Boom Con) (WA380_7-DB9QKR-400-A-Z0-


A)

Action level Failure code CAN2 Disconnection (Bucket Boom Controller)


Failure
L03 DB9QKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize work equipment controller over CAN
failure communication-2 line (KOMNET/c).
• Do not update CAN communication date.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
• Failure codes related to work equipment controller are not displayed
Problem on • Monitoring code data are not updated.
machine • Adjustment function cannot be used.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• For CAN communication error over CAN communication-2 line, monitor controller can
generate six failure codes; [D8AQKR], [DAQQKR], [DAZQKR], [DB2QKR], [DB9QKR],
and [DSJ0KR]. When all of these six failure codes are displayed simultaneously on
screen, ground fault, short circuit, or hot short circuit may occur in wiring harness (CAN
communication line). In this case, check whether air conditioner is operated (ON/OFF and
Related air flow adjustment) from air conditioner operation screen since air conditioner is also
information controlled over CAN communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply to
1 Perform troubleshooting for failure codes [DB90KK] and [DB91KA].
work equipment controller
Defective CAN2 Perform checks on causes 4 to 9 in troubleshooting for failure code
2 communication system [DB2QKR].
If no failure is found by above checks, work equipment controller is
Defective work equipment defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
4 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-568 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB9RKR] CAN1 Discon (Bucket Boom Con) (WA500_7-DB9RKR-400-A-Z0-


A)

Action level Failure code CAN1 Disconnection (Bucket Boom Controller)


Failure
L03 DB9RKR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize work equipment controller over CAN
failure communication-1 line (KOMNET/r).
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
• Information and failure code to be obtained from work equipment controller is not
Problem on displayed. Or received data are not updated.
machine • Adjustment function does not work.
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses two other failure codes, [DAQRKR] and [DB2RKR], to indicate
failure in CAN communication through CAN 1 line. When failure code [DAQRKR] or
[DB2RKR] is displayed simultaneously on screen, ground fault, short circuit, or hot short
Related circuit may occur in wiring harness (CAN communication line).
information • CAN1 terminating resistor on operator's cab side is located in machine monitor and that
on engine side is connector "B_RES" (connector B_RES is not located on CAN
communication-1 line (KOMNET/r) but is connected to it via connector "J2").
• Since each controller is connected directly to battery, it is supplied with power even after
starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective power supply
1 system to work equipment Perform troubleshooting for failure codes [DB90KK] and [DB91KA].
controller
Defective CAN-1 Perform checks on causes 2 to 9 in troubleshooting for failure code
2 [DB2RKR].
communication line
If no failure is found by above checks, work equipment controller is
Defective work equipment defective.
3
controller
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
4 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-569
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DB9RMA] Inconsistency of Option Selection (BBC) (WA380_7-


DB9RMA-400-A-Z0-A)

Action level Failure code Inconsistency of Option Selection (Bucket Boom Controller)
Failure
L03 DB9RMA (Work equipment controller system)
Detail of • When starting switch is turned to the ON position, the option setting information sent from
failure machine monitor differs from that stored in the work equipment controller.
Action of • Controls with the option settings stored in the controller.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
Problem on • The option installed does not work normally.
machine
• Perform initial setting and initial adjustment similar to those required when the work
Related equipment controller is replaced.
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
The option setting of monitor controller is probably incorrect. After
Defective option setting of replacing the monitor controller or work equipment controller, set the
1
monitor controller options correctly. For details, see Testing and Adjusting.
If no failure is found by check on cause 1, the work equipment controller
Defective work equipment may be defective. (Since this is an internal defect, troubleshooting
2
controller cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
3 Defective monitor controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-570 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DBE5KX] Failure of 5V Power Source (WA380_7-DBE5KX-400-A-Z0-A)

Action level Failure code Failure of 5V Power Source


Failure
L01 DBE5KX (Transmission controller system)
Detail of • Voltage of 5 V sensor power supply system is outside of normal voltage output range of
failure 4.7 to 5.3 V.
• Does not detect input signal normally because erroneous signal is input from
Action of potentiometer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Sensor failure codes [DK55KA], [DK555Y], and [DK55L5] are displayed.
machine • No particular problem occurs, as long as directional (FNR) lever switch is normal.
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L02.
Defective directional 3. Turn starting switch to ON position.
1 (FNR) lever If failure code [DBE5KX] disappears, directional (FNR) lever potentiometer is
potentiometer defective.
a Other failure codes also appear due to disconnection of connector. Ignore
displayed failure codes other than this failure code.
1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and L02, and connect T-adapter to either
Ground fault in wiring
2 female side.
harness
Between ground and L61 (female) (22) or L02
Resistance (female) (10) Min. 1 Mz

1. Turn starting switch to OFF position.


Defective transmission 2. Disconnect connector L61, and connect T-adapter to male side.
3 3. Turn starting switch to ON position.
controller
Voltage Between L61 (male) (22) and (21) 4.7 to 5.3 V
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L02, and connect T-adapter to female side.
4 wiring harness 3. Turn starting switch to ON position.
Voltage Between L02 (female) (10) and (12) 4.7 to 5.3 V

WA470-7 40-571
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 5 V sensor power supply

40-572 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DBE6KX] Failure of 24 V Power Source (WA470_7-DBE6KX-400-A-Z0-A)

Action level Failure code Failure of 24 V Power Source


Failure
L01 DBE6KX (Transmission controller system)
Detail of • 24 V sensor power supply system is shorted to ground.
failure
Action of • Cannot normally sense input signals of sensors that uses this power supply since sensor
controller signal is error.
Problem on • Sensor failure codes [DHT1KX], [DHT5KX], and [DHT7KX] are displayed.
machine
• Method of reproducing failure code: Turn starting switch to ON position.
Related • Voltage of each sensor is indicated as 0 V.
information (Codes: 41202 Brake Oil Press Sensor Volt, 32602 T/C In. Oil Press Sensor Volt, 32604
T/C Out. Oil Press Sensor Volt)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors of the following sensors one by one and turn
starting switch ON each time.
a If this failure code goes out, disconnected sensor is defective.
Defective pressure
1 sensor a Since connector is disconnected, other failure codes appear. Ignore all
(internal short circuit) of displayed failure codes other than this one.
3. Each time troubleshooting is finished, return to step 1.
Brake oil pressure sensor R73
Connector Torque converter input pressure sensor TCIN.P
Torque converter outlet pressure sensor R91
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors R73, R91, TCIN.P, and L61.
2 3. Connect T-adapter to female side of connector L61.
(contact with ground
circuit) Resistance Between L61 (female) (16) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
Defective transmission 2. Disconnect connector L61, and connect T-adapter to male side.
3 3. Turn starting switch ON (with connector disconnected).
controller
Voltage Between L61 (male) (16) and (4) 20 to 30 V

WA470-7 40-573
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 24 V sensor power supply output

40-574 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DD1ALD] Ground Fault of Remote Positioner Set SW (WA470_7-


DD1ALD-400-A-Z0-A)

Action level Failure code Ground Fault of Remote Positioner Set Switch
Failure
L01 DD1ALD (Work equipment controller system)
• Due to ground fault in remote positioner set switch (boom) circuit, remote positioner
Detail of cannot be set for boom RAISE and LOWER.
failure • Continuous operation for 30 seconds is detected on remote positioner set switch (boom).
• Cancels boom RAISE set position if boom is positioned above horizontal.
• Cancels boom LOWER set position if boom is positioned below horizontal.
Action of • Does not perform remote stop for canceled side.
controller • Turns off remote positioner set indicator for canceled side.
• If cause of failure disappears, machine becomes normal by itself.
Problem on • Both boom RAISE and LOWER set positions cannot be set.
machine • Remote positioner does not perform stop for canceled side.
• Input signal (ON/OFF) from remote positioner set switch can be checked with monitoring
Related function. (Code: 02218 BBC Input 2, Boom Positioner Set SW)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH6, and connect T-adapters to male side.
Remote positioner set
Defective remote Max. 1 z
positioner set switch Between S_RH6 (male) switch: Boom set ON
1 Remote positioner set
(boom) (5) and (6)
Resistance switch: Other than boom Min. 1 Mz
set ON
Between ground and each of S_RH6 (male) (5) and
(6) Min. 1 Mz

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors L72 and S_RH6, and connect T-adapter to either
harness female side.
2 Between ground and L72 (female) (3) or S_RH6
(contact with ground (female) (6) Min. 1 Mz
circuit) Resistance
Between ground and L72 (female) (12) or S_RH6
(female) (4) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L72.
3. Turn starting switch to ON position.
Defective work Remote positioner set
3 equipment controller Max. 1 V
Between L72 (3) and switch: Boom set ON
Voltage Remote positioner set
ground
switch: Other than boom 7 to 10 V
set ON

WA470-7 40-575
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to remote positioner set switch

40-576 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDAAL6] Discon of Engine Shutdown Secondary


Switch (WA470_7-DDAAL6-400-A-Z0-A)
Action level Failure code Discon of Engine Shutdown Secondary Switch
Failure
L03 DDAAL6 (Machine monitor system)
Detail of • Monitor controller determines that engine shutdown secondary switch circuit has open
failure circuit.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • None in particular.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position.
information
No. Cause Procedure, measuring location, criteria and remarks
Incorrect operation of
1 engine shutdown Check that engine shutdown secondary switch is in OFF position.
secondary switch
1. Turn starting switch to OFF position.
Defective engine 2. Disconnect connector S-FS and connect T-adapters to male side.
2 shutdown secondary a Engine shutdown secondary switch at OFF
switch Between S-FS (male) (1) and (2) Max. 1 z
Resistance
Between S-FS (male) (4) and (5) Max. 1 z
1. Turn starting switch to OFF position.
2. Set battery disconnect switch to OFF position.
3. Disconnect connector MCM1 A, and connect T-adapters to female side.
a Engine shutdown secondary switch at OFF
Open circuit in wiring
harness Resistance Between MCM1 A (female) (24) and (31) Max. 1 z
3 (wire breakage or a If no failure is found by above checks, this check is not required.
defective contact of 1. Turn starting switch to OFF position.
connector) 2. Set battery disconnect switch to OFF position.
3. Disconnect connectors MCM1 A and S-FS, and connect T-adapters to
each female side.
Between MCM1 A (female) (31) and each of S-FS
Resistance (female) (1) and (4) Max. 1 z
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
4 this is an internal defect, troubleshooting cannot be performed).
controller

WA470-7 40-577
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to engine shutdown secondary switch

40-578 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDB6L4] Neutral Signal Malfunction (WA470_7-DDB6L4-400-A-Z0-A)

Action level Failure code Neutral Signal Malfunction


Failure
L03 DDB6L4 (Transmission controller system)
• Controller indicates this failure code when all of following conditions are satisfied.
1. Parking brake switch signal is ON. (Neutralizer input signal (pin 6 of L62) is OPEN.)
Detail of
failure 2. Parking brake is released (judged from signals from monitor controller through CAN
communication).
3. Transmission oil temperature is 25°C or higher.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Machine cannot travel forward and in reverse, or parking brake indicator is kept off.
machine
• Input signal (ON/OFF) to machine monitor from parking brake indicator switch can be
checked with monitoring function. (Code: 04510 Parking Brake Press SW)
• Input signal (ON/OFF) from parking brake switch can be checked with monitoring
function.
(Code: 02215 Parking Brake Switch)
Related • If failure code [DGF1KA] "Disconnection of T/M Oil Temp. Sensor" or failure code
information [DGF1KB] "Ground Fault of T/M Oil Temp. Sensor" is also displayed, perform
troubleshooting for it first.
• If failure code [DAQRKR] "CAN1 Discon (Transmission Con)" or failure code [DAQQKR]
"CAN2 Discon (Transmission Con)" is also displayed, perform troubleshooting for it first.
• Method of reproducing failure code: Turn starting switch to ON position and turn parking
brake switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector PB.SW, and connect T-adapter to male side.
Parking brake pressure:
Defective parking brake When parking brake is
released, Min. 0.61 MPa Max. 1 z
1 indicator switch (internal
open circuit) Between PB.SW (male) {Min. 6.2 kg/cm 2 }
Resistance (1) and (2)
Parking brake pressure:
When parking brake is
applied, Max. 0.34 MPa Min. 1 Mz
{Min. 3.5 kg/cm }
2

1. Turn starting switch to OFF position.


2. Disconnect connector S_FA and connect T-adapter to male side.
Parking brake switch:
Between S_FA (3) and Min. 1 Mz
ON.
Defective parking brake (4) Parking brake switch:
Max. 1 z
2 switch (internal open OFF
circuit) Parking brake switch:
Resistance Between S_FA (5) and Max. 1 z
ON.
(6) Parking brake switch:
Min. 1 Mz
OFF
Between S_FA (3) and Parking brake switch: Min. 1 Mz
(6) ON

WA470-7 40-579
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors MCM1 A, PB.SW, and S_FA, and connect T-
harness adapters to each female side.
3 (wire breakage or Between MCM1 A (female) (71) and PB.SW
(female) (1) Max. 1 z
defective contact of
connector) Resistance Between PB.SW (female) (2) and ground
Max. 1 z
Between S_FA (female) (3) and L62 (female) (6) Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Turn starting switch to ON position.
Defective transmission Parking brake switch:
4 Max. 1 V
controller ON.
Between L62 (female) After turn starting switch
Voltage
(6) and ground to ON position, turn
20 to 30 V
parking brake switch to
ON and then OFF.

40-580 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to parking brake

WA470-7 40-581
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDD1LD] Failure of Bucket Positioner Set Switch (WA470_7-


DDD1LD-400-A-Z0-A)

Action level Failure code Failure of Bucket Positioner Set Switch


Failure
L01 DDD1LD (Work equipment controller system)
• Due to ground fault in remote positioner set switch (bucket) circuit, bucket stop angle
Detail of cannot be set to desired angle.
failure • Continuous operation for 30 seconds is detected on remote positioner bucket angle set
switch.
• Judges that remote positioner bucket angle set switch is ON.
Action of • Changes setting to default (stopping at level position) 1 second after this failure code is
controller generated.
• If cause of failure disappears, machine becomes normal by itself.
Problem on • Remote positioner (bucket) set is turned to default (level position).
machine • Setting cannot be changed upward or downward direction.
• Input signal (ON/OFF) from remote positioner set switch can be checked with monitoring
Related function. (Code: 02218 BBC Input 2, Bucket Positioner Set SW)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH6, and connect T-adapters to male side.
Remote positioner set
Defective remote switch: Bucket angle set Max. 1 z
positioner set switch Between S_RH6 (male) ON
1
(bucket) (4) and (5) Remote positioner set
Resistance switch: Other than Min. 1 Mz
bucket angle set ON
Between ground and each of S_RH6 (male) (4) and
(5) Min. 1 Mz

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connectors L72 and S_RH6, and connect T-adapter to either
harness female side.
2 Between ground and L72 (female) (3) or S_RH6
(contact with ground (female) (6) Min. 1 Mz
circuit) Resistance
Between ground and L72 (female) (12) or S_RH6
(female) (4) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L72.
3. Turn starting switch to ON position.
Defective work Remote positioner set
3 equipment controller switch: Bucket angle set Max. 1 V
Between L72 (female) ON
Voltage
(12) and ground Remote positioner set
switch: Other than 7 to 10 V
bucket angle set ON

40-582 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to remote positioner set switch

WA470-7 40-583
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDK3KA] FNR SW Input Signal Disconnection (WA470_7-DDK3KA-400-


A-Z0-A)

Action level Failure code FNR Switch Input Signal Disconnection


Failure
L03 DDK3KA (Transmission controller system)
• Due to open circuit or ground fault in input signal circuit from R.H. directional selector
Detail of (FNR) switch, controller does not recognize R.H. directional selector (FNR) switch
failure signals.
• Takes an input signal from R.H. directional selector (FNR) switch as neutral.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until R.H.
directional selector (FNR) switch is set to N (neutral) position.
• Machine does not travel with R.H. directional selector (FNR) switch.
Problem on • Machine can travel by operating directional (FNR) lever.
machine • Shift lever position pilot lamp goes out.
• Input signal (ON/OFF) from R.H. directional selector (FNR) switch can be checked with
monitoring function.
(Code: 02211 Option FNR Signal F, Option FNR signal N, or Option FNR signal R)
Related • Only for the machine equipped with R.H. directional selector (FNR) switch (if equipped).
information • Method of reproducing failure code:Turn starting switch to ON position, set directional
selector switch actuation switch to ON position, and operate R.H. directional selector
(FNR) switch.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse No. 2 in If fuse is blown, circuit probably has ground fault, etc. (See check on cause 4.)
1
fuse box 1
1. Turn starting switch to OFF position.
2. Disconnect connector S_RHB, and connect T-adapter to male side.
R.H. directional selector
(FNR) switch: F (forward) Max. 1 z
Between S_RHB (male)
(1) and (2) R.H. directional selector
(FNR) switch: Other than Min. 1 Mz
F
R.H. directional selector
(FNR) switch: N (neutral) Max. 1 z
Defective R.H. Between S_RHB (male)
directional selector (1) and (3) R.H. directional selector
2 (FNR) switch (internal (FNR) switch: Other than Min. 1 Mz
open or short circuit) Resistance N
R.H. directional selector
(FNR) switch: R Max. 1 z
Between S_RHB (male) (reverse)
(1) and (4) R.H. directional selector
(FNR) switch: Other than Min. 1 Mz
R (reverse)
Between ground and
each of S_RHB (male) Continuous Min. 1 Mz
(1), (2), (3), and (4)
1. Turn starting switch to OFF position.
2. Remove fuse No. 2 in fuse box 1.
3. Disconnect connectors L62 and S_RHB, and connect T-adapters to each
Open circuit in wiring female side.
harness (wire breakage Between fuse No. 2 in fuse box 1 and S_RHB
3 (female) (1) Max. 1 z
or defective contact of
connector) Between L62 (female) (26) and S_RHB (female) (4) Max. 1 z
Resistance
Between L62 (female) (36) and S_RHB (female) (3) Max. 1 z
Between L62 (female) (5) and S_RHB (female) (2) Max. 1 z

40-584 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Remove fuse No. 2 in fuse box 1.
3. Disconnect connectors L62 and S_RHB, and connect T-adapter to either
female side.
Between ground and fuse No. 2 in fuse box 1 or
Ground fault in wiring S_RHB (female) (1) Min. 1 Mz
4 harness (contact with
Between ground and L62 (female) (26) or S_RHB
ground circuit) Min. 1 Mz
(female) (4)
Resistance
Between ground and L62 (female) (36) or S_RHB
(female) (3) Min. 1 Mz
Between ground and L62 (female) (5) or S_RHB
(female) (2) Min. 1 Mz

1.Turn starting switch to OFF position.


2.Insert T-adapter into connector L62.
3.Turn starting switch to ON position.
4.Operate R.H. directional selector (FNR) switch.
R.H. directional selector
(FNR) switch: F (forward) 20 to 30 V
Between L62 (5) and
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
F
Defective transmission R.H. directional selector
5
controller (FNR) switch: N (neutral) 20 to 30 V
Between L62 (36) and
Voltage ground R.H. directional selector
(FNR) switch: Other than Max 1 V
N
R.H. directional selector
(FNR) switch: R 20 to 30 V
Between L62 (26) and (reverse)
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
R (reverse)

WA470-7 40-585
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R.H. directional selector (FNR) switch

40-586 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDK3KB] FNR SW Input Signal Short Circuit (WA470_7-DDK3KB-400-A-


Z0-A)

Action level Failure code FNR Switch Input Signal Short Circuit
Failure
L03 DDK3KB (Transmission controller system)
Detail of • Due to hot short circuit of R.H. directional selector (FNR) switch input signal system,
failure multiple signals of R.H. directional selector (FNR) switch are inputted.
• Takes an input signal from R.H. directional selector (FNR) switch as neutral.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until R.H.
directional selector (FNR) switch is set in N (neutral) position.
• Machine does not travel with R.H. directional selector (FNR) switch.
Problem on • Machine can travel by operating directional (FNR) lever.
machine • Multiple pilot lamps of shift lever position light up.
• Input signal (ON/OFF) from R.H. directional selector (FNR) switch can be checked with
monitoring function.
(Code: 02211 Option FNR Signal F, Option FNR signal N, or Option FNR signal R)
Related • Only for machines equipped with R.H. directional selector (FNR) switch (if equipped).
information • Method of reproducing failure code:Turn starting switch to ON position, set directional
selector switch actuation switch to ON position, and operate R.H. directional selector
(FNR) switch.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector S_RHB.
R.H. directional selector
(FNR) switch: F (forward) 20 to 30 V
Between S_RHB (2) and
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
F
R.H. directional selector
Defective R.H. (FNR) switch: N (neutral) 20 to 30 V
Between S_RHB (3) and
directional selector R.H. directional selector
1 ground
(FNR) switch (internal (FNR) switch: Other than Max 1 V
short circuit) Voltage
N
R.H. directional selector
(FNR) switch: R 20 to 30 V
Between S_RHB (4) and (reverse)
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
R (reverse)
Between S_RHB (1) and
ground Continuous 20 to 30 V

1. Turn starting switch to OFF position.


2. Disconnect connector S_RHB, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness (contact Between L62 (female) (5) and ground Max. 1 V
with 24 V circuit) Between L62 (female) (26) and ground Max. 1 V
Voltage
Between L62 (female) (36) and ground Max. 1 V

WA470-7 40-587
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
3. Turn starting switch to ON position.
4. Operate R.H. directional selector (FNR) switch.
R.H. directional selector
(FNR) switch: F (forward) 20 to 30 V
Between L62 (5) and
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
F
Defective transmission R.H. directional selector
3
controller (FNR) switch: N (neutral) 20 to 30 V
Between L62 (36) and
Voltage ground R.H. directional selector
(FNR) switch: Other than Max 1 V
N
R.H. directional selector
(FNR) switch: R 20 to 30 V
Between L62 (26) and (reverse)
ground R.H. directional selector
(FNR) switch: Other than Max 1 V
R (reverse)

Circuit diagram related to R.H. directional selector (FNR) switch

40-588 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDK6KA] FNR Lever Input Signal Disconnection (WA380_7-DDK6KA-


400-A-Z0-A)

Action level Failure code FNR Lever Input Signal Disconnection


Failure
L03 DDK6KA (Transmission controller system)
Detail of • No signal of directional (FNR) lever switch is input and analog signal recognizes F
failure because of open circuit or ground fault in directional (FNR) lever switch signal system.
• Follows signal before abnormality for 2 seconds after detection.
• Sounds alarm buzzer after continuous detection for 2 seconds and follows analog signal.
Action of • Lights up centralized warning lamp and sounds alarm buzzer after continuous detection
controller for 20 seconds.
• Keeps following analog signal until directional (FNR) lever signal matches with analog
signal, even if cause of failure disappears.
Problem on • Shift lever position pilot lamp goes out.
machine
• Input signal (ON/OFF) from directional (FNR) lever switch can be checked with monitoring
Related function (Code: 02211, Main FNR Signal F, Main FNR Signal N, or Main FNR Signal R).
information • Method of reproducing failure code: Turn starting switch ON and operate directional
(FNR) lever
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse No. 2 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause
1 4.)
box 1
1. Turn starting switch OFF.
2. Insert T-adapter into connector L02.
3. Turn starting switch ON.
Between L02 (1) and
(9) Constant 20 to 30 V
Directional (FNR)
Between L02 (3) and lever: N (NEUTRAL) 20 to 30 V
Defective directional (FNR) (9) Directional (FNR)
2 lever switch (internal short Max. 1 V
lever: Other than N
circuit) Directional (FNR)
Voltage 20 to 30 V
Between L02 (2) and lever: F (FORWARD)
(9) Directional (FNR)
Max. 1 V
lever: Other than F
Directional (FNR)
Between L02 (4) and lever: R (REVERSE) 20 to 30 V
(9) Directional (FNR)
Max. 1 V
lever: Other than R
1. Turn starting switch OFF.
2. Disconnect connectors L62 and L02, and connect T-adapters to
each female side.
3. Remove fuse No. 2 in fuse box 1.
Between fuse No. 2 in fuse box 1 and L02
(female) (1) Max. 1 z
Open circuit in wiring harness
3 (wire breakage or defective Between L62 (female) (15) and L02 (female)
(4) Max. 1 z
contact of connector)
Resis- Between L62 (female) (25) and L02 (female)
tance (3) Max. 1 z
Between L62 (female) (35) and L02 (female)
(2) Max. 1 z
Between L02 (female) (9) and ground Max. 1 z

WA470-7 40-589
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch OFF.
2. Disconnect connectors L62 and L02, and connect T-adapters to
each female side.
3. Remove fuse No. 2 in fuse box 1.
Between ground and fuse No. 2 of fuse box 1
Ground fault in wiring Min. 1 Mz
or L02 (female) (1)
4 harness
Between ground and L62 (female) (15) or L02
(contact with ground circuit) Min. 1 Mz
Resis- (female) (4)
tance Between ground and L62 (female) (25) or L02
(female) (3) Min. 1 Mz
Between ground and L62 (female) (35) or L02
(female) (2) Min. 1 Mz

1. Turn starting switch OFF.


2. Insert T-adapter into connector L62.
3. Turn starting switch ON.
Right directional (FNR)
Between L62 (25) and lever: N (NEUTRAL) 20 to 30 V
ground Right directional (FNR)
Max. 1 V
Defective transmission lever: Other than N
5 Right directional (FNR)
controller 20 to 30 V
Between L62 (35) and lever: F (FORWARD)
Voltage
ground Right directional (FNR)
Max. 1 V
lever: Other than F
Right directional (FNR)
Between L62 (15) and lever: R (REVERSE) 20 to 30 V
ground Right directional (FNR)
Max. 1 V
lever: Other than R

40-590 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to directional (FNR) lever

WA470-7 40-591
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDK6KB] FNR Lever Input Signal Short Circuit (WA380_7-DDK6KB-400-
A-Z0-A)

Action level Failure code FNR Lever Input Signal Short Circuit
Failure
L03 DDK6KB (Transmission controller system)
Detail of • Multiple signals of directional (FNR) lever switch are input due to hot short in directional
failure (FNR) lever switch signal system.
• Follows lever position recognition by analog input.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Multiple pilot lamps of shift lever position light up.
machine
• Input signal (ON/OFF) from directional (FNR) lever switch can be checked with monitoring
Related function (Code: 02211, Main FNR Signal F, Main FNR Signal N, or Main FNR Signal R).
information • Method of reproducing failure code: Turn starting switch ON and operate directional
(FNR) lever
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch OFF.
2. Insert T-adapter into connector L02.
3. Turn starting switch ON.
Between L02 (1) and
(9) Constant 20 to 30 V
Directional (FNR)
Between L02 (3) and lever: N (NEUTRAL) 20 to 30 V
Defective directional (FNR) (9) Directional (FNR)
1 lever switch (internal short Max. 1 V
lever: Other than N
circuit) Directional (FNR)
Voltage 20 to 30 V
Between L02 (2) and lever: F (FORWARD)
(9) Directional (FNR)
Max. 1 V
lever: Other than F
Directional (FNR)
Between L02 (4) and lever: R (REVERSE) 20 to 30 V
(9) Directional (FNR)
Max. 1 V
lever: Other than R
1. Turn starting switch OFF.
2. Disconnect connector L02 and connect T-adapter to female side.
Hot short circuit in wiring 3. Turn starting switch ON.
2 harness (contact with 24 V
Between L02 (female) (4) and ground Max. 1 V
circuit)
Voltage Between L02 (female) (3) and ground Max. 1 V
Between L02 (female) (2) and ground Max. 1 V

40-592 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch OFF.
2. Insert T-adapter into connector L62.
3. Turn starting switch ON.
Directional (FNR)
Between L62 (25) and lever: N (NEUTRAL) 20 to 30 V
ground Directional (FNR)
Max. 1 V
Defective transmission lever: Other than N
3 Directional (FNR)
controller 20 to 30 V
Between L62 (35) and lever: F (FORWARD)
Voltage
ground Directional (FNR)
Max. 1 V
lever: Other than F
Directional (FNR)
Between L62 (15) and lever: R (REVERSE) 20 to 30 V
ground Directional (FNR)
Max. 1 V
lever: Other than R

Circuit diagram related to directional (FNR) lever

WA470-7 40-593
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDNRKY] Hot Short of Work Equipment Lock SW (WA470_7-


DDNRKY-400-A-Z0-A)

Action level Failure code Hot Short of Work Equipment Lock Switch
Failure
L03 DDNRKY (Work equipment controller system)
Detail of Due to hot short circuit in work equipment lock switch circuit, work equipment lock remains
failure released or applied.
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
• Condition of work equipment lock switches (work equipment lock is released if it has been
Problem on applied, or it is applied if it has been released).
machine • Once condition of work equipment lock is changed, it is fixed and cannot be changed.
• Output signal (ON/OFF) from work equipment lock switch can be checked with monitoring
Related function. (Code: 02217BBC Input 1, Work Equipment Lock SW)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RHC and replace switch with another one of
same type.
3. Turn starting switch to ON position.
If failure code [DDNRKY] disappears, original work equipment lock switch is
Defective work defective.
1 equipment lock switch 4. Turn starting switch to OFF position.
5. Disconnect connector S_RHC and connect T-adapter to male side.
Work equipment lock
Between S_RHC (male) Min. 1 Mz
switch: OFF
Resistance (5) and (6)
Work equipment lock
Max. 1 z
switch: ON
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector S_RHC and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between S_RHC (female) (6) and ground Max. 1 V
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

40-594 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment lock switch

WA470-7 40-595
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDT0L4] Failure of Shift Mode Select SW (WA470_7-DDT0L4-400-A-Z0-A)

Action level Failure code Failure of Shift Mode Select Switch


Failure
L01 DDT0L4 (Transmission controller system)
Detail of • Impossible combination of signals is inputted from transmission shift mode selector
failure switch.
Action of • Sets transmission to manual shift mode.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Position of transmission shift mode selector switch does not match with shift mode in
machine auto-shift mode.
• Input signal to machine monitor from transmission shift mode selector switch can be
checked with monitoring function.
Related (Code: 02213 Shift Mode Switch Manual and Shift Mode Switch H)
information • Current selection of shift mode can be checked by auto-shift pilot lamp.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH3 and connect T-adapter to male side.
Defective transmission Shift mode: Manual shift Max. 1 z
Between S_RH3 (male)
auto/manual shift mode Shift mode: Auto shift (L) Min. 1 Mz
1 (4) and (5)
selector switch (internal Shift mode: Auto shift (H) Min. 1 Mz
defect) Resistance
Shift mode: Manual shift Min. 1 Mz
Between S_RH3 (male)
Shift mode: Auto shift (L) Min. 1 Mz
(5) and (6)
Shift mode: Auto shift (H) Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector S_RH3 and connect T-adapter to female side.
wiring harness (contact 3. Turn starting switch to ON position.
2 with 24 V wiring
harness) Between S_RH3 (female) (6) and ground Max 1 V
Voltage
Between S_RH3 (female) (4) and ground Max 1 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L61.
3. Turn starting switch to ON position.
Shift mode: Manual shift 20 to 30 V
Defective transmission Between L61 (female)
3 Shift mode: Auto shift (L) Max 1 V
controller (18) and ground
Shift mode: Auto shift (H) Max 1 V
Voltage
Shift mode: Manual shift Max 1 V
Between L61 (female)
Shift mode: Auto shift (L) Max 1 V
(24) and ground
Shift mode: Auto shift (H) 20 to 30 V

40-596 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to shift mode switch

WA470-7 40-597
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDT4LD] Ground Fault of T/M Cut Off Set SW Signal (WA470_7-
DDT4LD-400-A-Z0-A)

Action level Failure code Ground Fault of Transmission Cut Off Set Switch Signal
Failure
L01 DDT4LD (Transmission controller system)
Detail of • Transmission cut-off is not performed normally due to ground fault in transmission cut-off/
failure set switch circuit.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • Transmission cut-off is performed at unintended timing.
machine
• Input signal (ON/OFF) from transmission cut-off switch can be checked with monitoring
Related function. (Code: 02214 T/M Cut Off Switch)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1, and connect T-adapters to male side.
Transmission cut-off set
Defective transmission Between S_RH1 (male) Max. 1 z
switch: ON
1 cut-off switch (internal (4) and (5) Transmission cut-off set
short circuit) Min. 1 Mz
Resistance switch: OFF
Between ground and
each of S_RH1 (male) Continuous Min. 1 Mz
(4) and (5)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (30) or S_RH1
circuit) Resistance (female) (4) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapters into connector L63.
3. Turn starting switch to ON position.
Defective transmission
3 Transmission cut-off set
controller Max. 1 V
Between L63 (30) and switch: ON
Voltage
ground Transmission cut-off set
7 to 9 V
switch: OFF

40-598 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission cut-off/set switch

WA470-7 40-599
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDT9LD] Ground Fault of T/M Cut Off SW Signal (WA470_7-DDT9LD-
400-A-Z0-A)

Action level Failure code Ground Fault of Transmission Cut Off Switch Signal
Failure
L01 DDT9LD (Transmission controller system)
Detail of • Transmission cut-off is not normally performed due to ground fault in transmission cut-off
failure set switch system.
• Recognizes input of transmission cut-off once when ground fault occurs, and then does
Action of not control transmission cut-off any more.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Transmission cut-off is performed at unintended timing.
machine
• Input signal (ON/OFF) from transmission cut-off switch can be checked with monitoring
Related function. (Code: 02214 T/M Cut Off Switch)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1, and connect T-adapters to male side.
Transmission cut-off
Defective transmission Between S_RH1 (male) Max. 1 z
switch:ON
1 cut-off switch (internal (5) and (6) Transmission cut-off
short circuit) Min. 1 Mz
Resistance switch:OFF
Between ground and
each of S_RH1 (male) Continuous Min. 1 Mz
(5) and (6)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (20) or S_RH1
circuit) Resistance (female) (6) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapters into connector L63.
3. Turn starting switch to ON position.
Defective transmission
3 Transmission cut-off
controller Max 1 V
Between L63 (20) and switch:ON
Voltage
ground Transmission cut-off
7 to 9 V
switch:OFF

40-600 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission cut-off switch

WA470-7 40-601
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDW9LD] Ground Fault of Kickdown Switch (WA470_7-DDW9LD-400-A-Z0-


A)

Action level Failure code Ground Fault of Kickdown Switch


Failure
L01 DDW9LD (Transmission controller system)
Detail of • Kickdown cannot be performed due to ground fault in kickdown switch system.
failure
• Performs kickdown once when ground fault occurs, and then does not control kickdown
Action of any more.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Transmission is kicked down once when ground fault occurs.
machine • Transmission is not kicked down any more after that.
• Input condition (ON/OFF) from the kickdown switch can be checked with monitoring
Related function
information (Code: 02212 Kick Down Switch)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Defective kickdown Between L14 (male) (1) Kickdown switch: ON Max. 1 z
1 switch and (2) Kickdown switch: OFF Min. 1 Mz
(internal short circuit) Resistance Between ground and
each of L14 (male) (1) Continuous Min. 1 Mz
and (2)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and L14, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (9) or L14
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
3
controller
Between L63 (9) and Kickdown switch: ON Max. 1 V
Voltage
ground Kickdown switch: OFF 7 to 9 V

40-602 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to kick-down switch and hold switch

WA470-7 40-603
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DDWLLD] Ground Fault of T/M Shift Hold SW (WA470_7-DDWLLD-400-A-


Z0-A)

Action level Failure code Ground Fault of Transmission Shift Hold SWITCH
Failure
L01 DDWLLD (Transmission controller system)
Detail of • Holding operation cannot be performed because of ground fault in hold switch system.
failure
• Performs holding operation once when ground fault occurs, and then does not control
Action of holding operation any more.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Transmission is held once when ground fault occurs.
machine
• Input condition (ON/OFF) from the kickdown switch can be checked with monitoring
Related function
information (Code: 02212 Hold Switch)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Defective hold switch Between L14 (male) (3) Hold switch:ON Max. 1 z
1 and (4) Hold switch:OFF Min. 1 Mz
(internal short circuit)
Resistance Between ground and
each of L14 (male) (3) Continuous Min. 1 Mz
and (4)
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and L14, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L63 (female) (19) or L14
circuit) Resistance (female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
3
controller
Between L63 (19) and Hold switch:ON Max 1 V
Voltage
ground Hold switch:OFF 7 to 9 V

40-604 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to kick-down switch and hold switch

WA470-7 40-605
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DF10KA] Disconnection of Shift Lever Input (WA380_7-DF10KA-400-A-Z0-


A)

Action level Failure code Disconnection of Shift Lever Input


Failure
L03 DF10KA (Transmission controller system)
Detail of • No transmission shift lever switch signal is input due to open circuit or ground fault in
failure transmission shift lever switch signal input circuit.
Action of • Fixes shift range to that before occurrence of failure.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Transmission is not set to selected gear speed.
machine • Shift indicator indicates shift range before occurrence of failure.
• Input condition (ON/OFF) from each shift switch can be checked with monitoring function
Related (Code: 02212 Shift Lever 1, Shift Lever 2, Shift Lever 3, Shift Lever 4).
information
• Method of reproducing failure code: Turn starting switch ON and operate shift lever.
No. Cause Procedure, measuring location, criteria and remarks
• Force may be applied to depress lever while shift lever is not
Defective operation of shift operated.
1
lever
• Shift lever is stopped intermediate point between two positions.
Defective fuse No. 2 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause
2 5.)
box 1
1. Turn starting switch OFF.
2. Insert T-adapter into connector L02.
3. Turn starting switch ON.
4. Operate shift lever to troubleshoot.
Between L02 (1) and
(9) Constant 20 to 30 V
Shift range: 1st 20 to 30 V
Between L02 (5) and
(9) Shift range: Other than
Max. 1 V
1st
Shift range: 2nd 20 to 30 V
3 Defective shift lever Between L02 (6) and
Voltage (9) Shift range: Other than
Max. 1 V
2nd
Shift range: 3rd 20 to 30 V
Between L02 (7) and
(9) Shift range: Other than
Max. 1 V
3rd
Shift range: 4th 20 to 30 V
Between L02 (8) and
(9) Shift range: Other than
Max. 1 V
4th
If harness is normal and voltage in each selected range is below
standard value, shift lever power supply or ground circuit is defective.
1. Turn starting switch OFF.
2. Remove No. 2 in fuse box 1.
3. Disconnect connectors L61 and L02, and connect T-adapters to
each female side.
Open circuit in wiring harness Between fuse No. 2 in fuse box 1 and L02
(female) (1) Max. 1 z
4 (wire breakage or defective
contact of connector) Between L61 (female) (23) and L02 (female) (5) Max. 1 z
Resis- Between L61 (female) (17) and L02 (female) (6) Max. 1 z
tance
Between L61 (female) (11) and L02 (female) (7) Max. 1 z
Between L61 (female) (5) and L02 (female) (8) Max. 1 z
Between L02 (female) (9) and ground Max. 1 z

40-606 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by checks on causes 2 and 3, this check is not
required.
1. Turn starting switch OFF.
2. Remove fuse No. 2 in fuse box 1.
3. Disconnect connectors L61 and L02, and connect T-adapter to
either female side.
Between ground and fuse No. 2 in fuse box 1 or
Ground fault in wiring harness L02 (female) (1) Min. 1 Mz
5
(contact with ground circuit) Between ground and L61 (female) (23) or L02
(female) (5) Min. 1 Mz
Resis- Between ground and L61 (female) (17) or L02
(female) (6) Min. 1 Mz
tance
Between ground and L61 (female) (11) or L02
(female) (7) Min. 1 Mz
Between ground and L61 (female) (5) or L02
(female) (8) Min. 1 Mz
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
6 performed.)
controller
a For voltage between any pins of controller, see following codes.

Circuit diagram related to shift lever

WA470-7 40-607
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DF10KB] Ground Fault of Shift Lever Input (WA380_7-DF10KB-400-A-Z0-A)

Action level Failure code Ground Fault of Shift Lever Input


Failure
L03 DF10KB (Transmission controller system)
Detail of • Multiple signals of transmission shift lever switch are input due to hot short in transmission
failure shift lever switch input signal system.
Action of • Uses shift range input of higher gear speed.
controller • If cause of failure disappears, machine becomes normal by itself.
• Transmission is not set to selected gear speed. (Transmission is not set to 1st or 2nd
Problem on even if transmission shift lever is operated.)
machine • Shift indicator indicates shift range input of higher gear speed.
• Input condition (ON/OFF) from each shift switch can be checked with monitoring function
Related (Code: 02212 Shift Lever 1, Shift Lever 2, Shift Lever 3, Shift Lever 4).
information • Method of reproducing failure code: Turn starting switch ON and operate shift lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch OFF.
2. Disconnect connector L02 and connect T-adapter to female side.
Hot short circuit in wiring 3. Turn starting switch ON.
1 harness (contact with 24 V Between L02 (female) (5) and ground Max. 1 V
circuit) Between L02 (female) (6) and ground Max. 1 V
Voltage
Between L02 (female) (7) and ground Max. 1 V
Between L02 (female) (8) and ground Max. 1 V
1. Turn starting switch OFF.
2. Disconnect connectors L61 and L02, and connect T-adapter to
female side of L61.
a Check by using multimeter in continuity range.
Between L61 (female) (23) and No continuity
Short circuit in wiring harness each pin other than pin (23) (No sound is heard)
2 (Short circuit between wiring
Between L61 (female) (17) and No continuity
harnesses)
each pin other than pin (17) (No sound is heard)
Continuity
Between L61 (female) (11) and No continuity
each pin other than pin (11) (No sound is heard)
Between AL61 (female) (5) and No continuity
each pin other than pin (5) (No sound is heard)
1. Turn starting switch OFF.
2. Insert T-adapter into connector L02.
3. Turn starting switch ON.
4. Operate shift lever to troubleshoot.
Between L02 (1) and
(9) Constant 20 to 30 V
Shift range: 1st 20 to 30 V
Between L02 (5) and
(9) Shift range: Other than
Max. 1 V
1st
Shift range: 2nd 20 to 30 V
3 Defective shift lever Between L02 (6) and
Voltage (9) Shift range: Other than
Max. 1 V
2nd
Shift range: 3rd 20 to 30 V
Between L02 (7) and
(9) Shift range: Other than
Max. 1 V
3rd
Shift range: 4th 20 to 30 V
Between L02 (8) and
(9) Shift range: Other than
Max. 1 V
4th
If harness is normal and voltage in each selected range is below
standard value, shift lever power supply or ground circuit is defective.

40-608 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found in above checks, transmission controller is
defective.
a Reference
1.Turn starting switch OFF.
2.Insert T-adapter into connector L61.
3.Turn starting switch ON.
4.Operate shift lever to troubleshoot.
Shift range:
20 to 30 V
Between L61 (23) and 1st
ground Shift range:
Max. 1 V
Other than 1st
Defective transmission Shift range:
4
controller 20 to 30 V
Between L61 (17) and 2nd
ground Shift range:
Max. 1 V
Voltage Other than 2nd
Shift range:
20 to 30 V
Between L61 (11) and 3rd
ground Shift range:
Max. 1 V
Other than 3rd
Shift range:
20 to 30 V
Between L61 (5) and 4th
ground Shift range:
Max. 1 V
Other than 4th

WA470-7 40-609
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to shift lever

40-610 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGF1KA] Disconnection of T/M Oil Temp. Sensor (WA380_7-


DGF1KA-400-A-Z0-A)

Action level Failure code Disconnection of Transmission Oil Temperature Sensor


Failure
L01 DGF1KA (Transmission controller system)
• Due to open circuit in transmission oil temperature sensor signal system, transmission oil
Detail of temperature signal is higher than normal range (Transmission oil temperature sensor
failure signal voltage: Min. 4.56 V (Max. 15°C)), and torque converter oil temperature sensor
signal voltage: Max. 3.7 V (Min. 55°C).
Action of • Cannot determine transmission oil temperature correctly.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Gear shift shock may occur.
machine
• Input voltage from transmission oil temperature sensor can be checked with monitoring
function.
(Code: 32501 T/M Oil Temp. Sensor Volt)
• Oil temperature sensed by transmission oil temperature sensor can be checked with
monitoring function.
(Code: 32500 T/M Oil Temperature)
Related • Input voltage from torque converter oil temperature sensor can be checked with
information monitoring function.
(Code: 30101 T/C Oil Temp. Sensor Volt)
• Oil temperature sensed by torque converter oil temperature sensor can be checked with
monitoring function.
(Code: 30100: T/C Oil Temperature)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector TM.T and connect T-adapter to male side.
Defective transmission Transmission oil
1 Between temperature: 25°C
oil temperature sensor 35 to 50 kz *
TM.T
Resistance (male) (1) (Normal temperature)
and (2) Transmission oil
temperature: 100°C 3.1 to 4.5 kz *

1. Turn starting switch to OFF position.


2. Disconnect connector TM.T and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit, short
circuit, ground fault, hot a Voltage of approx. 5 V is applied to temperature sensor signal circuits
2 short circuit of wiring through resistor in transmission controller.
harness, or defective
a Shake the wiring harness by hand while measuring the voltage. If the
transmission controller
voltage drops to approximately 0 V during shaking, circuit is open around
this point.
Voltage Between TM.T (female) (1) and (2) Approx. 5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L61, and connect T-adapters to female side.
a Voltage of approx. 5 V is applied to temperature sensor signal circuits
Open or short circuit in
3 through resistor in transmission controller.
wiring harness
Transmission oil
Between temperature:25°C 35 to 50 kz
L61
Resistance (female) (9) (Normal temperature)
and (4) Transmission oil 3.1 to 4.5 kz
temperature:100°C

WA470-7 40-611
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connector L61, and connect T-adapters to female side.
defective contact of 3. Disconnect connector TM.T and connect T-adapter to female side.
connector) Between L61 (female) (4) and TM.T (female) (2) Max. 1 z
Resistance
Between L61 (female) (9) and TM.T (female) (1) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller
For average resistance of sensors at each temperature, see [DGR2KB].

Circuit diagram related to transmission oil temperature sensor

40-612 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGF1KB] Ground Fault of T/M Oil Temp. Sensor (WA380_7-DGF1KB-
400-A-Z0-A)

Action level Failure code Ground Fault of Transmission Oil Temperature Sensor
Failure
L01 DGF1KB (Transmission controller system)
• Due to ground fault of transmission oil temperature sensor signal system, transmission oil
Detail of temperature signal is lower than the normal range.
failure (Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Cannot determine transmission oil temperature correctly.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Gear shift shock may occur.
machine
• Input voltage from transmission oil temperature sensor can be checked with monitoring
function.
(Code: 32501 T/M Oil Temp. Sensor Volt)
Related • Oil temperature sensed by transmission oil temperature sensor can be checked with
information monitoring function.
(Code: 32500 T/C Oil Temperature)
• Method of reproducing failure code: Turn starting switch ON.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch OFF.
2. Disconnect connector TM.T and connect T-adapter to male side.
Defective transmission oil Between Oil temperature: 25°C
1 temperature sensor 35 to 50 kz *
Resis- TM.T (Normal temperature)
tance (male) (1)
and (2) Oil temperature: 100°C 3.1 to 4.5 kz *
1. Turn starting switch OFF.
2. Disconnect connector L61 and connect T-adapter to female side.
Open or short circuit in wiring Between Oil temperature: 25°C
2 37 to 50 kz
harness Resis- L61 (Normal temperature)
tance (female)
(9) and (4) Oil temperature: 100°C 3.1 to 4.5 kz
1. Turn starting switch OFF.
2. Disconnect connectors L61 and TM.T, and connect T-adapters to
3 Ground fault in wiring harness each female side.
Resis- Between ground and L61 (female) (9) or TM.T
(female) (1) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed).
*: For average resistance of sensors at each temperature, see [DGR2KB].

WA470-7 40-613
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission oil temperature sensor

40-614 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGH2KX] Out of Range of HYD Oil Temp. Sensor (WA470_7-DGH2KX-
400-A-Z0-A)

Action level Failure code Out of Range of Hydraulic Oil Temperature Sensor
Failure
L01 DGH2KX (Transmission controller system)
• Due to ground fault in signal circuit of hydraulic oil temperature sensor, hydraulic oil
Detail of temperature signal is lower than normal range.
failure (Signal voltage from hydraulic oil temperature sensor: 0.97 V or below (150°C or above))
Action of • Cannot determine hydraulic oil temperature correctly.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Pointer of hydraulic oil temperature gauge is not displayed.
machine
• Input voltage from hydraulic oil temperature sensor can be checked with monitoring
function.
(Code: 04404 Hydr. Oil Temp. Sensor Volt)
Related • Oil temperature sensed by hydraulic oil temperature sensor can be checked with
information monitoring function.
(Code: 04401 Hydr. Oil Temperature)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R47 and connect T-adapter to male side.
Defective hydraulic oil Hydraulic oil
1 temperature: 25°C 35 to 50 kz
temperature sensor Between R47 (male) (1) (normal temperature) *
Resistance and (2)
Hydraulic oil 3.1 to 4.5
temperature: 100°C kz *
1. Turn starting switch to OFF position.
2. Disconnect connector R47 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Open circuit, short
circuit, ground fault, hot a Voltage of approx. 5 V is applied to temperature sensor signal circuits
2 short circuit of wiring through resistor in transmission controller.
harness, or defective
a Shake the wiring harness by hand while measuring the voltage. If the
transmission controller
voltage drops to approximately 0 V during shaking, circuit is open around
this point.
Voltage Between R47 (female) (1) and (2) Approx. 5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L61 and connect T-adapter to female side.
Open or short circuit in Hydraulic oil
3 wiring harness temperature: 25°C 35 to 50 kz
Between L61 (female) (normal temperature)
Resistance (20) and (4)
Hydraulic oil 3.1 to 4.5
temperature: 100°C kz
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors L61 and R47, and connect T-adapter to either
4
harness female side.
Between ground and L61 (female) (20) or R47
Resistance (female) (1) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller
* For average resistance of sensors at each temperature, see [DGR2KB].

WA470-7 40-615
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to hydraulic oil temperature

40-616 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR2KB] Ground Fault of Brake Oil Temp. Sensor (WA380_7-
DGR2KB-400-A-Z0-A)

Action level Failure code Ground Fault of Brake Oil Temperature Sensor
Failure
L01 DGR2KB (Monitor controller system)
Detail of • Voltage of signal circuit of brake oil temperature sensor (rear) drops below 0.97 V or
failure increases above 175 °C.
Action of • Light up system caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Oil temperature gauge is disabled due to failure code in sensor.
machine
• Signal from brake oil temperature sensor can be checked with monitoring function.
Related (Code: 30202 (°C), 30205 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R60 and connect T-adapter to male side.
Rear brake oil
temperature: 25°C 42.7 kz *
Rear brake oil
Defective brake oil temperature: 30°C 35.13 kz *
1 temperature sensor (rear) Resis- Between R60 (male) Rear brake oil
(1) and (2) temperature: 80°C 6.556 kz *
tance
Rear brake oil
temperature: 90°C 4.925 kz *
Rear brake oil
temperature: 100°C 3.75 kz *

1. Turn starting switch to OFF position.


Ground fault in wiring harness 2. Disconnect connectors MCM1 A, R60 and connect T-adapter to
2 either female side.
(contact with ground circuit)
Resis- Between ground and MCM1 A (female) (27) or
R20 (female) (1) Min. 1 Mz
tance
Defective monitor controller If no failure is found by above checks, monitor controller is defective.
3 (Since this is an internal defect, troubleshooting cannot be performed).
(When system is normal)
*: Sensor resistance at various temperatures are only the average figures and they may vary.

Electrical circuit diagram related to brake oil temperature sensor (rear)

WA470-7 40-617
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGR2KZ] Failure of Brake Oil Temp. Sensor (WA380_7-DGR2KZ-400-A-Z0-


A)

Action level Failure code Failure of Brake Oil Temperature Sensor


Failure
L01 DGR2KZ (Monitor controller system)
Detail of • Signal voltage of brake oil temperature sensor (rear) circuit is open circuit or not short
failure circuit.
Action of • Light up system caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on
• None
machine

• Signal from brake oil temperature sensor can be checked with monitoring function.
Related (Code: 30202 (°C), 30205 (V))
information • Method of reproducing failure code: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector R60, and connect T-adapters to female side.
3. Turn starting switch to ON position.
Open circuit or short
a If voltage is 0 V, wiring harness has open-circuit, ground fault, or short
1 circuit or ground fault in
circuit.
wiring harness
a Voltage of approximately 5 V is applied to temperature sensor signal
circuits through resistor in monitor controller.
Voltage Between R60 (female) (1) and (2) Approx. 5 V
a If no failure is found by check on cause 1, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 A and R60, and connect T-adapters to each
Open circuit in wiring female side.
2
harness Between MCM1 A (female) (27) and R60 (female)
(1) Max. 1 z
Resistance
Between MCM1 A (female) (9) and R60 (female)
(2) Max. 1 z

a If no failure is found by check on cause 1, this check is not required.


1. Turn starting switch to OFF position.
Hot short circuit in 2. Insert T-adapter into connector MCM1 A or R60.
3 wiring harness 3. Turn starting switch to ON position.
Between MCM1 A (27) and (9), or between R60
Voltage Max. 4.5 V
(female) (1) and (2)
1. Turn starting switch to OFF position.
2. Disconnect connector R60 and connect T-adapter to male side.
Rear brake oil
temperature: 25°C 42.7 kz *

Defective brake oil Rear brake oil


temperature: 30°C 35.13 kz *
4 temperature sensor
(rear) Between R60 (male) (1) Rear brake oil
Resistance and (2) temperature: 80°C 6.556 kz *
Rear brake oil
temperature: 90°C 4.925 kz *
Rear brake oil
temperature: 100°C 3.75 kz *
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
5 this is an internal defect, troubleshooting cannot be performed).
controller
*: Sensor resistance at various temperatures are only the average figures and they may vary.

40-618 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to brake oil temperature sensor

WA470-7 40-619
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGT1KA] Disconnection of T/C Oil Temp. Sensor (WA470_7-


DGT1KA-400-A-Z0-A)

Action level Failure code Disconnection of Torque Converter Oil Temperature Sensor
Failure
L01 DGT1KA (Transmission controller system)
• Due to open circuit in torque converter oil temperature sensor signal system, torque
Detail of converter oil temperature signal is higher than normal range (torque converter oil
failure temperature sensor signal voltage: Min. 4.56 V (Max. 15°C)), and transmission oil
temperature sensor signal voltage: Max. 3.7 V (Min. 55°C).
• Cannot determine torque converter oil temperature correctly.
Action of • Controls fan, ignoring torque converter oil temperature.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Fan speed may not be set properly, and that can cause overheat.
machine
• Input voltage from transmission oil temperature sensor can be checked with monitoring
function.
(Code: 32501 T/M Oil Temp. Sensor Volt)
• Oil temperature sensed by transmission oil temperature sensor can be checked with
monitoring function.
(Code: 32500 T/M Oil Temperature)
Related • Input voltage from torque converter oil temperature sensor can be checked with
information monitoring function.
(Code: 30101 T/C Oil Temp. Sensor Volt)
• Oil temperature sensed by torque converter oil temperature sensor can be checked with
monitoring function.
(Code: 30100: T/C Oil Temperature)
• Method of reproducing failure code: Turn starting switch to ON position.
a To access connector TC.T, see the illustration.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector TC.T and connect T-adapter to male side.
Torque converter oil
Defective torque temperature: 35 to 50 kz
1 converter oil 25°C (Normal *
temperature sensor Between TC.T (male) (1)
Resistance and (2) temperature)
Torque converter oil
temperature: 3.1 to 4.5
kz *
100°C
1. Turn starting switch to OFF position.
2. Disconnect connector TC.T and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit, short
circuit, ground fault, hot a Voltage of approx. 5 V is applied to temperature sensor signal circuits
short circuit of wiring through resistor in transmission controller.
2
harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the
transmission controller voltage drops to approximately 0 V during shaking, circuit is open around
this point.
Voltage Between TC.T (female) (1) and (2) Approx. 5 V

40-620 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L61, and connect T-adapters to female side.
a Voltage of approx. 5 V is applied to temperature sensor signal circuits
through resistor in transmission controller.
Open or short circuit in
3 Torque converter oil
wiring harness
temperature:
35 to 50 kz
25°C (Normal
Between L61 (female)
Resistance (3) and (4) temperature)
Torque converter oil
temperature: 3.1 to 4.5
kz
100°C

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connector L61, and connect T-adapters to female side.
defective contact of 3. Disconnect connector TC.T and connect T-adapter to female side.
connector) Between L61 (female) (4) and TC.T (female) (2) Max. 1 z
Resistance
Between L61 (female) (3) and TC.T (female) (1) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller
For average resistance of sensors at each temperature, see [DGR2KB].

Circuit diagram related to torque converter oil temperature sensor

WA470-7 40-621
40 Troubleshooting
Troubleshooting by failure code (Display of code)

How to access to TC.T connector

• Remove the right cover of the transmission.


• Remove bolt (1) and clamp (2).
• Connector TC.T is seen in upper section when hose (3) is moved.

40-622 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DGT1KB] Ground Fault of T/C Oil Temp. Sensor (WA470_7-DGT1KB-
400-A-Z0-A)

Action level Failure code Ground Fault of Torque Converter Oil Temperature Sensor
Failure
L01 DGT1KB (Transmission controller system)
• Due to ground fault of torque converter oil temperature sensor signal system, torque
Detail of converter oil temperature signal is lower than the normal range.
failure (Torque converter oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
• Cannot determine torque converter oil temperature correctly.
Action of • Controls fan, ignoring torque converter oil temperature.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Fan speed may not be set properly, and that can cause over-cooling.
machine
• Input voltage from torque converter oil temperature sensor can be checked with
monitoring function.
(Code: 30101 T/C Oil Temp. Sensor Volt)
Related • Oil temperature sensed by torque converter oil temperature sensor can be checked with
information monitoring function.
(Code: 30100: T/C Oil Temperature)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector TC.T and connect T-adapter to male side.
Torque converter oil
Defective torque temperature: 35 to 50 kz
1 converter oil 25°C (Normal *
temperature sensor Between TC.T (male) (1)
Resistance and (2) temperature)
Torque converter oil
temperature: 3.1 to 4.5
kz *
100°C
1. Turn starting switch to OFF position.
2. Disconnect connector L61, and connect T-adapters to female side.
Torque converter oil
temperature:
Open or short circuit in 35 to 50 kz
2 wiring harness 25°C (Normal
Between L61 (female)
Resistance (3) and (4) temperature)
Torque converter oil
temperature: 3.1 to 4.5
kz
100°C
1. Turn starting switch to OFF position.
2. Disconnect connector L61 and TC.T, connect T-adapter to either female
Ground fault in wiring
3 side.
harness
Between ground and L61 (female) (3) or TC.T
Resistance (female) (1) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed).
controller
For average resistance of sensors at each temperature, see [DGR2KB].

WA470-7 40-623
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to torque converter oil temperature sensor

How to access to TC.T connector

• Remove the right cover of the transmission.


• Remove bolt (1) and clamp (2).
• Connector TC.T is seen in upper section when hose (3) is moved.

40-624 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DH21KA] Failure of Loader Pump Press. Sensor (WA470_7-DH21KA-


400-A-Z0-A)

Action level Failure code Failure of Loader Pump Pressure Sensor


Failure
L01 DH21KA (Work equipment controller system)
• Due to open circuit or ground fault in loader pump pressure sensor system, loader pump
Detail of pressure signal voltage is lower than the normal range.
failure (Work equipment pump pressure sensor signal voltage: Max. 0.3 V)
Action of • Operates, assuming loader pump pressure to be 0 MPa.
controller • If cause of failure disappears, machine becomes normal by itself.
• Cut-off operation is not performed when oil is relieved.
• Accuracy of remote positioner decreases.
Problem on • Engine does not pick up normally.
machine • Komatsu SmartLoader Logic malfunctions.
• Eco guidance function does not work normally.
• Input voltage from loader pump pressure sensor can be checked with monitoring function.
(Code: 94701 Loader Pump Pres. Sensor Volt)
Related • Oil pressure sensed by loader pump pressure sensor can be checked with monitoring
information function.
(Code: 94700 Loader Pump Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of loader pump 2. Disconnect connector F10 and connect T-adapter to female side.
pressure sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between F10 (female) (B) and (A)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F10.
3. Start engine.
Defective loader pump Loader pump pressure: 0.50 to 4.40
pressure sensor Continuous V
2
(internal open or short Voltage Between F10 (C) and (A) Loader pump pressure: 0.50 to 0.90
circuit) At NEUTRAL V
Loader pump pressure: 2.80 to 3.20
At bucket tilt relief V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and F10, and connect T-adapters to each
female side.
Open circuit in wiring Between L71 (female) (9) and F10 (female) (C) Max. 1 z
harness
3 a If no failure is found by check on cause 1, this
(wire breakage or Max. 1 z
check is not required.
defective contact of
connector) Resistance Between L71 (female) (22) and F10 (female) (B)
a If no failure is found by check on cause 1, this
check is not required. Max. 1 z
Between L71 (female) (4) and F10 (female) (A)

WA470-7 40-625
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71 and F10, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L71 (female) (9) or F10
circuit) Resistance (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L71 and F10, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between L71 (female) (9) and (4) or between F10
Resistance (female) (A) and (C) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
Defective work 3. Start engine and tilt bucket
6 equipment controller Loader pump pressure: 0.50 to 4.40
Continuous V
Between L71 (9) and Loader pump pressure: 0.50 to 0.90
Voltage
ground at Neutral V
Loader pump pressure: 2.80 to 3.20
Bucket tilt V

Circuit diagram related to loader pump pressure sensor

40-626 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DH21KB] Loader Pump Press. Sensor Short Circuit (WA470_7-
DH21KB-400-A-Z0-A)

Action level Failure code Loader Pump Pressure Sensor Short Circuit
Failure
L01 DH21KB (Work equipment controller system)
• Due to hot short in loader pump pressure sensor system, loader pump pressure sensor
Detail of signal voltage is higher than the normal range.
failure (Loader pump pressure sensor signal voltage: Min. 4.42 V)
Action of • Operates, assuming loader pump pressure to be 0 MPa.
controller • If cause of failure disappears, machine becomes normal by itself.
• Cut-off operation is not performed when oil is relieved.
• Accuracy of remote positioner decreases.
Problem on • Engine does not pick up normally.
machine • Komatsu SmartLoader Logic malfunctions.
• Eco guidance function does not work normally.
• Input voltage from loader pump pressure sensor can be checked with monitoring function.
(Code: 94701 Loader Pump Pres. Sensor Volt)
Related • Oil pressure sensed by loader pump pressure sensor can be checked with monitoring
information function.
(Code: 94700 Loader Pump Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of loader pump 2. Disconnect connector F10 and connect T-adapter to female side.
pressure sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between F10 (female) (B) and (A)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F10.
3. Start engine.
Defective loader pump Loader pump pressure: 0.50 to 4.40
pressure sensor Continuous V
2
(internal open or short Voltage Between F10 (C) and (A) Loader pump pressure: 0.50 to 0.90
circuit) At Neutral V
Loader pump pressure: 2.80 to 3.20
At bucket tilt relief V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector F10 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(contact with 24V
circuit) Voltage Between F10 (female) (C) and ground Max 1 V
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
Defective work 3. Start engine and tilt bucket
4 equipment controller Loader pump pressure: 0.50 to 4.40
Continuous V
Between L71 (9) and Loader pump pressure: 0.50 to 0.90
Voltage
ground at Neutral V
Loader pump pressure: 2.80 to 3.20
Bucket tilt V

WA470-7 40-627
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to loader pump pressure sensor

40-628 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHA4KA] Failure of Air Cleaner Sensor Circuit (WA470_7-DHA4KA-400-


A-Z0-A)

Action level Failure code Failure of Air Cleaner Sensor Circuit


Failure
L01 DHA4KA (Machine monitor system)
• Machine monitor determines that air cleaner clogging sensor circuit is open (open of
Detail of sensor contacts) because signal voltage from air cleaner clogging switch is not 1 V or
failure below when starting switch is turned to ON position.
Action of • Lights up air cleaner clogging caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • If machine continues to be used, clogging of air cleaner cannot be detected correctly,
machine inducing damage to engine.
• Voltage at MCM1 A (53) is GND level when air cleaner is normal and Min. 10 V when air
cleaner is clogged (circuit is open).
• Input signal (ON/OFF) from air cleaner clogging sensor can be checked with monitoring
Related function.
information (Code: 04509 "Air cleaner clogging sensor")
• Method of reproducing failure code: Turn starting switch to OFF position.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
Dust indicator does not indicate red
When air cleaner is normal
1 Air cleaner clogging zone.
Dust indicator indicates red zone. Air cleaner clogging
1. Turn starting switch to OFF position.
Defective air cleaner 2. Disconnect connector E45 and connect T-adapter to male side.
2 clogging sensor Between E45 (male) (1) Air cleaner is normal. Max. 1z
Resistance and (2)
Air cleaner is clogged. Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector E45, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
3 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
monitor controller this point.
Voltage Between E45 (female) (1) and (2) Min. 10 V
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors MCM1 A and E45, and connect T-adapters to each
harness female side.
3 (wire breakage or Between MCM1 A (female) (53) and E45 (female)
(1) Max. 1z
defective contact of
connector) Resistance
Between E45 (female) (2) and each of MCM1 A
(female) (13) and (17) Max. 1z

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector E45.
Defective monitor 3. Turn starting switch to ON position.
4
controller
Air cleaner is normal. Max. 1 V
Voltage Between E45 (1) and (2)
Air cleaner is clogged. Min. 10 V

WA470-7 40-629
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to air cleaner clogging sensor

40-630 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHPCKX] Out of Range of Boom Bottom Press.


Sensor (WA470_7-DHPCKX-400-A-Z0-A)
Action level Failure code Out of Range of Boom Bottom Pressure Sensor
Failure
L01 DHPCKX (Work equipment controller system)
• Due to open circuit, ground fault, or hot short circuit in boom cylinder bottom pressure
Detail of sensor circuit, signal voltage of boom cylinder pressure is out of normal range.
failure (Signal voltage from boom cylinder bottom pressure sensor: Less than 0.3 V, or 4.42 V or
above)
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
• Load is not displayed.
Problem on • Komatsu SmartLoader Logic cannot be used.
machine • Eco guidance function does not work normally.
• Input voltage from boom cylinder bottom pressure sensor can be checked with monitoring
function.
(Code: 40402 Boom Bottom Pres. Sensor Volt)
Related • Oil pressure sensed by boom cylinder bottom pressure sensor can be checked with
information monitoring function.
(Code: 40400 Boom Bottom Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting
for it first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of boom cylinder 2. Disconnect connector F12, and connect T-adapter to female side.
bottom pressure sensor 3. Turn starting switch to ON position.
Power
Voltage Between F12 (female) (B) and (A) supply 5.0 to 5.2 V
input
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F12.
3. Start engine, and move lever to boom RAISE to perform
troubleshooting.
Defective boom cylinder 0.50 to 4.40
Continuous
2 bottom pressure sensor V
(internal open or short circuit) Between F12 (C) and 0.50 to 0.90
Voltage Boom: At NEUTRAL
(A) V
Boom cylinder bottom: 2.80 to 3.20
Hydraulic relief V
Sensor voltage is measured with wiring harness connected. Accordingly,
if voltage is abnormal, check harness for failure, and then determine
whether sensor is defective or not.
1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72, and F12, and connect T-adapters
Open circuit in wiring harness to each female side.
3 (wire breakage or defective Between L72 (female) (6) and F12 (female) (C) Max. 1 z
contact of connector) Resis- Between L71 (female) (22) and F12 (female)
(B) Max. 1 z
tance
Between L71 (female) (4) and F12 (female) (A) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors L72 and F12, and connect T-adapter to either
4 harness female side.
(contact with ground circuit) Resis- Between ground and L72 (female) (6) or F12 Min 1 Mz
tance (female) (C)

WA470-7 40-631
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72 and F12, and connect T-adapter to
5 Short circuit in wiring harness either female side.
Resis- Between L72 (female) (6) and L71 (female) (4)
or between F12 (female) (A) and (C) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector F12, and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
harness
Voltage Between F12 (female) (C) and ground Max. 1 V
If no failure is found by above checks, work equipment controller is
defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
Defective work equipment 3. Start engine and raise boom.
7
controller Between L71 (22) and ground 5.0 to 5.2 V
0.50 to 4.40
Continuous
V
Voltage Between L72 (6) and 0.50 to 0.90
Boom: At Neutral
ground V
Boom cylinder bottom: 2.80 to 3.20
Hydraulic relief V

Circuit diagram related to boom cylinder bottom pressure sensor

40-632 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHPDKX] Out of Range of Boom Head Press. Sensor (WA470_7-
DHPDKX-400-A-Z0-A)

Action level Failure code Out of Range of Boom Head Pressure Sensor
Failure
L01 DHPDKX (Work equipment controller system)
• Due to open circuit, ground fault, or hot short circuit in boom cylinder head pressure
Detail of sensor circuit, signal voltage of boom cylinder pressure is out of normal range.
failure (Signal voltage from boom cylinder head pressure sensor: Less than 0.3 V, or 4.42 V or
above)
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • Load is not displayed.
machine
• Input voltage from boom cylinder head pressure sensor can be checked with monitoring
function.
(Code: 40501 Boom Head Pres. Sensor Volt)
Related • Oil pressure sensed by boom cylinder head pressure sensor can be checked with
information monitoring function.
(Code: 40500 Boom Head Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply
system of boom 1. Turn starting switch to OFF position.
1 2. Disconnect connector F13 and connect T-adapter to female side.
cylinder head pressure
sensor 3. Turn starting switch to ON position.
Power
Voltage Between F13 (female) (B) and (A)
supply input 5.0 to 5.2 V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F13.
3. Start engine, and troubleshoot by lowering boom.
Defective boom cylinder 0.50 to 4.40
Continuous
head pressure sensor V
2 (internal open or short 0.50 to 0.90
Voltage Between F13 (C) and (A) Boom: At Neutral
circuit) V
Boom cylinder head: 2.80 to 3.22
Hydraulic relief V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71, L72, and F13, and connect T-adapters to
each female side.
3 (wire breakage or Between L72 (female) (16) and F13 (female) (C) Max. 1 z
defective contact of
Resistance Between L71 (female) (22) and F13 (female) (B) Max. 1 z
connector)
Between L71 (female) (4) and F13 (female) (A) Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L72 and F13, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L72 (female) (16) or F13
circuit) Resistance (female) (C) Min. 1 Mz

WA470-7 40-633
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72 and F13, and connect T-adapter to
5 Short circuit in wiring harness either female side.
Resis- Between L72 (female) (16) and L71 (female)
(4) or between F13 (female) (A) and (C) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector F13 and connect T-adapter to female side.
6 3. Turn starting switch to ON position.
harness
Voltage Between F13 (female) (C) and ground Max 1 V
If no failure is found by above checks, work equipment controller is
defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
Defective work equipment 3. Start engine and lower boom
7
controller Between L71 (22) and ground 5.0 to 5.2 V
0.50 to 4.40
Continuous
V
Voltage Between L72 (16) and 0.50 to 0.90
Boom: At Neutral
ground V
Boom cylinder head: 2.80 to 3.20
Hydraulic relief V

Circuit diagram related to boom cylinder head pressure sensor

40-634 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT1KX] Out of Range of T/M Cut Off Press. Sensor (WA470_7-
DHT1KX-400-A-Z0-A)

Action level Failure code Out of Range of Transmission Cut Off Pressure Sensor
Failure
L01 DHT1KX (Transmission controller system)
• Due to open circuit or ground fault in transmission cut-off pressure sensor system,
Detail of transmission cut-off pressure signal voltage is lower than the normal range.
failure (Transmission cut-off pressure sensor signal voltage: Max. 0.3 V)
• Turns off transmission cut-off function.
Action of • Disables change of transmission cut-off setting.
controller • If cause of transmission cut-off failure disappears, machine becomes normal by itself.
Problem on • Transmission cut-off indicator goes out.
machine • Transmission cut-off function does not work.
• Input voltage from transmission cut-off pressure sensor can be checked with monitoring
function.
(Code: 41202 Brake Oil Press Sensor Volt)
Related • Oil pressure sensed by transmission cut-off pressure sensor can be checked with
information monitoring function.
(Code: 41201. Brake Oil Pressure)
• Method of reproducing failure code:Turn starting switch ON and turn transmission cut-off
switch ON.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DBE6KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of transmission 2. Disconnect connector R73 and connect T-adapter to female side.
cut-off pressure sensor 3. Turn starting switch to ON position.
Power
Voltage Between R73 (female) (B) and (A)
supply input 20 to 30 V
a
Replace sensor and check whether failure code disappears.
1.
Turn starting switch to OFF position.
2.
Insert T-adapter into connector R73.
3.
Start engine.
Defective transmission 4.
Turn transmission cut-off switch ON.
cut-off pressure sensor When brake is released 0.9 to 1.1 V
2 (internal open or short When brake pedal is
circuit) Voltage Between R73 (C) and (A) depressed (both right 1.1 to 5.1 V
and left)
Continuous 0.9 to 5.1 V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L61 and R73, and connect T-adapters to each
harness female side.
3 (wire breakage or a Open circuit of 5 V circuit
defective contact of Between L61 (female) (13) and R73 (female) (C) Max. 1 z
connector)
Resistance Between L61 (female) (16) and R73 (female) (B) Max. 1 z
Between L61 (female) (4) and R73 (female) (A) Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L61 and R73, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L61 (female) (13) or R73
circuit) Resistance (female) (C) Min. 1 Mz

WA470-7 40-635
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and R73, and connect T-adapter to
5 Short circuit in wiring harness either female side.
Resis- Between L61 (female) (13) and (4) or between
R73 (female) (A) and (C) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L61.
Defective transmission 3. Start engine and tilt bucket
6
controller
When brake is
0.9 to 1.1 V
released
Between L61 (13) and When brake pedal is
Voltage depressed (both right 1.1 to 5.1 V
ground
and left)
Continuous 0.9 to 5.1 V

Circuit diagram related to transmission cut-off (left brake) pressure sensor

40-636 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT5KX] Out of Range of T/C Input Pressure Sensor (WA470_7-
DHT5KX-400-A-Z0-A)

Action level Failure code Out of Range of Torque Converter Input Pressure Sensor
Failure
L01 DHT5KX (Transmission controller system)
Detail of • Voltage of signal circuit of torque converter input pressure sensor drops below 0.5 V or
failure increases above 4.5 V.
Action of • Controls it by fixing torque converter input pressure to set pressure stored in controller.
controller
Problem on • Large shocks are made when torque converter lockup clutch is engaged.
machine
• Input voltage from torque converter input pressure sensor can be checked with monitoring
function.
(Code: 32602 T/C In. Oil Press Sensor Volt)
Related • Oil pressure sensed by torque converter input pressure sensor can be checked with
information monitoring function.
(Code: 32601 T/C Input Oil Pressure)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DBE6KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective sensor power 2. Disconnect connector TCIN.P, and connect T-adapter to female side.
1 supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 5.
Power
Voltage Between TCIN.P (female) (B) and (A)
supply input 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and TCIN.P, and connect T-adapter to either
Ground fault in wiring female side.
2 3. Disconnect connector TCIN.P, and connect T-adapter to female side.
harness
Between ground and L61 (female) (7) or TCIN.P
Resistance (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.


Hot short circuit in 2. Disconnect connector TCIN.P, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between TCIN.P (female) (C) and ground Max 1 V
a Replace sensor and check whether failure code disappears.
Defective torque 1. Turn starting switch to OFF position.
4 converter oil pressure 2. Insert T-adapter into connector TCIN.P.
sensor 3. Turn starting switch to ON position.
Voltage Between TCIN.P (C) and (A) 0.9 to 5.1 V

WA470-7 40-637
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and TCIN.P, and connect T-adapters to each
female side.
Open circuit in wiring
harness a If power supply voltage is normal, this check is
not required. Max. 1 z
5 (wire breakage or Between L61 (female) (16) and TCIN.P (female) (B)
defective contact of
connector) Resistance
a If power supply voltage is normal, this check is
not required. Max. 1 z
Between L61 (female) (4) and TCIN.P (female) (A)
Between L61 (female) (7) and TCIN.P (female) (C) Max. 1 z
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
Defective transmission
6 1. Turn starting switch to OFF position.
controller
2. Insert T-adapter into connector L61.
3. Turn starting switch to ON position.
Between L61 (16) and (4) 20 to 30 V
Voltage
Between L61 (7) and (4) 0.9 to 5.1 V

Circuit diagram related to torque converter oil pressure sensor

40-638 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT7KX] Out of Range of T/C Output Pressure


Sensor (WA470_7-DHT7KX-400-A-Z0-A)
Action level Failure code Out of Range of Torque Converter Output Pressure Sensor
Failure
L01 DHT7KX (Transmission controller system)
Detail of • Voltage of signal circuit of torque converter output pressure sensor drops below 0.5 V or
failure increases above 4.5 V.
Action of • Fixes torque converter output pressure to set pressure in controller and continues control.
controller
Problem on • Large shocks are made when torque converter lockup clutch is engaged.
machine
• Input voltage from torque converter output pressure sensor can be checked with
monitoring function.
(Code: 32604 T/C Out. Oil Press Sensor Volt)
Related • Oil pressure sensed by torque converter output pressure sensor can be checked with
information monitoring function.
(Code: 32603 T/C Output Oil Pressure)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DBE6KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective sensor power 2. Disconnect connector R91, and connect T-adapter to female side.
1 supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 5.
Power
Voltage Between R91 (female) (B) and (A)
supply input 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and R91, and connect T-adapter to either
Ground fault in wiring
2 female side.
harness
Between ground and L61 (female) (1) or R91
Resistance (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.


Hot short circuit in 2. Disconnect connector R91, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between R91 (female) (C) and ground Max. 1 V
a Replace sensor and check whether failure code disappears.
Defective torque 1. Turn starting switch to OFF position.
4 converter oil pressure 2. Insert T-adapter into connector R91.
sensor 3. Turn starting switch to ON position.
Voltage Between R91 (C) and (A) 0.9 to 5.1 V

WA470-7 40-639
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and R91, and connect T-adapters to each
female side.
Open circuit in wiring
harness a If power supply voltage is normal, this check is
not required. Max. 1 z
5 (wire breakage or Between L61 (female) (16) and R91 (female) (B)
defective contact of
connector) Resistance
a If power supply voltage is normal, this check is
not required. Max. 1 z
Between L61 (female) (4) and R91 (female) (A)
Between L61 (female) (1) and R91 (female) (C) Max. 1 z
If no failure is found by above checks, transmission controller may be
defective. (Since this is an internal defect, troubleshooting cannot be
performed).
a Reference
Defective transmission
6 1. Turn starting switch to OFF position.
controller
2. Insert T-adapter into connector L61.
3. Turn starting switch to ON position.
Between L61 (16) and (4) 20 to 30 V
Voltage
Between L61 (1) and (4) 0.9 to 5.1 V

Circuit diagram related to torque converter oil pressure sensor

40-640 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT8KA] Failure of Steering Pump Press. Sensor (WA470_7-


DHT8KA-400-A-Z0-A)

Action level Failure code Failure of Steering Pump Pressure Sensor


Failure
L01 DHT8KA (Work equipment controller system)
• Due to open circuit or ground fault in steering pump pressure sensor system, steering
Detail of pump pressure signal voltage is lower than the normal range.
failure (Steering pump pressure sensor signal voltage: Max. 0.3 V)
Action of • Operates, assuming steering pump pressure to be 0 MPa.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine does not pick up normally at the low engine speed.
machine
• Input voltage from steering pump pressure sensor can be checked with monitoring
function.
(Code: 95303 Steering Pump Pres. Sensor Volt)
Related • Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
information function.
(Code: 95302 Steering Pump Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of steering 2. Disconnect connector R86 and connect T-adapter to female side.
pump pressure sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between R86 (female) (3) and (1)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R86.
3. Start engine and operate steering.
Defective steering 0.50 to 4.5
pump pressure sensor Continuous
V
2 (internal open or short
Voltage Between R86 (2) and (1) Steering: At NEUTRAL 0.50 to 0.90
circuit) V
Steering: At Relief 3.02 to 3.42
V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and R86, and connect T-adapters to each
female side.
Open circuit in wiring
harness a If no failure is found by check on cause 1, this
check is not required. Max. 1 z
3 (wire breakage or Between L71 (female) (4) and R86 (female) (1)
defective contact of
connector) Resistance
a If no failure is found by check on cause 1, this
check is not required. Max. 1 z
Between L71 (female) (22) and R86 (female) (3)
Between L71 (female) (3) and R86 (female) (2) Max. 1 z

WA470-7 40-641
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71 and R86, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L71 (female) (3) or R86
circuit) Resistance (female) (2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L71 and R86, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between L71 (female) (3) and (4), or between R86
Resistance (female) (2) and (1) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
Defective work 3. Start engine and operate steering.
6 equipment controller 0.50 to 4.5
Continuous
V
Between L71 (3) and 0.50 to 0.90
Voltage Steering: At Neutral
ground V
Steering: Relieved 3.02 to 3.42
V

Circuit diagram related to steering pump pressure sensor

40-642 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT8KB] Steering Pump Press. Sensor Short Circuit (WA470_7-
DHT8KB-400-A-Z0-A)

Action level Failure code Steering Pump Pressure Sensor Short Circuit
Failure
L01 DHT8KB (Work equipment controller system)
• Due to hot short in steering pump pressure sensor system, steering pump pressure
Detail of sensor signal voltage is higher than the normal range.
failure (Steering pump pressure sensor signal voltage: Min. 4.7 V)
Action of • Operates, assuming steering pump pressure to be 0 MPa.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine does not pick up normally at the low engine speed.
machine
• Input voltage from steering pump pressure sensor can be checked with monitoring
function.
(Code: 95303 Steering Pump Pres. Sensor Volt)
Related • Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
information function.
(Code: 95302 Steering Pump Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply 1. Turn starting switch to OFF position.
1 system of steering 2. Disconnect connector R86 and connect T-adapter to female side.
pump pressure sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between R86 (female) (3) and (1)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R86.
3. Start engine and operate steering.
Defective steering 0.50 to 4.5
pump pressure sensor Continuous
V
2 (internal open or short
Voltage Between R86 (2) and (1) Steering: At Neutral 0.50 to 0.90
circuit) V
Steering: At Relief 3.02 to 3.42
V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector R86 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(contact with 24V
circuit) Voltage Between R86 (female) (2) and ground Max 1 V
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
Defective work 3. Start engine and operate steering.
4 equipment controller 0.50 to 4.5
Continuous
V
Between L71 (3) and 0.50 to 0.90
Voltage Steering: At Neutral
ground V
Steering: At Relief 3.02 to 3.42
V

WA470-7 40-643
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to steering pump pressure sensor

40-644 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHT8ZG] Steering Oil Pressure Low (WA380_7-DHT8ZG-400-A-Z0-A)

Action level Failure code Steering Oil Pressure Low


Failure
L03 DHT8ZG (Work equipment controller system)
Detail of • Steering pump pressure is lower than normal range.
failure
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Problem on • When machine is steered, turning response is poor.
machine
• Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
function.
(Code: 95302 Steering Pump Pressure)
• Input voltage from steering pump pressure sensor can be checked with monitoring
Related function.
information (Code: 95303 Steering Pump Pres. Sensor Volt)
• This failure code is displayed on only machines equipped with emergency steering
(optional).
• Failure code [DHT8KA] of open circuit in steering pump pressure sensor is also displayed.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Perform troubleshooting according to [H-9] (Turning response is poor) in troubleshooting (H mode) for
1 hydraulic and mechanical system.
If no failure is found by above checks, troubleshoot for [DHT8KA] and [DHT8KB].

WA470-7 40-645
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUDKA] Failure of Emrg. Steering Press. Sensor (WA470_7-


DHUDKA-400-A-Z0-A)

Action level Failure code Failure of Emergency Steering Pressure Sensor


Failure
L01 DHUDKA (Work equipment controller system)
• Due to open circuit or ground fault in emergency steering pump pressure sensor system,
Detail of emergency steering pump pressure signal voltage is lower than the normal range.
failure (Emergency steering pump pressure sensor signal voltage: Max. 0.3 V)
Action of • Judges that no emergency steering pump pressure is applied.
controller • If cause of failure disappears, machine becomes normal by itself.
• Emergency steering self-check ends abnormally.
Problem on • Emergency steering operation indicator does not light up while emergency steering is in
machine operation.
• Only for the machine equipped with emergency steering (optional).
• Input voltage from emergency steering pump pressure sensor can be checked with
monitoring function.
(Code: 07705 Emrg. Steering Pres. S. Volt)
Related • Oil pressure sensed by emergency steering pump pressure sensor can be checked with
information monitoring function.
(Code: 07703 Emrg. Steering Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply
system of emergency 1. Turn starting switch to OFF position.
1
steering pump pressure 2. Disconnect connector R37 and connect T-adapter to female side.
sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between R37 (female) (3) and (1)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R37.
3. Start engine.
4. Turn emergency steering ON and operate steering.
Defective emergency
0.50 to 4.5
steering pump pressure Continuous
V
2 sensor
When emergency 0.50 to 0.90
(internal open or short Voltage Between R37 (2) and (1) steering is stopped V
circuit)
When emergency
steering is turned ON 0.50 to 3.05
and steering is operated V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and R37, and connect T-adapters to each
female side.
Open circuit in wiring
harness a If no failure is found by check on cause 1, this
check is not required. Max. 1 z
3 (wire breakage or Between L71 (female) (4) and R37 (female) (1)
defective contact of
connector) Resistance
a If no failure is found by check on cause 1, this
check is not required. Max. 1 z
Between L71 (female) (22) and R37 (female) (3)
Between L71 (female) (12) and R37 (female) (2) Max. 1 z

40-646 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71 and R37, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L71 (female) (12) or R37
circuit) Resistance (female) (2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L71 and R37, and connect T-adapter to either
Short circuit in wiring
5 female side.
harness
Between L71 (female) (12) and (4) or between R37
Resistance (female) (2) and (1) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
3. Start engine.
Defective work 4. Turn emergency steering ON and operate steering.
6 equipment controller 0.50 to 4.5
Continuous
V
When emergency 0.50 to 0.90
Between L71 (12) and steering is stopped
Voltage V
ground
When emergency
steering is turned ON 0.50 to 3.05
and steering is operated V

Circuit diagram related to emergency steering pump pressure sensor

WA470-7 40-647
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DHUDKB] Emrg. Steering Press. S. Short Circuit (WA470_7-DHUDKB-


400-A-Z0-A)

Action level Failure code Emergency Steering Pressure Sensor Short Circuit
Failure
L01 DHUDKB (Work equipment controller system)
• Due to hot short in emergency steering pump pressure sensor system, emergency
Detail of steering pump pressure sensor signal voltage is higher than the normal range.
failure (Emergency steering pump pressure sensor signal voltage: Min. 4.7 V)
Action of • Judges that no emergency steering pump pressure is applied.
controller • If cause of failure disappears, machine becomes normal by itself.
• Emergency steering self-check ends abnormally.
Problem on • Emergency steering operation indicator does not light up while emergency steering is in
machine operation.
• Only for the machine equipped with emergency steering (optional).
• Input voltage from emergency steering pump pressure sensor can be checked with
monitoring function.
(Code: 07705 Emrg. Steering Pres. S. Volt)
Related • Oil pressure sensed by emergency steering pump pressure sensor can be checked with
information monitoring function.
(Code: 07703 Emrg. Steering Pressure)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
a If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
Defective power supply
system of emergency 1. Turn starting switch to OFF position.
1
steering pump pressure 2. Disconnect connector R37 and connect T-adapter to female side.
sensor 3. Turn starting switch to ON position.
Power 5.00 to 5.20
Voltage Between R37 (female) (3) and (1)
supply input V
a Replace sensor and check whether failure code disappears.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector R37.
3. Start engine.
4. Turn emergency steering ON and operate steering.
Defective emergency
0.50 to 4.5
steering pump pressure Continuous
V
2 sensor
When emergency 0.50 to 0.90
(internal open or short Voltage Between R37 (2) and (1) steering is stopped V
circuit)
When emergency
steering is turned ON 0.50 to 3.05
and steering is operated V
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check harness for failure, and then determine whether
sensor is defective or not.
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector R37 and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(contact with 24V
circuit) Voltage Between R37 (female) (2) and ground Max 1 V

40-648 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, work equipment controller is defective.
(Since this is an internal defect, troubleshooting cannot be performed.)
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
3. Start engine.
Defective work 4. Turn emergency steering ON and operate steering.
4 equipment controller 0.50 to 4.5
Continuous
V
When emergency 0.50 to 0.90
Between L71 (12) and steering is stopped
Voltage V
ground
When emergency
steering is turned ON 0.50 to 3.05
and steering is operated V

Circuit diagram related to emergency steering pump pressure sensor

WA470-7 40-649
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DJF1KA] Disconnection of Fuel Level Sensor (WA470_7-DJF1KA-400-A-


Z0-A)

Action level Failure code Disconnection of Fuel Level Sensor


Failure
L01 DJF1KA (Machine monitor system)
Detail of • Voltage of signal circuit of fuel level sensor is 2.0 V or above.
failure
Action of • Light up system caution lamp.
controller • If cause of failure disappears, machine becomes normal by itself.

Problem on • Fuel level gauge pointer disappears.


machine

• Signal from fuel level sensor can be checked with monitoring function. (code: 04200 (V),
Related 04201 (z))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R33 and connect T-adapters to male side.
Defective fuel level
1 Between Fuel level: Full Max. 12 z
sensor
Resistance R33 (male)
(1) and (2) Fuel level: Empty 80 to 100 z
1. Turn starting switch to OFF position.
2. Disconnect connector R33, and connect T-adapters to female side.
Open circuit, short 3. Turn starting switch to ON position.
circuit, ground fault, hot
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
monitor controller this point.
Voltage Between R33 (female) (1) and (2) Approx. 3.3
V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector MCM1 A, and connect T-adapters to female side.
3 wiring harness Between Fuel level: Full Max. 12 z
MCM1 A
Resistance (female) (8)
Fuel level: Empty 80 to 100 z
and (9)
a If no failure is found by check on cause 2, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and R33, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of Between MCM1 A (female) (8) and R33 (female)
(1) Max. 1 z
connector) Resistance
Between MCM1 A (female) (9) and R33 (female)
(2) Max. 1 z
Defective monitor If no failure is found by above checks, monitor controller may be defective.
5 (Since this is an internal defect, troubleshooting cannot be performed).
controller

40-650 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fuel level sensor

WA470-7 40-651
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK55KA] Failure of FNR Lever Potentio (WA380_7-DK55KA-400-A-Z0-A)

Action level Failure code Failure of FNR Lever Potentiometer


Failure
L01 DK55KA (Transmission controller system)
• Due to open circuit or ground fault in directional (FNR) lever analog signal system, analog
Detail of signal voltage from directional (FNR) lever is lower than normal range. (Analog signal
failure voltage from directional (FNR) lever: Below 1.2 V).
• Judges that the lever position to be determined from analog signal is N (Neutral).
Action of • Continues to take it that lever position to be determined from analog signal is N (Neutral)
controller until it receives analog signal showing lever position of N (Neutral), even if cause of failure
disappears.
Problem on • No particular problem occurs, as long as directional (FNR) lever switch is normal.
machine
• Analog signal input voltage from lever can be checked with monitoring function. (Code:
Related 91105 Shift lever Volt)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DBE5KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L02, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L02 (female) (10) and (12) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L02.
3. Turn starting switch to ON position.
4. Move directional (FNR) lever to perform troubleshooting.
a If power supply voltage is normal and sensor output voltage is abnormal
(0.5 V or lower), it cannot be determined whether ground fault or defective
Defective analog signal sensor is the cause. In this case, go to check on cause 4.
system of directional a If no failure is found in check on cause 4, analog signal system of
2 (FNR) lever directional (FNR) lever is defective.
(internal open circuit or Directional (FNR) lever
ground fault) position: 1.2 to 1.8 V
F (forward)
Between L02 (11) and Directional (FNR) lever
Voltage 1.7 to 3.3 V
(12) position: N (neutral)
Directional (FNR) lever
position: 3.2 to 3.8 V
R (reverse)
1. Turn starting switch to OFF position.
2. Disconnect connectors L61 and L02, and connect T-adapters to each
female side.
Open circuit in wiring
harness a If no failure is found by check on cause 1, this
check is not required. Max. 1 z
3 (wire breakage or Between L61 (female) (22) and L02 (female) (10)
defective contact of
connector) Resistance Between L61 (female) (8) and L02 (female) (11) Max. 1 z
a If no failure is found by check on cause 1, this Max. 1 z
check is not required.
Between L61 (female) (21) and L02 (female) (12)

40-652 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
4 2. Disconnect connectors L61 and L02, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and L61 (female) (8) or L02
Resistance (female) (11) Min. 1 Mz
If no failure is found by above checks, transmission controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L61.
3. Turn starting switch to ON position.
4. Move directional (FNR) lever to perform troubleshooting.
Between L61 (22) and
ground Continuous 5.0 to 5.2 V
Defective transmission
5 Directional (FNR) lever
controller
position: 1.2 to 1.8 V
F (forward)
Voltage
Between L61 (8) and Directional (FNR) lever
ground position: N (neutral) 1.7 to 3.3 V
Directional (FNR) lever
position: 3.2 to 3.8 V
R (reverse)

WA470-7 40-653
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to directional (FNR) lever potentiometer

40-654 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK55KY] Hot Short of FNR Lever Potentio Circuit (WA380_7-
DK55KY-400-A-Z0-A)

Action level Failure code Hot Short of FNR Lever Potentiometer Circuit
Failure
L01 DK55KY (Transmission controller system)
• Due to hot short circuit in directional (FNR) lever analog signal system, analog signal
Detail of voltage from directional (FNR) lever is higher than normal range. (Signal voltage from
failure FNR lever potentiometer: Above 3.8 V)
• Judges that the lever position to be determined from analog signal is N (Neutral).
Action of • Continues to take it that lever position to be determined from analog signal is N (Neutral)
controller until it receives analog signal showing lever position of N (Neutral), even if cause of failure
disappears.
Problem on • No particular problem occurs, as long as directional (FNR) lever switch is normal.
machine
• Analog signal input voltage from directional (FNR) lever can be checked with monitoring
Related function. (Code: 91105 Shift lever Volt)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DBE5KX] is also displayed, perform troubleshooting for it first.

Defective 5 V sensor 1. Turn starting switch to OFF position.


1 power supply system 2. Disconnect connector L02, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Voltage Between L02 (female) (10) and (12) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L02.
Defective analog signal 3. Turn starting switch to ON position.
system of directional If this failure code [DK55KY] is not displayed, analog signal system of
2 (FNR) lever directional (FNR) lever is defective. (If this failure code is still displayed, wiring
(internal short circuit) harness or transmission controller is defective.)
a Since connector L02 is disconnected, many failure codes appear. Ignore
all of displayed failure codes other than this failure code [DK55KY].
Hot short circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connector L02, and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
(contact with 24 V
circuit) Voltage Between L02 (female) (11) and ground Max. 1 V
If no failure is found by above checks, transmission controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L61.
3. Turn starting switch to ON position.
4. Move directional (FNR) lever to perform troubleshooting.
Between L61 (22) and
ground Continuous 5.0 to 5.2 V
Defective transmission
4 Directional (FNR) lever
controller
position: 1.2 to 1.8 V
F (forward)
Voltage
Between L61 (8) and Directional (FNR) lever
ground position: N (neutral) 1.7 to 3.3 V
Directional (FNR) lever
position: 3.2 to 3.8 V
R (reverse)

WA470-7 40-655
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to directional (FNR) lever potentiometer

40-656 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK55L5] Failure of FNR Lever Potentio (WA380_7-DK55L5-400-A-Z0-A)

Action level Failure code Failure of FNR Lever Potentiometer


Failure
L01 DK55L5 (Transmission controller system)
• Input analog signal from directional (FNR) lever is impossible relative to input signal (ON/
OFF) from directional (FNR) lever switch where devices are normal.
• This failure code is displayed under following conditions when short circuit to power
supply line not detected for directional (FNR) lever switch.
(In any case of [A], [B], and [C])
[A]
1. directional (FNR) lever switch recognizes that directional (FNR) lever is in F (Forward)
position.
2. directional (FNR) lever analog signal voltage is equal to or higher than 2.2 V.
3. Neither of open circuit and ground fault is detected in analog signal system of
Detail of directional (FNR) lever.
failure [B]
1. directional (FNR) lever switch recognizes that directional (FNR) lever is in R (Reverse)
position.
2. directional (FNR) lever analog signal voltage is higher than 2.8 V.
3. Short circuit to power supply line is not detected for directional (FNR) lever analog
signal system.
[C]
1. directional (FNR) lever switch recognizes that directional (FNR) lever is in N (Neutral)
position.
2. Analog signal system of directional (FNR) lever recognizes that directional (FNR) lever
is in F (Forward) or R (Reverse) position.
• Takes it that lever position to be determined from analog signal is N (Neutral).
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • No particular problem occurs, as long as directional (FNR) lever switch is normal.
machine
• Analog signal input voltage from lever can be checked with monitoring function. (Code:
91105 Shift lever Volt)
Related • Input signal (ON/OFF) from directional (FNR) lever switch can be checked with monitoring
information function. (Code: 02211 Main directional (FNR) Signal F, Main directional (FNR) Signal N,
Main directional (FNR) Signal R).
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective directional (FNR) directional (FNR) lever may be defective.
1
lever (Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-657
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK59KA] Failure of Boom Lever Potentio (Main) (WA470_7-DK59KA-


400-A-Z0-A)

Action level Failure code Failure of Boom Lever Potentiometer (Main)


Failure
L03 DK59KA (Work equipment controller system)
• Controller determines that boom lever potentiometer (main: A line) circuit has open circuit
Detail of or ground fault because signal voltage from boom lever potentiometer (main: A line) is
failure lower than normal range.
(Signal voltage from boom lever potentiometer (main: A line): Max. 0.3 V)
• Controls boom by using signal voltage from boom lever potentiometer (sub: B line) if it is
normal.
However, in this case, bucket detent control does not work, and work equipment speed
Action of
decreases to 30 % of normal speed.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
• Boom lowers momentarily, then it can be controlled by using signals from sub
Problem on potentiometer.
machine However, in this case, bucket detent control does not work, and work equipment speed
decreases to 30 % of normal speed.
• Input voltage from boom lever potentiometer (main: A line) can be checked with
monitoring function.
(Code: 42000 Boom Lever Volt(Main))
Related • Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
information function.
(Code: 42001 Boom Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L28A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L28A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to male side.
Between L28A (male) (1) and ground
Between L28A (male) (2) and ground
Resistance Between L28A (male) (3) and ground Min. 1 Mz
Between L28A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L28A.
5. Set work equipment lock switch to LOCK position.
Defective boom lever 6. Turn starting switch to ON position.
2 potentiometer (internal 7. Operate boom lever to perform troubleshooting.
open or short circuit) 2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 3.38 to 4.04
position) V
Between L28A (3) and Boom lever: RAISE (at 3.90 to 4.40
Voltage
(2) detent position) V
Boom lever: LOWER
(just before the detent 0.96 to 1.62
position) V
0.60 to 1.10
Boom lever: FLOAT
V

40-658 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and L28A, and connect T-adapters to each
female side.
Open circuit in wiring
harness a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
3 (wire breakage or Between L71 (female) (22) and L28A (female) (1)
defective contact of
connector) Resistance
a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
Between L71 (female) (4) and L28A (female) (2)
Between L71 (female) (8) and L28A (female) (3) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
4 2. Disconnect connectors L71 and L28A, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and L71 (female) (8) or L28A
Resistance (female) (3) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate boom lever to perform troubleshooting.
Between L71 (22) and
(4) Boom lever: Continuous 5.0 to 5.2 V

Defective work 2.38 to 2.62


Boom lever: NEUTRAL
5 equipment controller V
Boom lever: RAISE (just
before the detent 3.38 to 4.04
position) V
Voltage
Boom lever: RAISE (at 3.90 to 4.40
Between L71 (8) and (4)
detent position) V
Boom lever: LOWER
(just before the detent 0.96 to 1.62
position) V
0.60 to 1.10
Boom lever: FLOAT
V

WA470-7 40-659
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom lever potentiometer

40-660 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK59KY] Hot Short of Boom Lever Potentio (Main) (WA470_7-
DK59KY-400-A-Z0-A)

Action level Failure code Hot Short of Boom Lever Potentiometer (Main)
Failure
L03 DK59KY (Work equipment controller system)
• Controller determines that boom lever potentiometer (main: A line) circuit has hot short
Detail of because signal voltage from boom lever potentiometer (main: A line) is higher than normal
failure range.
(Signal voltage from boom lever potentiometer (main: A line): Min. 4.7 V)
• Controls boom by using signal voltage from boom lever potentiometer (sub: B line) if it is
normal.
However, in this case, bucket detent control does not work, and work equipment speed
Action of
decreases 30%.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
• Boom rises momentarily, then it is controlled normally by using signals from sub
Problem on potentiometer.
machine However, in this case, bucket detent control does not work, and work equipment speed
decreases 30%.
• Input voltage from boom lever potentiometer (main: A line) can be checked with
monitoring function.
(Code: 42000 Boom Lever Volt(Main))
Related • Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
information function.
(Code: 42001 Boom Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L28A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L28A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to male side.
Between L28A (male) (1) and ground
Between L28A (male) (2) and ground
Resistance Min. 1 Mz
Between L28A (male) (3) and ground
Defective boom lever
Between L28A (male) (4) and ground
2 potentiometer (internal
short circuit) 3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L28A.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
7. Operate boom lever to perform troubleshooting.

WA470-7 40-661
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 3.38 to 4.04
position) V
Defective boom lever
Between L28A (3) and Boom lever: RAISE (at 3.90 to 4.40
2 potentiometer (internal Voltage
(2) detent position) V
short circuit)
Boom lever: LOWER
(just before the detent 0.96 to 1.62
position) V
0.60 to 1.10
Boom lever: FLOAT
V
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L28A, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between L28A (female) (3) and (2) or ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and L28A, and connect T-adapters to female
Short circuit in wiring side of L71.
4 3. Turn starting switch to ON position.
harness
Between L71 (female) (8) and each No continuity
Continuity
pin other than L71 (female) (8) (No sound is heard)
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate boom lever to perform troubleshooting.
Between L71 (22) and
(4) Boom lever: Continuous 5.0 to 5.2 V

Defective work 2.38 to 2.62


Boom lever: NEUTRAL
5 equipment controller V
Boom lever: RAISE (just
before the detent 3.38 to 4.04
position) V
Voltage
Boom lever: RAISE (at 3.90 to 4.40
Between L71 (8) and (4)
detent position) V
Boom lever: LOWER
(just before the detent 0.96 to 1.62
position) V
0.60 to 1.10
Boom lever: FLOAT
V

40-662 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom lever potentiometer

WA470-7 40-663
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK59L8] Boom Lever Potentio (Main & Sub)


Disagree (WA470_7-DK59L8-400-A-Z0-A)
Action level Failure code Boom Lever Potentiometer (Main & Sub) Disagree
Failure
L03 DK59L8 (Work equipment controller system)
• Input signals from boom lever potentiometers (main: A line and sub: B line) disagree with
each other.
Detail of (Signal voltages from boom lever potentiometers (Total of signal voltages from main: A
failure line and sub: B line): Min. 4.65 V) or
(Signal voltages from boom lever potentiometers (Total of signal voltages from main: A
line and sub: B line): Min. 5.35 V)
• Operates by using potentiometer sensor signal from either main: A line or sub: B line
which shows the standard voltage when lever is in NEUTRAL position.
In this case work equipment speed decreases 30% and stops boom detent output.
• Stops output to boom detent solenoid, boom tilt EPC solenoid and boom dump EPC
Action of
solenoid if signal voltages from both main: A line and sub: B line potentiometers show out
controller
of the standard value voltage when lever is in NEUTRAL position.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
• If either main: A line or sub: B line potentiometer malfunctions, machine operates normally
Problem on with no boom detent output and decreasing work equipment speed 30% after lever is
machine once set to NEUTRAL.
• If both main: A line and sub: B line potentiometers malfunction, boom does not move.
• Input voltage from boom lever potentiometer (main: A line) can be checked with
monitoring function.
(Code: 42000 Boom Lever Volt(Main))
Related • Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
information function.
(Code: 42001 Boom Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L28A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L28A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to male side.
Defective boom lever Between L28A (male) (1) and ground
2 potentiometer (internal Between L28A (male) (2) and ground
open or short circuit) Resistance Between L28A (male) (3) and ground Min. 1 Mz
Between L28A (male) (4) and ground

40-664 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L28A.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
7. Operate boom lever to perform troubleshooting.
2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 3.38 to 4.04
position) V
Between L28A (3) and Boom lever: RAISE (at 3.90 to 4.40
(2) detent position) V
Boom lever: LOWER
Defective boom lever
(just before the detent 0.96 to 1.62
2 potentiometer (internal V
position)
open or short circuit)
0.60 to 1.10
Boom lever: FLOAT
Voltage V
2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 0.96 to 1.62
position) V
Between L28A (4) and Boom lever: RAISE (at 0.60 to 1.10
(2) detent position) V
Boom lever: LOWER
(just before the detent 3.38 to 4.04
position) V
3.90 to 4.40
Boom lever: FLOAT
V
1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and L28A, and connect T-adapters to each
female side.
Open circuit in wiring a If power supply voltage in check on cause 1 is
harness normal, this check is not required. Max. 1 z
3 (wire breakage or Between L71 (female) (22) and L28A (female) (1)
defective contact of
connector) Resistance a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
Between L71 (female) (4) and L28A (female) (2)
Between L71 (female) (8) and L28A (female) (3) Max. 1 z
Between L71 (female) (2) and L28A (female) (4) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and L28A, and connect T-adapter to either
female side.
Ground fault in wiring Between ground and L71 (female) (8) or L28A
harness (female) (3) Min. 1 Mz
4
(contact with ground Between L71 (female) (8) and (4) or between L28A
circuit) (female) (3) and (2) Min. 1 Mz
Resistance
Between ground and L71 (female) (2) or L28A
(female) (4) Min. 1 Mz
Between L71 (female) (2) and (4) or between L28A Min. 1 Mz
(female) (4) and (2)

WA470-7 40-665
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
5 wiring harness
Between L28A (female) (3) and (2) or ground Max. 1 V
Voltage
Between L28A (female) (4) and (2) or ground Max. 1 V
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate boom lever to perform troubleshooting.
Between L71 (22) and
(4) Boom lever: Continuous 5.0 to 5.2 V
2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 3.38 to 4.04
position) V
Boom lever: RAISE (at 3.90 to 4.40
Between L71 (8) and (4)
detent position) V
Defective work
6 equipment controller Boom lever: LOWER
(just before the detent 0.96 to 1.62
position) V

Voltage 0.60 to 1.10


Boom lever: FLOAT
V
2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 0.96 to 1.62
position) V
Boom lever: RAISE (at 0.60 to 1.10
Between L71 (2) and (4)
detent position) V
Boom lever: LOWER
(just before the detent 3.38 to 4.04
position) V
3.90 to 4.40
Boom lever: FLOAT
V

40-666 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom lever potentiometer

WA470-7 40-667
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5AKA] Failure of Boom Lever Potentio (Sub) (WA470_7-DK5AKA-


400-A-Z0-A)

Action level Failure code Failure of Boom Lever Potentiometer (Sub)


Failure
L03 DK5AKA (Work equipment controller system)
• Due to open circuit or ground fault in boom lever potentiometer (Sub: B line) system,
Detail of boom lever potentiometer (Sub: B line) signal voltage is lower than the normal range
failure (Boom lever potentiometer (Sub: B line) signal voltage: Max. 0.3 V).
• Controls boom by using signal voltage from boom lever potentiometer (main: A line) if it is
normal.
Action of In this case, however, boom detent control does not work, and work equipment speed
controller decreases to 30% of normal speed.
• Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
Problem on • Boom detent control does not work.
machine • Work equipment speed decreases 30%.
• Input voltage from boom lever potentiometer (main: A line) can be checked with
monitoring function.
(Code: 42000 Boom Lever Volt(Main))
Related • Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
information function.
(Code: 42001 Boom Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L28A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L28A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to male side.
Between L28A (male) (1) and ground
Between L28A (male) (2) and ground
Resistance Min. 1 Mz
Between L28A (male) (3) and ground
Between L28A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L28A.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
Defective boom lever
2 potentiometer (internal 7. Operate boom lever to perform troubleshooting.
open or short circuit) 2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 0.96 to 1.62
position) V
Boom lever: RAISE (at 0.60 to 1.10
Between L28A (4) and
Voltage detent position) V
(2)
Boom lever: LOWER
(just before the detent 3.38 to 4.04
position) V
3.90 to 4.40
Boom lever: FLOAT V

40-668 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and L28A, and connect T-adapters to each
female side.
Open circuit in wiring
harness a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
3 (wire breakage or Between L71 (female) (22) and L28A (female) (1)
defective contact of
connector) Resistance
a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
Between L71 (female) (4) and L28A (female) (2)
Between L71 (female) (2) and L28A (female) (4) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
4 2. Disconnect connectors L71 and L28A, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and L71 (female) (2) or L28A
Resistance (female) (4) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate boom lever to perform troubleshooting.
Between L71 (22) and
(4) Boom lever: Continuous 5.0 to 5.2 V

Defective work 2.38 to 2.62


Boom lever: NEUTRAL
5 equipment controller V
Boom lever: RAISE (just
before the detent 0.96 to 1.62
position) V
Voltage
Boom lever: RAISE (at 0.60 to 1.10
Between L71 (2) and (4)
detent position) V
Boom lever: LOWER
(just before the detent 3.38 to 4.04
position) V
3.90 to 4.40
Boom lever: FLOAT
V

WA470-7 40-669
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom lever potentiometer

40-670 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5AKY] Hot Short of Boom Lever Potentio (Sub) (WA470_7-
DK5AKY-400-A-Z0-A)

Action level Failure code Hot Short of Boom Lever Potentiometer (Sub)
Failure
L03 DK5AKY (Work equipment controller system)
• Due to hot short in boom lever potentiometer (Sub: B line) system, boom lever
Detail of potentiometer (Sub: B line) signal voltage is higher than the normal range (Boom lever
failure potentiometer (Sub: B line) signal voltage: Min. 4.7 V).
• Controls boom by using signal voltage from boom lever potentiometer (main: A line) if it is
normal.
However, in this case, bucket detent control does not work, and work equipment speed
Action of
decreases 30%.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
Problem on • Boom detent control does not work.
machine • Work equipment speed decreases 30%.
• Input voltage from boom lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42000 Boom Lever Volt(Main))
Related • Input voltage from boom lever potentiometer (sub: B line) can be checked with monitoring
information function. (Code: 42001 Boom Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L28A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L28A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A, and connect T-adapter to male side.
Between L28A (male) (1) and ground
Between L28A (male) (2) and ground
Resistance Min. 1 Mz
Between L28A (male) (3) and ground
Between L28A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L28A.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
Defective boom lever 7. Operate boom lever to perform troubleshooting.
2 potentiometer (internal
short circuit) 2.38 to 2.62
Boom lever: NEUTRAL
V
Boom lever: RAISE (just
before the detent 0.96 to 1.62
position) V
Boom lever: RAISE (at 0.60 to 1.10
Between L28A (4) and
Voltage detent position) V
(2)
Boom lever: LOWER
(just before the detent 3.38 to 4.04
position) V
3.90 to 4.40
Boom lever: FLOAT V

WA470-7 40-671
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Hot short circuit in
3 2. Disconnect connector L28A, and connect T-adapter to female side.
wiring harness
Voltage Between L29A (female) (4) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector L28A.
Short circuit in wiring 3. Disconnect connector L71, and connect T-adapter to female side.
4
harness
Between L71 (female) (2) and each No continuity
Continuity
pin other than L71 (female) (2) (No sound is heard)
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L71.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate boom lever to perform troubleshooting.
Between L71 (22) and
(4) Boom lever: Continuous 5.0 to 5.2 V

Defective work 2.38 to 2.62


Boom lever: NEUTRAL
5 equipment controller V
Boom lever: RAISE (just
before the detent 0.96 to 1.62
position) V
Voltage
Boom lever: RAISE (at 0.60 to 1.10
Between L71 (2) and (4)
detent position) V
Boom lever: LOWER
(just before the detent 3.38 to 4.04
position) V
3.90 to 4.40
Boom lever: FLOAT
V

40-672 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom lever potentiometer

WA470-7 40-673
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5BKA] Failure of Bucket Lever Potentio (Main) (WA470_7-


DK5BKA-400-A-Z0-A)

Action level Failure code Failure of Bucket Lever Potentiometer (Main)


Failure
L03 DK5BKA (Work equipment controller system)
• Controller determines that bucket lever potentiometer (main: A line) circuit has open
Detail of circuit or ground fault because signal voltage from bucket lever potentiometer (main: A
failure line) is lower than normal range. (Signal voltage from bucket lever potentiometer (main: A
line): Max. 0.3 V)
• Controls bucket by using signal voltage from bucket lever potentiometer (sub: B line) if it is
normal.
In this case, however, bucket detent control does not work, and work equipment speed
Action of
decreases to 30% of normal speed.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until bucket lever is
set in NEUTRAL.
• Bucket makes dump movement momentarily, then it is controlled normally by using
Problem on signals from sub potentiometer.
machine In this case, however, bucket detent control does not work, and work equipment speed
decreases to 30% of normal speed.
• Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Related • Input voltage from bucket lever potentiometer (sub: B line) can be checked with
information monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L29A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L29A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L29A, and connect T-adapter to male side.
Between L29A (male) (1) and ground
Between L29A (male) (2) and ground
Resistance Min. 1 Mz
Between L29A (male) (3) and ground
Between L29A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L29A.
5. Set work equipment lock switch to LOCK position.
Defective bucket lever
2 potentiometer (internal 6. Turn starting switch to ON position.
open or short circuit) 7. Operate bucket lever to perform troubleshooting.
2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
before the detent 3.38 to 4.04
position) V
Between L29A (3) and
Voltage
(2) Bucket lever: TILT (at 3.90 to 4.40
detent position) V
0.60 to 1.10
Bucket lever: Full DUMP V

40-674 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72, and L29A, and connect T-adapters to
each female side.
Open circuit in wiring
harness a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
3 (wire breakage or Between L71 (female) (4) and L29A (female) (2)
defective contact of
connector) Resistance
a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
Between L72 (female) (1) and L29A (female) (1)
Between L71 (female) (20) and L29A (female) (3) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
4 2. Disconnect connectors L71 and L29A, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and L71 (female) (20) or L29A
Resistance (female) (3) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate bucket lever to perform troubleshooting.
Between L72 (1) and L71
Defective work (4) Bucket lever: Continuous 5.0 to 5.2 V
5 equipment controller 2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
Voltage before the detent 3.38 to 4.04
Between L71 (20) and position) V
(4)
Bucket lever: TILT (at 3.90 to 4.40
detent position) V
0.60 to 1.10
Bucket lever: Full DUMP
V

WA470-7 40-675
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket lever potentiometer

40-676 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5BKY] Hot Short of Bucket Lever Potentio (Main) (WA470_7-
DK5BKY-400-A-Z0-A)

Action level Failure code Hot Short of Bucket Lever Potentiometer (Main)
Failure
L03 DK5BKY (Work equipment controller system)
• Due to hot short circuit of bucket lever potentiometer (main: A line) system, signal voltage
Detail of from bucket lever potentiometer (main: A line) is higher than normal range.
failure (Signal voltage from bucket lever potentiometer (main: A line): Min. 4.7 V)
• Controls bucket by using signal voltage from bucket lever potentiometer (sub: B line) if it is
normal.
In this case, however, bucket detent control does not work, and work equipment speed
Action of
decreases to 30% of normal speed.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until bucket lever is
set in NEUTRAL.
• Bucket tilts momentarily, then it is controlled normally by using signals from sub
Problem on potentiometer.
machine In this case, however, bucket detent control does not work, and work equipment speed
decreases to 30% of normal speed.
• Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Related • Input voltage from bucket lever potentiometer (sub: B line) can be checked with
information monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L29A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L29A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L29A, and connect T-adapter to male side.
Between L29A (male) (1) and ground
Between L29A (male) (2) and ground
Resistance Min. 1 Mz
Between L29A (male) (3) and ground
Between L29A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L29A.
5. Set work equipment lock switch to LOCK position.
Defective bucket lever
2 potentiometer (internal 6. Turn starting switch to ON position.
short circuit) 7. Operate bucket lever to perform troubleshooting.
2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
before the detent 3.38 to 4.04
position) V
Between L29A (3) and
Voltage
(2) Bucket lever: TILT (at 3.90 to 4.40
detent position) V
0.60 to 1.10
Bucket lever: Full DUMP V

WA470-7 40-677
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connectors L71, L72, and L29A, and connect T-adapters to
3 wiring harness each female side.
Voltage Between L71 (female) (20) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L71 and L29A, and connect T-adapter to female
Short circuit in wiring side of L71.
4
harness No continuity
Between L71 (female) (20) and each
Continuity
pin other than L71 (female) (20) (No sound is heard)
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate bucket lever to perform troubleshooting.
Between L72 (1) and L71
Defective work (4) Bucket lever: Continuous 5.0 to 5.2 V
5 equipment controller 2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
Voltage before the detent 3.38 to 4.04
Between L71 (20) and position) V
(4)
Bucket lever: TILT (at 3.90 to 4.40
detent position) V
0.60 to 1.10
Bucket lever: Full DUMP
V

40-678 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket lever potentiometer

WA470-7 40-679
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5BL8] Bucket Lever Potentio (Main&Sub)


Disagree (WA470_7-DK5BL8-400-A-Z0-A)
Action level Failure code Bucket Lever Potentiometer (Main & Sub) Disagree
Failure
L01 DK5BL8 (Work equipment controller system)
• Input signals from bucket EPC lever potentiometers (main: A line and sub: B line)
disagree with each other.
Detail of • (Signal voltage from bucket EPC lever potentiometer (total of main: A line and sub: B
failure line): Max. 4.65 V) or (signal voltage from bucket EPC lever potentiometer (total of main:
A line and sub: B line): Min. 5.35 V)
• Operates by using potentiometer sensor signal from either main: A line or sub: B line
which detects the standard voltage when lever is in NEUTRAL position.
In this case work equipment speed decreases to 30% of normal speed and stops bucket
detent solenoid output.
Action of • Stops output to bucket detent solenoid, bucket tilt EPC solenoid and bucket dump EPC
controller solenoid if signal voltages from both main: A line and sub: B line potentiometers show out
of the standard voltage when lever is in NEUTRAL position.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until bucket lever is
set in NEUTRAL.
• If either main: A line or sub: B line potentiometer malfunctions, machine operates normally
Problem on with no bucket detent solenoid output and decreasing work equipment speed to 30% of
machine normal speed after lever is once set to NEUTRAL.
• If both main: A line and sub: B line potentiometers malfunction, bucket does not move.
• Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Related • Input voltage from bucket lever potentiometer (sub: B line) can be checked with
information monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L29A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L29A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L29A, and connect T-adapter to male side.
Defective bucket EPC 3. Turn starting switch to ON position.
lever potentiometer Between L29A (male) (1) and ground
2 (internal open or short Between L29A (male) (2) and ground
circuit) Resistance Between L29A (male) (3) and ground Min. 1 Mz
Between L29A (male) (4) and ground

40-680 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L29A.
3. Turn work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Move bucket EPC lever to perform troubleshooting.
Bucket EPC lever: 2.38 to 2.62
NEUTRAL V
Bucket EPC lever: TILT
(just before the detent 3.38 to 4.04
Between L29A (3) and position) V
Defective bucket EPC (2)
lever potentiometer Bucket EPC lever: TILT 3.90 to 4.40
2 (internal open or short (Detent position) V
circuit) Bucket EPC lever: Full 0.60 to 1.10
Voltage DUMP V
Bucket EPC lever: 2.38 to 2.62
NEUTRAL V
Bucket EPC lever: TILT
(just before the detent 0.96 to 1.62
Between L29A (4) and position) V
(2)
Bucket EPC lever: TILT 0.60 to 1.10
(Detent position) V
Bucket EPC lever: Full 3.90 to 4.40
DUMP V
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L71 and L29A, and connect T-adapters to each
harness female side.
3 (wire breakage or Between L71 (female) (14) and L29A (female) (4) Max. 1 z
defective contact of Between L71 (female) (20) and L29A (female) (3) Max. 1 z
connector) Resistance
Between L71 (female) (4) and L29A (female) (2) Max. 1 z
Between L72 (female) (1) and L29A (female) (1) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors L71 and L29A, and connect T-adapter to either
harness female side.
4 Between ground and L71 (female) (14) or L29A
(contact with ground (female) (4) Min. 1 Mz
circuit) Resistance
Between ground and L71 (female) (20) or L29A
(female) (3) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector L29A, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
5 wiring harness Between L29A (female) (4) and ground Max. 1 V
Voltage Max. 1 V
Between L29A (female) (3) and ground

WA470-7 40-681
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock lever in LOCK position.
4. Turn starting switch to ON position.
5. Move bucket EPC lever to perform troubleshooting.
Between L72 (1) and L71
(4) Continuous 5.0 to 5.2 V
Bucket EPC lever: 2.38 to 2.62
NEUTRAL V
Bucket EPC lever: TILT
(just before the detent 3.38 to 4.04
Defective work Between L71 (20) and V
6 position)
equipment controller L71 (4)
Bucket EPC lever: TILT 3.90 to 4.40
(Detent position) V
Voltage Bucket EPC lever: Full 0.60 to 1.10
DUMP V
Bucket EPC lever: 2.38 to 2.62
NEUTRAL V
Bucket EPC lever: TILT
(just before the detent 0.96 to 1.62
Between L71 (14) and position) V
L71 (4)
Bucket EPC lever: TILT 0.60 to 1.10
(Detent position) V
Bucket EPC lever: Full 3.90 to 4.40
DUMP V

40-682 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket lever potentiometer

WA470-7 40-683
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5CKA] Failure of Bucket Lever Potentio (Sub) (WA470_7-DK5CKA-


400-A-Z0-A)

Action level Failure code Failure of Bucket Lever Potentiometer (Sub)


Failure
L03 DK5CKA (Work equipment controller system)
• Controller determines that bucket lever potentiometer (sub: B line) circuit has open circuit
Detail of or ground fault because signal voltage from bucket lever potentiometer (sub: B line) is
failure lower than normal range. (Signal voltage from bucket lever potentiometer (sub: B line):
Max. 0.3 V)
• Controls bucket by using signal voltage from bucket lever potentiometer (main: A line) if it
is normal.
Action of In this case, however, bucket detent control does not work, and work equipment speed
controller decreases 30%.
• Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
Problem on • Bucket detent control does not work.
machine • Work equipment speed decreases 30 %.
• Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Related • Input voltage from bucket lever potentiometer (sub: B line) can be checked with
information monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L29A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L29A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L29A, and connect T-adapter to male side.
Between L29A (male) (1) and ground
Between L29A (male) (2) and ground
Resistance Min. 1 Mz
Between L29A (male) (3) and ground
Between L29A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L29A.
5. Set work equipment lock switch to LOCK position.
Defective bucket lever
2 potentiometer (internal 6. Turn starting switch to ON position.
open or short circuit) 7. Operate bucket lever to perform troubleshooting.
2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
before the detent 0.96 to 1.62
position) V
Between L29A (4) and
Voltage
(2) Bucket lever: TILT (at 0.60 to 1.10
detent position) V
3.90 to 4.40
Bucket lever: Full DUMP V

40-684 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72, and L29A, and connect T-adapters to
each female side.
Open circuit in wiring
harness a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
3 (wire breakage or Between L72 (female) (1) and L29A (female) (1)
defective contact of
connector) Resistance
a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
Between L71 (female) (4) and L29A (female) (2)
Between L71 (female) (14) and L29A (female) (4) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring
1. Turn starting switch to OFF position.
harness
4 2. Disconnect connectors L71 and L29A, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and L71 (female) (14) or L29A
Resistance (female) (4) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate bucket lever to perform troubleshooting.
Between L72 (1) and L71
Defective work (4) Bucket lever: Continuous 5.0 to 5.2 V
5 equipment controller 2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
Voltage before the detent 0.96 to 1.62
Between L71 (14) and position) V
(4)
Bucket lever: TILT (at 0.60 to 1.10
detent position) V
3.90 to 4.40
Bucket lever: Full DUMP
V

WA470-7 40-685
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket lever potentiometer

40-686 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5CKY] Hot Short of Bucket Lever Potentio (Sub) (WA470_7-
DK5CKY-400-A-Z0-A)

Action level Failure code Hot Short of Bucket Lever Potentiometer (Sub)
Failure
L03 DK5CKY (Work equipment controller system)
• Controller determines that bucket lever potentiometer (sub: B line) circuit has hot short
Detail of because signal voltage from bucket lever potentiometer (sub: B line) is higher than normal
failure range. (Signal voltage from bucket lever potentiometer (sub: B line): Min. 4.7 V)
• Controls bucket by using signal voltage from bucket lever potentiometer (main: A line) if it
is normal.
However, in this case, bucket detent control does not work, and work equipment speed
Action of
decreases 30 %.
controller
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until bucket lever is
set in NEUTRAL.
Problem on • Bucket detent control does not work.
machine • Work equipment speed decreases 30 %.
• Input voltage from bucket lever potentiometer (main: A line) can be checked with
monitoring function. (Code: 42002 Bucket Lever Volt(Main))
Related • Input voltage from bucket lever potentiometer (sub: B line) can be checked with
information monitoring function. (Code: 42003 Bucket Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
When failure code [DB96KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L29A, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L29A (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L29A, and connect T-adapter to male side.
Between L29A (male) (1) and ground
Between L29A (male) (2) and ground
Resistance Min. 1 Mz
Between L29A (male) (3) and ground
Between L29A (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L29A.
5. Set work equipment lock switch to LOCK position.
Defective bucket lever
2 potentiometer (internal 6. Turn starting switch to ON position.
short circuit) 7. Operate bucket lever to perform troubleshooting.
2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
before the detent 0.96 to 1.62
position) V
Between L29A (4) and
Voltage
(2) Bucket lever: TILT (at 0.60 to 1.10
detent position) V
3.90 to 4.40
Bucket lever: Full DUMP V

WA470-7 40-687
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Hot short circuit in
3 2. Disconnect connector L71, and connect T-adapter to female side.
wiring harness
Voltage Between ground and L71 (female) (14) or L29A (4) Max 1 V
1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connector L71 and connect T-adapter to female side.
4
harness Between L71 (female) (14) and each No continuity
Continuity
pin other than L71 (female) (14) (No sound is heard)
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate bucket lever to perform troubleshooting.
Between L72 (1) and L71
Defective work (4) Bucket lever: Continuous 5.0 to 5.2 V
5 equipment controller 2.38 to 2.62
Bucket lever: NEUTRAL
V
Bucket lever: TILT (just
Voltage before the detent 0.96 to 1.62
Between L71 (14) and position) V
(4)
Bucket lever: TILT (at 0.60 to 1.10
detent position) V
3.90 to 4.40
Bucket lever: Full DUMP
V

40-688 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket lever potentiometer

WA470-7 40-689
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5DKA] Failure of 3rd Lever Potentio (Main) (WA470_7-DK5DKA-400-A-


Z0-A)

Action level Failure code Failure of 3rd Lever Potentiometer (Main)


Failure
L03 DK5DKA (Work equipment controller system)
• Controller determines that 3rd (attachment) lever potentiometer (main: A line) circuit has
Detail of open circuit or ground fault because signal voltage from 3rd (attachment) lever
failure potentiometer (main: A line) is lower than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (main: A line): Max. 0.3 V)
• Controls attachment by using signals from 3rd (attachment) lever potentiometer (sub: B
line) if 3rd (attachment) lever potentiometer (sub: B line) is normal.
Action of However, in this case, decreases work equipment speed 30 %.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
• Attachment cylinder retracts momentarily, then attachment is controlled normally by using
Problem on signals from sub potentiometer.
machine However, work equipment speed decreases 30 %.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Between L30 (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
Defective 3rd 5. Set work equipment lock switch to LOCK position.
2 (attachment) lever
potentiometer 6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 3.90 to 4.40
Voltage Between L30 (3) and (2) cylinder fully V
3rd (attachment) lever: 0.60 to 1.10
Operated to retract V
cylinder fully

40-690 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72, and L30, and connect T-adapters to
each female side.
Open circuit in wiring a If power supply voltage in check on cause 1 is
harness (wire breakage normal, this check is not required. Max. 1 z
3 or defective contact of L71 (female) (22) and L30 (female) (1)
connector) Resistance
a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
L71 (female) (4) and L30 (female) (2)
L72 (female) (35) and L30 (female) (3) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness (contact with 2. Disconnect connectors L72 and L30, and connect T-adapter to either
ground circuit) female side.
Between ground and L72 (female) (35) or L30
Resistance (female) (3) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate 3rd (attachment) lever to perform troubleshooting.
Between L71 (22) and 3rd (attachment) lever:
Defective work 5.0 to 5.2 V
5 L71 (4) Continuous
equipment controller
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Voltage 3.90 to 4.40
Between L72 (35) and Operated to extend
cylinder fully V
L71 (4)
3rd (attachment) lever:
Operated to retract 0.60 to 1.10
cylinder fully V

WA470-7 40-691
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd (attachment) lever potentiometer

40-692 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5DKY] Hot Short of 3rd Lever Potentio (Main) (WA470_7-DK5DKY-
400-A-Z0-A)

Action level Failure code Hot Short of 3rd Lever Potentiometer (Main)
Failure
L03 DK5DKY (Work equipment controller system)
• Controller determines that 3rd (attachment) lever potentiometer (main: A line) circuit has
Detail of hot short because signal voltage from 3rd (attachment) lever potentiometer (main: A line)
failure is higher than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (main: A line): Max. 4.7 V)
• Controls attachment by using signals from 3rd (attachment) lever potentiometer (sub: B
line) if 3rd (attachment) lever potentiometer (sub: B line) is normal.
Action of However, in this case, decreases work equipment speed 30 %.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
• Attachment cylinder extends momentarily, then attachment is controlled normally by using
Problem on signals from sub potentiometer.
machine However, work equipment speed decreases 30 %.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Between L30 (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
Defective 3rd 5. Set work equipment lock switch to LOCK position.
2 (attachment) lever
potentiometer 6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 3.90 to 4.40
Voltage Between L30 (3) and (2) cylinder fully V
3rd (attachment) lever: 0.60 to 1.10
Operated to retract V
cylinder fully

WA470-7 40-693
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L30, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between L30 (male) (3) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L72 and L30, and connect T-adapter to female
side of L72.
Short circuit in wiring
4
harness a Check by using multimeter in continuity mode.
Between L72 (female) (35) and each No continuity
Continuity
pin other than L72 (female) (35) (No sound is heard)
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate 3rd (attachment) lever to perform troubleshooting.
Between L71 (22) and 3rd (attachment) lever:
Defective work 5.0 to 5.2 V
5 (4) Continuous
equipment controller
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Voltage 3.90 to 4.40
Between L72 (35) and Operated to extend
cylinder fully V
L71 (4)
3rd (attachment) lever:
Operated to retract 0.60 to 1.10
cylinder fully V

Circuit diagram related to 3rd (attachment) lever potentiometer

40-694 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5DL8] 3rd Lever Potentio (Main & Sub) Disagree (WA470_7-
DK5DL8-400-A-Z0-A)

Action level Failure code 3rd Lever Potentiometer (Main & Sub) Disagree
Failure
L03 DK5DL8 (Work equipment controller system)
• Input signals from 3rd (attachment) lever potentiometers (main: A line and sub: B line)
disagree with each other.
(Signal voltage from 3rd (attachment) lever potentiometers (total of main: A line and sub:
B line): Max. 4.65 V) or
Detail of (signals voltage from 3rd (attachment) lever potentiometers (total of main: A line and sub:
failure B line): Min. 5.35 V)
For PCS (type D and G),
(Total of signal voltages from main: A line and sub: B line is 4.58 V or less) or
(Total of signal voltages from main: A line and sub: B line is 5.42 V or above)
• Operates by using potentiometer sensor signal from either main: A line or sub: B line
which shows the standard voltage when lever is in NEUTRAL position.
However, in this case, decreases work equipment speed 30 %.
• Stops output to 3rd EPC solenoid (extension) and 3rd EPC solenoid (retract) if signal
Action of voltages from both main: A line and sub: B line potentiometers show out of the standard
controller voltage when lever is in NEUTRAL position.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
• If either main: A line or sub: B line potentiometer malfunctions, machine operates normally
Problem on with work equipment speed decreases 30% after lever is once set to NEUTRAL.
machine • If both of main: A line and sub: B line potentiometers malfunction, cylinder that is
controlled by 3rd valve (attachment) does not move.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Defective 3rd
Between L30 (male) (4) and ground
2 (attachment) lever
potentiometer 3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
5. Set work equipment lock switch to LOCK position.
6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.

WA470-7 40-695
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 3.90 to 4.40
Between L30 (3) and (2) cylinder fully V
3rd (attachment) lever:
Operated to retract 0.60 to 1.10
Defective 3rd cylinder fully V
2 (attachment) lever Voltage
potentiometer 3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 0.60 to 1.10
Between L30 (4) and (2) cylinder fully V
3rd (attachment) lever:
Operated to retract 3.90 to 4.40
cylinder fully V

1. Turn starting switch to OFF position.


2. Disconnect connectors L71, L72, and L30, and connect T-adapters to
each female side.
a If power supply voltage in check on cause 1 is
Open circuit in wiring normal, this check is not required. Max. 1 z
harness (wire breakage L71 (female) (22) and L30 (female) (1)
3 or defective contact of
connector) Resistance a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
L71 (female) (4) and L30 (female) (2)
L72 (female) (35) and L30 (female) (3) Max. 1 z
L72 (female) (25) and L30 (female) (4) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors L72 and L30, and connect T-adapter to either
4 harness (contact with female side.
ground circuit) Between ground and L72 (female) (35) or L30
(female) (3) Min. 1 Mz
Resistance
Between ground and L72 (female) (25) or L30
(female) (4) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector L30, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
5 wiring harness
Between L30 (male) (3) and ground Max. 1 V
Voltage
Between L30 (male) (4) and ground Max. 1 V
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
Defective work 2. Insert T-adapters into connectors L71 and L72.
6 equipment controller 3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate 3rd (attachment) lever to perform troubleshooting.

40-696 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Between L71 (22) and 3rd (attachment) lever:
(4) 5.0 to 5.2 V
Continuous
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 3.90 to 4.40
Between L72 (35) and
cylinder fully V
L71 (4)
3rd (attachment) lever:
Defective work Operated to retract 0.60 to 1.10
6 Voltage V
equipment controller cylinder fully
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 3.90 to 4.40
Between L72 (25) and
cylinder fully V
L71 (4)
3rd (attachment) lever:
Operated to retract 0.60 to 1.10
cylinder fully V

Circuit diagram related to 3rd (attachment) lever potentiometer

WA470-7 40-697
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5EKA] Failure of 3rd Lever Potentio (Sub) (WA470_7-DK5EKA-400-A-


Z0-A)

Action level Failure code Failure of 3rd Lever Potentiometer (Sub)


Failure
L03 DK5EKA (Work equipment controller system)
• Controller determines that 3rd (attachment) lever potentiometer (sub: B line) circuit has
Detail of open circuit or ground fault because signal voltage from 3rd (attachment) lever
failure potentiometer (sub: B line) is lower than normal range. (Signal voltage from 3rd
(attachment) lever potentiometer (sub: B line): Max. 0.3 V)
• Controls attachment by using signals from 3rd (attachment) lever potentiometer (main: A
line) if it is normal.
Action of However, in this case, decreases work equipment speed 30 %.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
Problem on • Work equipment speed decreases 30%.
machine
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Between L30 (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
Defective 3rd 5. Set work equipment lock switch to LOCK position.
2 (attachment) lever
potentiometer 6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 0.60 to 1.10
Voltage Between L30 (4) and (2) cylinder fully V
3rd (attachment) lever: 3.90 to 4.40
Operated to retract V
cylinder fully

40-698 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72, and L30, and connect T-adapters to
each female side.
Open circuit in wiring a If power supply voltage in check on cause 1 is
harness (wire breakage normal, this check is not required. Max. 1 z
3 or defective contact of L71 (female) (22) and L30 (female) (1)
connector) Resistance
a If power supply voltage in check on cause 1 is
normal, this check is not required. Max. 1 z
L71 (female) (4) and L30 (female) (2)
L72 (female) (25) and L30 (female) (4) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness (contact with 2. Disconnect connectors L72 and L30, and connect T-adapter to either
ground circuit) female side.
Between ground and L72 (female) (25) or L30
Resistance (female) (4) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate 3rd (attachment) lever to perform troubleshooting.
Between L71 (22) and 3rd (attachment) lever:
Defective work 5.0 to 5.2 V
5 L71 (4) Continuous
equipment controller
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Voltage 3.90 to 4.40
Between L72 (25) and Operated to extend
cylinder fully V
L71 (4)
3rd (attachment) lever:
Operated to retract 0.60 to 1.10
cylinder fully V

WA470-7 40-699
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd (attachment) lever potentiometer

40-700 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DK5EKY] Hot Short of 3rd Lever Potentio (Sub) (WA470_7-DK5EKY-
400-A-Z0-A)

Action level Failure code Hot Short of 3rd Lever Potentiometer (Sub)
Failure
L03 DK5EKY (Work equipment controller system)
• Controller determines that 3rd (attachment) lever potentiometer (sub: B line) circuit has
Detail of hot short because signal voltage from 3rd (attachment) lever potentiometer (sub: B line) is
failure higher than normal range.
(Signal voltage from 3rd (attachment) lever potentiometer (sub: B line): Min. 4.7 V)
• Controls attachment by using signals from 3rd (attachment) lever potentiometer (main: A
line) if it is normal.
Action of However, in this case, decreases work equipment speed 30 %.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until 3rd
(attachment) lever is set in NEUTRAL.
Problem on • Work equipment speed decreases 30 %.
machine
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment). (If this failure code is displayed on the machine, select "None" for 3rd valve
(attachment) setting on option setting screen of machine monitor.)
Related • Input voltage from 3rd (attachment) lever potentiometer (main: A line) can be checked
information with monitoring function. (Code: 42006 3rd Lever Volt(Main))
• Input voltage from 3rd (attachment) lever potentiometer (sub: B line) can be checked with
monitoring function. (Code: 42007 3rd Lever Volt(Sub))
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector L30, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between L30 (female) (1) and (2) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector L30, and connect T-adapters to male side.
Between L30 (male) (1) and ground
Between L30 (male) (2) and ground
Resistance Min. 1 Mz
Between L30 (male) (3) and ground
Between L30 (male) (4) and ground
3. Turn starting switch to OFF position.
4. Insert T-adapter into connector L30.
Defective 3rd 5. Set work equipment lock switch to LOCK position.
2 (attachment) lever
potentiometer 6. Turn starting switch to ON position.
7. Operated 3rd (attachment) lever to perform troubleshooting.
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Operated to extend 0.60 to 1.10
Voltage Between L30 (4) and (2) cylinder fully V
3rd (attachment) lever: 3.90 to 4.40
Operated to retract V
cylinder fully

WA470-7 40-701
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L30, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between L30 (male) (4) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L72 and L30, and connect T-adapter to female
side of L72.
Short circuit in wiring
4
harness a Check by using multimeter in continuity mode.
Between L72 (female) (25) and each No continuity
Continuity
pin other than L72 (female) (25) (No sound is heard)
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connectors L71 and L72.
3. Set work equipment lock switch to LOCK position.
4. Turn starting switch to ON position.
5. Operate 3rd (attachment) lever to perform troubleshooting.
Between L71 (22) and 3rd (attachment) lever:
Defective work 5.0 to 5.2 V
5 (4) Continuous
equipment controller
3rd (attachment) lever: 2.38 to 2.62
NEUTRAL V
3rd (attachment) lever:
Voltage 3.90 to 4.40
Between L72 (25) and Operated to extend
cylinder fully V
L71 (4)
3rd (attachment) lever:
Operated to retract 0.60 to 1.10
cylinder fully V

Circuit diagram related to 3rd (attachment) lever potentiometer

40-702 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DKA0KA] Failure of Boom Angle Sensor (WA470_7-DKA0KA-400-A-Z0-A)

Action level Failure code Failure of Boom Angle Sensor


Failure
L01 DKA0KA (Work equipment controller system)
• Due to open circuit or ground fault in boom angle sensor system, signal voltage from
Detail of boom angle sensor is lower than normal range. (Signal voltage from boom angle sensor:
failure Max. 0.3 V)
• Determines that boom is at lowest position.
• Disables remote positioner function.
• Disables semi-auto digging.
Action of • Disables boom FLOAT detent function when remote positioner LOWER stop function is
controller ON, and allows boom FLOAT detent function to work normally when remote positioner
LOWER stop function is OFF.
• Disables boom RAISE detent function.
• If cause of failure disappears, machine becomes normal by itself.
• Remote positioner malfunctions (boom does not stop).
Problem on • Semi-auto digging system malfunctions (does not work).
machine • Komatsu SmartLoader Logic malfunctions.
• Input voltage from boom angle sensor can be checked with monitoring function.
(Code: 06005 Boom Angle Sensor Volt)
Related • Angle sensed by boom angle sensor can be checked with monitoring function.
information (Code: 06002 Boom Angle)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector F11, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between F11 (female) (C) and (A) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector F11, and connect T-adapter to male side.
Between F11 (male) (A) and (C) 4 to 6 kz
Between F11 (male) (A) and ground Min. 1 Mz
Resistance
Between F11 (male) (B) and ground Min. 1 Mz
Between F11 (male) (C) and ground Min. 1 Mz
Defective boom angle
sensor 1. Turn starting switch to OFF position.
2 2. Insert T-adapter into connector F11.
(internal open or short
circuit) 3. Turn starting switch to ON position.
4. Operate boom lever to perform troubleshooting.
1.13 to 4.02
Continuous
V
Voltage Between F11 (B) and (A) RAISE stroke end 3.52 to 4.02
V
1.13 to 1.63
LOWER stroke end
V
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L71, L72, and F11, and connect T-adapters to
harness each female side.
3 (wire breakage or Between F11 (female) (A) and L71 (female) (4) Max. 1 z
defective contact of Between F11 (female) (B) and L72 (female) (26) Max. 1 z
connector) Resistance
Between F11 (female) (C) and L71 (female) (22) Max. 1 z

WA470-7 40-703
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71, L72, and F11, and connect T-adapter to any
4 female side.
(contact with ground
Between ground and F11 (female) (B) or L72
circuit) Resistance (female) (26) Min. 1 Mz
If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Turn starting switch to ON position.
Defective work 4. Operate boom lever to perform troubleshooting.
5 equipment controller 1.13 to 4.02
Continuous
V
Between L72 (26) and 3.52 to 4.02
Voltage RAISE stroke end
ground V
1.13 to 1.63
LOWER stroke end
V

Circuit diagram related to boom angle sensor

40-704 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DKA0KY] Hot Short of Boom Angle Sensor Circuit (WA470_7-
DKA0KY-400-A-Z0-A)

Action level Failure code Hot Short of Boom Angle Sensor Circuit
Failure
L01 DKA0KY (Work equipment controller system)
Detail of • Due to hot short circuit in boom angle sensor system, signal voltage from boom angle
failure sensor is higher than normal range. (Signal voltage from boom angle sensor: Min. 4.7 V)
• Determines that boom is at lowest position.
• Disables remote positioner function.
• Disables semi-auto digging.
• Disables boom FLOAT detent function when remote positioner LOWER stop function is
Action of
ON, and allows boom FLOAT detent function to work normally when remote positioner
controller
LOWER stop function is OFF.
• Disables boom RAISE detent function.
• Even if cause of failure disappears, machine does not become normal until boom lever is
set in NEUTRAL.
• Remote positioner malfunctions.
Problem on • Semi-auto digging system malfunctions.
machine • Komatsu SmartLoader Logic malfunctions.
• Input voltage from boom angle sensor can be checked with monitoring function.
(Code: 06005 Boom Angle Sensor Volt)
Related • Angle sensed by boom angle sensor can be checked with monitoring function.
information (Code: 06002 Boom Angle)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.

Defective 5 V sensor 1. Turn starting switch to OFF position.


1 power supply system 2. Disconnect connector F11, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Voltage Between F11 (female) (C) and (A) 5.0 to 5.2 V

1. Turn starting switch to OFF position.


2. Disconnect connector F11, and connect T-adapter to male side.

Between F11 (male) (A) and (C) 4 to 6 kz


Between F11 (male) (A) and ground Min. 1 Mz
Resistance
Between F11 (male) (B) and ground Min. 1 Mz
Defective boom angle
Between F11 (male) (C) and ground Min. 1 Mz
2 sensor
(internal short circuit) 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector F11.
3. Turn starting switch to ON position.
4. Operate boom lever to perform troubleshooting.
1.13 to 4.02
Continuous
V
Voltage Between F11 (B) and (A) RAISE stroke end 3.52 to 4.02
V
1.13 to 1.63
LOWER stroke end
V
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F11, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between F11 (female) (B) and ground Max. 1 V

WA470-7 40-705
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Turn starting switch to ON position.
Defective work 4. Operate boom lever to perform troubleshooting.
4 equipment controller 1.13 to 4.02
Continuous
V
Between L72 (26) and 3.52 to 4.02
Voltage RAISE stroke end
ground V
1.13 to 1.63
LOWER stroke end
V

Circuit diagram related to boom angle sensor

40-706 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DKA0L0] Boom Angle Sensor Dislocation (WA470_7-DKA0L0-400-A-Z0-A)

Action level Failure code Boom Angle Sensor Dislocation


Failure
L01 DKA0L0 (Work equipment controller system)
• Due to boom angle sensor dislocation, boom angle is not sensed correctly.
Detail of (Boom angle: higher than upper limit by +5 degrees or lower than lower limit by -5
failure degrees)
• Disables remote positioner function.
• Disables semi-auto digging.
• Disables boom FLOAT detent function when remote positioner LOWER stop function is
ON, and allows boom FLOAT detent function to work normally when remote positioner
Action of LOWER stop function is OFF.
controller • Disables boom RAISE detent function.
• If cause of failure disappears, machine becomes normal by itself (when cause is defective
adjustment of angle sensor).
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when cause is not defective adjustment of angle sensor).
• Remote positioner malfunctions (boom does not stop).
Problem on • Semi-auto digging system malfunctions (does not work).
machine • Komatsu SmartLoader Logic malfunctions.
• This failure code may be displayed when initial setting of boom angle sensor fails.
In this case, reset boom angle sensor, see Testing and adjusting.
• Input voltage from boom angle sensor can be checked with monitoring function.
Related (Code: 06005 Boom Angle Sensor Volt)
information • Angle sensed by boom angle sensor can be checked with monitoring function.
(Code: 06002 Boom Angle)
• Method of reproducing failure code: Start engine and raise or lower boom to stroke end.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector F11, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between F11 (female) (C) and (A) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector F11, and connect T-adapter to male side.
Between F11 (male) (A) and (C) 4 to 6 kz
Between F11 (male) (A) and ground Min. 1 Mz
Resistance
Between F11 (male) (B) and ground Min. 1 Mz
Between F11 (male) (C) and ground Min. 1 Mz
Defective boom angle 1. Turn starting switch to OFF position.
sensor 2. Insert T-adapter into connector F11.
2
(internal open or short 3. Turn starting switch to ON position.
circuit) 4. Operate boom lever to perform troubleshooting.
1.13 to 4.02
Continuous
V
3.52 to 4.02
Voltage Between F11 (B) and (A) RAISE stroke end V
1.13 to 1.63
LOWER stroke end V

WA470-7 40-707
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Turn starting switch to ON position.
Defective work 4. Operate boom lever to perform troubleshooting.
3 equipment controller 1.13 to 4.02
Continuous
V
Between L72 (26) and 3.52 to 4.02
Voltage RAISE stroke end
ground V
1.13 to 1.63
LOWER stroke end
V

Circuit diagram related to boom angle sensor

40-708 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DKA1KA] Failure of Bucket Angle Sensor (WA470_7-DKA1KA-400-A-Z0-A)

Action level Failure code Failure of Bucket Angle Sensor


Failure
L01 DKA1KA (Work equipment controller system)
• Due to open circuit or ground fault in bucket angle sensor system, signal voltage from
Detail of bucket angle sensor is lower than normal range. (Signal voltage from bucket angle
failure sensor: Max. 0.3 V)
• Determines that bell crank angle is at its minimum.
• Disables bucket positioner function.
Action of • Disables semi-auto digging.
controller • Disables bucket detent function.
• If cause of failure disappears, machine becomes normal by itself.
• Bucket positioner malfunctions (does not work).
Problem on • Semi-auto digging system malfunctions (does not work).
machine • Komatsu SmartLoader Logic malfunctions.
• Input voltage from bucket angle sensor can be checked with monitoring function.
(Code: 55601 Bucket Link Angle Sensor Volt)
Related • Angle sensed by bucket angle sensor can be checked with monitoring function.
information (Code: 55600 Bucket Link Angle)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective 5 V sensor 2. Disconnect connector F32, and connect T-adapter to female side.
1 power supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and after.
Voltage Between F32 (female) (C) and (A) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector F32, and connect T-adapter to male side.
Between F32 (male) (A) and (C) 4 to 6 kz
Between F32 (male) (A) and ground Min. 1 Mz
Resistance
Between F32 (male) (B) and ground Min. 1 Mz
Between F32 (male) (C) and ground Min. 1 Mz
Defective bucket angle
sensor 1. Turn starting switch to OFF position.
2 2. Insert T-adapter into connector F32.
(internal open or short
circuit) 3. Turn starting switch to ON position.
4. Operate bucket lever to perform troubleshooting.
2.15 to 4.45
Continuous
V
Voltage Between F32 (B) and (A) Full TILT 3.95 to 4.45
V
2.15 to 2.65
Full DUMP
V
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71, L72, and F32, and connect T-adapters to
each female side.
3 (wire breakage or Between F32 (female) (A) and L71 (female) (4) Max. 1 z
defective contact of
connector) Resistance Between F32 (female) (B) and L72 (female) (36) Max. 1 z
Between F32 (female) (C) and L71 (female) (22) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors L71, L72, and F32, and connect T-adapter to any
harness
4 female side.
(contact with ground
Between ground and F32 (female) (B) or L72 Min. 1 Mz
circuit) Resistance (female) (36)

WA470-7 40-709
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, work equipment controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Turn starting switch to ON position.
Defective work 4. Operate bucket lever to perform troubleshooting.
5 equipment controller 2.15 to 4.45
Continuous
V
Between L72 (36) and 3.95 to 4.45
Voltage Full TILT
ground V
2.15 to 2.65
Full DUMP
V

Circuit diagram related to bucket angle sensor

40-710 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DKA1KY] Hot Short of Bucket Angle Sensor Circuit (WA470_7-
DKA1KY-400-A-Z0-A)

Action level Failure code Hot Short of Bucket Angle Sensor Circuit
Failure
L01 DKA1KY (Work equipment controller system)
Detail of • Due to hot short circuit in bucket angle sensor system, signal voltage from bucket angle
failure sensor is higher than normal range. (Signal voltage from bucket angle sensor: Min. 4.8 V)
• Determines that bell crank angle is at its minimum.
• Disables bucket positioner function.
Action of • Disables semi-auto digging.
controller • Disables bucket detent function.
• If cause of failure disappears, machine becomes normal by itself.
• Bucket positioner malfunctions (does not work).
Problem on • Semi-auto digging system malfunctions (does not work).
machine • Komatsu SmartLoader Logic malfunctions.
• Input voltage from bucket angle sensor can be checked with monitoring function.
(Code: 55601 Bucket Link Angle Sensor Volt)
Related • Angle sensed by bucket angle sensor can be checked with monitoring function.
information (Code: 55600 Bucket Link Angle)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
If failure code [DB95KX] is also displayed, perform troubleshooting for it
first.
1. Turn starting switch to OFF position.
Defective 5 V sensor power 2. Disconnect connector F32, and connect T-adapter to female side.
1 supply system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, go to check on cause 3 and
after.
Voltage Between F32 (female) (C) and (A) 5.0 to 5.2 V
1. Turn starting switch to OFF position.
2. Disconnect connector F32, and connect T-adapter to male side.
Between F32 (male) (A) and (C) 4 to 6 kz
Resis- Between F32 (male) (A) and ground Min. 1 Mz
tance Between F32 (male) (B) and ground Min. 1 Mz
Defective bucket angle Between F32 (male) (C) and ground Min. 1 Mz
2 sensor
1. Turn starting switch to OFF position.
(internal short circuit) 2. Insert T-adapter into connector F32.
3. Turn starting switch to ON position.
4. Operate bucket lever to perform troubleshooting.
Continuous 2.5 to 4.7 V
Between F32 (B) and
Voltage Full TILT 4.2 to 4.7 V
(A)
Full DUMP 2.5 to 3.0 V
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector F32, and connect T-adapter to female side.
3 3. Turn starting switch to ON position.
harness
Voltage Between F32 (female) (B) and ground Max. 1 V
If no failure is found by above checks, work equipment controller is
defective.
• Reference
1. Turn starting switch to OFF position.
Defective work equipment 2. Insert T-adapter into connector L72.
4 3. Turn starting switch to ON position.
controller
4. Operate bucket lever to perform troubleshooting.
Continuous 2.5 to 4.7 V
Between L72 (36) and
Voltage Full TILT 4.2 to 4.7 V
ground
Full DUMP 2.5 to 3.0 V

WA470-7 40-711
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket angle sensor

40-712 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF1KA] Disconnection of T/M Input Speed Sensor (WA380_7-


DLF1KA-400-A-Z0-A)

Action level Failure code Disconnection of transmission input speed sensor


Failure
L03 DLF1KA (Transmission controller system)
• Due to open circuit or hot short circuit in transmission input shaft speed sensor circuit,
signal voltage from transmission input shaft speed sensor is higher than normal range.
Detail of • This failure code appears if following conditions are met.
failure 1) Input voltage is 3 V or above.
2) Pulse voltage input is not recorded.
• Sets shift mode to manual mode.
Action of • Disengages lockup clutch.
controller • Maintains rotation speed before failure.
• If cause of failure disappears, machine becomes normal by itself.
• Auto-shift mode is unavailable (manual shift mode is selected).
Problem on • Lockup clutch is not engaged.
machine • Gear shifting shocks result.
Related • Input shaft speed input from transmission input shaft speed sensor can be checked with
information monitoring function. (Code: 31200 T/M Input Shaft Speed)
No. Cause Procedure, measuring location, criteria and remarks
For adjustment, screw in speed sensor until it contacts with gear for
Defective adjustment of speed sensing, then return sensor half turn to one turn.
1 transmission input shaft
speed sensor a For details, see Testing and adjusting, "Adjusting transmission input
shaft speed sensor".
1. Turn starting switch to OFF position.
2. Disconnect connector REV IN, and connect T-adapters to male side.
Defective transmission input 500 to 1,000
2 shaft speed sensor Between REV IN (male) (1) and (2)
Resis- z
tance Between ground and each of REV IN (male)
(1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Open or short circuit in wiring 2. Disconnect connector L62, and connect T-adapters to female side.
3
harness Resis- Between L62 (female) (40) and (39) 500 to 1,000
tance z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector L62, and connect T-adapters to female side.
harness 3. Disconnect connector REV IN, and connect T-adapter to female side.
4
(wire breakage or defective Between L62 (female) (40) and REV IN
contact of connector) Max. 1 z
Resis- (female) (1)
tance Between L62 (female) (39) and REV IN
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

WA470-7 40-713
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission input shaft speed sensor

40-714 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLF1LC] Failure of T/M Input Speed Sensor (WA380_7-DLF1LC-400-A-Z0-A)

Action level Failure code Failure of Transmission Input Speed Sensor


Failure
L03 DLF1LC (Transmission controller system)
• Due to ground fault in transmission input shaft speed sensor circuit, signal voltage from
transmission input shaft speed sensor is lower than normal range.
• This failure code appears if following conditions are met when engine is running at min.
500 rpm after clutch pressure builds up.
(In any case of [A] and [B])
[A]
1) Input shaft speed calculated from output shaft speed sensor value and reduction ratio
Detail of is 200 rpm or above.
failure 2) No pulse voltage is input from input shaft speed sensor.
3) Open circuit in input shaft speed sensor circuit is not detected.
[B]
1) Output shaft speed sensor value differs from output shaft speed calculated from input
shaft speed sensor value and reduction ratio by 200 rpm or above.
2) Pulse voltage is input from input shaft speed sensor.
3) Pulse voltage is input from output shaft speed sensor.
• Sets shift mode to manual mode.
Action of • Disengages lockup clutch.
controller • Maintains engine speed obtained before this failure is detected.
• If cause of failure disappears, machine becomes normal by itself.
• Auto-shift mode is unavailable (manual shift mode is selected).
Problem on • Lockup clutch is not engaged.
machine • Gear shifting shocks result.
Related • Input shaft speed from transmission input shaft speed sensor can be checked with
information monitoring function. (Code: 31200, T/M Input Shaft Speed)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector REV IN, and connect T-adapter to male side.
Defective transmission input 500 to 1,000
1 shaft speed sensor Between REV IN (male) (1) and (2)
Resis- z
tance Between ground and each of REV IN (male)
(1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connector L62, and connect T-adapter to female side.
harness 3. Disconnect connector REV IN, and connect T-adapter to female
2
side.
(contact with ground circuit)
Resis- Between ground and L62 (female) (40) or REV
Min. 1 Mz
tance IN (female) (1)
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector REV IN, and connect T-adapter to female
3 harness side.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between REV IN (female) (1) and ground Max. 1 V
1. Turn starting switch to OFF position.
2. Disconnect connector REV IN.
4 Short circuit in wiring harness 3. Disconnect connector L62, and connect T-adapter to female side.
Resis- Between L62 (female) (40) and each pin other
Min. 1 Mz
tance than pin (40)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

WA470-7 40-715
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission input shaft speed sensor

40-716 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM3KA] Disconnection of Radiator Fan Speed


Sensor (WA470_7-DLM3KA-400-A-Z0-A)
Action level Failure code Disconnection of Radiator Fan Speed Sensor
Failure
L01 DLM3KA (Transmission controller system)
• Due to open circuit or hot short in fan speed sensor system, signal voltage from fan speed
sensor is higher than normal range.
Detail of • This failure code appears if following conditions are met.
failure 1) Input voltage is 3 V or above.
2) Pulse voltage input is not recorded.
Action of • Stops feedback control of fan speed and switches fan speed control to open control.
controller
Problem on • Fan fails to accurately meet required fan speed.
machine
Related • Fan speed input by fan speed sensor can be checked with monitoring function. (Code:
information 10009 Radiator Fan Speed)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R89 and connect T-adapter to male side.
Defective radiator fan
1 speed sensor 1.0 to 4.0
Between R89 (male) (1) and (2)
Resistance kz
Between ground and each of R89 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R89 and connect T-adapters to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R89 (female) (1) and (2) 3.0 to 4.0 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L62, and connect T-adapter to female side.
3 wiring harness
a Coil resistance of radiator fan speed sensor
1.0 to 4.0
Resistance Between L62 (female) (30) and (39)
kz
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L62 and R89, and connect T-adapters to each
harness female side.
Between L62 (female) (30) and R89 (female) (1) Max. 1 z
4 (wire breakage or
defective contact of
connector) Resistance
Between L62 (female) (39) and R89 (female) (2) Max. 1 z

1. Turn starting switch to OFF position.


Hot short circuit in 2. Disconnect connector R89.
wiring harness 3. Insert T-adapters into connector L62, or connect T-adapter to female side
5 of R89.
(contact with 24 V 4. Turn starting switch to ON position.
circuit)
Between ground and L62 (female) (30) or R89
Voltage Max. 4.5 V
(female) (1)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
6
controller performed.)

WA470-7 40-717
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to radiator fan speed sensor

40-718 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLM3LC] Failure of Radiator Fan Speed Sensor (WA470_7-DLM3LC-


400-A-Z0-A)

Action level Failure code Failure of Radiator Fan Speed Sensor


Failure
L01 DLM3LC (Transmission controller system)
• Due to ground fault in fan speed sensor system, no pulse signal is input fan speed sensor.
• This failure code appears if the following conditions are met.
Detail of 1) Open circuit in fan speed sensor is not detected.
failure 2) Engine speed is 500 rpm or higher.
3) Fan is not in reverse rotation mode.
4) At least 10 seconds have passed after front and rear brake pressure is applied.
Action of • Stops feedback control of fan speed and switches fan speed control to open control.
controller
Problem on • Fan fails to accurately meet required fan speed.
machine
Related • Fan speed input by fan speed sensor can be checked with monitoring function. (Code:
information 10009 Radiator Fan Speed)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R89 and connect T-adapter to male side.
Defective radiator fan
1 speed sensor 1.0 to 4.0
Between R89 (male) (1) and (2)
Resistance kz
Between ground and each of R89 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector L62, and connect T-adapter to female side.
Open or short circuit in
2 wiring harness a Coil resistance of radiator fan speed sensor
1.0 to 4.0
Resistance Between L62 (female) (30) and (39)
kz
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and R89, and connect T-adapters to each
3 (wire breakage or female side.
defective contact of Between L62 (female) (30) and R89 (female) (1) Max. 1 z
connector) Resistance
Between L62 (female) (39) and R89 (female) (2) Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and R89, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L62 (female) (30) or R89
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector L62 and R89.
Short circuit in wiring 3. Connect T-adapter to female side of L62.
5
harness
Between L62 (female) (30) and each pin other than
Resistance pin (30) Min. 1 Mz

1. Turn starting switch to OFF position.


Hot short circuit in 2. Disconnect connector R89.
wiring harness 3. Insert T-adapters into connector L62, or connect T-adapter to female side
6 of R89.
(contact with 24 V 4. Turn starting switch to ON position.
circuit)
Between ground and L62 (female) (30) or R89
Voltage Max. 4.5 V
(female) (1)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
7
controller performed.)

WA470-7 40-719
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to radiator fan speed sensor

40-720 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLT3KA] Disconnection of Output Speed Sens.


(Main) (WA380_7-DLT3KA-400-A-Z0-A)
Action level Failure code Disconnection of Output Speed Sensor (Main)
Failure
L03 DLT3KA (Transmission controller system)
• Due to open circuit in transmission output shaft speed sensor system, signal voltage from
transmission output shaft speed sensor is lower than normal range.
Detail of • This failure code appears if following conditions are met.
failure
1. Input voltage is 3 V or above.
2. No pulse voltage is input.
• Switches shift mode to manual mode when auto-shift mode is selected.
• Selects manual mode for mode transmission signal to machine monitor, too, when auto-
shift mode is selected.
• Performs normal control as long as manual shift mode is selected.
• Disengages lockup clutch.
Action of • Calculates output shaft speed from input shaft speed sensor value and reduction ratio,
controller and uses it for machine control when input shaft speed sensor is normal.
• Transmits input value from sensor, without modifying it, to machine monitor as speed of
output shaft.
• Lights up centralized warning lamp and sounds alarm buzzer.
• If cause of failure disappears, machine becomes normal by itself.
• Auto-shift mode is unavailable (manual shift mode is selected).
Problem on • Lockup clutch is not engaged.
machine • Gear shifting shocks result.
• Auto-shift pilot lamp goes out.
• Output shaft speed input from transmission output shaft speed sensor can be checked
Related with monitoring function. (Code: 31400 T/M Output Shaft Speed)
information • Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
• For adjustment, screw in speed sensor until sensor contacts with
Defective adjustment of gear for speed sensing, then return sensor by half turn to one turn.
1 transmission output shaft
speed sensor a For details, see Testing and adjusting, "Adjusting transmission output
shaft speed sensor".
1. Turn starting switch to OFF position.
2. Disconnect connector REV OUT, and connect T-adapter to male
Defective transmission side.
2 output shaft speed sensor Between REV OUT (male) (1) and (2) 500 to 1,000
Resis- z
tance Between ground and each of REV OUT (male)
(1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Open or short circuit in wiring 2. Disconnect connector L62, and connect T-adapter to female side.
3
harness Resis- Between L62 (female) (20) and (29) 500 to 1,000
tance z
a If no failure is found by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector L62, and connect T-adapter to female side.
harness 3. Disconnect connector REV OUT, and connect T-adapter to female
4 side.
(wire breakage or defective
contact of connector) Between L62 (female) (20) and REV OUT
Max. 1 z
Resis- (female) (1)
tance Between L62 (female) (29) and REV OUT
(female) (2) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

WA470-7 40-721
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission output shaft speed sensor

40-722 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DLT3LC] Failure of Output Speed Sensor (Main) (WA380_7-DLT3LC-


400-A-Z0-A)

Action level Failure code Failure of Output Speed Sensor (Main)


Failure
L03 DLT3LC (Transmission controller system)
• Due to ground fault in transmission output shaft speed sensor circuit, signal voltage from
transmission output shaft speed sensor is lower than normal range.
1. Conditions for failure detection
This failure code appears if the following conditions are met when engine is running at
500 rpm or higher after clutch pressure builds up. (In any of case [A] and [B])
[A]
1) Output shaft speed calculated from input shaft speed sensor value and reduction ratio
Detail of is 200 rpm or above.
failure 2) No pulse voltage is input from output shaft speed sensor.
3) And open output shaft speed sensor is not open.
[B]
1) Output shaft speed sensor value differs from output shaft speed calculated from input
shaft speed sensor value and reduction ratio by 200 rpm or above.
2) Pulse voltage is input from input shaft speed sensor.
3) Pulse voltage is input from output shaft speed sensor.
• Switches shift mode to manual mode when auto-shift mode is selected.
• Selects manual mode for mode transmission signal to machine monitor, too, when auto-
shift mode is selected.
• Performs normal control as long as manual shift mode is selected.
Action of • Calculates output shaft speed from input shaft speed sensor value and reduction ratio,
controller and uses it for machine control when input shaft speed sensor is normal.
• Transmits input value from sensor, without modifying it, to machine monitor as speed of
output shaft.
• Disengages lockup clutch of torque converter.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Auto-shift mode is unavailable (manual shift mode is selected).
Problem on • Lockup clutch of toque converter is not engaged.
machine • Gear shifting shocks result.
• Input shaft speed from transmission output shaft speed sensor can be checked with
Related monitoring function. (Code: 31400 T/M Output Shaft Speed)
information • Method of reproducing failure code: Start engine and drive machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector REV OUT, and connect T-adapter to male
Defective transmission output side.
1 shaft speed sensor 500 to 1,000
Between REV OUT (male) (1) and (2)
Resis- z
tance Between ground and each of REV OUT (male)
(1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Ground fault in wiring 2. Disconnect connector L62, and connect T-adapter to female side.
harness 3. Disconnect connector REV OUT, and connect T-adapter to female
2
side.
(contact with ground circuit)
Resis- Between ground and L62 (female) (20) or REV
Min. 1 Mz
tance OUT (female) (1)
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector REV OUT, and connect T-adapter to female
3 harness side.
(contact with 24 V circuit) 3. Turn starting switch to ON position.
Voltage Between REV OUT (female) (1) and ground Max. 1 V

WA470-7 40-723
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector REV OUT.
4 Short circuit in wiring harness 3. Disconnect connector L62, and connect T-adapter to female side.
Resis- Between L62 (female) (20) and each pin other
Min. 1 Mz
tance than pin (20)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

Circuit diagram related to transmission output shaft speed sensor

40-724 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DPQ1KR] LIN Discon (Switch Panel) (WA470_7-DPQ1KR-400-A-Z0-A)

Action level Failure code LIN Disconnection (Switch Panel)


Failure
L01 DPQ1KR (Machine monitor system)
Detail of • Update of data received from switch panel (operation switches of machine monitor)
failure through LIN communication line is stopped.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
• Display operations in user menu and service menu are unavailable and setting operation
by using those menus is also unavailable.
Problem on • Operation of air conditioner is unavailable.
machine • Display of SMR is unavailable while starting switch is in OFF position.
• If engine start lock is enabled, engine cannot be started because you cannot enter
password.
• Since signal of active LIN communication line is pulse voltage, it cannot be measured by
using multimeter.
Related • If failure codes [DPQ2KR] and [DPQ3KR] are also displayed, LIN communication line
information probably has ground fault or hot short circuit.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Ground fault or hot short circuit
If failure code [DAFDKB] is also displayed, perform troubleshooting for
1 in 12 V power supply line of
[DAFDKB] first.
switch panel
1. Turn starting switch to OFF position.
2. Disconnect connector MOM1, and connect T-adapters to female
Open circuit in 12 V power
2 side.
supply line of switch panel
3. Turn starting switch to ON position.
Voltage Between MOM1 (female) (1) and (2) 9 to 14 V
1. Turn starting switch to OFF position.
2. Disconnect connector MOM1, and connect T-adapters to female
Defective 5 V power supply
3 side.
line of switch panel
3. Turn starting switch to ON position.
Voltage Between MOM1 (female) (4) and (2) 4 to 6 V
a If failure codes [DPQ2KR] and [DPQ3KR] are not displayed
Hot short circuit in wiring together with this failure code, this check is not required.
harness (LIN communication 1. Turn starting switch to OFF position.
4 line) 2. Disconnect connector MOM1, and connect T-adapters to female
(contact with 24 V circuit) side.
3. Turn starting switch to ON position.
Voltage Between MOM1 (female) (3) and (2) Approx. 9 V
a If failure codes [DPQ2KR] and [DPQ3KR] are not displayed
together with this failure code, this check is not required.
a If no failure is found by check on cause 4, this check is not required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
5
(contact with ground circuit) 2. Disconnect connectors MCM1 B, MDM2, MOM1, and RVM1, and
connect T-adapters to any female side.
Between ground and MCM1 B (female)
Resis- (108), MDM2 (female) (3), MOM1 (female)
Min. 1 Mz
tance (3) or RVM1 (female) (9)
• Perform this check when failure codes [DPQ2KR] and [DPQ3KR]
are also displayed.
Defective switch panel 1. Turn starting switch to OFF position.
6 (operation switches of 2. Disconnect connector MOM1.
machine monitor) 3. Turn starting switch to ON position.
If failure codes [DPQ2KR] and [DPQ3KR] disappear, switch panel is
defective.

WA470-7 40-725
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• Perform this check when failure codes [DPQ2KR] and [DPQ3KR]
are also displayed.
1. Turn starting switch to OFF position.
Defective LED unit (display
7 2. Disconnect connector MDM2.
unit of machine monitor)
3. Turn starting switch to ON position.
If failure codes [DPQ1KR] and [DPQ3KR] disappear, LED unit is
defective.
• Perform this check when failure codes [DPQ2KR] and [DPQ3KR]
are also displayed.
1. Turn starting switch to OFF position.
8 Defective rear view monitor 2. Disconnect connector RVM1.
3. Turn starting switch to ON position.
If failure codes [[DPQ1KR] and [DPQ2KR] disappear, rear view monitor
is defective.
If no failure is found by above checks, monitor controller may be
9 Defective monitor controller defective. (Since this is an internal defect, troubleshooting cannot be
performed).

40-726 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to LIN communication line

WA470-7 40-727
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DPQ2KR] LIN Discon (LED Unit) (WA470_7-DPQ2KR-400-A-Z0-A)

Action level Failure code LIN Disconnection (LED Unit)


Failure
L01 DPQ2KR (Machine monitor system)
Detail of • Update of data received from LED unit (display unit of machine monitor) through LIN
failure communication line is stopped.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
Indications of following items on LED unit differ from actual conditions.
• Turn signal (hazard) lamp
Problem on • High-beam
machine • Parking brake
• Accumulator pressure drop caution lamp
• Pilot lamp for clearance lamp
• Centralized warning lamp
• Since signal of active LIN communication line is pulse voltage, it cannot be measured by
using multimeter.
Related • If failure codes [DPQ1KR] and [DPQ3KR] are also displayed, LIN communication line
information probably has ground fault or hot short circuit.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Ground fault or hot short circuit If failure code [DAFDKB] is also displayed, perform troubleshooting for
1 in 12 V power supply line of [DAFDKB] first.
LED unit
1. Turn starting switch to OFF position.
2. Disconnect connector MDM2, and connect T-adapters to female
Open circuit in 12 V power
2 side.
supply line of LED unit
3. Turn starting switch to ON position.
Voltage Between MDM2 (female) (1) and (2) 9 to 14 V
1. Turn starting switch to OFF position.
2. Disconnect connector MDM2, and connect T-adapters to female
Open circuit in 5 V power
3 side.
supply line of LED unit
3. Turn starting switch to ON position.
Voltage Between MDM2 (female) (4) and (2) 4 to 6 V
a If failure codes [DPQ1KR] and [DPQ3KR] are not displayed
Hot short circuit in wiring together with this failure code, this check is not required.
harness (LIN communication 1. Turn starting switch to OFF position.
4 line) 2. Disconnect connector MDM2, and connect T-adapters to female
(contact with 24 V circuit) side.
3. Turn starting switch to ON position.
Voltage Between MDM2 (female) (3) and (2) Approx. 9 V
a If failure codes [DPQ1KR] and [DPQ3KR] are not displayed
together with this failure code, this check is not required.
a If no failure is found by check on cause 4, this check is not required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
5
(contact with ground circuit) 2. Disconnect connectors MCM1 B, MDM2, MOM1, and RVM1, and
connect T-adapters to any female side.
Between ground and MCM1 B (female)
Resistance (108), MDM2 (female) (3), MOM1 (female) Min. 1 Mz
(3) or RVM1 (female) (9)

40-728 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• Perform this check when failure codes [DPQ1KR] and [DPQ3KR]
are also displayed.
Defective switch panel 1. Turn starting switch to OFF position.
6 (operation switches of 2. Disconnect connector MOM1.
machine monitor) 3. Turn starting switch to ON position.
If failure codes [DPQ2KR] and [DPQ3KR] disappear, switch panel is
defective.
• Perform this check when failure codes [DPQ1KR] and [DPQ3KR]
are also displayed.
1. Turn starting switch to OFF position.
Defective LED unit (display
7 2. Disconnect connector MDM2.
unit of machine monitor)
3. Turn starting switch to ON position.
If failure codes [DPQ1KR] and [DPQ3KR] disappear, LED unit is
defective.
• Perform this check when failure codes [DPQ1KR] and [DPQ3KR]
are also displayed.
1. Turn starting switch to OFF position.
8 Defective rear view monitor 2. Disconnect connector RVM1.
3. Turn starting switch to ON position.
If failure codes [DPQ1KR] and [DPQ2KR] disappear, rear view monitor
is defective.
If no failure is found by above checks, monitor controller may be
9 Defective monitor controller defective. (Since this is an internal defect, troubleshooting cannot be
performed).

WA470-7 40-729
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to LIN communication line

40-730 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DPQ3KR] LIN Discon (Rear View Monitor) (WA470_7-DPQ3KR-400-A-Z0-A)

Action level Failure code LIN Disconnection (Rear View Monitor)


Failure
L01 DPQ3KR (Machine monitor system)
Detail of • Update of data received from rear view monitor through LIN communication line is
failure stopped.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller
• Various setting functions relevant to display of images from rear view camera (guide line
Problem on display, reverse-interlock mode selection, guide line position adjustment, and initialization
machine of rear view monitor) are unavailable.
• Since signal of active LIN communication line is pulse voltage, it cannot be measured by
using multimeter.
Related • If failure codes [DPQ1KR] and [DPQ2KR] are also displayed, LIN communication line
information probably has ground fault or hot short circuit.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1 Defective fuse-3 in fuse box 2 If fuse is blown, circuit may have ground fault. (See check on cause 5.)
Defective engine shutdown If failure code [DDAAL6] is also displayed, perform troubleshooting for
2 secondary switch system [DDAAL6] first.
1. Turn starting switch to OFF position.
2. Disconnect connector RVM1, and connect T-adapters to female
side.
3 Defective power supply line 3. Turn starting switch to ON position.
Between RVM1 (female) (1) and (2) 20 to 30 V
Voltage
Between RVM1 (female) (12) and (2) 20 to 30 V
a If failure codes [DPQ1KR] and [DPQ2KR] are not displayed together
Hot short circuit in wiring with this failure code, this check is not required.
harness (LIN communication 1. Turn starting switch to OFF position.
4 line) 2. Disconnect connector RVM1, and connect T-adapters to female
(contact with 24 V circuit) side.
3. Turn starting switch to ON position.
Voltage Between RVM1 (female) (9) and (2) Approx. 9 V
a If failure codes [DPQ1KR] and [DPQ2KR] are not displayed together
with this failure code, this check is not required.
a If no failure is found by check on cause 4, this check is not required.
Ground fault in wiring harness 1. Turn starting switch to OFF position.
5
(contact with ground circuit) 2. Disconnect connectors MCM1 B, MDM2, MOM1, and RVM1, and
connect T-adapters to any female side.
Between ground and MCM1 B (female) (108),
Resis- MDM2 (female) (3), MOM1 (female) (3) or
Min. 1 Mz
tance RVM1 (female) (9)
• Perform this check when failure codes [DPQ1KR] and [DPQ2KR]
are also displayed.
1. Turn starting switch to OFF position.
Defective switch panel
2. Disconnect connector RVM1.
6 (operation switches of
3. Turn starting switch to ON position.
machine monitor)
If failure codes [DPQ2KR] and [DPQ3KR] disappear, switch panel is
defective.

WA470-7 40-731
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• Perform this check when failure codes [DPQ1KR] and [DPQ2KR]
are also displayed.
1. Turn starting switch to OFF position.
Defective LED unit (display
7 2. Disconnect connector MDM2.
unit of machine monitor)
3. Turn starting switch to ON position.
If failure codes [DPQ1KR] and [DPQ3KR] disappear, LED unit is
defective.
• Perform this check when failure codes [DPQ1KR] and [DPQ2KR]
are also displayed.
1. Turn starting switch to OFF position.
8 Defective rear view monitor 2. Disconnect connector RVM1.
3. Turn starting switch to ON position.
If failure codes [[DPQ1KR] and [DPQ2KR] disappear, rear view monitor
is defective.
If no failure is found by above checks, monitor controller may be
9 Defective monitor controller defective. (Since this is an internal defect, troubleshooting cannot be
performed).

40-732 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to LIN communication line

WA470-7 40-733
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DSJ0KR] CAN2 Discon (Meter Unit) (WA500_7-DSJ0KR-400-A-Z0-A)

Action level Failure code CAN2 Disconnection (Meter Unit)


Failure
L01 DSJ0KR (Detected by monitor controller) (Machine monitor system)
Detail of • Monitor controller does not recognize meter unit (connector DPC3) of machine monitor
failure over CAN communication-2 line (KOMNET/c).
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Pointer of engine speed meter returns to zero point.
machine • Speedometer indicates "00".
• Method of reproducing failure code: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Monitor controller uses six failure codes, [D8AQKR], [DAQQKR], [DAZQKR], [DB1QKR],
[DB2QKR], and [DSJ0KR] to indicate failure in CAN communication through CAN 2 line.
When all of these six failure codes are displayed simultaneously on screen, ground fault,
short circuit, or hot short circuit may occur in wiring harness (CAN communication line). In
this case, check whether air conditioner is operated (ON/OFF and air flow adjustment)
Related from air conditioner operation screen since air conditioner is also controlled over CAN
information communication line.
a Air conditioner can be controlled even when failure code is displayed on screen. If air
conditioner is controlled, wiring harness (CAN communication line) does not have ground
fault, short circuit, or hot short circuit.
• Since each controller and machine monitor are connected directly to battery, they are
supplied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-3 and fuse-15 If fuse is blown, circuit probably has grounding fault.
1
in fuse box 2
• Starting switch ACC signal
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
3. Disconnect connector MDM3, and connect T-adapters to female
Defective power supply to side.
2
meter unit of machine monitor 4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between MDM3 (1) and (4) 20 to 30 V
Voltage
Between MDM3 (2) and (4) 20 to 30 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
Ground fault in wiring harness 3. Remove fuse-3 and fuse-15 in fuse box 2.
3 4. Disconnect connectors AL1, MCM1 A, S_FS, MDM3, TEL, L73, and
(contact with ground circuit)
RVM1, and connect T-adapter to female side of S_FS or MDM3.
Between ground and S_FS (female) (2), (5) or
Resis- MDM3 (female) (2) Min. 1 Mz
tance
Between MDM3 (female) (1) and ground Min. 1 Mz
Defective CAN2 Perform checks on causes 4 to 9 in troubleshooting for failure code
4 communication system [DB2QKR].
If no failure is found by above checks, meter unit of machine monitor is
Defective meter unit of defective.
5
machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, monitor controller is defective.
6 Defective monitor controller
(Since this is an internal defect, troubleshooting cannot be performed.)

40-734 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to machine monitor power supply

WA470-7 40-735
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DT20KB] Ground Fault of T/M Cut Off Indicator (WA470_7-DT20KB-400-
A-Z0-A)

Action level Failure code Ground Fault of Transmission Cut Off Indicator
Failure
L01 DT20KB (Transmission controller system)
Detail of • Controller determines that transmission cut-off indicator lamp circuit has ground fault
failure because output signal is not entered to indicator lamp.
• Stops driving transmission cut-off indicator lamp.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Transmission cut-off indicator lamp does not light up.
machine
Related • Method of reproducing failure code: Start engine and turn transmission cut-off switch to
information ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective transmission 2. Disconnect connector S_RH1, and connect T-adapters to male side.
cut-off indicator lamp
1 (LED) (internal short Between S_RH1 (male) (1) and (2) Min. 1 Mz
circuit) Resistance Between ground and each of S_RH1 (male) (1) and
(2) Min. 1 Mz

1. Turn starting switch to OFF position.


Short circuit in wiring 2. Disconnect connectors L62 and S_RH1, and connect T-adapter to female
2 side of S_RH1.
harness
Resistance Between S_RH1 (female) (1) and (2) Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors S_RH1 and E26, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L62 (female) (28) or S_RH1
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L62.
3. Turn starting switch to ON position.
4. Set transmission cut-off switch to ON and OFF positions to perform
troubleshooting.
Defective transmission
4 Starting
controller
switch: ON 20 to 30 V
position
Voltage Between L62 (28) and ground
Starting
switch: OFF Max. 1 V
position

40-736 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to transmission cut-off indicator lamp

WA470-7 40-737
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DT22KB] Ground Fault of Work Equip. Lock Indic. (WA470_7-
DT22KB-400-A-Z0-A)

Action level Failure code Ground Fault of Work Equipment Lock Indicator
Failure
L01 DT22KB (Work equipment controller system)
Detail of • Controller determines that output circuit to lamp built in work equipment lock switch has
failure ground fault because lamp built in work equipment lock switch is not driven.
• None in particular
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Lamp built in work equipment lock switch does not light up.
machine
• Output signal (ON/OFF) to lamp built in work equipment lock switch can be checked with
Related monitoring function. (Code: 03707 BBC Output 1, Work Equipment Lock Ind.)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective indicator lamp 2. Disconnect connector S_RHC, and connect T-adapter to male side.
(LED) of work
1 equipment lock switch Between S_RHC (male) (1) and (2) Min. 1 Mz
(internal short circuit) Resistance Between ground and each of S_RHC (male) (1)
and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Short circuit in wiring 2. Disconnect connectors L72 and S_RHC, and connect T-adapter to female
2 side of S_RHC.
harness
Resistance Between S_RHC (female) (1) and (2) Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors S_RHC and E26, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L72 (female) (28) or S_RHC
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L72.
Defective work 3. Turn starting switch to ON position.
4 equipment controller 4. Turn on and off work equipment lock switch, and perform troubleshooting.
Between L72 (female) (28) and LOCK 20 to 30 V
Voltage
ground Release Max 1 V

40-738 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment lock switch indicator lamp

WA470-7 40-739
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DV00KB] Ground Fault of Buzzer Output (WA380_7-DV00KB-400-A-Z0-A)

Action level Failure code Ground Fault of Buzzer Output


Failure
L01 DV00KB (Machine monitor system)
Detail of • When controller drives caution buzzer, abnormal current flows through circuit.
failure
• Stops driving alarm buzzer.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is set to OFF position.
Problem on
• Alarm buzzer does not sound.
machine
• Signal (ON/OFF) to alarm buzzer can be checked with monitoring function.
Related (Code: 04700 "Buzzer")
information • Method of reproducing failure code: Turn starting switch to ON position to drive alarm
buzzer.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L20, and connect T-adapter to female side.
3. Turn starting switch to ON position.
a If following voltages are normal and alarm buzzer does not sound, alarm
Defective alarm buzzer
1 buzzer is defective.
(internal defect) When no driving alarm
Max. 1 V
buzzer
Between L20 (female)
Voltage When driving alarm
(1) and (2)
buzzer (when starting 20 to 30 V
engine)
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 A and L20, and connect T-adapters to each
Open circuit in wiring
2 female side.
harness
Between MCM1 A (female) (20) and L20 (female)
Resistance (1) Max. 1z

Ground fault in wiring 1. Turn starting switch to OFF position.


harness 2. Disconnect connectors MCM1 A and L20, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and MCM1 A (female) (20) or L20
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector L20.
3. Turn starting switch to ON position.
Defective monitor When no driving alarm
4 Max. 1 V
controller buzzer
Between L20 (female)
Voltage When driving alarm
(1) and (2)
buzzer (when starting 20 to 30 V
engine)

40-740 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to buzzer

WA470-7 40-741
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4PKA] Disconnection of Boom EPC Solenoid


(Raise) (WA470_7-DW4PKA-400-A-Z0-A)
Action level Failure code Disconnection of Boom EPC Solenoid (Raise)
Failure
L03 DW4PKA (Work equipment controller system)
Detail of • Due to open circuit in output signal circuit to boom RAISE EPC solenoid, no current flows
failure when controller drives boom RAISE EPC solenoid.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on
• Boom does not rise.
machine
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
Related function. (Code: 41900 Boom Raise EPC Current)
information • Method of reproducing failure code: Start engine and move boom lever to RAISE position.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom RAISE 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F23, and connect T-adapter to male side.
open circuit) Resistance Between F23 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector F23 and connect T-adapters to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between F23 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L73, and connect T-adapter to female side.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L73 (female) (6) and (3) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F23, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (6) and F23 (female) (1) Max. 1 z
Resistance
Between L73 (female) (3) and F23 (female) (2) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-742 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom RAISE EPC solenoid

WA470-7 40-743
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4PKB] Ground Fault of Boom EPC Solenoid


(Raise) (WA470_7-DW4PKB-400-A-Z0-A)
Action level Failure code Ground Fault of Boom EPC Solenoid (Raise)
Failure
L03 DW4PKB (Work equipment controller system)
Detail of • Due to ground fault in signal output circuit to boom raise EPC solenoid, abnormal current
failure flows when controller drives boom RAISE EPC solenoid.
• Stops driving boom RAISE EPC solenoid.
• Stops driving boom RAISE detent.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on
• Boom does not rise.
machine
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
Related function. (Code: 41900 Boom Raise EPC Current)
information • Method of reproducing failure code: Start engine and move boom lever to RAISE position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective boom RAISE 2. Disconnect connector F23, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Between F23 (male) (1) and (2) 5 to 15 z
Resistance
Between ground and each of F23 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L73, and connect T-adapter to female side.
wiring harness
Resistance Between L73 (female) (6) and (3) 5 to 15 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L73 and F23, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L73 (female) (6) or F23
circuit) Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L73 and F23, and connect T-adapter to either
4
harness female side.
Between L73 (female) (6) and (3) or between F23
Resistance (female) (1) and (2) Min. 1 Mz
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-744 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom RAISE EPC solenoid

WA470-7 40-745
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4PKY] Hot Short of Boom EPC Solenoid (Raise) (WA470_7-
DW4PKY-400-A-Z0-A)

Action level Failure code Hot Short of Boom EPC Solenoid (Raise)
Failure
L03 DW4PKY (Work equipment controller system)
Detail of • Due to hot short circuit in signal output circuit to boom RAISE EPC solenoid, abnormal
failure voltage appears when controller does not drive boom RAISE EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd (attachment)
EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Boom RAISE EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom RAISE 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F23, and connect T-adapter to male side.
short circuit) Resistance Between F23 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F23 and connect T-adapters to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F23 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F23, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (6) and each No continuity
Continuity
pin other than pin (6) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-746 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom RAISE EPC solenoid

WA470-7 40-747
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4QKA] Disconnection of Boom EPC Solenoid


(Lower) (WA380_7-DW4QKA-400-A-Z0-A)
Action level Failure code Disconnection of Boom EPC Solenoid (Lower)
Failure
L03 DW4QKA (Work equipment controller system)
Detail of • Due to open circuit in signal output circuit to boom LOWER EPC solenoid, no current
failure flows when controller drives boom LOWER EPC solenoid.

• Lights up centralized warning lamp and sounds alarm buzzer.


Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.

Problem on
• Boom does not lower.
machine
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
Related function. (Code: 41901 Boom Lower EPC Current)
information • Method of reproducing failure code: Start engine and move boom lever to LOWER
position.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom 1. Turn starting switch to OFF position.
1 LOWER EPC solenoid 2. Disconnect connector F24 and connect T-adapter to male side.
(internal open circuit) Resistance Between F24 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector F24, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between F24 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L73, and connect T-adapter to female side.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L73 (female) (16) and (3) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F24, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (3) and F24 (female) (2) Max. 1 z
Resistance
Between L73 (female) (16) and F24 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-748 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom LOWER EPC solenoid

WA470-7 40-749
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4QKB] Ground Fault of Boom EPC Solenoid


(Lower) (WA380_7-DW4QKB-400-A-Z0-A)
Action level Failure code Ground Fault of Boom EPC Solenoid (Lower)
Failure
L03 DW4QKB (Work equipment controller system)
Detail of • Due to ground fault in signal output circuit to boom LOWER EPC solenoid, abnormal
failure current flows when controller drives boom LOWER EPC solenoid.
• Stops driving boom LOWER EPC solenoid.
• Stops driving boom FLOAT detent.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on
• Boom does not lower.
machine
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
Related function. (Code: 41901 Boom Lower EPC Current)
information • Method of reproducing failure code: Start engine and move boom lever to LOWER
position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector F24 and connect T-adapter to male side.
Defective boom LOWER EPC
1 solenoid (internal short circuit) Resis- Between F24 (male) (1) and (2) 5 to 15 z
Between ground and each of F24 (male) (1) and
tance Min. 1 Mz
(2)
1. Turn starting switch to OFF position.
Open or short circuit in wiring2. Disconnect connector L73, and connect T-adapter to female side.
2
harness Resis- Between L73 (female) (16) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L73 and F24, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L73 (female) (16) or F24
Min. 1 Mz
tance (female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors L73 and F24, and connect T-adapter to
either female side.
Resis- Between L73 (female) (16) and (3), or between
Min. 1 Mz
tance F24 (female) (1) and (2)
If no failure is found by above checks, work equipment controller may
Defective work equipment be defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-750 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom LOWER EPC solenoid

WA470-7 40-751
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4QKY] Hot Short of Boom EPC Solenoid (Lower) (WA470_7-
DW4QKY-400-A-Z0-A)

Action level Failure code Hot Short of Boom EPC Solenoid (Lower)
Failure
L03 DW4QKY (Work equipment controller system)
Detail of • Due to hot short circuit in signal output circuit to boom LOWER EPC solenoid, abnormal
failure voltage appears when controller does not drive boom LOWER EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd valve
(attachment) EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Boom LOWER EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom 1. Turn starting switch to OFF position.
1 LOWER EPC solenoid 2. Disconnect connector F24 and connect T-adapter to male side.
(internal short circuit) Resistance Between F24 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F24, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F24 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F24, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (16) and each No continuity
Continuity
pin other than pin (16) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-752 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to boom LOWER EPC solenoid

WA470-7 40-753
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4RKA] Disconnection of Bucket EPC Sol. (Tilt) (WA380_7-


DW4RKA-400-A-Z0-A)

Action level Failure code Disconnection of Bucket EPC Solenoid (Tilt)


Failure
L03 DW4RKA (Work equipment controller system)
Detail of • Due to open circuit in signal output circuit to bucket TILT EPC solenoid, no current flows
failure when controller drives bucket TILT EPC solenoid.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on
• Bucket does not tilt.
machine
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
Related function. (Code: 41902 Bucket Tilt EPC Current)
information • Method of reproducing failure code: Start engine and perform bucket TILT operation.
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket TILT 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F21 and connect T-adapter to male side.
open circuit) Resistance Between F21 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector F21 and connect T-adapters to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between F21 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L73, and connect T-adapter to female side.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L73 (female) (37) and (3) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F21, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (3) and F21 (female) (2) Max. 1 z
Resistance
Between L73 (female) (37) and F21 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-754 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket TILT EPC solenoid

WA470-7 40-755
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4RKB] Ground Fault of Bucket EPC Solenoid


(Tilt) (WA380_7-DW4RKB-400-A-Z0-A)
Action level Failure code Ground Fault of Bucket EPC Solenoid (Tilt)
Failure
L03 DW4RKB (Work equipment controller system)
Detail of • Due to ground fault in signal output circuit to bucket TILT EPC solenoid, abnormal current
failure flows when controller drives bucket TILT EPC solenoid.
• Stops driving bucket TILT EPC solenoid.
• Stops driving bucket TILT detent.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on
• Bucket does not tilt.
machine
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
Related function. (Code: 41902 Bucket Tilt EPC Current)
information • Method of reproducing failure code: Start engine and perform bucket TILT operation.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector F21 and connect T-adapter to male side.
Defective bucket TILT EPC
1 solenoid (internal short circuit) Resis- Between F21 (male) (1) and (2) 5 to 15 z
Between ground and each of F21 (male) (1) and
tance Min. 1 Mz
(2)
1. Turn starting switch to OFF position.
Open or short circuit in wiring2. Disconnect connector L73, and connect T-adapter to female side.
2
harness Resis- Between L73 (female) (37) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L73 and F21, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L73 (female) (37) or F21
Min. 1 Mz
tance (female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors L73 and F21, and connect T-adapter to
either female side.
Resis- Between L73 (female) (37) and (3), or between
Min. 1 Mz
tance F21 (female) (1) and (2)
If no failure is found by above checks, work equipment controller may
Defective work equipment be defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-756 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket TILT EPC solenoid

WA470-7 40-757
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4RKY] Hot Short of Bucket EPC Solenoid (Tilt) (WA470_7-
DW4RKY-400-A-Z0-A)

Action level Failure code Hot Short of Bucket EPC Solenoid (Tilt)
Failure
L03 DW4RKY (Work equipment controller system)
Detail of • Due to hot short circuit in signal output circuit to bucket TILT EPC solenoid, abnormal
failure voltage appears when controller does not drive bucket TILT EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd valve
(attachment) EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Bucket TILT EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket TILT 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F21 and connect T-adapter to male side.
short circuit) Resistance Between F21 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F21, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F21 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F21, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (37) and each No continuity
Continuity
pin other than pin (37) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-758 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket TILT EPC solenoid

WA470-7 40-759
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4SKA] Disconnection of Bucket EPC Sol. (Dump) (WA470_7-


DW4SKA-400-A-Z0-A)

Action level Failure code Disconnection of Bucket EPC Solenoid (Dump)


Failure
L03 DW4SKA (Work equipment controller system)
Detail of • Due to open circuit in signal output circuit to bucket DUMP EPC solenoid, no current flows
failure when controller drives bucket DUMP EPC solenoid.
• Lights up centralized warning lamp and sounds alarm buzzer.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Bucket does not move to dump position.
machine
• Output current value to bucket DUMP EPC solenoid can be checked with monitoring
Related function. (Code: 41903 Bucket Dump EPC Current)
information • Method of reproducing failure code: Start engine and perform bucket DUMP operation.
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket DUMP 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F22, and connect T-adapter to male side.
open circuit) Resistance Between F22 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connectors F22, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between F22 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L73, and connect T-adapter to female side.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L73 (female) (27) and (3) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and F22, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (3) and F22 (female) (2) Max. 1 z
Resistance
Between L73 (female) (27) and F22 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-760 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket DUMP EPC solenoid

WA470-7 40-761
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4SKB] Ground Fault of Bucket EPC Solenoid


(Dump) (WA470_7-DW4SKB-400-A-Z0-A)
Action level Failure code Ground Fault of Bucket EPC Solenoid (Dump)
Failure
L03 DW4SKB (Work equipment controller system)
Detail of • Due to ground fault in signal output circuit to bucket DUMP EPC solenoid, abnormal
failure current flows when controller drives bucket DUMP EPC solenoid.
• Stops driving bucket DUMP EPC solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Bucket does not move to dump position.
machine • Wiring harness or controller may be burnt out.
• Output current value to bucket DUMP EPC solenoid can be checked with monitoring
Related function. (Code: 41903 Bucket Dump EPC Current)
information • Method of reproducing failure code: Start engine and perform bucket DUMP operation.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective bucket DUMP 2. Disconnect connector F22, and connect T-adapter to male side.
1
EPC solenoid Between F22 (male) (1) and (2) 5 to 15 z
Resistance
Between ground and each of F22 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L73, and connect T-adapter to female side.
wiring harness
Resistance Between L73 (female) (27) and (3) 5 to 15 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L73 and F22, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L73 (female) (27) or F22
circuit) Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L73 and F22, and connect T-adapter to either
4
harness female side.
Between L73 (female) (27) and (3), or between F22
Resistance (female) (1) and (2) Min. 1 Mz
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-762 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket DUMP EPC solenoid

WA470-7 40-763
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW4SKY] Hot Short of Bucket EPC Solenoid (Dump) (WA470_7-
DW4SKY-400-A-Z0-A)

Action level Failure code Hot Short of Bucket EPC Solenoid (Dump)
Failure
L03 DW4SKY (Work equipment controller system)
Detail of • Due to hot short circuit in output signal circuit to bucket DUMP EPC solenoid, abnormal
failure voltage appears when controller does not drive bucket DUMP EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER, bucket TILT and DUMP, and 3rd valve
(attachment) EXTEND and RETRACT.
Action of • Stops driving every work equipment detent.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• All work equipment do not move because work equipment neutral lock solenoid is
Problem on energized.
machine • Bucket DUMP EPC solenoid may be burnt out.
• Output current value to boom RAISE EPC solenoid can be checked with monitoring
function. (Code: 41900 Boom Raise EPC Current)
• Output current value to boom LOWER EPC solenoid can be checked with monitoring
function. (Code: 41901 Boom Lower EPC Current)
• Output current value to bucket TILT EPC solenoid can be checked with monitoring
function. (Code: 41902 Bucket Tilt EPC Current)
Related • Output current value to bucket DUMP EPC solenoid can be checked with monitoring
information function. (Code: 41903 Bucket Dump EPC Current)
• Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Output current value to 3rd valve (attachment) RETRACT EPC solenoid can be checked
with monitoring function. (Code: 41907 3rd Retract EPC Current)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket DUMP 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector F22, and connect T-adapter to male side.
short circuit) Resistance Between F22 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connectors F22, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F22 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F22, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (27) and each No continuity
Continuity
pin other than pin (27) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-764 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket DUMP EPC solenoid

WA470-7 40-765
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7BKA] Disconnection of Fan Reverse Solenoid (WA470_7-


DW7BKA-400-A-Z0-A)

Action level Failure code Disconnection of Fan Reverse Solenoid


Failure
L01 DW7BKA (Transmission controller system)
Detail of • Due to open circuit in fan reverse solenoid system, no current flows when controller drives
failure fan reverse solenoid.
• Disables reverse rotation of fan.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Fan cannot rotate in reverse direction.
Problem on
• When this failure occurs with fan rotating in reverse direction, fan rotation direction
machine
switches to normal direction.
• Output current value to fan reverse solenoid can be checked with monitoring function.
Related (Code: 31646 Fan Reverse solenoid Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan reverse 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector R59 and connect T-adapter to male side.
(internal open circuit) Resistance Between R59 (male) (1) and (2) 5 to 10 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R59, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R59 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L63, and connect T-adapter to female side.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L63 (female) (35) and (23) 5 to 10 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and R59, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (23) and R59 (female) (2) Max. 1 z
Resistance
Between L63 (female) (35) and R59 (female) (1) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-766 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fan reverse solenoid

WA470-7 40-767
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7BKB] Ground Fault of Radiator Fan Rev. Sol. (WA470_7-
DW7BKB-400-A-Z0-A)

Action level Failure code Ground Fault of Radiator Fan Reverse Solenoid
Failure
L01 DW7BKB (Transmission controller system)
Detail of • Due to ground fault in fan reverse solenoid system, no current flows when controller
failure drives fan reverse solenoid.
• Stops driving fan reverse solenoid.
Action of • Disables reverse rotation of fan.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• Fan cannot rotate in reverse direction.
Problem on
• When this failure occurs with fan rotating in reverse direction, fan rotation direction
machine
switches to normal direction.
• Output current value to fan reverse solenoid can be checked with monitoring function.
Related (Code: 31646 Fan Reverse solenoid Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks

Defective fan reverse 1. Turn starting switch to OFF position.


solenoid 2. Disconnect connector R59 and connect T-adapter to male side.
1
Between R59 (male) (1) and (2) 5 to 15 z
(internal short circuit) Resistance
Between ground and each of R59 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (35) and (23) 5 to 15 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and R59, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L63 (female) (35) or R59
circuit) Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and R59, and connect T-adapter to either
4
harness female side.
Between L63 (female) (35) and (23), or between
Resistance R59 (female) (1) and (2) Min. 1 Mz
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-768 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fan reverse solenoid

WA470-7 40-769
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DW7BKY] Hot Short of Radiator Fan Rev. Sol. (WA470_7-DW7BKY-400-A-
Z0-A)

Action level Failure code Hot Short of Radiator Fan Reverse Solenoid
Failure
L01 DW7BKY (Transmission controller system)
Detail of • Due to hot short circuit in fan reverse solenoid system, abnormal voltage appears when
failure controller does not drive fan reverse solenoid.
• Disables reverse rotation of fan.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Fan does not rotate in normal direction.
machine • Radiator may overheat.
• Output current value to fan reverse solenoid can be checked with monitoring function.
Related (Code: 31646 Fan Reverse solenoid Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan reverse 1. Turn starting switch to OFF position.
1 solenoid 2. Disconnect connector R59 and connect T-adapter to male side.
(internal short circuit) Resistance Between R59 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector R59, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between R59 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and R59, and connect T-adapter to female
side of L63.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L63 (female) (35) and each No continuity
Continuity
pin other than pin (35) (No sound is heard)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
4
controller performed.)

Circuit diagram related to fan reverse solenoid

40-770 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWM1KA] Disconnection of Neutral Lock Solenoid (WA470_7-


DWM1KA-400-A-Z0-A)

Action level Failure code Disconnection of Neutral Lock Solenoid


Failure
L01 DWM1KA (Work equipment controller system)
Detail of • Due to open circuit in work equipment neutral lock solenoid circuit, no current flows when
failure controller drives work equipment neutral lock solenoid.
• Stops driving respective solenoids of work equipment according to input signal from work
Action of equipment lock switch.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Respective work equipment solenoids are locked normally according to signal from work
machine equipment lock switch.
• Output signal (ON/OFF) to work equipment neutral lock solenoid can be checked with
Related monitoring function. (Code: 41903 Bucket Dump EPC Current)
information • Method of reproducing failure code: Turn starting switch to ON position and set work
equipment lock switch to LOCK.
No. Cause Procedure, measuring location, criteria and remarks
Defective work 1. Turn starting switch to OFF position.
equipment neutral lock 2. Disconnect connector F31 and connect T-adapter to male side.
1 solenoid (internal open
circuit) Resistance Between F31 (male) (1) and (2) 35 to 45 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector F31 and connect T-adapters to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between F31 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors L72 and F29, and connect T-adapter to female
Open or short circuit in
3 side of L72.
wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L72 (female) (19) and ground 35 to 45 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L72 and F31, and connect T-adapters to each
defective contact of female side.
connector) Between F31 (female) (2) and ground Max. 1 z
Resistance
L72 (female) (19) and F31 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

WA470-7 40-771
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment neutral lock solenoid

40-772 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWM1KB] Ground Fault of Neutral Lock Solenoid (WA470_7-


DWM1KB-400-A-Z0-A)

Action level Failure code Ground Fault of Neutral Lock Solenoid


Failure
L01 DWM1KB (Work equipment controller system)
Detail of • Due to ground fault in work equipment neutral lock solenoid circuit, abnormal current
failure flows when controller drives work equipment neutral lock solenoid.
• Stops driving work equipment neutral lock solenoid.
• Stops driving respective solenoids of work equipment according to input signal from work
Action of equipment lock switch.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• Respective work equipment solenoids are locked normally according to signal from work
Problem on equipment lock switch.
machine • Wiring harness or controller may be burnt out.
• Output signal (ON/OFF) to work equipment neutral lock solenoid can be checked with
Related monitoring function. (Code: 41903 Bucket Dump EPC Current)
information • Method of reproducing failure code: Turn starting switch to ON position and set work
equipment lock switch to LOCK.
No. Cause Procedure, measuring location, criteria and remarks
Defective work 1. Turn starting switch to OFF position.
equipment neutral lock 2. Disconnect connector F31 and connect T-adapter to male side.
1 solenoid (internal short Between F31 (male) (1) and (2) 35 to 45 z
circuit) Resistance
Between ground and each of F31 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Defective diode F29 2. Disconnect connector F29 and connect T-adapter to the diode.
2 (internal open or short a Measure it with diode range of multimeter.
circuit) Between F29 (male) (1) (+) and (2) (-) No continuity
Continuity
Between F29 (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connectors L72 and F29, and connect T-adapter to female
3 wiring harness side of L72.
Resistance Between L72 (female) (19) and ground 35 to 45 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L72, F31, and F29, and connect T-adapter to
4 either female side.
(contact with ground
Between ground and L72 (female) (19) or F31
circuit) Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 3, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L72, F31, and F29, and connect T-adapter to
5
harness either female side.
Between ground and L72 (female) (19) or between
Resistance F31 (female) (1) and (2) Min. 1 Mz
If no failure is found by above checks, work equipment controller may be
Defective work
6 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

WA470-7 40-773
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment neutral lock solenoid

40-774 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWM1KY] Hot Short of Neutral Lock Solenoid (WA470_7-DWM1KY-400-


A-Z0-A)

Action level Failure code Hot Short of Neutral Lock Solenoid


Failure
L01 DWM1KY (Work equipment controller system)
Detail of • Due to hot short circuit in work equipment neutral lock solenoid circuit, abnormal voltage
failure appears when controller does not drive work equipment neutral lock solenoid.
• Stops driving work equipment neutral lock solenoid.
• Stops driving respective solenoids of work equipment according to input signal from work
Action of equipment lock switch.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • All work equipment do not move.
machine
• Disconnecting connector of work equipment neutral lock solenoid (open circuit state)
enables operating work equipment.
Related • Output signal (ON/OFF) to work equipment neutral lock solenoid can be checked with
information monitoring function. (Code: 41903 Bucket Dump EPC Current)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective blade 1. Turn starting switch to OFF position.
1 LOWERL EPC solenoid 2. Disconnect connector F31 and connect T-adapter to male side.
(internal open circuit) Resistance Between F31 (male) (1) and (2) 35 to 45 z
1. Turn starting switch to OFF position.
Defective diode F29 2. Disconnect connector F29 and connect T-adapter to the diode.
2 (internal open or short a Measure it with diode range of multimeter.
circuit) Between F29 (male) (1) (+) and (2) (-) No continuity
Continuity
Between F29 (male) (2) (+) and (1) (-) Continuity
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F31, and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between F31 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L72, F31, and F29 and connect T-adapter to
female side of L72.
Short circuit in wiring
4
harness a Check by using multimeter in continuity mode.
Between L72 (female) (19) and each No continuity
Continuity
pin other than pin (19) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

WA470-7 40-775
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to work equipment neutral lock solenoid

40-776 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWN6KA] Disconnection of Detent Solenoid (Boom) (WA470_7-


DWN6KA-400-A-Z0-A)

Action level Failure code Disconnection of Detent Solenoid (Boom)


Failure
L01 DWN6KA (Work equipment controller system)
Detail of • Controller determines that power supply circuit of boom magnet detent solenoid has open
failure circuit because no current flows when controller drives boom magnet detent solenoid.
• Continues to drive boom magnet detent solenoid normally.
Action of • Stops driving remote positioner stop lamp.
controller • If cause of failure disappears, machine becomes normal by itself.
• Remote positioner for boom RAISE does not work.
• Remote positioner for boom LOWER does not work.
Problem on • Boom kick-out does not work.
machine • Lever is not held in boom FLOAT detent position.
• Lever is not held in boom RAISE detent position.
• Output signal (ON/OFF) to boom magnet detent solenoid can be checked with monitoring
Related function. (Code: 03707 BBC Output 1, Boom Detent Sol.)
information • Method of reproducing failure code: Start engine and perform boom detent operation.
No. Cause Procedure, measuring location, criteria and remarks
Defective boom 1. Turn starting switch to OFF position.
magnet detent 2. Disconnect connector L28B, and connect T-adapter to male side.
1 solenoid (internal 100 to 123
open circuit) Resistance Between L28B (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connector L72, and connect T-adapter to female side.
Open or short circuit a If resistance is 1 Mz or higher, wiring harness has open circuit. If resistance
2 in wiring harness is 1 z or below, wiring harness has short circuit.
100 to 123
Resistance Between L72 (female) (18) and ground
z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L72 and L28A, and connect T-adapters to each
3
harness female side.
L72 (female) (18) and L28B (female) (1) Max. 1 z
Resistance
Between L28B (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Start engine.
Defective work 4. Set work equipment lock switch to LOCK position.
4 equipment controller 5. Operate boom lever to perform troubleshooting.
Boom lever: NEUTRAL Max. 4.5 V
Between L72 (18) and
Voltage Boom lever: Moved to
ground 20 to 30 V
RAISE detent position

WA470-7 40-777
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to magnet detent solenoid

40-778 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWN6KB] Ground Fault of Detent Solenoid (Boom) (WA470_7-


DWN6KB-400-A-Z0-A)

Action level Failure code Ground Fault of Detent Solenoid (Boom)


Failure
L01 DWN6KB (Work equipment controller system)
• Controller determines that power supply circuit of boom magnet detent solenoid has
Detail of
ground fault because abnormal current flows when controller drives boom magnet detent
failure
solenoid.
• Stops driving boom magnet detent solenoid.
Action of • Stops driving remote positioner stop lamp, and stops boom stop control.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• Remote boom positioner RAISE does not work.
• Remote positioner for boom LOWER does not work.
Problem on • Boom kick-out does not work.
machine • Lever is not held in boom FLOAT detent position.
• Lever is not held in boom RAISE detent position.
• Output signal (ON/OFF) to boom magnet detent solenoid can be checked with monitoring
Related function. (Code: 03707 BBC Output 1, Boom Detent Sol.)
information • Method of reproducing failure code: Start engine and perform boom RAISE detent
operation.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective boom
2. Disconnect connector L28B, and connect T-adapter to male side.
magnet detent
1 solenoid (internal 100 to 123
Between L28B (male) (1) and (2)
open circuit) Resistance z
Between L28B (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71 and L28B, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L72 (female) (18) or L28B
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


Short circuit in wiring 2. Disconnect connectors L72 and L28B.
3 3. Connect T-adapter to female side of L28B.
harness
Resistance Between L28B (female) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Start engine.
Defective work 4. Set work equipment lock switch to LOCK position.
4 equipment controller 5. Operate boom lever to perform troubleshooting.
Boom lever: NEUTRAL Max. 4.5 V
Between L72 (18) and
Voltage Boom lever: Moved to
ground 20 to 30 V
RAISE detent position

WA470-7 40-779
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to magnet detent solenoid

40-780 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWN6KY] Hot Short of Detent Solenoid (Boom) (WA470_7-DWN6KY-


400-A-Z0-A)

Action level Failure code Hot Short of Detent Solenoid (Boom)


Failure
L01 DWN6KY (Work equipment controller system)
• Controller determines that power supply circuit of boom magnet detent solenoid has hot
Detail of short circuit because abnormal voltage appears when controller does not drive boom
failure magnet detent solenoid.
• Stops driving boom magnet detent solenoid.
Action of • Stops driving remote positioner stop lamp, and stops boom stop control.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• When boom is put in detent condition, boom is not automatically released from detent
condition (it can be released manually).
• When boom is out of detent condition, boom lever does not return to NEUTRAL position
Problem on smoothly due to attraction of magnet (lever operability is degraded).
machine • Remote positioner for boom LOWER does not work.
• Boom kick-out does not work.
• Lever is not held in boom FLOAT detent position.
• Output signal (ON/OFF) to boom magnet detent solenoid can be checked with monitoring
Related function. (Code: 03707 BBC Output 1, Boom Detent Sol.)
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks

Defective boom magnet 1. Turn starting switch to OFF position.


1 detent solenoid (internal 2. Disconnect connector L28B, and connect T-adapter to male side.
open circuit) 100 to 123
Resistance Between L28B (male) (1) and (2)
z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L28B, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between L28B (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L72 and L28B, and connect T-adapter to female
side of L72.
a Check by using multimeter in continuity mode.
Between L72 (female) (18) and each No continuity (no sound
Continuity
pin other than (18) is heard)
Short circuit in wiring 1. Turn starting switch to OFF position.
3 2. Disconnect connectors L72, L33 and L28B.
harness
3. Connect T-adapter to either male or female side of connector L33.
a Check by using multimeter in continuity mode.
Between L33 (male) (2) and each pin No continuity (no sound
Continuity
other than pin (2) is heard)
Between L33 (female) (2) and each No continuity (no sound
Continuity is heard)
pin other than (2)

WA470-7 40-781
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Start engine.
Defective work 4. Set work equipment lock switch to LOCK position.
4 equipment controller 5. Operate boom lever to perform troubleshooting.
Boom lever: NEUTRAL Max. 4.5 V
Between L72 (female)
Voltage Boom lever: Moved to
(18) and ground 20 to 30 V
RAISE detent position

Circuit diagram related to magnet detent solenoid

40-782 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWN8KA] Disconnection of Detent Solenoid


(Bucket) (WA470_7-DWN8KA-400-A-Z0-A)
Action level Failure code Disconnection of Detent Solenoid (Bucket)
Failure
L01 DWN8KA (Work equipment controller system)
• Controller determines that power supply system of bucket TILT magnet detent solenoid
Detail of
has open circuit because no current flows when controller drives bucket TILT magnet
failure
detent solenoid.
Action of • Continues to drive bucket TILT magnet detent solenoid normally.
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Bucket leveler does not work.
machine • Lever is not held in bucket TILT detent position.
• Output signal (ON/OFF) to bucket TILT magnet detent solenoid can be checked with
Related monitoring function. (Code: 03707 BBC Output 1, Bucket Tilt Detent Sol.)
information • Method of reproducing failure code: Start engine and perform bucket TILT detent
operation.
No. Cause Procedure, measuring location, criteria and remarks

Defective bucket 1. Turn starting switch to OFF position.


1 magnet detent solenoid 2. Disconnect connector L29B, and connect T-adapter to male side.
(internal open circuit) 100 to 123
Resistance Between L29B (male) (1) and (2)
z
1. Turn starting switch to OFF position.
2. Disconnect connector L72, and connect T-adapter to female side.
Open or short circuit in a If resistance is 1 Mz or higher, wiring harness has open circuit. If
2 wiring harness resistance is 1 z or below, wiring harness has short circuit.
100 to 123
Resistance Between L72 (female) (9) and ground
z
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L72 and L29B, and connect T-adapters to each
3
harness female side.
L72 (female) (9) and L29B (female) (1) Max. 1 z
Resistance
Between L29B (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Start engine.
Defective work 4. Set work equipment lock switch to LOCK position.
4 equipment controller 5. Operate bucket lever to perform troubleshooting.
Bucket lever: NEUTRAL Max 4.5 V
Between L72 (9) and
Voltage Bucket lever: Bucket
ground 20 to 30 V
TILT detent position

WA470-7 40-783
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket magnet detent solenoid

40-784 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWN8KB] Ground Fault of Detent Solenoid (Bucket) (WA470_7-


DWN8KB-400-A-Z0-A)

Action level Failure code Ground Fault of Detent Solenoid (Bucket)


Failure
L01 DWN8KB (Work equipment controller system)
Detail of • Controller determines that power supply circuit of bucket TILT magnet detent solenoid has
failure ground fault because abnormal current flows to bucket TILT magnet detent solenoid.
• Stops driving bucket TILT magnet detent solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Bucket leveler does not work.
machine • Lever is not held in bucket TILT detent position.
• Output signal (ON/OFF) to bucket TILT magnet detent solenoid can be checked with
Related monitoring function. (Code: 03707 BBC Output 1, Bucket Tilt Detent Sol.)
information • Method of reproducing failure code: Start engine and perform bucket TILT detent
operation.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective bucket 2. Disconnect connector L29B, and connect T-adapter to male side.
1 magnet detent solenoid 100 to 123
(internal open circuit) Between L29B (male) (1) and (2)
Resistance z
Between L29B (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L71 and L29B, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and L72 (female) (9) or L29B
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


Short circuit in wiring 2. Disconnect connectors L72 and L29B.
3 3. Connect T-adapter to female side of L29B.
harness
Resistance Between L29B (female) (1) and (2) Min. 1 Mz
1.Turn starting switch to OFF position.
2.Insert T-adapter into connector L72.
3.Start engine.
Defective work 4.Set work equipment lock switch to LOCK position.
4 equipment controller 5.Operate bucket lever to perform troubleshooting.
Bucket lever: NEUTRAL Max 4.5 V
Between L72 (9) and
Voltage Bucket lever: TILT detent
ground 20 to 30 V
operation

WA470-7 40-785
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket magnet detent solenoid

40-786 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DWN8KY] Hot Short of Detent Solenoid (Bucket) (WA470_7-DWN8KY-


400-A-Z0-A)

Action level Failure code Hot Short of Detent Solenoid (Bucket)


Failure
L01 DWN8KY (Work equipment controller system)
• Controller determines that power supply circuit of bucket TILT magnet detent solenoid has
Detail of hot short circuit because abnormal voltage appears when controller does not drive bucket
failure TILT magnet detent solenoid.
• Stops driving bucket TILT magnet detent solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• When bucket is put in TILT detent condition, bucket is not automatically released from
Problem on detent condition (it can be released manually).
machine • When bucket is out of detent condition, bucket lever does not return to NEUTRAL position
smoothly due to attraction of magnet (lever operability is degraded).
• Output signal (ON/OFF) to bucket TILT magnet detent solenoid can be checked with
Related monitoring function. (Code: 03707 BBC Output 1, Bucket Tilt Detent Sol.)
information • Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks

Defective bucket 1. Turn starting switch to OFF position.


1 magnet detent solenoid 2. Disconnect connector L29B, and connect T-adapter to male side.
(internal open circuit) 100 to 123
Resistance Between L29B (male) (1) and (2)
z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector L29B, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between L29B (female) (1) and (2) Max 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L72 and L29B, and connect T-adapter to female
side of L72.
a Check by using multimeter in continuity mode.
Between L72 (female) (9) and each No continuity (no sound
Continuity
pin other than (9) is heard)
Short circuit in wiring 1. Turn starting switch to OFF position.
3
harness 2. Disconnect connectors L72, L33 and L29B.
3. Connect T-adapter to either male or female side of connector L33.
a Check by using multimeter in continuity mode.
Between L33 (male) (4) and each pin No continuity (no sound
Continuity
other than pin (4) is heard)
Between L33 (female) (4) and each No continuity (no sound
Continuity
pin other than (4) is heard)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L72.
3. Start engine.
Defective work 4. Set work equipment lock switch to LOCK position.
4 equipment controller 5. Operate bucket lever to perform troubleshooting.
Bucket lever: NEUTRAL Max 4.5 V
Between L72 (9) and
Voltage Bucket lever: Bucket
ground 20 to 30 V
TILT detent position

WA470-7 40-787
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to bucket magnet detent solenoid

40-788 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX16KA] Disconnection of Rad. Fan Pump EPC Sol. (WA470_7-
DX16KA-400-A-Z0-A)

Action level Failure code Disconnection of Radiator Fan Pump EPC Solenoid
Failure
L03 DX16KA (Transmission controller system)
Detail of • Due to open circuit in fan pump EPC solenoid circuit, no current flows when controller
failure drives fan pump EPC solenoid.
• Disables fan to rotate in reverse direction.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Fan rotates at its maximum speed.
Problem on • Fan cannot rotate in reverse direction.
machine • When this failure occurs with fan rotating in reverse direction, fan rotation direction
switches to normal direction.
• Output current value to fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 41400 Rad. Fan Pump EPC Sol. Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan pump 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector R29, and connect T-adapter to male side.
open circuit) Resistance Between R29 (male) (1) and (2) 5 to 10 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R29, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R29 (female) (1) and (2) Min. 20 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L63, and connect T-adapter to female side.
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L63 (female) (25) and (23) 5 to 10 z
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connectors L61, L62, L63, and R29, and connect T-adapters
to each female side of L61, L62, and L63.
a Check by using multimeter in continuity mode.
Between L63 (female) (25) and each No continuity
pin of L61 (female) (No sound is heard)
Continuity
Between L63 (female) (25) and each No continuity
pin of L62 (female) (No sound is heard)

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and R29, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (23) and R29 (female) (2) Max. 1 z
Resistance
Between L63 (female) (25) and R29 (female) (1) Max. 1 z
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

WA470-7 40-789
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fan pump EPC solenoid

40-790 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX16KB] Ground Fault of Rad. Fan Pump EPC Sol. (WA470_7-
DX16KB-400-A-Z0-A)

Action level Failure code Ground Fault of Radiator Fan Pump EPC Solenoid
Failure
L03 DX16KB (Transmission controller system)
Detail of • Due to ground fault in fan pump EPC solenoid circuit, abnormal current flows when
failure controller drives fan pump EPC solenoid.
• Disables fan to rotate in reverse direction.
Action of • Stops driving fan pump EPC solenoid.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
• Fan rotates at its maximum speed.
Problem on • Fan cannot rotate in reverse direction.
machine • When this failure occurs with fan rotating in reverse direction, fan rotation direction
switches to normal direction.
• Output current value to fan pump EPC solenoid can be checked with monitoring function.
Related (Code: 41400 Rad. Fan Pump EPC Sol. Current)
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective fan pump 2. Disconnect connector R29, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Between R29 (male) (1) and (2) 5 to 10 z
Resistance
Between ground and each of R29 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (25) and (23) 5 to 10 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and R29, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L63 (female) (25) or R29
circuit) Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and R29, and connect T-adapter to either
4
harness female side.
Between L63 (female) (25) and (23), or between
Resistance R29 (female) (1) and (2) Min. 1 Mz
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

WA470-7 40-791
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fan pump EPC solenoid

40-792 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DX16KY] Hot Short of Radiator Fan Pump EPC Sol. (WA470_7-
DX16KY-400-A-Z0-A)

Action level Failure code Hot Short of Radiator Fan Pump EPC Solenoid
Failure
L01 DX16KY (Transmission controller system)
Detail of • Due to hot short circuit in fan pump EPC solenoid circuit, abnormal voltage appears when
failure controller does not drive fan pump EPC solenoid.
• Disables fan to rotate in reverse direction.
Action of • Stops driving fan pump EPC solenoid.
controller • If cause of failure disappears, machine becomes normal by itself.
• Fan rotates at its minimum speed.
Problem on • Fan cannot rotate in reverse direction.
machine • When this failure occurs with fan rotating in reverse direction, fan rotation direction
switches to normal direction.
• Output current value to fan pump EPC solenoid can be checked with monitoring function.
(Code: 41400 Rad. Fan Pump EPC Sol. Current)
Related • Since female side voltage is 20 V or above when pump EPC solenoid connector is
information disconnected and starting switch is turned to ON position, check of hot short circuit in
wiring harness is not available.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective fan pump 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector R29, and connect T-adapter to male side.
short circuit) Resistance Between R29 (male) (1) and (2) 5 to 10 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and R29, and connect T-adapter to female
side of L63.
a Check by using multimeter in continuity mode.
Between L63 (female) (25) and each No continuity
Continuity
pin other than pin (25) (No sound is heard)
Short circuit in wiring 1. Turn starting switch to OFF position.
2
harness 2. Disconnect connectors L61, L62, L63, and R29, and connect T-adapters
to each female side of L61, L62, and L63.
a Check by using multimeter in continuity mode.
Between L63 (female) (25) and each No continuity
pin of L61 (female) (No sound is heard)
Continuity
Between L63 (female) (25) and each No continuity
pin of L62 (female) (No sound is heard)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

WA470-7 40-793
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to fan pump EPC solenoid

40-794 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXA1KA] Disconnection of Loader Pump EPC


Solenoid (WA380_7-DXA1KA-400-A-Z0-A)
Action level Failure code Disconnection of Loader Pump EPC Solenoid
Failure
L01 DXA1KA (Work equipment controller system)
Detail of • Due to open circuit in loader pump EPC solenoid system, current does not flow when
failure controller drives loader pump EPC solenoid.
• Continues to drive loader pump EPC solenoid normally.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Fuel consumption may degrade at low engine speed.
• Engine may stall.
Problem on • Cut-off of pump becomes unavailable during hydraulic relief.
machine • Engine acceleration may degrade.
• Boom may accelerate suddenly.
• Output current value to loader pump EPC solenoid can be checked with monitoring
function. (Code: 94500 Loader Pump EPC Current)
Related • Using "2-stage low idle" function allows increasing engine speed at low idle, thereby
information avoiding decrease in machine performance.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective loader pump 1. Turn starting switch to OFF position.
1 EPC solenoid (internal 2. Disconnect connector R71, and connect T-adapter to male side.
open circuit) Resistance Between R71 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R71, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R71 (female) (1) and (2) Min. 20 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L73, and connect T-adapter to female side.
3 wiring harness
a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resistance Between L73 (female) (35) and (23) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L73 and R71, and connect T-adapters to each
defective contact of female side.
connector) Between L73 (female) (23) and R71 (female) (1) Max. 1 z
Resistance
Between L73 (female) (35) and R71 (female) (2) Max. 1 z
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

WA470-7 40-795
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to loader pump EPC solenoid

40-796 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXA1KB] Ground Fault of Loader Pump EPC


Solenoid (WA380_7-DXA1KB-400-A-Z0-A)
Action level Failure code Ground Fault of Loader Pump EPC Solenoid
Failure
L01 DXA1KB (Work equipment controller system)
Detail of • Due to ground fault in loader pump EPC solenoid system, abnormal current flows when
failure controller drives loader pump EPC solenoid.
• Stops driving loader pump EPC solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Fuel consumption may degrade at low engine speed.
• Engine acceleration may degrade.
Problem on • Cut-off of pump becomes unavailable during hydraulic relief.
machine • Boom may accelerate suddenly.
• Wiring harness or controller may be burnt out.
• Output current value to loader pump EPC solenoid can be checked with monitoring
function. (Code: 94500 Loader Pump EPC Current)
Related • Using "2-stage low idle" function allows increasing engine speed at low idle, thereby
information avoiding decrease in machine performance.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective loader pump 2. Disconnect connector R71, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Between R71 (male) (1) and (2) 5 to 15 z
Resistance
Between ground and each of R71 (male) (1) and (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L73, and connect T-adapter to female side.
wiring harness
Resistance Between L73 (female) (35) and (23) 5 to 15 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L73 and R71, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L73 (female) (35) or R71
circuit) Resistance (female) (2) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L73 and R71, and connect T-adapter to either
4
harness female side.
Between L73 (female) (35) and (23), or between
Resistance R71 (female) (1) and (2) Min. 1 Mz
If no failure is found by above checks, work equipment controller may be
Defective work
5 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

WA470-7 40-797
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to loader pump EPC solenoid

40-798 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXA1KY] Hot Short of Loader Pump EPC Solenoid (WA380_7-
DXA1KY-400-A-Z0-A)

Action level Failure code Hot Short of Loader Pump EPC Solenoid
Failure
L01 DXA1KY (Work equipment controller system)
Detail of • Due to hot short circuit in loader pump EPC solenoid power supply system, abnormal
failure voltage appears when controller does not drive loader pump EPC solenoid.
• Stops driving loader pump EPC solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Flow rate of loader pump reaches minimum level, decreasing work equipment speed.
machine
• Output current value to loader pump EPC solenoid can be checked with monitoring
function. (Code: 94500 Loader Pump EPC Current)
Related • Since female side voltage is 20 V or above when pump EPC solenoid connector is
information disconnected and starting switch is turned to ON position, check of hot short circuit in
wiring harness is not available.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective loader pump EPC 2. Disconnect connector R71, and connect T-adapter to male side.
1 solenoid (internal short circuit) Resis-
Between R71 (male) (1) and (2) 5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and R71, and connect T-adapter to
female side of L73.
a Check by using multimeter in continuity mode.
Between L73 (female) (35) and No continuity
Continuity
each pin other than pin (35) (No sound is heard)

Short circuit in wiring harness 1. Turn starting switch to OFF position.


2
2. Disconnect connectors L71, L72, L73, and R71, and connect T-
adapters to each female side of L71, L72, and L73.
a Check by using multimeter in continuity mode.
Between L73 (female) (35) and No continuity
each pin of L71 (female) (No sound is heard)
Continuity
Between L73 (female) (35) and No continuity
each pin of L72 (female) (No sound is heard)
If no failure is found by above checks, work equipment controller may
Defective work equipment be defective. (Since this is an internal defect, troubleshooting cannot be
3
controller performed.)

WA470-7 40-799
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to loader pump EPC solenoid

40-800 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXANKA] Disconnection of Steering Pump EPC Sol. (WA470_7-


DXANKA-400-A-Z0-A)

Action level Failure code Disconnection of Steering Pump EPC Solenoid


Failure
L01 DXANKA (Work equipment controller system)
Detail of • Due to open circuit in steering pump EPC solenoid system, no current flows when
failure controller drives steering pump EPC solenoid.
• Continues to drive steering pump EPC solenoid normally.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Fuel consumption may degrade at low engine speed.
Problem on • Engine may stall.
machine • Engine acceleration may degrade.
• Turning speed may accelerate suddenly.
• Output current value to steering pump EPC solenoid can be checked with monitoring
function. (Code: 94600 Steering Pump EPC Current)
Related • Using "2-stage low idle" function allows increasing engine speed at low idle, thereby
information avoiding decrease in machine performance.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective steering 1. Turn starting switch to OFF position.
1 pump EPC solenoid 2. Disconnect connector R90 and connect T-adapter to male side.
(internal short circuit) Resistance Between R90 (male) (2) and (1) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R90 and connect T-adapters to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R90 (female) (2) and (1) Min. 20 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L73, and connect T-adapter to female side.
Between L73 (female) (25) and each of (21), (31),
Resistance (32), and (33) 5 to 15 z

a If no failure is found by check on cause 3, this check is not required.


Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L73 and R90, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of Between R90 (female) (1) and each of L73 (female)
connector) Max. 1 z
Resistance (21), (31), (32), and (33)
Between L73 (female) (25) and R90 (female) (2) Max. 1 z
Defective work If no failure is found by above checks, work equipment controller is defective.
5 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-801
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to steering pump EPC solenoid

40-802 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXANKB] Ground Fault of Steering Pump EPC


Solenoid (WA470_7-DXANKB-400-A-Z0-A)
Action level Failure code Ground Fault of Steering Pump EPC Solenoid
Failure
L01 DXANKB (Work equipment controller system)
Detail of • Due to ground fault in steering pump EPC solenoid system, abnormal current flows when
failure controller drives steering pump EPC solenoid.
• Stops driving steering pump EPC solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Fuel consumption may degrade at low engine speed.
Problem on • Engine acceleration may degrade.
machine • Turning speed may accelerate suddenly.
• Wiring harness or controller may be burnt out.
• Output current value to steering pump EPC solenoid can be checked with monitoring
function. (Code: 94600 Steering Pump EPC Current)
Related • Using "2-stage low idle" function allows increasing engine speed at low idle, thereby
information avoiding decrease in machine performance.
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective steering 2. Disconnect connector R90 and connect T-adapter to male side.
1 pump EPC solenoid
(internal short circuit) Between R90 (male) (1) and (2) 5 to 15 z
Resistance
Between ground and R90 (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector L73, and connect T-adapter to female side.
2 wiring harness Between L73 (female) (25) and each of (21), (31),
Resistance (32), and (33) 5 to 15 z

Ground fault in wiring 1. Turn starting switch to OFF position.


harness 2. Disconnect connectors L73 and R90, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L73 (female) (25) or R90
circuit) Resistance (female) (2) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L73 and R90, and connect T-adapter to either
4
harness female side.
Between L73 (female) (25) and each of (21), (31),
Resistance (32), and (33), or between R90 (female) (1) and (2) Min. 1 Mz
Defective work If no failure is found by above checks, work equipment controller is defective.
5 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

WA470-7 40-803
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to steering pump EPC solenoid

40-804 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXANKY] Hot Short of Steering Pump EPC Solenoid (WA470_7-
DXANKY-400-A-Z0-A)

Action level Failure code Hot Short of Steering Pump EPC Solenoid
Failure
L01 DXANKY (Work equipment controller system)
Detail of • Due to hot short circuit in steering pump EPC solenoid power supply system, abnormal
failure voltage appears when controller does not drive steering pump EPC solenoid.
• Stops driving steering pump EPC solenoid.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Flow rate of steering pump reaches minimum level, decreasing turning speed.
machine
• Output current value to steering pump EPC solenoid can be checked with monitoring
function. (Code: 94600 Steering Pump EPC Current)
Related • Since female side voltage is 20 V or above when pump EPC solenoid connector is
information disconnected and starting switch is turned to ON position, check of hot short circuit in
wiring harness is not available.
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective steering 1. Turn starting switch to OFF position.
1 pump EPC solenoid 2. Disconnect connector R90 and connect T-adapter to male side.
(internal short circuit) Resistance Between R90 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L71, L72, L73, and R90, and connect T-adapters
to each female side of L71, L72, and L73.
Short circuit in wiring a Check by using multimeter in continuity mode.
2
harness Between L73 (female) (25) and each No continuity
pin of L71 (female) (No sound is heard)
Resistance
Between L73 (female) (25) and each No continuity
pin of L72 (female) (No sound is heard)
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to steering pump EPC solenoid

WA470-7 40-805
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH1KA] Disconnection of ECMV Solenoid (Lockup) (WA380_7-


DXH1KA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (Lockup)


Failure
L03 DXH1KA (Transmission controller system)
Detail of • Due to open circuit in lockup clutch ECMV solenoid circuit, no current flows when
failure controller drives lockup clutch ECMV solenoid.
• Stops driving lockup clutch ECMV solenoid.
Action of • Judges that lockup switch is at OFF and controls machine.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.

Problem on • Torque converter lockup clutch does not engage.


machine

• Output current value to lockup clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31609 ECMV Current (Lockup))
information • Method of reproducing failure code: Start engine, turn on lockup switch, and drive
machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective lockup clutch 2. Disconnect connector LC.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between LC.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector LC.PS, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between LC.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L63, and connect T-adapter to female side.
Resistance Between L63 (female) (36) and (23) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and LC.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (36) and LC.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (23) and LC.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-806 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch ECMV solenoid

WA470-7 40-807
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH1KB] Ground Fault of ECMV Solenoid (Lockup) (WA380_7-


DXH1KB-400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (Lockup)


Failure
L03 DXH1KB (Transmission controller system)
Detail of • Due to ground fault in lockup clutch ECMV solenoid circuit, abnormally large current flows
failure when controller drives lockup clutch ECMV solenoid.
• Stops driving lockup clutch ECMV solenoid.
Action of • Judges that lockup switch is at OFF and controls machine.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Torque converter lockup clutch does not engage.
machine
• Output current value to lockup clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31609 ECMV Current (Lockup))
information • Method of reproducing failure code: Start engine, turn on lockup switch, and drive
machine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective lockup clutch 2. Disconnect connector LC.PS, and connect T-adapter to male side.
1
ECMV solenoid Between LC.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and LC.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (36) and (23) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and LC.PS, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and L63 (female) (36) or LC.PS
Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and LC.PS, and connect T-adapter to either
4
harness female side.
Between L63 (female) (36) and (23), or between
Resistance LC.PS (female) (1) and (2) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-808 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch ECMV solenoid

WA470-7 40-809
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH1KY] Hot Short of ECMV Solenoid (Lockup) (WA380_7-DXH1KY-


400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (Lockup)


Failure
L03 DXH1KY (Transmission controller system)
Detail of • Due to hot short circuit in lockup clutch ECMV solenoid circuit, abnormal voltage appears
failure when controller does not drive lockup clutch ECMV solenoid.
• Maintains transmission in neutral position.
• If directional (FNR) lever or R.H. directional (FNR) switch is set to N (neutral) position,
Action of controller stops maintaining transmission in NEUTRAL position.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
• Transmission is maintained in NEUTRAL position until directional (FNR) lever or R.H.
Problem on directional (FNR) switch is set to N (meutral) position.
machine • Lockup clutch remains engaged.
• Output current value to lockup clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31609 ECMV Current (Lockup))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective lockup clutch 2. Disconnect connector LC.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between LC.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector LC.PS, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness a If failure code [DXH1KA] for open circuit appears, wiring harness does not
have hot short circuit. (Lockup clutch ECMV solenoid is defective.)
Voltage Between LC.PS (female) (1) and (2) Max 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connector LC.PS.
3. Disconnect connector L63, and connect T-adapter to female side.
Between L63 (female) (36) and each No continuity
Continuity
pin other than (36) (No sound is heard)

Short circuit in wiring 1. Turn starting switch to OFF position.


3 2. Disconnect connector L63.
harness
3. Disconnect connectors LT1 and LC.PS.
4. Connect T-adapter to either male or female side of connector LT1.
Between LT1 (female) (13) and each No continuity
pin other than (13) (No sound is heard)
Continuity
Between LT1 (male) (13) and each pin No continuity
other than (13) (No sound is heard)
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-810 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to lockup clutch ECMV solenoid

WA470-7 40-811
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH4KA] Disconnection of ECMV Solenoid (1st) (WA380_7-DXH4KA-


400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (1st)


Failure
L03 DXH4KA (Transmission controller system)
Detail of • Due to open circuit in 1st clutch ECMV solenoid circuit, no current flows when controller
failure drives 1st clutch ECMV solenoid.
• Stops driving 1st clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 1st clutch is not engaged (machine can travel with any gear speed other than 1st).
machine
• Output current value to 1st clutch ECMV solenoid can be checked with monitoring
function. (Code: 31602 ECMV Current (1st))
Related • Method of reproducing failure code: Turn starting switch to ON position and set
information transmission shift mode selector switch to AUTO shift mode, or set transmission shift
mode selector switch to MANUAL shift mode and select 1st gear speed by using shift
down switch or gear shift lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 1st clutch 2. Disconnect connector 1.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between 1.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector 1.PS, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, wiring harness is open
transmission controller at this point.
Voltage Between 1.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L63, and connect T-adapter to female side.
Resistance Between L63 (female) (27) and (13) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and 1.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (27) and 1.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (13) and 1.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-812 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 1st clutch ECMV solenoid

WA470-7 40-813
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH4KB] Ground Fault of ECMV Solenoid (1st) (WA380_7-DXH4KB-


400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (1st)


Failure
L03 DXH4KB (Transmission controller system)
Detail of • Due to ground fault in 1st clutch ECMV solenoid circuit, abnormally large current flows
failure when controller drives 1st clutch ECMV solenoid.
• Stops driving 1st clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 1st clutch is not engaged (machine can travel with any gear speed other than 1st).
machine
• Output current value to 1st clutch ECMV solenoid can be checked with monitoring
function. (Code: 31602 ECMV Current (1st))
Related • Method of reproducing failure code: Turn starting switch to ON position and set
information transmission shift mode selector switch to AUTO shift mode, or set transmission shift
mode selector switch to MANUAL shift mode and select 1st gear speed by using shift
down switch or gear shift lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 1st clutch 2. Disconnect connector 1.PS, and connect T-adapter to male side.
1
ECMV solenoid Between 1.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 1.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (27) and (13) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector L63, and connect T-adapter to female side.
Ground fault in wiring 3. Disconnect connector 1.PS, and connect T-adapter to female side.
3
harness
Between ground and L63 (female) (27) or 1.PS
Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and 1.PS, and connect T-adapter to either
4
harness female side.
Between L63 (female) (27) and (13), or between 1.
Resistance PS (female) (1) and (2) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-814 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 1st clutch ECMV solenoid

WA470-7 40-815
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH4KY] Hot Short of ECMV Solenoid (1st) (WA380_7-DXH4KY-400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (1st)


Failure
L03 DXH4KY (Transmission controller system)
Detail of • Due to hot short circuit in 1st clutch ECMV solenoid circuit, abnormal voltage appears
failure when controller does not drive 1st clutch ECMV solenoid.
• Stops driving 2nd, 3rd and 4th clutch ECMV solenoids.
• When not driving ECMV solenoids of speed clutches (other than 1st clutch), controller
Action of also stops driving F (forward) and R (reverse) clutch ECMV solenoids.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
Problem on • 2nd, 3rd, and 4th clutches are not engaged (machine can travel with 1st gear speed).
machine
• Output current value to 1st clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31602 ECMV Current (1st))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 1st clutch 2. Disconnect connector 1.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between 1.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector 1.PS, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness a If failure code [DXH4KA] for open circuit appears, wiring harness does not
have hot short circuit. (1st clutch ECMV solenoid is defective.)
Voltage Between 1.PS (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connector 1.PS.
3. Disconnect connector L63, and connect T-adapter to female side.
Between L63 (female) (27) and each No continuity
Continuity
pin other than (27) (No sound is heard)

Short circuit in wiring 1. Turn starting switch to OFF position.


3 2. Disconnect connector L63.
harness
3. Disconnect connectors LT1 and 1.PS.
4. Connect T-adapter to either male or female side of connector LT1.
Between LT1 (female) (1) and each No continuity
pin other than (1) (No sound is heard)
Continuity
Between LT1 (male) (1) and each pin No continuity
other than (1) (No sound is heard)
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-816 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 1st clutch ECMV solenoid

WA470-7 40-817
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH5KA] Disconnection of ECMV Solenoid (2nd) (WA380_7-


DXH5KA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (2nd)


Failure
L03 DXH5KA (Transmission controller system)
Detail of • Due to open circuit in 2nd clutch ECMV solenoid circuit, no current flows when controller
failure drives 2nd clutch ECMV solenoid.
• Stops driving 2nd clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 2nd clutch is not engaged (machine can travel with any gear speed other than 2nd).
machine
• Output current value to 2nd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31603 ECMV Current (2nd))
Related • Method of reproducing failure code: Turn starting switch to ON position and set
information transmission shift mode selector switch to AUTO shift mode, or set transmission shift
mode selector switch to MANUAL shift mode and select 2nd gear speed by using shift
down switch or gear shift lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 2nd clutch 2. Disconnect connector 2.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between 2.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector 2.PS, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between 2.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L63, and connect T-adapter to female side.
Resistance Between L63 (female) (37) and (3) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and 2.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (37) and 2.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (3) and 2.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-818 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 2nd clutch ECMV solenoid

WA470-7 40-819
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH5KB] Ground Fault of ECMV Solenoid (2nd) (WA380_7-DXH5KB-


400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (2nd)


Failure
L03 DXH5KB (Transmission controller system)
Detail of • Due to ground fault in 2nd clutch ECMV solenoid circuit, abnormally large current flows
failure when controller drives 2nd clutch ECMV solenoid.
• Stops driving 2nd clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 2nd clutch is not engaged (machine can travel with any gear speed other than 2nd).
machine
• Output current value to 2nd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31603 ECMV Current (2nd))
Related • Method of reproducing failure code: Turn starting switch to ON position and set
information transmission shift mode selector switch to AUTO shift mode, or set transmission shift
mode selector switch to MANUAL shift mode and select 2nd gear speed by using shift
down switch or gear shift lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 2nd clutch 2. Disconnect connector 2.PS, and connect T-adapter to male side.
1
ECMV solenoid Between 2.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 2.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (37) and (3) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and 2.PS, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and L63 (female) (37) or 2.PS
Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and 2.PS, and connect T-adapter to either
4
harness female side.
Between L63 (female) (37) and (3), or between 2.
Resistance PS (female) (1) and (2) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-820 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 2nd clutch ECMV solenoid

WA470-7 40-821
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH5KY] Hot Short of ECMV Solenoid (2nd) (WA380_7-DXH5KY-400-A-Z0-


A)

Action level Failure code Hot Short of ECMV Solenoid (2nd)


Failure
L03 DXH5KY (Transmission controller system)
Detail of • Due to hot short circuit in 2nd clutch ECMV solenoid circuit, abnormal voltage appears
failure when controller does not drive 2nd clutch ECMV solenoid.
• Stops driving 1st, 3rd, and 4th clutch ECMV solenoids.
• When not driving ECMV solenoids of speed clutches (other than 2nd clutch), controller
Action of also stops driving F (forward) and R (reverse) clutch ECMV solenoids.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
Problem on • 1st, 3rd, and 4th clutches are not engaged (machine can travel with 2nd gear speed).
machine
• Output current value to 2nd clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31603 ECMV Current (2nd))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 2nd clutch 2. Disconnect connector 2.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between 2.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector 2.PS, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness a If failure code [DXH5KA] for open circuit appears,wiring harness does not
have hot short circuit. (2nd clutch ECMV solenoid is defective.)
Voltage Between 2.PS (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connector 2.PS.
3. Disconnect connector L63, and connect T-adapter to female side.
Between L63 (female) (37) and each No continuity
Continuity
pin other than (37) (No sound is heard)

Short circuit in wiring 1. Turn starting switch to OFF position.


3 2. Disconnect connector L63.
harness
3. Disconnect connectors LT1 and 2.PS.
4. Connect T-adapter to either male or female side of connector LT1.
Between LT1 (female) (3) and each No continuity
pin other than (3) (No sound is heard)
Continuity
Between LT1 (male) (3) and each pin No continuity
other than (3) (No sound is heard)
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-822 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 2nd clutch ECMV solenoid

WA470-7 40-823
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH6KA] Disconnection of ECMV Solenoid (3rd) (WA380_7-DXH6KA-


400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (3rd)


Failure
L03 DXH6KA (Transmission controller system)
Detail of • Due to open circuit in 3rd clutch ECMV solenoid circuit, no current flows when controller
failure drives 3rd clutch ECMV solenoid.
• Stops driving 3rd clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 3rd clutch is not engaged (machine can travel with any gear speed other than 3rd).
machine
• Output current value to 3rd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31604 ECMV Current (3rd))
Related • Method of reproducing failure code: Turn starting switch to ON position and set
information transmission shift mode selector switch to AUTO shift mode, or set transmission shift
mode selector switch to MANUAL shift mode and select 3rd gear speed by using shift
down switch or gear shift lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd clutch 2. Disconnect connector 3.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between 3.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector 3.PS, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between 3.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L63, and connect T-adapter to female side.
Resistance Between L63 (female) (6) and (3) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and 3.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (6) and 3.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (3) and 3.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-824 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd clutch ECMV solenoid

WA470-7 40-825
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH6KB] Ground Fault of ECMV Solenoid (3rd) (WA380_7-DXH6KB-


400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (3rd)


Failure
L03 DXH6KB (Transmission controller system)
Detail of • Due to ground fault in 3rd clutch ECMV solenoid circuit, abnormally large current flows
failure when controller drives 3rd clutch ECMV solenoid.
• Stops driving 3rd clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 3rd clutch is not engaged (machine can travel with any gear speed other than 3rd).
machine
• Output current value to 3rd clutch ECMV solenoid can be checked with monitoring
function. (Code: 31604 ECMV Current (3rd))
Related • Method of reproducing failure code:Turn starting switch to ON position, set transmission
information shift mode selector switch to AUTO and MANUAL repeatedly, and select 3rd gear speed
by using shift down switch or gear shift lever.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd clutch 2. Disconnect connector 3.PS, and connect T-adapter to male side.
1
ECMV solenoid Between 3.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and 3.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (6) and (3) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and 3.PS, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and L63 (female) (6) or 3.PS
Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and 3.PS, and connect T-adapter to either
4
harness female side.
Between L63 (female) (6) and (3), or between 3.PS
Resistance (female) (1) and (2) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-826 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd clutch ECMV solenoid

WA470-7 40-827
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH6KY] Hot Short of ECMV Solenoid (3rd) (WA380_7-DXH6KY-400-A-Z0-


A)

Action level Failure code Hot Short of ECMV Solenoid (3rd)


Failure
L03 DXH6KY (Transmission controller system)
Detail of • Due to hot short circuit in 3rd clutch ECMV solenoid circuit, abnormal voltage appears
failure when controller does not drive 3rd clutch ECMV solenoid.
• Stops driving 1st, 2nd, and 4th clutch ECMV solenoids.
• When not driving ECMV solenoids of speed clutches (other than 3rd clutch), controller
Action of also stops driving F (forward) and R (reverse) clutch ECMV solenoids.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
Problem on • 1st, 2nd and 4th clutches are not engaged (machine can travel with 3rd gear speed).
machine
• Output current value to 3rd clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31604 ECMV Current (3rd))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd clutch 2. Disconnect connector 3.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between 3.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector 3.PS, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness a If failure code [DXH6KA] for open circuit appears, wiring harness does not
have hot short circuit. (3rd clutch ECMV solenoid is defective.)
Voltage Between 3.PS (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connector 3.PS.
3. Disconnect connector L63, and connect T-adapter to female side.
Between L63 (female) (6) and each No continuity
Continuity
pin other than (6) (No sound is heard)

Short circuit in wiring 1. Turn starting switch to OFF position.


3 2. Disconnect connector L63.
harness
3. Disconnect connectors LT1 and 3.PS.
4. Connect T-adapter to either male or female side of connector LT1.
Between LT1 (female) (5) and each No continuity
pin other than (5) (No sound is heard)
Continuity
Between LT1 (male) (5) and each pin No continuity
other than (5) (No sound is heard)
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-828 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd clutch ECMV solenoid

WA470-7 40-829
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH7KA] Disconnection of ECMV Solenoid


(Reverse) (WA380_7-DXH7KA-400-A-Z0-A)
Action level Failure code Disconnection of ECMV Solenoid (Reverse)
Failure
L03 DXH7KA (Transmission controller system)
Detail of • Due to open circuit in R (reverse) clutch ECMV solenoid circuit, no current flows when
failure controller drives R (reverse) clutch ECMV solenoid.
• Stops driving R (reverse) clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • R (reverse) clutch is not engaged (machine can travel with F (forward) clutch).
machine
• Output current value to R (reverse) clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31606 ECMV Current (Reverse))
information • Method of reproducing failure code:Turn starting switch to ON position and set directional
(FNR) lever or R.H. directional selector (FNR) switch to R (reverse).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective R (reverse) 2. Disconnect connector R.PS and connect T-adapter to male side.
1
clutch ECMV solenoid
Resistance Between R.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Open circuit, short 2. Disconnect connector R.PS, and connect T-adapter to female side.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring a Shake the wiring harness by hand while measuring the voltage. If the
harness, or defective voltage drops to approximately 0 V during shaking, circuit is open around
transmission controller this point.
Voltage Between R.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L63, and connect T-adapter to female side.
Resistance Between L63 (female) (5) and (13) 5 to 15 z

Open circuit in wiring a If no failure is found by check on cause 3, this check is not required.
harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors L63 and R.PS, and connect T-adapters to each
defective contact of female side.
connector) Between L63 (female) (5) and R.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (13) and R.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-830 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch ECMV solenoid

WA470-7 40-831
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH7KB] Ground Fault of ECMV Solenoid (Reverse) (WA380_7-


DXH7KB-400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (Reverse)


Failure
L03 DXH7KB (Transmission controller system)
Detail of • Due to ground fault in R (reverse) clutch ECMV solenoid circuit, abnormally large current
failure flows when controller drives R (reverse) clutch ECMV solenoid.
• Stops driving R (reverse) clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • R (reverse) clutch is not engaged (machine can travel with F (forward) clutch).
machine
• Output current value to R (reverse) clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31606 ECMV Current (Reverse))
information • Method of reproducing failure code:Turn starting switch to ON position and set directional
(FNR) lever or R.H. directional selector (FNR) switch to R (reverse).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective R clutch 2. Disconnect connector R.PS and connect T-adapter to male side.
1
ECMV solenoid Between R.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and R.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (5) and (13) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and R.PS, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and L63 (female) (5) or R.PS
Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and R.PS, and connect T-adapter to either
4
harness female side.
Between L63 (female) (5) and (13), or between R.
Resistance PS (female) (1) and (2) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-832 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch ECMV solenoid

WA470-7 40-833
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH7KY] Hot Short of ECMV Solenoid (Reverse) (WA380_7-DXH7KY-


400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (Reverse)


Failure
L03 DXH7KY (Transmission controller system)
Detail of • Due to hot short circuit in R (reverse) clutch ECMV solenoid circuit, abnormal voltage
failure appears when controller does not drive R (reverse) clutch ECMV solenoid.
• When directional (FNR) lever or directional selector (FNR) switch is set to R (reverse),
controller drives R (reverse) clutch ECMV solenoid as usual.
• When shift lever is set to N (neutral) or F (forward), controller sets transmission to N
Action of (neutral).
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
Problem on • Machine can travel only in R (reverse) direction.
machine
• Output current value to R (reverse) clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31606 ECMV Current (Reverse))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective R (reverse) 2. Disconnect connector R.PS and connect T-adapter to male side.
1
clutch ECMV solenoid
Resistance Between R.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector R.PS, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness a If failure code [DXH7KA] for open circuit appears, wiring harness does not
have hot short circuit. (R clutch ECMV solenoid is defective.)
Voltage Between R.PS (female) (1) and (2) Max 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connector R.PS.
3. Disconnect connector L63, and connect T-adapter to female side.
Between L63 (female) (5) and each No continuity
Continuity
pin other than (5) (No sound is heard)

Short circuit in wiring 1. Turn starting switch to OFF position.


3 2. Disconnect connector L63.
harness
3. Disconnect connector LT1 and R.PS.
4. Connect T-adapter to either male or female side of connector LT1.
Between LT1 (female) (9) and each No continuity
pin other than (9) (No sound is heard)
Continuity
Between LT1 (male) (9) and each pin No continuity
other than (9) (No sound is heard)
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-834 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to R clutch ECMV solenoid

WA470-7 40-835
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH8KA] Disconnection of ECMV Solenoid


(Forward) (WA380_7-DXH8KA-400-A-Z0-A)
Action level Failure code Disconnection of ECMV Solenoid (Forward)
Failure
L03 DXH8KA (Transmission controller system)
Detail of • Due to open circuit in F (forward) clutch ECMV solenoid circuit, no current flows when
failure controller drives F (forward) clutch ECMV solenoid.
• Stops driving F (forward) clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • F (forward) clutch is not engaged (machine can travel with R (reverse) clutch).
machine
• Output current value to F (forward) clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31608 ECMV Current (Forward))
information • Method of reproducing failure code:Turn starting switch to ON position and set directional
(FNR) lever or R.H. directional selector (FNR) switch to F (forward).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective F (forward) 2. Disconnect connector F.PS, and connect T-adapter to male side.
1
clutch ECMV solenoid
Resistance Between F.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector FPS and connect T-adapter to female side of
Open circuit, short connector.
circuit, ground fault, hot 3. Turn starting switch to ON position.
2 short circuit of wiring
harness, or defective a Shake the wiring harness by hand while measuring the voltage. If the
transmission controller voltage drops to approximately 0 V during shaking, circuit is open around
this point.
Voltage Between F.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in 1. Turn starting switch to OFF position.
3 wiring harness 2. Disconnect connector L63, and connect T-adapter to female side.
Resistance Between L63 (female) (26) and (3) 5 to 15 z
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and F.PS, and connect T-adapters to each
4
(open circuit or female side.
defective contact) Between L63 (female) (26) and F.PS (female) (1) Max. 1 z
Resistance
Between L63 (female) (3) and F.PS (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-836 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to F clutch ECMV solenoid

WA470-7 40-837
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH8KB] Ground Fault of ECMV Solenoid (Forward) (WA380_7-


DXH8KB-400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (Forward)


Failure
L03 DXH8KB (Transmission controller system)
Detail of • Due to ground fault in F (forward) clutch ECMV solenoid circuit, abnormally large current
failure flows when controller drives F (forward) clutch ECMV solenoid.
• Stops driving F (forward) clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • F (forward) clutch is not engaged (machine can travel with R (reverse) clutch).
machine
• Output current value to F (forward) clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31608 ECMV Current (Forward))
information • Method of reproducing failure code:Turn starting switch to ON position and set directional
(FNR) lever or R.H. directional selector (FNR) switch to F (forward).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective F (forward) 2. Disconnect connector F.PS, and connect T-adapter to male side.
1
clutch ECMV solenoid Between F.PS (male) (1) and (2) 5 to 15 z
Resistance
Between ground and F.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L63, and connect T-adapter to female side.
wiring harness
Resistance Between L63 (female) (26) and (3) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and F.PS, and connect T-adapter to either
Ground fault in wiring
3 female side.
harness
Between ground and L63 (female) (26) or F.PS
Resistance (female) (1) Min. 1 Mz

a If no failure is found by check on cause 2, this check is not required.


1. Turn starting switch to OFF position.
Short circuit in wiring 2. Disconnect connectors L63 and F.PS, and connect T-adapter to either
4
harness female side.
Between L63 (female) (26) and (3), or between F.
Resistance PS (female) (1) and (2) Min. 1 Mz
Defective transmission If no failure is found by above checks, transmission controller is defective.
5 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-838 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to F clutch ECMV solenoid

WA470-7 40-839
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXH8KY] Hot Short of ECMV Solenoid (Forward) (WA380_7-DXH8KY-


400-A-Z0-A)

Action level Failure code Hot Short of ECMV Solenoid (Forward)


Failure
L03 DXH8KY (Transmission controller system)
Detail of • Due to hot short circuit in F (forward) clutch ECMV solenoid circuit, abnormal voltage
failure appears when controller does not drive F (forward) clutch ECMV solenoid.
• When directional (FNR) lever or R.H. directional selector (FNR) switch is set to F
(forward), controller drives F (forward) clutch ECMV solenoid as usual.
• When shift lever is set to N (neutral) or R (reverse), controller sets transmission to N
Action of (neutral).
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or R.H. directional selector (FNR) switch is set to N (neutral) position.
Problem on • Machine can travel only in F (forward) direction.
machine
• Output current value to F (forward) clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31608 ECMV Current (Forward))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective F (forward) 2. Disconnect connector F.PS, and connect T-adapter to male side.
1
clutch ECMV solenoid
Resistance Between F.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector FPS and connect T-adapter to female side of
connector.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness
a If failure code [DXH8KA] for open circuit appears, wiring harness does not
have no hot short circuit. (F clutch ECMV solenoid is defective.)
Voltage Between F.PS (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connector F.PS.
3. Disconnect connector L63, and connect T-adapter to female side.
Between L63 (female) (26) and each No continuity
Continuity
pin other than (26) (No sound is heard)

Short circuit in wiring 1. Turn starting switch to OFF position.


3 2. Disconnect connector L63.
harness
3. Disconnect connector LT1 and F.PS.
4. Connect T-adapter to either male or female side of connector LT1.
Between LT1 (female) (11) and each No continuity
pin other than (11) (No sound is heard)
Continuity
Between LT1 (male) (11) and each pin No continuity
other than (11) (No sound is heard)
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-840 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to F clutch ECMV solenoid

WA470-7 40-841
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHHKA] Disconnection of ECMV Solenoid (4th) (WA380_7-


DXHHKA-400-A-Z0-A)

Action level Failure code Disconnection of ECMV Solenoid (4th)


Failure
L03 DXHHKA (Transmission controller system)
Detail of • Due to open circuit in 4th clutch ECMV solenoid system, no current flows when controller
failure drives 4th clutch ECMV solenoid.
• Stops driving 4th clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 4th clutch is not engaged (machine can travel with gear speed other than 4th).
machine
• Output current value to 4th clutch ECMV solenoid can be checked with monitoring
function. (Code: 31605 ECMV Current (4th))
Related • Method of reproducing failure code: Turn starting switch to ON position and set
information transmission to auto shift, or set manual shift selector switch to MANUAL and select 4th
using shift down switch or set gear shift lever to 4th.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 4th clutch ECMV 2. Disconnect connector 4.PS, and connect T-adapters to male side.
1
solenoid Resis- Between 4.PS (male) (1) and (2) 5 to 15 z
tance Between ground and 4.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector 4.PS, and connect T-adapter to female side.
Open circuit, short circuit, hot 3. Turn starting switch to ON position.
2 short circuit of wiring harness, a Shake the wiring harness by hand while measuring the voltage. If
or defective monitor controller the voltage drops to approximately 0 V during shaking, circuit is
open around this point.
Voltage Between 4.PS (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
Open or short circuit in wiring 1. Turn starting switch to OFF position.
3 2. Disconnect connector L63 and connect T-adapters to female side.
harness
Resis- Between L63 (female) (16) and (13)
5 to 15 z
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors L63 and 4.PS, and connect T-adapters to
4 (wire breakage or defective each female side.
contact of connector) Between L63 (female) (16) and 4.PS (female)
Max. 1 z
Resis- (1)
tance Between L63 (female) (13) and 4.PS (female)
(2) Max. 1 z
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-842 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 4th clutch ECMV solenoid

WA470-7 40-843
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHHKB] Ground Fault of ECMV Solenoid (4th) (WA380_7-DXHHKB-


400-A-Z0-A)

Action level Failure code Ground Fault of ECMV Solenoid (4th)


Failure
L03 DXHHKB (Transmission controller system)
Detail of • Due to ground fault in 4th clutch ECMV solenoid system, abnormally large current flows
failure when controller drives 4th clutch ECMV solenoid.
• Stops driving 4th clutch ECMV solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • 4th clutch is not engaged (machine can travel with gear speed other than 4th).
machine
• Output current value to 4th clutch ECMV solenoid can be checked with monitoring
function. (Code: 31605 ECMV Current (4th))
Related • Method of reproducing failure code: Turn starting switch to ON position and set
information transmission to auto shift, or set manual shift selector switch to MANUAL and select 4th
using shift down switch or set gear shift lever to 4th.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 4th clutch ECMV 2. Disconnect connector 4.PS, and connect T-adapters to male side.
1
solenoid Resis- Between 4.PS (male) (1) and (2) 5 to 15 z
tance Between ground and 4.PS (male) (1) or (2) Min. 1 Mz
1. Turn starting switch to OFF position.
Open or short circuit in wiring2. Disconnect connector L63 and connect T-adapters to female side.
2
harness Resis- Between L63 (female) (16) and (13)
5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connectors L63 and 4.PS, and connect T-adapter to
3 Ground fault in wiring harness either female side.
Resis- Between ground and L63 (female) (16) or 4.PS
(female) (1) Min. 1 Mz
tance
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors L63 and 4.P3, and connect T-adapter to
either female side.
Resis- Between L63 (female) (16) and (13), or
between 4.PS (female) (1) and (2) Min. 1 Mz
tance
If no failure is found by above checks, transmission controller is
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-844 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 4th clutch ECMV solenoid

WA470-7 40-845
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHHKY] Hot Short of ECMV Solenoid (4th) (WA380_7-DXHHKY-400-A-Z0-


A)

Action level Failure code Hot Short of ECMV Solenoid (4th)


Failure
L03 DXHHKY (Transmission controller system)
Detail of • Due to hot short circuit in 4th clutch ECMV solenoid circuit, abnormal voltage appears
failure when controller does not drive 4th clutch ECMV solenoid.
• Stops driving 1st, 2nd and 3rd clutch ECMV solenoids.
• When not driving ECMV solenoids of speed clutches (other than 4th clutch), controller
Action of also stops driving F (forward) and R (reverse) clutch ECMV solenoid.
controller • Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until directional
(FNR) lever or directional selector (FNR) switch is set to N (neutral) position.
Problem on • 1st, 2nd, and 3rd clutches are not engaged (machine can travel with 4th gear speed).
machine
• Output current value to 4th clutch ECMV solenoid can be checked with monitoring
Related function. (Code: 31605 ECMV Current (4th))
information • Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 4th clutch 2. Disconnect connector 4.PS, and connect T-adapter to male side.
1
ECMV solenoid
Resistance Between 4.PS (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
2. Disconnect connector 4.PS, and connect T-adapter to female side.
Hot short circuit in 3. Turn starting switch to ON position.
2 wiring harness a If failure code [DXHHKA] for open circuit appears, wiring harness does not
have hot short circuit. (4th clutch ECMV solenoid is defective.)
Voltage Between 4.PS (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connector 4.PS.
3. Disconnect connector L63, and connect T-adapter to female side.
Between L63 (female) (16) and each No continuity
Continuity
pin other than (16) (No sound is heard)

Short circuit in wiring 1. Turn starting switch to OFF position.


3 2. Disconnect connector L63.
harness
3. Disconnect connectors LT1 and 4.PS.
4. Connect T-adapter to either male or female side of connector LT1.
Between LT1 (female) (7) and each No continuity
pin other than (7) (No sound is heard)
Continuity
Between LT1 (male) (7) and each pin No continuity
other than (7) (No sound is heard)
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed.)
controller

40-846 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 4th clutch ECMV solenoid

WA470-7 40-847
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHJKA] Disconnection of 3rd EPC Solenoid (EXT) (WA380_7-


DXHJKA-400-A-Z0-A)

Action level Failure code Disconnection of 3rd EPC Solenoid (Extension)


Failure
L03 DXHJKA (Work equipment controller system)
• Due to open circuit in signal output circuit to 3rd valve (attachment) EXTEND EPC
Detail of
solenoid, no current flows when controller drives 3rd valve (attachment) EXTEND EPC
failure
solenoid.
• Continues driving solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not extend.
machine
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
• If this failure code is displayed on the machine, select "None" for 3rd (attachment) lever
setting on option setting screen of machine monitor.
Related • Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
information with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine and move 3rd (attachment) lever to
EXTEND position.
No. Cause Procedure, measuring location, criteria and remarks

Defective 3rd valve 1. Turn starting switch to OFF position.


(attachment) EXTEND EPC 2. Disconnect connector F25, and connect T-adapter to male side.
1
solenoid (internal open circuit) Resis- Between F25 (male) (1) and (2) 5 to 15 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector F25 and connect T-adapters to female side.
Open circuit, short circuit, 3. Turn starting switch to ON position.
ground fault, hot short circuit
2 of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If
work equipment controller the voltage drops to approximately 0 V during shaking, circuit is
open around this point.
Voltage Between F25 (female) (1) and (2) 1 to 4.5 V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L73, and connect T-adapter to female side.
Open or short circuit in wiring
3
harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resis- Between L73 (female) (26) and (3)
5 to 15 z
tance
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or defective 2. Disconnect connectors L73 and F25, and connect T-adapters to
contact of connector) each female side.
Resis- Between L73 (female) (3) and F25 (female) (2) Max. 1 z
tance Between L73 (female) (26) and F25 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may
Defective work equipment be defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-848 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd valve (attachment) EXTEND EPC solenoid

WA470-7 40-849
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHJKB] Ground Fault of 3rd EPC Solenoid (EXT) (WA380_7-
DXHJKB-400-A-Z0-A)

Action level Failure code Ground Fault of 3rd EPC Solenoid (Extension)
Failure
L03 DXHJKB (Work equipment controller system)
• Due to ground fault in signal output circuit to 3rd valve (attachment) EXTEND EPC
Detail of
solenoid, abnormal current flows when controller drives 3rd valve (attachment) EXTEND
failure
EPC solenoid.
• Stops driving 3rd valve (attachment) EXTEND EPC solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not extend.
machine • Wiring harness or controller may be burnt out.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine that is not equipped with 3rd valve
(attachment), select "None" for 3rd (attachment) lever setting on option setting screen of
Related machine monitor.
information • Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd valve 2. Disconnect connector F25, and connect T-adapter to male side.
1 (attachment) EXTEND EPC Between F25 (male) (1) and (2) 5 to 15 z
solenoid (internal short circuit) Resis- Between ground and each of F25 (male) (1) and
tance Min. 1 Mz
(2)
1. Turn starting switch to OFF position.
2. Disconnect connector L73, and connect T-adapter to female side.
Open or short circuit in wiring
2 a Coil resistance of solenoid
harness
Resis- Between L73 (female) (26) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L73 and F25, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L73 (female) (26) or F25
Min. 1 Mz
tance (female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors L73 and F25, and connect T-adapter to
either female side.
Resis- Between L73 (female) (26) and (3), or between
Min. 1 Mz
tance F25 (female) (1) and (2)
If no failure is found by above checks, work equipment controller may
Defective work equipment be defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-850 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd valve (attachment) EXTEND EPC solenoid

WA470-7 40-851
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHJKY] Hot Short of 3rd EPC Solenoid (EXT) (WA380_7-DXHJKY-400-
A-Z0-A)

Action level Failure code Hot Short of 3rd EPC Solenoid (Extension)
Failure
L03 DXHJKY (Work equipment controller system)
• Due to hot short circuit in output signal circuit to 3rd valve (attachment) EXTEND EPC
Detail of
solenoid, abnormal voltage appears when controller does not drive 3rd valve (attachment)
failure
EXTEND EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER EPC solenoids, bucket TILT and DUMP EPC
solenoids, 3rd valve (attachment) EXTEND and RETRACT EPC solenoids, and 4th valve
Action of (attachment) EXTEND and RETRACT EPC solenoids.
controller • Stops driving every work equipment detent.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not extend.
machine • 3rd valve (attachment) EXTEND EPC solenoid may be burnt.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine, select "None" for 3rd (attachment) lever
Related setting on option setting screen of machine monitor.
information • Output current value to 3rd valve (attachment) EXTEND EPC solenoid can be checked
with monitoring function. (Code: 41906 3rd Extend EPC Current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Turn starting switch to ON position.
No. Cause Procedure, measuring location, criteria and remarks
Defective 3rd valve 1. Turn starting switch to OFF position.
(attachment) EXTEND 2. Disconnect connector F25, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Resistance Between F25 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F25, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F25 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F25, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (26) and each No continuity
Continuity
pin other than pin (26) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-852 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd valve (attachment) EXTEND EPC solenoid

WA470-7 40-853
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHKKA] Disconnection of 3rd EPC Solenoid (RET) (WA380_7-


DXHKKA-400-A-Z0-A)

Action level Failure code Disconnection of 3rd EPC Solenoid (Retract)


Failure
L03 DXHKKA (Work equipment controller system)
• Due to open circuit in output signal circuit to 3rd valve (attachment) RETRACT EPC
Detail of
solenoid, no current flows when controller drives 3rd valve (attachment) RETRACT EPC
failure
solenoid.
• Continues driving solenoid.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not retract.
machine
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine, select "None" for 3rd (attachment) lever
setting on option setting screen of machine monitor.
Related • Output current value to 3rd valve (attachment) retract EPC solenoid can be checked with
information monitoring function. (Code: 41907 3rd retract EPC current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine and move 3rd (attachment) lever to
RETRACT position.
No. Cause Procedure, measuring location, criteria and remarks

Defective 3rd valve 1. Turn starting switch to OFF position.


1 (attachment) RETRACT EPC 2. Disconnect connector F26, and connect T-adapter to male side.
solenoid (internal open circuit) Resis- Between F26 (male) (1) and (2) 5 to 15 z
tance

1. Turn starting switch to OFF position.


2. Disconnect connector F26 and connect T-adapters to female side.
Open circuit, short circuit, 3. Turn starting switch to ON position.
ground fault, hot short circuit
2 of wiring harness, or defective a Shake the wiring harness by hand while measuring the voltage. If
work equipment controller the voltage drops to approximately 0 V during shaking, circuit is
open around this point.

Voltage Between F26 (female) (1) and (2) 1 to 4.5 V


a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector L73, and connect T-adapter to female side.
Open or short circuit in wiring
3
harness a If resistance is 1 Mz or higher, wiring harness has open circuit. If
resistance is 1 z or below, wiring harness has short circuit.
Resis- Between L73 (female) (36) and (3)
5 to 15 z
tance
a If no failure is found by check on cause 3, this check is not required.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or defective 2. Disconnect connectors L73 and F26, and connect T-adapters to
contact of connector) each female side.
Resis- Between L73 (female) (3) and F26 (female) (2) Max. 1 z
tance Between L73 (female) (36) and F26 (female) (1) Max. 1 z
If no failure is found by above checks, work equipment controller may
Defective work equipment be defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-854 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd (attachment) valve RETRACT EPC solenoid

WA470-7 40-855
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHKKB] Ground Fault of 3rd EPC Solenoid (RET) (WA380_7-
DXHKKB-400-A-Z0-A)

Action level Failure code Ground Fault of 3rd EPC Solenoid (Retract)
Failure
L03 DXHKKB (Work equipment controller system)
• Due to ground fault in output signal circuit to 3rd valve (attachment) retract EPC solenoid,
Detail of
abnormal current flows when controller drives 3rd valve (attachment) retract EPC
failure
solenoid.
• Stops driving 3rd valve (attachment) retract EPC solenoid.
• Stops driving every work equipment detent.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not retract.
machine • Wiring harness or controller may be burnt.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine that is not equipped with 3rd valve
(attachment), select "None" for 3rd (attachment) lever setting on option setting screen of
Related machine monitor.
information • Output current value to 3rd valve (attachment) retract EPC solenoid can be checked with
monitoring function. (Code: 41907 3rd retract EPC current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective 3rd valve 2. Disconnect connector F26, and connect T-adapter to male side.
1 (attachment) Rretract EPC Between F26 (male) (1) and (2) 5 to 15 z
solenoid (internal short circuit) Resis- Between ground and each of F26 (male) (1) and
tance Min. 1 Mz
(2)
1. Turn starting switch to OFF position.
Open or short circuit in wiring2. Disconnect connector L73, and connect T-adapter to female side.
2
harness Resis- Between L73 (female) (36) and (3)
5 to 15 z
tance
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L73 and F26, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L73 (female) (36) or F26
Min. 1 Mz
tance (female) (1)
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
4 Short circuit in wiring harness 2. Disconnect connectors L73 and F26, and connect T-adapter to
either female side.
Resis- Between L73 (female) (36) and (3), or between
Min. 1 Mz
tance F26 (female) (1) and (2)
If no failure is found by above checks, transmission controller may be
Defective transmission defective. (Since this is an internal defect, troubleshooting cannot be
5
controller performed.)

40-856 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd valve (attachment) retract EPC solenoid

WA470-7 40-857
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DXHKKY] Hot Short of 3rd EPC Solenoid (RET) (WA380_7-DXHKKY-
400-A-Z0-A)

Action level Failure code Hot Short of 3rd EPC Solenoid (Retract)
Failure
L03 DXHKKY (Work equipment controller system)
• Due to hot short circuit in output signal circuit to 3rd valve (attachment) retract EPC
Detail of
solenoid, abnormal voltage appears when controller does not drive 3rd valve (attachment)
failure
retract EPC solenoid.
• Drives work equipment neutral lock solenoid.
• Stops driving boom RAISE and LOWER EPC solenoids, bucket TILT and DUMP EPC
solenoids, 3rd valve (attachment) EXTEND and RETRACT EPC solenoids, and 4th valve
Action of (attachment) EXTEND and RETRACT EPC solenoids.
controller • Stops driving every work equipment detent.
• Lights up centralized warning lamp and sounds alarm buzzer.
• Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • Cylinder connected to 3rd valve (attachment) does not retract.
machine • 3rd valve (attachment) retract EPC solenoid may be burnt out.
• This failure code does not appear on a machine that is not equipped with 3rd valve
(attachment).
If this failure code is displayed on the machine, select "None" for 3rd (attachment) lever
Related setting on option setting screen of machine monitor.
information • Output current value to 3rd valve (attachment) retract EPC solenoid can be checked with
monitoring function. (Code: 41907 3rd Retract EPC Current)
• Only for machines equipped with 3rd valve (attachment)
• Method of reproducing failure code: Start engine.
No. Cause Procedure, measuring location, criteria and remarks
Defective 3rd valve 1. Turn starting switch to OFF position.
(attachment) retract 2. Disconnect connector F26, and connect T-adapter to male side.
1 EPC solenoid (internal
short circuit) Resistance Between F26 (male) (1) and (2) 5 to 15 z
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector F26, and connect T-adapter to female side.
2 wiring harness 3. Turn starting switch to ON position.
Voltage Between F26 (female) (1) and (2) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L73 and F26, and connect T-adapter to female
side of L73.
Short circuit in wiring
3
harness a Check by using multimeter in continuity mode.
Between L73 (female) (36) and each No continuity
Continuity
pin other than pin (36) (No sound is heard)
If no failure is found by above checks, work equipment controller may be
Defective work
4 defective. (Since this is an internal defect, troubleshooting cannot be
equipment controller
performed.)

40-858 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to 3rd (attachment) valve RETRACT EPC solenoid

WA470-7 40-859
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DY30MA] Malfunction 1 of Emerg. Steering Motor (WA470_7-


DY30MA-400-A-Z0-A)

Action level Failure code Malfunction 1 of Emergency Steering Motor


Failure
L01 DY30MA (Work equipment controller system)
• Emergency steering pump pressure is detected although work equipment controller does
Detail of not send emergency steering operation command.
failure • Emergency steering pump pressure is 0.098 MPa or above.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
• Emergency steering motor (pump) operates although emergency steering switch is not
Problem on operated. Motor burns out due to prolonged operation.
machine • Emergency steering operation indicator lights up.
• Input voltage from emergency steering pump pressure sensor can be checked with
monitoring function. (Code: 07705 Emrg. Steering Pres. S. Volt)
• Oil pressure sensed by emergency steering pump pressure sensor can be checked with
Related monitoring function. (Code: 07703 Emrg. Steering Pressure)
information • Input voltage from steering pump pressure sensor can be checked with monitoring
function. (Code: 95303 Steering Pump Pres. Sensor Volt)
• Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
function. (Code: 95302 Steering Pump Pressure)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to ON position (wait for 30 seconds).
Defective emergency
1 steering motor system a If emergency steering motor starts to operate, perform check on causes 2
and after. If not, go to check on cause 11.
• Emergency steering relay
1. Turn starting switch to OFF position.
2. Disconnect emergency steering relay L126.
Defective emergency 3. Turn starting switch to ON position (wait for 30 seconds).
steering motor,
emergency steering a If emergency steering motor starts to operate, perform check on causes 2
relay, emergency and after. If not, go to check on cause 11.
2
steering switch, work • Emergency steering switch and work equipment controller
equipment controller, or 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect switch S_RH8 and connector L72.
3. Turn starting switch to ON position (wait for 30 seconds).
If emergency steering motor starts to operate, perform check on causes 6 and
7. If not, go to check on causes 8 and after.
• Emergency steering relay (L126)
1. Turn starting switch to OFF position.
Short circuit 1 in wiring 2. Disconnect connector L126, and connect T-adapter to female side.
3
harness
1Mz
Resistance Between L126 (female) (3) and (5)

40-860 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• Emergency steering motor
1. Turn starting switch to OFF position.
2. Disconnect terminal R18 of emergency steering relay.
3. Turn starting switch to ON position (wait for 30 seconds).
a If emergency steering motor starts to operate, hot short circuit is in wiring
harness.
• Emergency steering relay (L126)
1. Turn starting switch to OFF position.
Hot short circuit 1 in 2. Disconnect connector L126, and connect T-adapter to female side.
wiring harness 3. Turn starting switch to ON position (wait for 30 seconds).
4
(contact with 24V Voltage Between L126 (female) (5) and (2) Max 1 V
circuit) • Emergency steering relay (L126)
1. Turn starting switch to OFF position.
2. Disconnect ground terminal of emergency steering motor.
a To prevent current from flowing through emergency steering motor
while it is being checked
3. Turn starting switch to ON position (wait for 30 seconds).
Between terminals R13 and R14 Max 1 V
Voltage
Between terminals R18 and R14 Max 1 V
Defective emergency If measured voltage at terminal R13 is 1 V or below in check on cause 4 and
5 steering pressure output from terminal R09 is unusual, emergency steering relay (motor side) is
sensor defective.
• Emergency steering switch
Short circuit 2 in wiring 1. Turn starting switch to OFF position.
6 2. Disconnect connector S_RH8 and connect T-adapter to female side.
harness
Resistance Between S_RH8 (male) (5) and (6) Min. 1M z
1. Turn starting switch to OFF position.
Hot short circuit 2 in 2. Disconnect connectors S_RH8 and L72, and connect T-adapter to female
wiring harness side.
7 3. Turn starting switch to ON position (wait for 30 seconds).
(contact with 24V
circuit) Between ground and S_RH8 (female) (6) or L72
Voltage Max 1 V
(female) (8)
1. Turn starting switch to OFF position.
Defective emergency 2. Replace emergency steering relay L126 with horn relay L119.
steering relay (L126) 3. Turn starting switch to ON position (wait for 30 seconds).
8
If emergency steering motor does not start to operate, original emergency
steering relay (L126) is defective. If it starts to operate, go to check on next
cause.
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH8, and connect T-adapter to male side.
Defective emergency Between When manual emergency steering
9 steering switch Max. 1 z
S_RH8 switch is in "ON" position
Resistance (male) (5)
When manual emergency steering
and (6) switch is in "OFF" position Min. 1M z

1. Turn starting switch to OFF position.


2. Disconnect connector S_RH8.
Defective work 3. Turn starting switch to ON position (wait for 30 seconds).
10 equipment controller
a If emergency steering motor starts to operate, work equipment controller is
defective.
Defective emergency
11 steering pressure Perform troubleshooting for failure code [DHUDKB].
sensor system

WA470-7 40-861
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering motor

40-862 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DY30MC] Malfunction 2 of Emerg. Steering Motor (WA470_7-


DY30MC-400-A-Z0-A)

Action level Failure code Malfunction 2 of Emergency Steering Motor


Failure
L03 DY30MC (Work equipment controller system)
• Emergency steering pump pressure is not detected although work equipment controller
Detail of sends emergency steering operation command.
failure • Emergency steering pump pressure is 0.098 MPa or below.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • Emergency steering motor (pump) does not operate although emergency steering switch
machine is operated.
• Input voltage from emergency steering pump pressure sensor can be checked with
monitoring function. (Code: 07705 Emrg. Steering Pres. S. Volt)
• Oil pressure sensed by emergency steering pump pressure sensor can be checked with
Related monitoring function. (Code: 07703 Emrg. Steering Pressure)
information • Input voltage from steering pump pressure sensor can be checked with monitoring
function. (Code: 95303 Steering Pump Pres. Sensor Volt)
• Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
function. (Code: 95302 Steering Pump Pressure)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Loose terminal or open Check ground terminal of emergency steering motor 100R, emergency
1
circuit steering motor terminal 100B, and emergency steering relay terminal R18 for
looseness and breakage. If any terminal is loosened or broken, repair it.
1. Turn starting switch to OFF position.
2. Disconnect ground terminal of emergency steering motor.
Defective emergency a To prevent current from flowing through emergency steering motor
steering relay, or while it is being checked
defective emergency 3. Open left engine cover.
steering relay L126,
2 emergency steering a To check operation sound of emergency steering relay
switch, emergency 4. Turn starting switch to ON position.
steering pressure 5. Turn emergency steering switch on.
sensor, or wiring
harness a If operation sound of emergency steering relay is not heard, go to check
on next cause.
a If operation sound is heard, go to check on cause 11.
Defective fuse-4 in fuse If fuse-4 in fuse box FS08 is blown, perform check on cause 11 first.
3
box FS08
Defective 50 A slow- If 50 A fuse on terminal R06A side of slow-blow fuse is blown, perform check
4
blow fuse on cause 10 first.
Defective 120 A slow- If 120 A fuse on terminal R05A side of slow-blow fuse is blown, perform check
5
blow fuse on cause 10 first.
Defective emergency 1. Turn starting switch to OFF position.
steering relay L126 2. Replace emergency steering relay L126 with horn relay L119.
3. Turn starting switch to ON position (wait for 30 seconds).
6 (internal open circuit or
defective contact of If this failure code [DY30MC] does not appear, original relay (L126) is
connector) defective.

WA470-7 40-863
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


• Emergency steering relay
1. Turn starting switch to OFF position.
Resistance Between R14 and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect ground terminal of emergency steering motor.
a To prevent current from flowing through emergency steering motor
while it is being checked
3. Turn starting switch to ON position.
4. Turn emergency steering switch on.
a Check to where 24 V power is supplied to isolate cause.
a If no failure is found by this check, following check is not required.
Between terminal R17 and ground 20 to 30 V
Voltage Between terminals R13 and R14 20 to 30 V
Between terminals R18 and R14 20 to 30 V
1. Turn starting switch to OFF position.
Defective emergency 2. Insert T-adapters into connectors L126 and S_RH8.
7 steering pressure 3. Turn starting switch to ON position.
sensor 4. Turn emergency steering switch on.
a If no failure is found by this check, following check is not required.
Between S_RH8 (5) and ground 20 to 30 V
Between S_RH8 (6) and ground 20 to 30 V
Voltage Between L126 (3) and ground 20 to 30 V
Between L126 (5) and ground 20 to 30 V
Between L126 (1) and ground 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L126, L71, and R37, and connect T-adapter to
female side.
Between L126 (female) (2) and ground Max. 1 z
Between S_RH8 (female) (5) and FS08–4 Max. 1 z
Between FS08–4 and terminal R06A Max. 1 z
Resistance Between terminals R10 and R05 Max. 1 z
Between terminals R05 and R04 Max. 1 z
Max. 1 z
Between terminals R01 and R02

40-864 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

No. Cause Procedure, measuring location, criteria and remarks


Defective emergency In check on cause 7, if only measured voltage at terminal R18 is unusual in
8 steering relay emergency steering relay check, emergency steering relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH8, and connect T-adapter to male side.
Defective emergency Between When emergency steering switch is in
9 steering switch Max. 1 z
S_RH8 ON position
Resistance (male) (5)
When emergency steering switch is in
and (6) OFF position Min. 1M z

1. Turn starting switch to OFF position.


2. Disconnect connectors S_RH8 and L126, and connect T-adapter to
female side.
Between ground and S_RH8 (female) (6) or L126
Ground fault in wiring (female) (1) Max. 1 z
10 harness (contact with Between ground and L126 (female) (5) or R13 Max. 1 z
ground circuit)
Resistance Between ground and terminal FS08–4 or R06A Max. 1 z
Between ground and terminal R10 or R05 Max. 1 z
Between ground and terminal R05 or R04 Max. 1 z
Between ground and terminal R18 or 100R Max. 1 z
Open circuit 2 in wiring 1. Turn starting switch to OFF position.
harness (wire breakage 2. Disconnect connector L72, and connect T-adapter to female side.
11 or defective contact of
Between L72 (female) (8) and ground 200 to 400
connector) Resistance
a Coil resistance of L126 z
Defective emergency
12 steering pressure Perform troubleshooting for failure code [DHUDKA].
sensor system
Open circuit 3 in wiring • Emergency steering motor system
harness (wire breakage 1. Turn starting switch to OFF position.
13 or defective contact of
Between terminals R18 and 100R Max. 1 z
connector) Resistance
Between terminal 100B and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect ground terminal of emergency steering motor.
a To prevent current from flowing through emergency steering motor
Defective emergency while it is being checked
14 steering motor
3. Turn starting switch to ON position.
4. Turn emergency steering switch on.
Between 100R (motor terminal) and ground
Voltage 20 to 30 V
(chassis ground)
1. Turn starting switch to OFF position.
2. Disconnect connector L71 and insert T-adapter into it.
3. Turn starting switch to ON position.
Defective work 4. Start engine.
15 equipment controller
a If measured voltage is normal in this check, controller is defective.
Voltage Between L71 (12) and (4) 0.50 to 4.5
V

WA470-7 40-865
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering motor

40-866 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [DY30ME] Emerg. Steering Long-Time Activated (WA470_7-DY30ME-


400-A-Z0-A)

Action level Failure code Emergency Steering Long-Time Activated


Failure
L02 DY30ME Work equipment controller system
Detail of • Emergency steering pump pressure is continuously detected for 1 minute or longer.
failure • Emergency steering pump pressure is 0.098 MPa or above.
Action of • Lights up centralized warning lamp and sounds alarm buzzer.
controller
• Warning is generated if emergency steering continues to operate for 1 minute or longer
Problem on (emergency steering motor may be malfunctioning or may be burnt out.).
machine • Indicator lights up although emergency steering motor is not in operation.
• Emergency steering remains activated.
• Input voltage from emergency steering pump pressure sensor can be checked with
monitoring function. (Code: 07705 Emrg. Steering Pres. S. Volt)
• Oil pressure sensed by emergency steering pump pressure sensor can be checked with
Related monitoring function. (Code: 07703 Emrg. Steering Pressure)
information • Input voltage from steering pump pressure sensor can be checked with monitoring
function. (Code: 95303 Steering Pump Pres. Sensor Volt)
• Oil pressure sensed by steering pump pressure sensor can be checked with monitoring
function. (Code: 95302 Steering Pump Pressure)
No. Cause Procedure, measuring location, criteria and remarks
Defective emergency
1 Perform troubleshooting for failure code [DY30MA].
steering motor system

WA470-7 40-867
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Circuit diagram related to emergency steering motor

40-868 WA470-7
40 Troubleshooting
Troubleshooting by failure code (Display of code)

Failure code [LA00L3] Failure of Fan Reverse (WA380_7-LA00L3-400-A-Z0-A)

Action level Failure code


Failure Failure of Fan Reverse
L01 LA00L3
Detail of • When controller drives fan REVERSE solenoid, fan speed does not decrease (does not
failure lower to 100 rpm or below). As a result, fan rotation direction is not switched.
• Leaves fan rotating normal or in reverse and disables fan reverse function.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on
• Fan cannot switch its rotation direction.
machine
• Output current value to fan reverse solenoid can be checked with monitoring function.
Related (Code: 31646 Fan reverse solenoid current)
information • Fan speed can be checked with monitoring function. (Code: 10009 Radiator Fan speed)
• Method of reproducing failure code: Start engine and switch fan rotation direction.
No. Cause Procedure, measuring location, criteria and remarks
Defective radiator fan reverse See troubleshooting for failure codes "DW7BKA", "DW7BKB", and
1
solenoid "DW7BKY".
Fan motor may malfunction. Perform troubleshooting of hydraulic and
2 Internal failure of fan motor mechanical systems.

WA470-7 40-869
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)

E-1 Engine does not start (WA470_7-A20-400-A-Z0-A)

Failure Engine does not start (engine does not crank).


• Engine starting circuit has following two start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by directional lever and R.H. directional selector (FNR) switch positions
(engine can start only when in NEUTRAL).
Related • If failure symptom "Battery relay operation sound is not heard" appears when starting
information switch is turned to ON position, perform troubleshooting for E-1 as well.
• If failure symptom "Machine monitor does not light up" appears when turning starting
switch to ON position, main electric power supply system is supposed to be defective.
Perform the troubleshooting for E-5 (lines of slow-blow fuse, fuses-1 and -5 of fuse box 2).
• Battery charge voltage sensed by transmission controller can be checked with monitoring
function. (Code: 04307 (V))
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Loose terminal or open
1 Check terminals of starting motor, alternator, battery relay, and ground
circuit at terminal
terminals R50, E14, etc.
1. Turn starting switch to OFF position.
Poor contact Between battery relay terminal R16 and ground
2 (grounding) between a Use machine frame as grounding point for
battery relay and frame Resistance measurement.
Max. 1 z

a Loose or rusted terminal R50


a Be ready with starting switch at OFF position, then perform
Insufficient battery troubleshooting without turning starting switch to ON position.
3 capacity Battery voltage (two batteries) Min. 24 V
Specific gravity of electrolyte (each battery) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated with
Defective engine
4 failure codes [DB2QKR] and [DB2RKR]. If these codes appear, perform
controller system
troubleshooting for causes 1 to 3 of [DB2QKR] first.
Defective transmission If failure code [DAQQKR] or [DAQRKR] is displayed, perform troubleshooting
5 controller system for [DAQQKR] or [DAQRKR].
Defective directional If failure code [DF10KA] or [DF10KB] is displayed, perform troubleshooting for
6 lever system [DF10KA] or [DF10KB].
R.H. directional selector If failure code [DDK3KA] or [DDK3KB] is displayed, perform troubleshooting
7 (FNR) switch system for [DDK3KA] or [DDK3KB].
1. Turn starting switch to ON position (to connect ACC).
Defective battery relay
8 system a If battery relay operation sound is not heard, go to checks on causes 19
and after.
1. Turn starting switch to OFF position.
Defective starting 2. Remove fuse-6 (30 A) in fuse box 2. (To prevent engine from starting
switch, gear shift lever during troubleshooting)
switch, neutral safety 3. Insert T-adapters into connector E01.
9 relay L116, neutral keep 4. Turn starting switch to START position and hold it (two persons required
relay L121, personal for this check).
code relay L113, battery
relay, or wiring harness a If voltage is abnormal, go to check on cause 13 and after.
Voltage Between E01 (1) and ground 20 to 30 V
1. Turn starting switch to OFF position.
Defective alternator 2. Insert T-adapters into connector E01.
10 3. Turn starting switch to ON position.
(internal short circuit)
Between E01 (female) Input from alternator Max. 1 V
Voltage
(2) and ground generation

40-870 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapters into connector E01.
3. Turn starting switch to START position.
Defective starting motor Between starting motor
Power supply 20 to 30 V
11 terminal B and ground
(internal defect)
Between E01 (1) and Starting input to starting
Voltage 20 to 30 V
ground motor
Between E01 (2) and Input from alternator
ground generation Max. 1 V

a If no failure is found by check on cause 9, this check is not required.


a Check that directional lever and R.H. directional selector (FNR) switch are
Output inhibition to in NEUTRAL position.
12 transmission controller 1. Turn starting switch to OFF position.
is input 2. Disconnect connector L62, and connect T-adapter to female side.
3. Turn starting switch to ON position (to connect ACC).
Between L62 (female) (25) and ground 20 to 30 V
Voltage
Between L62 (female) (36) and ground 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connector D12.
3. Insert T-adapters into connector L63.
4. Turn starting switch to ON position.
Defective transmission
13 a Check that directional lever and R.H. directional selector (FNR) switch are
controller
in NEUTRAL position.
a If check result on cause 12 is normal and the following voltages are
abnormal, transmission controller is defective.
Voltage Between L63 (female) (8) and ground 20 to 30 V
1. Turn starting switch to OFF position.
Defective neutral safety 2. Replace neutral safety relay L116 with horn relay L119.
14 relay
3. Start engine.
If engine starts, original neutral safety relay is defective.
1. Turn starting switch to OFF position.
Defective neutral keep 2. Replace neutral keep relay L121 with horn relay L119.
15 relay 3. Start engine.
If engine starts, original neutral keep relay is defective.
1. Turn starting switch to OFF position.
Defective personal lock 2. Replace personal code relay L113 with horn relay L119.
16 relay
3. Start engine.
If engine starts, original personal code relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors D04, D05, D11, D12 and connect T-adapters to
diode.
a Measure it with diode range of multimeter.
No
Between D04 (male) (1) (+) and (2) (-)
continuity
Defective diode D04, Between D04 (male) (2) (+) and (1) (-) Continuity
D05, D11, or D12 No
17 (internal open circuit or Between D05 (male) (1) (+) and (2) (-)
continuity
short circuit) Between D05 (male) (2) (+) and (1) (-) Continuity
Continuity No
Between D11 (male) (1) (+) and (2) (-)
continuity
Between D11 (male) (2) (+) and (1) (-) Continuity
No
Between D12 (male) (1) (+) and (2) (-)
continuity
Between D12 (male) (2) (+) and (1) (-) Continuity

WA470-7 40-871
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by check on cause 9, this check is not required.
1. Check that system operating lamp does not light up, and then turn battery
disconnect switch to the OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector S40.
Defective starting 4. Turn starting switch to the ON and START positions to perform
18 switch troubleshooting again.
(internal open circuit) Between S40 (male) (1) Starting switch: OFF. Min. 1 Mz
and (2) (terminal BR) Starting switch: ON Max. 1 z
Between S40 (male) (1) Starting switch: OFF. Min. 1 Mz
Resistance and (4) (terminal ACC)
Starting switch: ON Max. 1 z
Between S40 (male) (1) Starting switch: OFF. Min. 1 Mz
and (3) (terminal C) Starting switch: START Max. 1 z
• Battery relay
1. Turn starting switch to OFF position.
Resistance Between terminal R16 and ground Max. 1 z
• Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
a Check where 24 V power is reached to, and locate open section.
Between terminals R01 and R16 20 to 30 V
Voltage Between terminals R15 and R16 20 to 30 V
Between terminals R04 and R16 20 to 30 V
• Alternator and starting motor
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
Open circuit 1 in wiring disconnect switch to OFF position.
harness 3. Insert T-adapters into connectors S40, L116, L121, L113, and D05.
19 (wire breakage or 4. Turn battery disconnect switch to ON position.
defective contact of 5. Turn starting switch to START position to perform troubleshooting.
connector)
a Check where 24 V power is reached to, and locate open section.
Between S40 (3) and ground 20 to 30 V
Between L116 (3) and ground 20 to 30 V
Between L116 (5) and ground 20 to 30 V
Between L113 (6) and ground 20 to 30 V
Between L113 (3) and ground 20 to 30 V
Voltage Between D05 (2) and ground 20 to 30 V
Between D05 (1) and ground 20 to 30 V
Between E01 (1) and ground 20 to 30 V
Between L121 (1) and ground 20 to 30 V
Between L121 (5) and ground 20 to 30 V
Between L116 (1) and ground 20 to 30 V

40-872 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found in "alternator, starting motor" by check on cause 19,
this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors S40, L113, L116, L121, D04, D05, E01, and
connect T-adapters to each female side.
Between S40 (female) (3) and L116 (female) (3) Max. 1 z
Open circuit 2 in wiring Between L116 (female) (5) and L113 (female) (6) Max. 1 z
harness Between L113 (female) (3) and D04 (female) (2) Max. 1 z
20 (wire breakage or Between D04 (female) (2) and D05 (female) (2) Max. 1 z
defective contact of Between D04 (female) (1) and D05 (female) (1) Max. 1 z
connector) Between D04 (female) (1) and E01 (female) (1) Max. 1 z
Resistance
Between L116 (female) (5) and L121 (female) (3) Max. 1 z
Between L121 (female) (5) and D11 (female) (2) Max. 1 z
Between D11 (female) (1) and L116 (female) (1) Max. 1 z
Between L116 (female) (3) and L121 (female) (1) Max. 1 z
Between L121 (female) (2) and ground Max. 1 z
Between L116 (female) (2) and ground Max. 1 z
Defective battery relay If voltage of terminal R04 only is unusual in battery relay checks on cause 19,
21 battery relay is defective.
(does not turn ON)
1. Turn starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn battery
disconnect switch to OFF position.
3. Disconnect connectors S40, L116, L121, L113, D05, D04, D11, E01, D12,
Ground fault in wiring L62, L80B, L73, R15, and MCM1 A.
harness 4. Connect T-adapters to female side of L116, D11, and D04.
22 Between L116 (female) (1) and ground Min. 1 Mz
(contact with ground
circuit) Between L116 (female) (3) and ground Min. 1 Mz
Between L116 (female) (5) and ground Min. 1 Mz
Resistance
Between D11 (female) (2) and ground Min. 1 Mz
Between D04 (female) (1) and ground Min. 1 Mz
Between D04 (female) (2) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector E01 and connect T-adapter to female side.
3. Disconnect terminal E02.
Hot short circuit in 4. Turn starting switch to ON position.
23 wiring harness
a If a hot short circuit occurs, the charging lamp lights up when the starting
switch is turned ON.
Voltage Between E01 (female) (2) and ground Max. 1 V

WA470-7 40-873
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine starting circuit

40-874 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

WA470-7 40-875
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-2 Manual preheating system does not work (WA470_7-FEM-400-A-00-A)

Failure Manual preheating system does not work.


a This troubleshooting describes procedures to be followed when manual preheating does
not function to heat electrical intake air heater mounting section.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
preheating works, preheating monitor lights up. (When only preheating monitor does not
Related light up, perform troubleshooting for "E-4 While preheating is working, preheating monitor
information does not light up").
• If failure symptom "Machine monitor displays nothing" or "Battery relay does not make
operating sound" appears when starting switch is turned to ON position, main electric
power supply system may be defective. In these cases, perform troubleshooting for E-5
and E-1 respectively.
• Before performing troubleshooting, check that no related failure code is displayed.
No. Cause Procedure, measuring location, criteria and remarks
If fuse 6 in fuse box 2 is broken, circuit probably has ground fault. In this case,
Defective fuse 6 in fuse
1 perform check on cause 10 first.
box 2
Defective slow-blow If slow-blow fuse is blown out, circuit probably has ground fault. In this case,
2 perform check on cause 10 first.
fuse
3 Defective fuse (200 A) If fuse is blown out, circuit probably has ground fault. In this case, perform
check on cause 10 first.
Loose terminal or open 1. Turn starting switch to OFF position.
4
circuit at terminal Check terminals of heater relay, battery relay, electrical intake air heater, etc.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to the OFF position.
a Heater relay coil resistance
Approx. 20
Resistance Between terminal R of starting switch and ground
z
a If slow-blow fuse or fuse is blown, replace it in advance.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to the ON position
Open circuit or ground 3. Turn starting switch to ON position.
5 fault in wiring harness Voltage Between heater relay terminal E05 and ground 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect heater relay terminal E07A.
a To prevent current from flowing through heater when starting switch is
turned to HEAT position
3. Turn starting switch to the HEAT position (connect R).
Voltage Between heater relay terminal E06 and ground 20 to 30 V
1. Turn starting switch to OFF position.
Continuity Between heater relay terminal E and ground Continuity
Defective heater relay
If no failure is found by check on cause 5 and heater relay operation sound is
6 (does not engage) not heard, heater relay is defective.
(Terminal E07A)
1. Turn starting switch to OFF position.
Diode (E06A) is 2. Disconnect connector E06A and connect T-adapters to diode.
defective. a Check by using multimeter in diode range.
7
(internal open or short No
circuit) Between E06A (male) (1) (+) and (2) (-)
Continuity continuity
Between E06A (male) (2) (+) and (1) (-) Continuity
Defective electrical 1. Turn starting switch to OFF position.
8 intake air heater 2. Disconnect terminal E07B.
(internal open circuit) Continuity Between terminal E07B and ground Continuity

40-876 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to the OFF position.
Defective starting 3. Turn starting switch to the OFF and the HEAT positions to perform
9 troubleshooting.
switch
OFF Min. 1 Mz
Resistance Between terminal B and terminal R
HEAT Max. 1 z
a If no failure is found by check on cause 5, this check is not required.
a If slow-blow fuse or fuse is blown, replace it in advance.
1.Turn starting switch to OFF position.
2.Turn the battery disconnect switch to the OFF position.
Ground fault in wiring 3.Remove fuses 1 to 5 and 7 in fuse box 2 (FS9).
harness 4.Disconnect connectors MCM1 A and E06A, and terminals E05, E06,
10 E07B, R03, R04, R05, and R12
(contact with ground
circuit) Between heater relay terminal E05 (wiring harness
side) and ground Min. 1 Mz
Between heater relay terminal E06 (wiring harness
Resistance side) and ground Min. 1 Mz
Between heater terminal E07B (wiring harness
side) and ground Min. 1 Mz

WA470-7 40-877
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-878 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-3 Automatic preheating system does not work (WA470_7-FE1-400-A-Z0-A)

Failure Automatic preheating system does not work.


• Automatic preheating starts when coolant temperature is below -5°C.
(Code: 04107 Engine coolant temperature)
• If automatic preheating function does not work, check whether manual preheating
Related function works first.
information • Engine controller checks primary (coil) side of preheat relay (connector L125) and
generates failure code [CA2555] or [CA2556] if it is defective.
• Engine controller checks engine coolant temperature sensor and generates failure code
[CA144] or [CA145] if it is defective.
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow If slow-blow fuse is blown out, circuit probably has ground fault. In this case,
1 perform check on cause 6 first.
fuse
Defective fuse 6 in fuse If fuse 6 in fuse box 2 is broken, circuit probably has ground fault. In this case,
2 perform check on cause 6 first.
box 2
1. Turn starting switch to OFF position.
Defective preheater 2. Replace preheat relay (connector L125) with horn relay (connector L119).
3 relay L125 (internal 3. Turn starting switch to ON position.
open or short circuit) If automatic preheating starts when coolant temperature is below -5°C,
original auto preheat relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 A and L125, and connect T-adapters to
female side of L125.
Open circuit or ground a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or
4 fault in wiring harness below, harness has short circuit.
a Heater relay coil resistance
Approx. 20
Resistance Between L125 (female) (5) and ground
z
a If slow-blow fuse is blown, replace it in advance.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to the OFF position.
Open circuit in wiring 3. Disconnect connectors L125 and MCM1 A, and connect T-adapters to
harness female side of L125.
5 (wire breakage or Between L125 (female) (3) and terminal R01 of
defective contact of battery relay Max. 1 z
connector)
Resistance a If no failure is found by check on cause 4, this
check is not required. Max. 1 z
Between L125 (female) (5) and heater relay
terminal E06
If slow-blow fuse or fuse is not blown out, this check is not required.
Ground fault in wiring a If slow-blow fuse is blown, replace it in advance.
harness 1.Turn starting switch to OFF position.
6 2.Remove fuses 1 to 7 in fuse box 2.
(contact with ground
circuit) 3.Disconnect connectors MCM1 A, L125, EC3, and connect T-adapter to
female side of L125.
Resistance Between L125 (female) (3) and ground Min. 1 Mz

WA470-7 40-879
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-880 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-4 While preheating is working, preheating monitor does not light


up (WA470_7-FE2-400-A-Z0-A)
Failure While preheating is working, preheating monitor does not light up.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
Related preheating works, preheating monitor lights up.
information • Check whether manual preheating function works first.
• "Socket-type box" is available for monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors MCM1 A and L125, and connect T-adapters to
harness each female side.
1 (wire breakage or Between terminal R of starting switch and MCM1 A
(female) (12) Max. 1 z
defective contact of
connector) Resistance
Between L125 (female) (5) and MCM1 A (female)
(12) Max. 1 z
Defective machine If no failure is found by above checks, machine monitor is defective.
2
monitor

WA470-7 40-881
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine preheating system

40-882 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-5 All of LCD unit, LED unit, and meter unit on machine monitor display
nothing (WA470_7-FH7-400-A-Z0-A)
Failure All of LCD unit, LED unit, and meter unit on machine monitor display nothing.
• Display of rearview monitor is normal.
Related
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
information
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
Incorrect operation of
1 battery disconnect Check that battery disconnect switch is at ON position.
switch
Incorrect operation of
2 engine shutdown Check that engine shutdown secondary switch is at lower (OFF) position.
secondary switch
Defective slow-blow If slow-blow fuse is blown out, circuit probably has ground fault. In this case,
3 perform check on cause 8 first.
fuse
Defective fuse 1 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 8.)
4
box 2
Defective fuses 3 and If fuse is blown, circuit may have ground fault. (See check on cause 8.)
5
15 in fuse box 2
Defective continuous
6 Perform troubleshooting for failure code [DAF3KK].
power supply system
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MCM1 A, and connect T-adapters to female side.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a Check that engine shutdown secondary switch is at lower (OFF) position.
Between MCM1 A (female) (43) and (2) 20 to 30 V
Voltage Between MCM1 A (female) (31) and (2) 20 to 30 V
Between MCM1 A (female) (24) and (3) 20 to 30 V
Open circuit in wiring
harness a If no failure is found by above checks, this check is not required.
7 (wire breakage or 1. Check that system operating lamp does not light up, and then set battery
defective contact of disconnect switch to OFF position.
connector) 2. Turn starting switch to OFF position.
3. Disconnect connectors MCM1 A and S_FS, and connect T-adapters to
each female side.
Between MCM1 A (female) (24) and (43) Max. 1 z
Between MCM1 A (female) (24) and S_FS (female)
(2) Max. 1 z
Between MCM1 A (female) (31) and S_FS (female)
Max. 1 z
Resistance (1)
Between S_FS (female) (1) and (4) Max. 1 z
Between S_FS (female) (2) and (5) Max. 1 z
Between S_FS (female) (2) and terminal ACC of Max. 1 z
starting switch

WA470-7 40-883
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector MCM1 A, and connect T-adapters to female side.
3. Remove fuses 1 to 7 in fuse box 2 (FS9).

Ground fault in wiring a For FS9, see circuit diagram for E-4.
harness Between ground and MCM1 A (female) (1), (4), or
8 Min. 1 Mz
(contact with ground FS9-3
circuit) Between ground and MCM1 A (female) (24), (43),
Min. 1 Mz
Resistance or FS9-15
Between MCM1 A (female) (31) and ground Min. 1 Mz
Between FS9-1 (both terminals) and ground Min. 1 Mz
Between FS9-15 (both terminals) and ground Min. 1 Mz
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective starting 3. Disconnect cable from terminal B of starting switch.
9 switch (internal defect) Between starting switch Starting switch: OFF Min. 1 Mz
terminals B and ACC
Resistance
Between starting switch Starting switch: ON Max. 1 z
terminals B and ACC
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
10 this is an internal defect, troubleshooting cannot be performed.)
controller

40-884 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to monitor controller

WA470-7 40-885
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-6 LCD unit on machine monitor displays nothing (WA380_7-FH8-400-A-Z0-A)

Failure LCD unit on machine monitor displays nothing.


• Display of LED unit, meter unit, and rearview monitor is normal.
• Make harness checker. For details, see "Processing procedure of harness checker
for troubleshooting of machine monitor LCD unit" in General information on
Related information troubleshooting.
a Harness checker for troubleshooting of machine monitor LCD unit is simply referred
to as "harness checker".
No. Cause Procedure, measuring location, criteria and remarks
1. Turn the battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between LCD unit of
machine monitor and monitor controller, and repeat connection and
1 Defective harness connector disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
a When using harness checker
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective LCD unit of machine 3. Disconnect connector MCM2, and connect harness checker to
2
monitor female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between harness checker (5) and (3) 6.2 to 9.1 V
Voltage
Between harness checker (7) and (3) 6.2 to 9.1 V
a When performing troubleshooting by using new wiring harness
between machine monitor LCD unit and monitor controller
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
Open circuit in wiring harness
2. Turn starting switch to OFF position.
3 (wire breakage or defective 3. Replace wiring harness between LCD unit of machine monitor and
contact of connector) monitor controller with new one.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, wiring harness between LCD unit of
machine monitor and monitor controller is defective.
1. Turn battery disconnect switch to ON position.
Defective LCD unit of machine 2. Turn starting switch to ON position.
4
monitor
If display of LED unit and meter unit is normal, LCD unit is defective.
1. Turn battery disconnect switch to ON position.
2. Turn starting switch to ON position.
5 Defective monitor controller
If display of LED unit and meter unit is unusual, monitor controller is
defective.

40-886 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LCD unit of machine monitor

Circuit diagram between monitor controller and LCD unit of machine monitor

WA470-7 40-887
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-7 Backlight of LCD unit on machine monitor is abnormal (Backlight


goes out or flickers) (WA500_7-FH9-400-A-Z0-A)
Failure Backlight of LCD unit on machine monitor is abnormal (Backlight goes out or flickers).
• Display of LED unit, meter unit, and rearview monitor is normal.
• Make harness checker. For details, see "Processing procedure of harness checker
for troubleshooting of machine monitor LCD unit" in General information on
Related information troubleshooting.
a Harness checker for troubleshooting of machine monitor LCD unit is simply referred
to as "harness checker".
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between LCD unit of
machine monitor and monitor controller, and repeat connection and
1 Defective harness connector
disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
a When using harness checker
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective LCD unit of machine 3. Disconnect connector MCM2, and connect harness checker for
2
monitor troubleshooting of LCD unit of machine monitor to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between harness checker (4) and (3) Min. 0.3 V
Voltage
Between harness checker (7) and (3) 6.2 to 9.1 V
a When performing troubleshooting by using new wiring harness
between machine monitor LCD unit and monitor controller
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
Open circuit in wiring harness
2. Turn starting switch to OFF position.
3 (wire breakage or defective 3. Replace wiring harness between LCD unit of machine monitor and
contact of connector) monitor controller with new one.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, wiring harness between LCD unit of
machine monitor and monitor controller is defective.
1. Turn battery disconnect switch to ON position.
Defective LCD unit of machine 2. Turn starting switch to ON position.
4
monitor
If display of LED unit and meter unit is normal, LCD unit is defective.
1. Turn battery disconnect switch to ON position.
2. Turn starting switch to ON position.
5 Defective monitor controller
If display of LED unit and meter unit is unusual, monitor controller is
defective.

40-888 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LCD unit of machine monitor

Circuit diagram between monitor controller and LCD unit of machine monitor

WA470-7 40-889
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-8 LCD on machine monitor does not display properly (WA500_7-FHA-400-A-Z0-A)

Failure LCD on machine monitor does not display properly.


• Display of LED unit, meter unit, and rearview monitor is normal.
• Make harness checker. For details, see "Processing procedure of harness checker
for troubleshooting of machine monitor LCD unit" in General information on
Related information troubleshooting.
a Harness checker for troubleshooting of machine monitor LCD unit is simply referred
to as "harness checker".
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between LCD unit of
machine monitor and monitor controller, and repeat connection and
1 Defective harness connector
disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
a When using harness checker
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
Defective LCD unit of machine 3. Disconnect connector MCM2, and connect harness checker for
2
monitor troubleshooting of LCD unit of machine monitor to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between harness checker (1) and (3) Min. 0.3 V
Voltage
Between harness checker (2) and (3) Min. 0.3 V
a When performing troubleshooting by using new wiring harness
between machine monitor LCD unit and monitor controller
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
Open circuit in wiring harness
2. Turn starting switch to OFF position.
3 (wire breakage or defective 3. Replace wiring harness between LCD unit of machine monitor and
contact of connector) monitor controller with new one.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, wiring harness between LCD unit of
machine monitor and monitor controller is defective.
1. Turn battery disconnect switch to ON position.
Defective LCD unit of machine 2. Turn starting switch to ON position.
4
monitor
If display of LED unit and meter unit is normal, LCD unit is defective.
1. Turn battery disconnect switch to ON position.
2. Turn starting switch to ON position.
5 Defective monitor controller
If display of LED unit and meter unit is unusual, monitor controller is
defective.

40-890 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LCD unit of machine monitor

Circuit diagram between monitor controller and LCD unit of machine monitor

WA470-7 40-891
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-9 Meter unit display on machine monitor is abnormal (WA380_7-FHB-400-A-Z0-A)

• Meter unit on machine monitor displays nothing.


• Pointer of meter on machine monitor does not swing.
Failure • Meter unit LCD display on machine monitor is abnormal.
• Backlight of meter unit on machine monitor is unusual.
• Display of LCD unit, LED unit, and rearview monitor is normal.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information a If fuse 3 or 15 in fuse box 2 (FS9) is blown, machine monitor displays nothing (see
troubleshooting E-5).
a Machine monitor connector DPC2 is a 070 type connector with 8 pins, and T-adapter
for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors of wiring harness between meter unit of
machine monitor and monitor controller, and repeat connection and
1 Defective harness connector
disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
Display abnormality record in the service mode of machine monitor. If
Defective CAN
2 failure code [DSJ0KR] of action level L01 is logged, perform
communication system
troubleshooting for failure code [DSJ0KR].
a When using T-adapters for connector MDM3 (070-8)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MDM3, and connect T-adapters to female
side.
Open circuit in wiring harness 4. Turn battery disconnect switch to ON position.
3 (wire breakage or defective 5. Turn starting switch to ON position.
contact of connector) Between MDM3 (female) (1) and (4) 20 to 30 V
Between MDM3 (female) (2) and (4) 20 to 30 V
Between MDM3 (female) (3) and (4)
Voltage 1 to 4 V
a CAN communication line
Between MDM3 (female) (8) and (4)
1 to 4 V
a CAN communication line
If no failure is found by check on cause 3, meter unit of machine monitor
is defective.
a When not using T-adapter for connector MDM3 (070-8)
Defective meter unit of
4 1. Turn battery disconnect switch to ON position.
machine monitor
2. Turn starting switch to ON position.
If display of LCD unit and LED unit of machine monitor is normal, meter
unit of machine monitor is defective.
1. Turn battery disconnect switch to ON position.
2. Turn starting switch to ON position.
5 Defective monitor controller
If display of LCD unit and LED unit of machine monitor is unusual,
monitor controller is defective.

40-892 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and meter unit of machine monitor

WA470-7 40-893
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram between monitor controller and meter unit of machine monitor

40-894 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-10 Night lighting lamp of meter unit on machine monitor is


abnormal (WA380_7-FHC-400-A-Z0-A)
Failure Night lighting lamp of meter unit on machine monitor is abnormal.
• Night lighting lamp of meter unit of machine monitor lights up only when clearance
lamp is turned on while monitor brightness selector switch is at the night mode.
• Check whether night lighting lamp of rearview monitor is also abnormal or not.
Related information • As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
a Machine monitor connector MDM3 is a 070 type connector with 8 pins, and T-
adapter for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to meter unit
of machine monitor and connector of night lighting switch, and
1 Defective harness connector
repeat connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
a If night lighting lamp of rearview monitor lights up, this check is not
required.
1. Turn starting switch to OFF position.
Defective monitor brightness 2. Disconnect connector S_F7 and connect T-adapter to male side.
2 selector (night lighting) switch Between S_F7 Brightness selector
Min. 1 Mz
Resis- (female) (5) and (4) switch: OFF
tance Between S_F7 Brightness selector
(female) (5) and (4) Max. 1 z
switch: ON
a When using T-adapter for connector MDM3 (070-8)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MDM3, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
6. Lighting up of clearance lamp
Between MDM3 (female) (1) and (4) 20 to 30 V
Between MDM3 (female) (2) and (4) 20 to 30 V
Open circuit in wiring harness Voltage Between MDM3 Night lighting switch:
(female) (5) and (4) Max. 0.2 V
3 (wire breakage or defective OFF
contact of connector) Between MDM3 Night lighting switch:
(female) (5) and (4) 20 to 30 V
ON
a If no failure is found by above checks, this check is not required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors MDM3, S_F7, S_RV, and connect T-
adapters to each female side.
Between S_F7 (female) (4) and MDM3
Max. 1 z
Resis- (female) (5)
tance Between S_RV (female) (3) and S_F7
(female) (5) Max. 1 z

WA470-7 40-895
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by check on cause 3, meter unit of machine monitor
is defective.
a When not using T-adapter for connector MDM3 (070-8)
Defective meter unit of 1. Turn battery disconnect switch to ON position.
4 2. Turn starting switch to ON position.
machine monitor
3. Turn on night lighting switch.
If night lighting of LCD unit , LED unit, switch panel, and rearview
monitor of machine monitor is normal, meter unit of machine monitor is
defective.

Wiring harness between monitor controller and meter unit of machine monitor

40-896 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram between monitor controller and meter unit of machine monitor

WA470-7 40-897
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-11 Caution LED on machine monitor is abnormal (WA500_7-FHD-400-A-Z0-A)

Failure LED unit lamp of machine monitor does not light up, or does not go out.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information
a Machine monitor connector MDM2 is a 070 type connector with 6 pins, and T-
adapter for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to LED unit of
machine monitor and connector of monitor controller, and repeat
1 Defective harness connector
connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code [DPQ2KR] of action level L01 is logged, perform
2
line troubleshooting for failure code [DPQ2KR].
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code [DAFDKB] of action level L01 is logged, perform
system
troubleshooting for failure code [DAFDKB].
a When using T-adapter for connector MDM2 (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MDM2, and connect T-adapters to female
side.
Open circuit in wiring harness 4. Turn battery disconnect switch to ON position.
4 (wire breakage or defective 5. Turn starting switch to ON position.
contact of connector) Between MDM2 (female) (1) and (2) 9.3 to 14.1
a 12 V power supply V
Between MDM2 (female) (3) and (2)
Voltage Approx. 9 V
a LIN communication line
Between MDM2 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
If no failure is found by check on cause 4, LED unit of machine monitor
is defective.
Defective LED unit of machine
5 a When not using T-adapter for connector MDM2 (070-6), if no failure
monitor
is found by checks on causes 2 and 3, replace LED unit of machine
monitor to check whether LED unit is defective.
If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
If you cannot perform check on cause 4 for some reason, take it that
7 Defective wiring harness
wiring harness is defective.

40-898 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and LED unit of machine monitor

Circuit diagram between monitor controller and LED unit of machine monitor

WA470-7 40-899
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-12 LED of switch panel on machine monitor is abnormal or switches


does not operate properly (WA500_7-FHE-400-A-Z0-A)
• Night lighting lamp of switch panel on machine monitor does not light up, or does not
Failure go out.
• Switch of switch panel of machine monitor does not work.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information
a Machine monitor connector MOM1 is a 070 type connector with 6 pins, and T-
adapter for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
1 Defective harness connector
repeat connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code [DPQ1KR] of action level L01 is logged, perform
2
line troubleshooting for failure code [DPQ1KR].
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code [DAFDKB] of action level L01 is logged, perform
system
troubleshooting for failure code [DAFDKB].
a When using T-adapter for connector MOM1 (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MOM1, and connect T-adapters to female
side.
Open circuit in wiring harness 4. Turn battery disconnect switch to ON position.
4 (wire breakage or defective 5. Turn starting switch to ON position.
contact of connector) Between MOM1 (female) (1) and (2) 9.3 to 14.1
a 12 V power supply V
Between MOM1 (female) (3) and (2)
Voltage Approx. 9 V
a LIN communication line
Between MOM1 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
Defective switch panel of
5 a When not using T-adapter for connector MOM1 (070-6), if no failure
machine monitor
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.
If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
If you cannot perform check on cause 4 for some reason, take it that
7 Defective wiring harness
wiring harness is defective.

40-900 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and switch panel of machine monitor

Circuit diagram between monitor controller and switch panel of machine monitor

WA470-7 40-901
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-13 Two switches operation of switch panel on machine monitor does


not function (WA500_7-FHF-400-A-Z0-A)
Failure Two switches operation of switch panel on machine monitor does not function
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information
a Machine monitor connector MOM1 is a 070 type connector with 6 pins, and T-
adapter for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
1 Defective harness connector
repeat connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code [DPQ1KR] of action level L01 is logged, perform
2
line troubleshooting for failure code [DPQ1KR].
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code [DAFDKB] of action level L01 is logged, perform
system
troubleshooting for failure code [DAFDKB].
a When using T-adapter for connector MOM1 (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MOM1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
a "Simultaneous operation of up and down switch" denotes turning on
Up switch (A) and Down switch (B) at the same time. (See
description of LCD check function in Testing and adjusting, "Special
Open circuit in wiring harness functions of machine monitor".)
4 Between MOM1 (female) (1) and (2) 9.3 to 14.1
(wire breakage or defective
contact of connector) a 12 V power supply V
Between MOM1 (female) (3) and (2)
Approx. 9 V
a LIN communication line
Between MOM1 (female) (4) and (2)
4 to 6.1 V
Voltage a 5 V power supply
When Up and Down
Between MOM1 switches are not
(female) (5) and (2) operated Max. 0.2 V
simultaneously
When Up and Down
Between MOM1
switches are operated Min. 2.2 V
(female) (5) and (2)
simultaneously
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
Defective switch panel of
5 a When not using T-adapter for connector MOM1 (070-6), if no failure
machine monitor
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.

40-902 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
If you cannot perform check on cause 4 for some reason, take it that
7 Defective wiring harness
wiring harness is defective.

Wiring harness between monitor controller and switch panel of machine monitor

WA470-7 40-903
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram between monitor controller and switch panel of machine monitor

40-904 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-14 Switch panel buzzer of machine monitor is abnormal (WA500_7-FHG-400-A-Z0-A)

Failure Switch panel buzzer of machine monitor does not sound or does not stop sounding.
• As T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related information
a Machine monitor connector MOM1 is a 070 type connector with 6 pins, and T-
adapter for this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector of wiring harness connected to switch
panel of machine monitor and connector of monitor controller, and
1 Defective harness connector
repeat connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
Display abnormality record in the service mode of machine monitor. If
Defective LIN communication failure code [DPQ1KR] of action level L01 is logged, perform
2
line troubleshooting for failure code [DPQ1KR].
Display abnormality record in the service mode of machine monitor. If
Defective 12 V power supply
3 failure code [DAFDKB] of action level L01 is logged, perform
system
troubleshooting for failure code [DAFDKB].
a When using T-adapter for connector MOM1 (070-6)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector MOM1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Open circuit in wiring harness Between MOM1 (female) (1) and (2) 9.3 to 14.1
4 (wire breakage or defective a 12 V power supply V
contact of connector)
Between MOM1 (female) (3) and (2)
Approx. 9 V
a LIN communication line
Voltage Between MOM1 (female) (4) and (2)
4 to 6.1 V
a 5 V power supply
Between MOM1 When turning on
(female) (6) and (2) Max. 0.2 V
buzzer
Between MOM1 When turning off
(female) (6) and (2) 7 to 15 V
buzzer
If no failure is found by check on cause 4, switch panel of machine
monitor is defective.
Defective switch panel of
5 a When not using T-adapter for connector MOM1 (070-6), if no failure
machine monitor
is found by checks on causes 2 and 3, replace switch panel of
machine monitor to check whether switch panel is defective.
If no failure is found by above checks, monitor controller may be
6 Defective monitor controller
defective.
If you cannot perform check on cause 4 for some reason, take it that
7 Defective wiring harness
wiring harness is defective.

WA470-7 40-905
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness between monitor controller and switch panel of machine monitor

Circuit diagram between monitor controller and switch panel of machine monitor

40-906 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-15 Rear view monitor does not light up or backlight flickers (WA380_7-FHH-400-A-
Z0-A)

Failure Rearview monitor does not light up or backlight flickers.


Related information
No. Cause Procedure, measuring location, criteria and remarks
If fuse is blown, circuit may have ground fault, etc. (See check on cause
1 Defective fuse 3 in fuse box 2 4.)

1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RVM1) of wiring harness connected to
rearview monitor, and repeat connection and disconnection of
2 Defective harness connector
connector.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RVM1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RVM1 (female) (1) and (2) 20 to 30 V
Voltage
Open circuit in wiring harness Between RVM1 (female) (12) and (2) 20 to 30 V
3 (wire breakage or defective 1. Check that system operating lamp does not light up, and then set
contact of connector) battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RVM1 and S_FS, and connect T-adapters to
each female side.
4. Remove fuse 3 in fuse box 2 (FS9).
Between RVM1 (female) (1) and FS9-3 Max. 1 z
Resis- Between RVM1 (female) (2) and ground Max. 1 z
tance Between RVM1 (female) (12) and S_FS
(female) (4) Max. 1 z

1. Turn starting switch to OFF position.


2. Disconnect connector RVM1, and connect T-adapters to female
Ground fault in wiring harness side.
4
(contact with ground circuit) 3. Remove fuse 3 in fuse box 2 (FS9).
Resis- Between ground and RVM1 (female) (1) or
Min. 1 Mz
tance FS9-3
If no failure is found by above checks, rearview monitor may be
5 Defective rearview monitor
defective.
If you cannot perform check on cause 3 for some reason, take it that
6 Defective wiring harness
wiring harness is defective.

WA470-7 40-907
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to rearview monitor power supply

40-908 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness of rearview monitor

WA470-7 40-909
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-16 Rear view monitor images are not displayed clearly (WA380_7-FHJ-400-A-Z0-A)

Failure Rearview monitor images are not displayed clearly.


• As T-adapter for monitor controller connector is "socket-type box", operating voltage
Related cannot be measured at monitor controller connector.
information a Rearview monitor connector RVM2 is a 070 type connector with 8 pins, and T-adapter for
this connector is newly developed.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connectors (RVM1) and (RVM2) of wiring harness
Defective harness connected to rearview monitor, and repeat connection and disconnection
1
connector of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RVM1, and connect T-adapters to female side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RVM1 (female) (1) and (2) 20 to 30 V
Voltage
Open circuit in wiring Between RVM1 (female) (12) and (2) 20 to 30 V
harness a If no failure is found by above checks, this check is not required.
2 (wire breakage or 1. Check that system operating lamp does not light up, and then set battery
defective contact of disconnect switch to OFF position.
connector) 2. Turn starting switch to OFF position.
3. Disconnect connectors RVM1 and S_FS, and connect T-adapters to each
female side.
4. Remove fuse 3 in fuse box 2 (FS9).
Between RVM1 (female) (1) and FS9-3 Max. 1 z
Between RVM1 (female) (2) and ground Max. 1 z
Resistance
Between RVM1 (female) (12) and S_FS (female)
(4) Max. 1 z

1. Check that system operating lamp does not light up, and then set battery
disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Insert T-adapter into connector RVM1.
4. Disconnect connector RVM2 and connect T-adapters to male side.
Defective rearview 5. Turn battery disconnect switch to ON position.
3
monitor 6. Turn starting switch to ON position.
Between RVM2 (male) (1) and RVM1 (2) 8 ± 0.8 V
Voltage Between RVM2 (male) (5) and RVM1 (2) Max. 0.2 V
Between RVM2 (male) (8) and RVM1 (2) Max. 0.2 V

40-910 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector G06 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between G06 (female) (1) and (4) 8 ± 0.8 V
Open circuit in wiring
harness 1. Turn starting switch to OFF position.
4 2. Disconnect connectors G06 and RVM2, and connect T-adapters to each
(wire breakage or
female side.
defective contact of
3. Turn starting switch to ON position.
connector)
Between G06 (female) (1) and RVM2 (female) (1) Max. 1 z
Between G06 (female) (2) and RVM2 (female) (2) Max. 1 z
Resistance
Between G06 (female) (4) and RVM2 (female) (5),
(8) Max. 1 z
Defective rearview If no failure is found by above checks, rearview camera may be defective.
5
camera
Defective wiring
If T-adapter is not available, take it that wiring harness or rearview monitor is
6 harness or rearview
defective.
monitor

Wiring harness of rearview monitor

WA470-7 40-911
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to rearview monitor power supply

40-912 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-17 Rear view monitor brightness cannot be adjusted (WA380_7-FHK-400-A-Z0-A)

Failure Rearview monitor brightness cannot be adjusted.


Related information
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse 11 in fuse box
1 If fuse is blown, circuit may have ground fault. (See check on cause 5.)
1 (FS8)
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RVM1) of wiring harness connected to
rearview monitor, and repeat connection and disconnection of
connector.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
2 Defective harness connector
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (S_RV) of wiring harness connected to
brightness switch, and repeat connection and disconnection of
connector.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RVM1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between RVM1 Brightness adjustment
(female) (5) and (2) switch (+): OFF Max. 0.2 V
Between RVM1 Brightness adjustment
(female) (5) and (2) switch (+): ON 20 to 30 V
Voltage
Between RVM1 Brightness adjustment
(female) (6) and (2) switch (-): OFF Max. 0.2 V
Open circuit in wiring harness
3 (wire breakage or defective Between RVM1 Brightness adjustment
(female) (6) and (2) switch (-): ON 20 to 30 V
contact of connector)
a If no failure is found by above checks, this check is not required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RVM1 and S_RV, and connect T-adapters to
each female side.
4. Remove fuse No. 11 in fuse box 1 (FS8).
Between S_RV (female) (5) and FS8-11 Max. 1 z
Between S_RV (female) (4) and RVM1
Resis- (female) (5) Max. 1 z
tance
Between S_RV (female) (6) and RVM1
(female) (6) Max. 1 z
4 Defective rearview monitor If no failure is found by above checks, rearview monitor is defective.

WA470-7 40-913
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RVM1 and S_RV, and connect T-adapters to
Ground fault in wiring harness female side of S_RV.
5 4. Remove fuse No. 11 in fuse box 1 (FS8).
(contact with ground circuit)
Resis- Between ground and S_RV (female) (5) or
Min. 1 Mz
tance FS8-11
Between S_RV (female) (4) and ground Min. 1 Mz
Between S_RV (female) (6) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Remove brightness adjustment switch.
Between S_RV (male) Brightness adjustment
(5) and (4) switch (+): OFF Min. 1 Mz
Defective brightness Between S_RV (male) Brightness adjustment
6 adjustment switch Max. 1 z
Resis- (5) and (4) switch (+): ON
tance Between S_RV (male) Brightness adjustment
(5) and (6) switch (-): OFF Min. 1 Mz
Between S_RV (male) Brightness adjustment
(5) and (6) switch (-): ON Max. 1 z
Defective brightness
If T-adapter is not available, take it that brightness adjustment switch,
7 adjustment switch, wiring
wiring harness, or rearview monitor is probably defective.
harness, or rearview monitor

Wiring harness of rearview monitor

40-914 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to brightness adjustment switch of rearview monitor

WA470-7 40-915
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-18 Night lighting lamp of rear view monitor is abnormal (WA380_7-FHL-400-A-Z0-A)

Failure Night lighting lamp of rearview monitor is abnormal.


• Night lighting lamp of rearview monitor lights up only when clearance lamp is turned
Related information on while monitor brightness selector switch is at the night mode.
• Check whether night lighting lamp of meter unit of machine monitor is also unusual.
No. Cause Procedure, measuring location, criteria and remarks
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Visually check connector (RVM1) of wiring harness connected to
rearview monitor and connector of night lighting switch, and repeat
1 Defective harness connector
connection and disconnection of connectors.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
If normal conditions are restored, cause of failure is defective contact of
connector.
a If night lighting lamp of meter unit lights up, this check is not
required.
1. Turn starting switch to OFF position.
Defective monitor brightness 2. Disconnect connector S_F7 and connect T-adapter to male side.
2 selector (night lighting) switch Between S_F7 (male) Brightness selector
Min. 1 Mz
Resis- (5) and (4) switch: OFF
tance Between S_F7 (male) Brightness selector
(5) and (4) Max. 1 z
switch: ON
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connector RVM1, and connect T-adapters to female
side.
4. Turn battery disconnect switch to ON position.
5. Turn starting switch to ON position.
6. Lighting up of clearance lamp
Between RVM1 Night lighting switch:
(female) (8) and (2) Max. 0.2 V
OFF
Open circuit in wiring harness Voltage
Between RVM1 Night lighting switch:
3 (wire breakage or defective (female) (8) and (2) 20 to 30 V
ON
contact of connector)
a If no failure is found by above checks, this check is not required.
1. Check that system operating lamp does not light up, and then set
battery disconnect switch to OFF position.
2. Turn starting switch to OFF position.
3. Disconnect connectors RVM1, S_F7, S_RV, and connect T-
adapters to each female side.
Between S_F7 (female) (4) and RVM1
Max. 1 z
Resis- (female) (8)
tance Between L04 (female) (2) and S_F7 (female)
(5) Max. 1 z
If no failure is found by check on cause 3, rearview monitor is defective.
a When not using T-adapter for connector RVM1 (070-12)
1. Turn battery disconnect switch to ON position.
4 Defective rearview monitor 2. Turn starting switch to ON position.
3. Turn on night lighting switch.
If night lighting of LCD unit , meter unit, LED unit, and switch panel of
machine monitor is normal, rearview monitor is defective.

40-916 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Wiring harness of rearview monitor

Circuit diagram related to night lighting switch of rearview monitor

WA470-7 40-917
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-19 Some items of gauges and caution lamps on machine monitor are
not displayed properly (WA500_7-FHP-400-A-Z0-A)
Failure Some gauges and caution lamps are not displayed normally.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
Perform troubleshooting for failure code related to defective sensor or
1 Defective sensor or switch
switch.
Defective CAN communication Perform troubleshooting for failure code related to defective CAN
2 system communication.
If no failure is found by above checks, machine monitor is defective.
3 Defective machine monitor
(Since this is an internal defect, troubleshooting cannot be performed.)

40-918 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-20 Parking brake indicator lamp does not light when the parking brake
is set to ON (Parking) position (WA500_7-HP6-400-A-Z0-A)
k Be sure to chock the wheels. When performing troubleshooting with parking brake released, be
sure to depress foot brake pedal (two persons required for this work).
• Parking brake indicator lamp does not light when the parking brake is set to ON (Parking)
position.
• Short circuit or ground fault of parking brake indicator switch circuit
Failure • The parking brake detector circuit (MCM1 A (71 pin)) is at GND level even when the
parking brake switch is operated.
• The parking brake does not apply.
• If normal, the parking brake indicator (oil pressure) switch turns OFF when the parking
brake switch is set to ON (Parking) because oil pressure will not act on the switch.
• When 24 V is applied to parking brake solenoid, parking brake is released.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
Related • For operation of parking brake relay (L120), see failure code [2F00MA].
information • Make sure that fuse No. 3 of fuse box 1 is not blown.
• Input signal (ON/OFF) from the parking brake indicator switch can be checked with
monitoring function (Code: 04510 Parking Brake Press SW).
• Input signal (ON/OFF) (neutralizer signal) from the parking brake switch can be checked
with monitoring function (Code: 02215 Parking Brake Switch).
• See E-33.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Interchange relay L120 with horn relay L119.
Defective parking brake relay 3. Turn starting switch to ON position.
1 (L120) 4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L120 is
defective.
• When failure code [D1E6KA], [D1E6KB] or [D1E6KY] is displayed,
perform troubleshooting for it first.
1. Turn starting switch to OFF position.
2. Interchange relay L133 with horn relay L119.
Defective auto-idle stop
2 3. Turn starting switch to ON position.
parking brake relay L133
4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L133 is
defective.
1. Turn starting switch to OFF position.
Defective parking brake 2. Disconnect connector PB.SW and connect T-adapters to female
indicator switch side.
3
Between PB.SW (male) (1) and (2) Min. 1 Mz
(internal short circuit) Resis-
Between ground and each of PB.SW
tance Min. 1 Mz
(male) (1) and (2)

WA470-7 40-919
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


• Parking brake switch operation line
1. Turn starting switch to OFF position.
2. Disconnect connectors L62 and L63, and insert T-adapters into
them.
3. Turn starting switch to ON position.
Parking brake
20 to 30 V
Between L62 (6) and switch: Release
Voltage
L63 (31) Parking brake
switch: Parking Max. 3 V
• Parking brake oil pressure switch line
1. Turn starting switch to OFF position.
Open circuit, short circuit, or 2. Disconnect connectors MCM1 A and PB.SW, and connect T-
4 hot short circuit in wiring adapters to each female side.
harness Between MCM1 A (female) (71) and PB.
Resis- SW (female) (1) Max. 1 z
tance
Between PB.SW (female) (2) and ground Max. 1 z
• Parking brake solenoid line
1. Turn starting switch to OFF position.
2. Disconnect connector PB.PS and connect T-adapters to female
side.
3. Turn starting switch to ON position.
Parking brake
20 to 30 V
Between PB.PS (1) and switch: Release
Voltage
(2) Parking brake
switch: Parking Max. 3 V

1. Turn starting switch to OFF position.


Ground fault in wiring harness 2. Disconnect connectors MCM1 A and PB.SW, and connect T-
5 adapters to either female side.
(contact with ground circuit)
Resis- Between ground and MCM1 A (female)
Min. 1 Mz
tance (71) or PB.SW (female) (1)
1. Turn starting switch to OFF position.
2. Connect T-adapters to connector S_FA (male).
3. Start engine.
Parking brake
Max. 1 z
Between S_FA (male) switch: Release
Defective parking brake
6 (3) and (4) Parking brake
switch Min. 1 Mz
Resis- switch: Parking
tance Parking brake
Min. 1 Mz
Between S_FA (male) switch: Release
(5) and (6) Parking brake
switch: Parking Max. 1 z

1. Turn starting switch to OFF position.


Defective parking brake 2. Disconnect connector PB.PS and connect T-adapters to male side.
7
solenoid Resis- Between PB.PS (male) (1) and (2) 20 to 60 z
tance Between PB.PS (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector DIODE, and connect T-adapters to diode.
Defective diode DIODE
8
(internal open or short circuit) a Check by using multimeter in diode range.
Continu- Between DIODE (male) (1) (+) and (2) (-) No continuity
ity Between DIODE (male) (2) (+) and (1) (-) Continuity

40-920 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
9
controller
Between L63 (18) and Parking brake
Voltage Max. 4.5 V
(31) switch: Parking
Check parking brake oil pressure. (See "Testing and adjusting".)
Defective parking brake a Start engine and perform troubleshooting.
10 hydraulic circuit
Parking brake 0.34 MPa {3.5
Parking brake pressure
switch: ON. kg/cm2 } Max
If no failure is found by above checks, monitor controller is defective.
11 Defective monitor controller (Since this is an internal defect, troubleshooting cannot be performed).

WA470-7 40-921
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to parking brake

40-922 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-21 When brake accumulator oil pressure drops, the brake oil pressure
caution lamp does not light (WA470_7-FP7-400-A-Z0-A)
When brake accumulator oil pressure drops, the brake oil pressure caution lamp does not
Failure light.
• Short circuit or ground fault of front brake accumulator pressure switch
• If normal, the brake accumulator pressure switch turns OFF when the brake oil pressure
drops.
Related • When front brake accumulator oil pressure drops, the brake oil pressure caution lamp
information does not light.
• Input signal (ON/OFF) from the front brake accumulator pressure switch can be checked
with monitoring function (Code: 04510 "Front Brake Oil Press").
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective front brake 2. Make sure that the brake oil pressure is 3.9 MPa {40 kg/cm2} or lower.
accumulator pressure 3. Disconnect connector R52 and connect T-adapters to male side.
1 switch (internal short
circuit) Between R52 (male) (1) and (2) Min. 1 Mz
Resistance
Between R52 (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and R52, and connect T-adapters to
2 either female side.
(contact with ground
Between ground and MCM1 A (female) (73) or R52
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors MCM1 A and R52, and connect T-adapters to
Short circuit in wiring
3 either female side.
harness
Between MCM1 A (female) (73) and (17), or
Resistance between R52 (female) (1) and (2) Min. 1 Mz
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
4 this is an internal defect, troubleshooting cannot be performed).
controller

WA470-7 40-923
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

• When the rear brake accumulator oil pressure drops, the brake oil pressure caution lamp
Failure does not light.
• Short circuit or ground fault of rear brake accumulator pressure switch
• If normal, the brake accumulator pressure switch turns OFF when the brake oil pressure
drops.
Related • When the rear brake accumulator oil pressure drops, the brake oil pressure caution lamp
information does not light.
• Input signal (ON/OFF) from the rear brake accumulator pressure switch can be checked
with monitoring function (Code: 04510 "Rear Brake Oil Press").
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective rear brake 2. Make sure that the brake oil pressure is 3.9 MPa {40 kg/cm2} or lower.
accumulator pressure 3. Disconnect connector R54 and connect T-adapters to male side.
1 switch (internal short
circuit) Between R54 (male) (1) and (2) Min. 1 Mz
Resistance
Between R54 (male) (1) and ground Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and R54, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and MCM1 A (female) (72) or R54
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors MCM1 A and R54, and connect T-adapters to
Short circuit in wiring
3 either female side.
harness
Between MCM1 A (female) (72) and (17), or
Resistance between R54 (female) (1) and (2) Min. 1 Mz
Defective monitor If no failure is found by above checks, monitor controller is defective. (Since
4 this is an internal defect, troubleshooting cannot be performed).
controller

Circuit diagram related to brake accumulator

40-924 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-22 Air cleaner clogging indicator lamp does not light (WA470_7-HP1-400-A-Z0-A)

Failure When the air cleaner is clogged, air cleaner clogging indicator lamp does not light up.
• Ground fault in dust indicator circuit
• When the air cleaner is clogged, its sensor circuit is held to the "CLOSE" (not clogged)
state.
• Voltage at MCM1 A (53) is GND level when air cleaner is normal, and 16 to 24 V when air
General
cleaner is clogged (circuit is open).
information
• Input signal (ON/OFF) from air cleaner clogging sensor can be checked with monitoring
function. (Code: 04509 Air cleaner clogging sensor).
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector E45, and connect T-adapter to male side.
Defective air cleaner 3. Turn starting switch to ON position.
1 clogging sensor
Air cleaner is normal. Max. 1 z
Resistance Between E45 (1) and (2)
Air cleaner is clogged. Min. 1 Mz
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and E45, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and MCM1 A (female) (53) or E45
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors MCM1 A and E45, and connect T-adapters to each
Short circuit in wiring
3 female side.
harness
Between MCM1 A (female) (53) and (17), or
Resistance between E45 (female) (1) and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapter into connector E45.
Defective monitor 3. Turn starting switch to ON position.
4
controller
Air cleaner is normal. Max. 1 V
Voltage Between E45 (1) and (2)
Air cleaner is clogged. 16 to 24 V

Circuit diagram related to air cleaner clogging sensor

WA470-7 40-925
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-23 Radiator coolant level caution lamp does not light (WA380_7-HP2-400-A-Z0-A)

When the radiator coolant (or cooling water) is insufficient, the radiator coolant level caution
Failure lamp does not light.
• Short circuit or ground fault of coolant level sensor
• When the radiator coolant (or cooling water) is insufficient, both radiator coolant level
sensor is closed (normal).
Related (The engine may be damaged.)
information • Input signal (ON/OFF) from coolant level sensor can be checked with monitoring function.
(Code: 04509 Engine coolant level sensor)
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R32, and connect T-adapters to each male side.
Defective radiator Radiator coolant level
1 Max. 1 z
coolant level switch Between R32 (male) (1) normal
Resistance and (2)
Radiator coolant level
Min. 1 Mz
low
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A, R32, and connect T-adapter to either
2 female side.
(contact with ground
Between ground and MCM1 A (female) (48) or R32
circuit) Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connector MCM1 A, and connect T-adapters to female side.
Short circuit in wiring 3. Turn starting switch to ON position.
3 Between MCM1 A (female) (48) and (9)
harness Min. 1 Mz
Resistance Between MCM1 A (female) (48) and (13) Min. 1 Mz
Between MCM1 A (female) (48) and (17) Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector R32.
3. Turn starting switch to ON position.
Defective monitor
4 Radiator coolant level
controller Max. 1 V
Voltage Between R32 (1) and (2) normal
Radiator coolant level
16 to 24 V
low

40-926 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to radiator coolant level sensor

WA470-7 40-927
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-24 Indication of hydraulic oil temperature gauge does not increase, or


hydraulic oil temperature caution lamp does not light (WA470_7-BE4-400-A-Z0-A)
• Indication of hydraulic oil temperature gauge does not increase, or hydraulic oil
Failure temperature caution lamp does not light.
• Open circuit of hydraulic oil temperature sensor
• When the hydraulic oil temperature increases, the indication of hydraulic oil temperature
gauge does not increase.
• When the hydraulic oil temperature exceeds 110°C, the hydraulic oil temperature caution
lamp does not light.
Related • Input voltage from hydraulic oil temperature sensor can be checked with monitoring
information function.
(Code: 04404 Hydraulic Oil Temperature Sensor Voltage)
• Oil temperature sensed by hydraulic oil temperature sensor can be checked with
monitoring function.
(Code: 04401 Hydraulic Oil Temperature)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R47 and connect T-adapter to male side.
Defective hydraulic oil Hydraulic oil
1 temperature sensor Between temperature: Max. 25°C 35 to 50 kz *
Resistance R47 (male) (room temperature)
(1) and (2) Hydraulic oil
temperature: 100°C 3.1 to 4.5 kz *

1. Turn starting switch to OFF position.


2. Disconnect connector L61 and connect T-adapter to female side.
Open or short circuit in Hydraulic oil
2 Between temperature: Max. 25°C
wiring harness 35 to 50 kz
L61 (room temperature)
Resistance (female)
(20) and (4) Hydraulic oil
temperature: 100°C 3.1 to 4.5 kz
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L61 and R47, and connect T-adapters to each
3 (wire breakage or female side.
defective contact of Between L61 (female) (20) and R47 (female) (1) Max. 1 z
connector) Resistance
Between L61 (female) (4) and R47 (female) (2) Max. 1 z
Defective transmission If no failure is found by above checks, transmission controller is defective.
4 (Since this is an internal defect, troubleshooting cannot be performed).
controller
*: For average resistance of sensors at each temperature, see [DGR2KB].

40-928 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to hydraulic oil temperature sensor

WA470-7 40-929
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-25 Indication of torque converter oil temperature gauge does not


increase, or torque converter oil temperature caution lamp does not
light (WA500_7-BE3-400-A-Z0-A)
Indication of torque converter oil temperature gauge does not increase, or torque converter
Failure oil temperature caution lamp does not light.
• Open circuit of torque converter oil temperature sensor
• When the torque converter oil temperature increases, the indication of torque converter oil
temperature gauge does not increase.
• When the torque converter oil temperature exceeds 120°C, the torque converter oil
temperature caution lamp does not light.
Related • Input status (oil temperature) from torque converter oil temperature sensor can be
information checked with monitoring function.
(Code: 32100 T/C Oil Temperature)
• Input status (voltage) from torque converter oil temperature sensor can be checked with
monitoring function.
(Code: 32101 T/C Oil Temp. Sensor Volt)
No. Cause Procedure, measuring location, criteria and remarks
Defective torque converter oil
1 Troubleshoot for failure code [DGT1KA].
temperature gauge

40-930 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-26 Fuel level gauge does not indicate correct level (WA470_7-FGB-400-A-Z0-A)

Failure Fuel level gauge does not indicate correct level.


• Input voltage from fuel level sensor can be checked with monitoring function.
Related (Code: 04200 Fuel Level Sensor [V])
information • Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective fuel level 2. Disconnect connector R33, and connect T-adapters to male side.
sensor
1 Between R33 (male) (1) and (2) FULL Max. 12 z
(internal open or short
circuit) Resistance a Fuel level sensor characteristics EMPTY 80 to 100 z
Between R33 (male) (2) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector R33, and connect T-adapters to female side.
3. Turn starting switch to ON position.
Open circuit, short a If voltage is 0 V, wiring harness has open circuit, ground fault, or short
2 circuit, or ground fault in circuit, and if voltage is 24 V, wiring harness has hot short circuit.
wiring harness
a Voltage of approximately 3.3 V is applied to fuel level sensor signal line
through resistor inside monitor controller.
Voltage Between R33 (female) (1) and (2) Approx. 3.3
V
a If no failure is found by check on cause 2, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connector MCM1 A, and connect T-adapters to female side.
Open or short circuit in a Use fuel level sensor characteristics table for check on cause 1 as
3 wiring harness resistance criteria.
a If resistance is 1 Mz or higher, harness has open circuit. If it is 1 z or
below, harness has short circuit.
Approx. 4 to
Resistance Between MCM1 A (female) (8) and (9)
100 z
a If no failure is found by check on cause 2 or 3, this check is not required.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and R33, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of Between MCM1 A (female) (8) and R33 (female)
(1) Max. 1 z
connector) Resistance
Between MCM1 A (female) (9) and R33 (female)
(2) Max. 1 z

a If no failure is found by check on cause 2, this check is not required.


Ground fault in wiring
1. Turn starting switch to OFF position.
harness
5 2. Disconnect connectors MCM1 A and R33, and connect T-adapter to either
(contact with ground female side.
circuit) Between ground and MCM1 A (female) (8) or R33
Resistance (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors MCM1 A and R33, and connect T-adapters to
female side of MCM1 A.
Short circuit in wiring
6
harness a Check by using multimeter in continuity mode.
Between MCM1 A (female) (8) and No continuity
Continuity
each pin other than pin (8) (No sound is heard)
Defective monitor If no failure is found by above checks, monitor controller is defective.
7
controller

WA470-7 40-931
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to fuel level sensor

40-932 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-27 Seat belt caution lamp indication is abnormal (WA500_7-FHQ-400-A-Z0-A)

Seat belt caution lamp lights up even when seat belt is fastened, or caution lamp does
Failure not light up when seat belt is not fastened.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Connect T-adapters to connector SBS (male).
3. Check switch itself.
1 Defective seat belt switch When seat belt is
Between SBS (male) fastened Max. 1 z
Resis-
tance (1) and (2) When seat belt is not
Min. 1 Mz
fastened
1. Turn starting switch to OFF position.
2. Disconnect connectors MCM1 A and SBS, and connect T-adapters
Open circuit in wiring harness to each female side.
2 (wire breakage or defective Between MCM1 A (female) (29) and SBS
Max. 1 z
contact of connector) Resis- (female) (1)
tance Between MCM1 A (female) (13) and SBS
(female) (2) Max. 1 z

1. Turn starting switch to OFF position.


Ground fault in wiring harness 2. Disconnect connectors MCM1 A and SBS.
3 3. Connect T-adapter to MCM1 A.
(contact with ground circuit)
Resis- Between ground and MCM1 A (female) (29) or
SBS (female) (1) Min. 1 Mz
tance
If no failure is found by above checks, monitor controller is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector SBS.
4 Defective monitor controller 3. Turn starting switch to ON position.
When seat belt is
Between SBS (1) and fastened Max. 1 V
Voltage
(2) When seat belt is not
7 to 9 V
fastened

Circuit diagram related to seat belt switch

WA470-7 40-933
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-28 Horn does not sound (WA470_7-KA2-400-A-Z0-A)

Failure Horn does not sound.


Related
information
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse 1 in fuse If fuse 1 in fuse box 1 is blown, circuit probably has ground fault. In this case,
1 perform check on cause 7 first.
box 1
1. Turn starting switch to OFF position.
Defective horn relay 2. Replace horn relay (connector: L119) with another relay.
2 (internal open or short 3. Turn starting switch to ON position.
circuit) 4. Sound horn.
If horn sounds, original horn relay is defective.

Defective horn switch 1. Turn starting switch to OFF position.


2. Disconnect connector S_RHA and connect T-adapters to each male side.
3 (internal open or short
circuit) Between S_RHA (male) Switch: OFF Min. 1 Mz
Resistance (1) and (2) Switch: ON Max. 1 z
Defective horn high 1. Turn starting switch to OFF position.
sound (F03) or horn low 2. Disconnect connectors F03 and F04.
4 sound (F04) (internal Continuity Between F03 (male) (1) and (2) Continuity
open or short circuit) Continuity Between F04 (male) (1) and (2) Continuity
1.Turn starting switch to OFF position.
2.Disconnect connector L119, and connect T-adapters to female side.
Defective wiring 3.Turn starting switch to ON position.
5 4.Press horn switch.
harness
Between L119 (female) (1) and (2) 20 to 30 V
Voltage
Between L119 (female) (3) and (2) 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L119, F03, F04, and connect T-adapters to each
female side.
3. Press horn switch.
Between F03 (female) (1) and ground Continuity
Continuity Between F04 (female) (1) and ground Continuity
Open circuit in wiring Between L119 (female) (2) and ground Continuity
harness
a If no failure is found in above checks, this check is not required.
6 (wire breakage or
1. Turn starting switch to OFF position.
defective contact of
2. Remove fuse 1 in fuse box 1.
connector)
3. Disconnect connectors L119 and S_RHA, and connect T-adapters to each
female side.
Between FS8-1 and L119 (female) (1) Max. 1 z
Between L119 (female) (1) and (3) Max. 1 z
Resistance Between S_RHA (female) (1) and L119 (female) (2) Max. 1 z
Between S_RHA (female) (2) and ground Max. 1 z

40-934 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


a If fuse is not blown, this check is not required.
1.Turn starting switch to OFF position.
Ground fault in wiring 2.Remove fuse 1 in fuse box 1.
harness 3.Disconnect connectors L119, F03, F04, and connect T-adapters to female
7
(contact with ground side of L119.
circuit) Between L119 (female) (1) and ground Min. 1 Mz
Resistance Between L119 (female) (3) and ground Min. 1 Mz
Between L119 (female) (5) and ground Min. 1 Mz
Defective horn
8 If no failure is found by above checks, horn may be defective.
(internal defect)

WA470-7 40-935
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to horn

40-936 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-29 Horn does not stop sounding (WA470_7-KB2-400-A-Z0-A)

Failure Horn does not stop sounding.


Related
information
No. Cause Procedure, measuring location, criteria and remarks
Defective horn relay 1. Turn starting switch to OFF position.
(L119) 2. Remove horn relay (connector L119).
1 3. Turn starting switch to ON position.
(internal open or short
circuit) If horn stops sounding, original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors F03 and F04, and connect T-adapters to each
Hot short circuit in female side.
2 wiring harness 3. Turn starting switch to ON position.
Between F03 (female) (2) and (1) Max. 1 V
Voltage
Between F04 (female) (2) and (1) Max. 1 V

WA470-7 40-937
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to horn

40-938 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-30 Alarm buzzer does not sound (WA380_7-KA7-400-A-Z0-A)

Failure Alarm buzzer does not sound.


• Open circuit or ground fault of alarm buzzer output circuit
• Output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked
with monitoring function.
Related
(Code: 04700 Buzzer)
information
• If failure code [DV00KB] (alarm buzzer short circuit) is displayed, troubleshoot it first.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L20, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Defective alarm buzzer a If following voltages are normal and alarm buzzer does not sound, alarm
1 (internal short circuit) buzzer is defective.
Alarm buzzer: OFF Max. 1 V
Between L20 (female) When driving alarm
Voltage
(1) and (2) buzzer (when starting 20 to 30 V
engine)

Open circuit in wiring 1. Turn starting switch to OFF position.


harness 2. Disconnect connectors MCM1 A and L20, and connect T-adapters to each
female side.
2 (wire breakage or Between MCM1 A (female) (20) and L20 (female)
defective contact of Max. 1 z
connector) Resistance (1)
Between L20 (female) (2) and ground Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors MCM1 A and L20, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and MCM1 A (female) (20) or L20
circuit) Resistance (female) (1) Min. 1 Mz
Defective monitor If no failure is found by above checks, monitor controller is defective.
4
controller

Circuit diagram related to alarm buzzer

WA470-7 40-939
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-31 When starting switch is in ON position, alarm buzzer does not stop
sounding (WA470_7-KB3-400-A-Z0-A)
Failure When starting switch is in ON position, alarm buzzer does not stop sounding.
• If any failure code is displayed, perform troubleshooting for that code first.
• Signal (ON/OFF) to alarm buzzer can be checked with monitoring function.
Related
(Code: 04700 Buzzer)
information
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L20, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Hot short circuit in Under condition that
1 wiring harness alarm buzzer does not Max. 1 V
sound
Voltage Between L20 (1) and (2)
For approx. 1 second
after starting switch is Min. 20 V
turned to ON position
Defective monitor If no failure is found by above checks, monitor controller is defective.
2
controller

Circuit diagram related to alarm buzzer

40-940 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-32 Kickdown does not work when kickdown switch is turned ON (WA380_7-
F80-400-A-Z0-A)

Failure Kickdown does not work when kickdown switch is turned ON.
• Open circuit or hot short circuit kickdown system
• Input condition (ON/OFF) from the kickdown switch can be checked with monitoring
Related information function
(Code: 02212 Kick Down Switch)
• If failure code [DDW9LD] is displayed, troubleshoot it first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Defective kickdown switch Between L14 (male) Kickdown switch: ON Max. 1 z
1
(internal open circuit) Resis- (1) and (2) Kickdown switch: OFF Min. 1 Mz
tance Between ground and each of L14 (male) (1)
and (2) Min. 1 Mz

1. Turn starting switch to OFF position.


Open circuit in wiring harness 2. Disconnect connectors L63 and L14, and connect T-adapters to
2 (wire breakage or defective each female side.
contact of connector) Resis- Between L63 (female) (9) and L14 (female) (1) Max. 1 z
tance Between L14 (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector L14, and connect T-adapters to female side.
3 3. Turn starting switch to ON position.
harness
Voltage Between L14 (female) (1) and (2) 7 to 9 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
4
controller
Between L63 (9) and Kickdown switch: ON Max. 1 V
Voltage
ground Kickdown switch: OFF 7 to 9 V

WA470-7 40-941
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to kick-down switch and hold switch

40-942 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-33 The hold switch does not work when it is pressed (WA380_7-F90-400-A-Z0-A)

Failure The hold switch does not work when it is pressed.


• Open circuit or hot short of hold switch system
• The hold switch cannot be switched.
• Input condition (ON/OFF) from the hold switch can be checked with monitoring
Related information function
(Code: 02212 Hold Switch)
• If failure code [DDWLLD] is displayed, troubleshoot it first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector L14 and connect T-adapter to male side.
Defective hold switch Between L14 (male) Hold switch: ON Max. 1 z
1
(internal open or short circuit) Resis- (3) and (4) Hold switch: OFF Min. 1 Mz
tance Between ground and each of L14 (male) (3)
and (4) Min. 1 Mz

1. Turn starting switch to OFF position.


Open circuit in wiring harness 2. Disconnect connectors L63 and L14, and connect T-adapters to
2 (wire breakage or defective each female side.
contact of connector) Resis- Between L63 (female) (19) and L14 (female)
(3) Max. 1 z
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector L14, and connect T-adapters to female side.
3 3. Turn starting switch to ON position.
harness
Voltage Between L14 (female) (3) and (4) 7 to 9 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
4
controller
Between L63 (19) and Hold switch: ON Max. 1 V
Voltage
ground Hold switch: OFF 7 to 9 V

WA470-7 40-943
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to kick-down switch and hold switch

40-944 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-34 Parking brake does not work even if it is applied, or the brake drags
when parking brake is released and FR drive is operated (WA470_7-BHM-400-A-Z0-A)
k Be sure to chock wheels. When performing troubleshooting with parking brake released, be sure
to depress the brake pedal (two persons required for this work).
Parking brake does not work even if it is applied, or the brake drags when parking brake is
Failure released and FR drive is operated.
• Input signal (ON/OFF status) from the neutralizer (parking brake) switch can be checked
with monitoring function (Code: 02215 Parking Brake Switch).
• When 24 V is applied to parking brake solenoid, parking brake is released.
• Since T-adapter for monitor controller connector is "socket-type box", operating voltage
cannot be measured at monitor controller connector.
• Parking brake relay L120 works as self-holding relay.
Related 1. When parking brake switch is operated, pin 5 and pin 6 of parking brake switch are
information connected with each other.
2. Parking brake relay is engaged and L120 works as self-holding relay.
3. When parking brake switch is set to Release position, pin 3 and pin 4 of parking brake
are connected with each other. Since L120 remains engaged, power is supplied to pin
4 of parking brake switch and then flows to L62 (6) pin of transmission controller.
4. If voltage of L62 (6) pin goes to 20 V or above, transmission controller drives parking
brake solenoid from L63 (18) pin (parking brake is released).
• See E-20, failure code [2F00MA].
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse 3 in fuse If fuse is blown, the circuit may be opened or shorted. (See Cause 6.)
1
box 1
1. Turn starting switch to OFF position.
2. Interchange relay L120 with horn relay L119.
Defective parking brake 3. Turn starting switch to ON position.
2 relay (L120) 4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L120 is defective.
• When failure code [D1E6KA], [D1E6KB] or [D1E6KY] is displayed,
perform troubleshooting for it first.
1. Turn starting switch to OFF position.
Defective auto-idle stop 2. Interchange relay L133 with horn relay L119.
3 parking brake relay 3. Turn starting switch to ON position.
L133 4. Turn the parking brake switch to the Parking position.
5. Start engine.
• If parking brake indicator lamp lights up, original relay L133 is defective.
1. Turn starting switch to OFF position.
Defective parking brake 2. Disconnect connector PB.PS and connect T-adapters to male side.
4
solenoid Between PB.PS (male) (1) and (2) 20 to 60 z
Resistance
Between PB.PS (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector DIODE, and connect T-adapters to diode.
Defective diode DIODE a Check by using multimeter in diode range.
5 (internal open or short No
circuit) Between DIODE (male) (1) (+) and (2) (-)
continuity
Continuity
Between DIODE (male) (2) (+) and (1) (-) Continuity

WA470-7 40-945
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Disconnect connector S_FA and connect T-adapter to male side.
3. Start engine.
Parking brake switch:
Max. 1 z
Between S_FA (male) (3) Release
Defective parking brake
6 and (4) Parking brake switch:
switch Min. 1 Mz
Parking
Resistance
Parking brake switch:
Min. 1 Mz
Between S_FA (male) (5) Release
and (6) Parking brake switch:
Parking Max. 1 z
• Parking brake switch operation line
1. Turn starting switch to OFF position.
2. Disconnect connectors L62 and L63, and insert T-adapters into them.
3. Turn starting switch to ON position.
Parking brake switch:
20 to 30 V
Between L62 (6) and L63 Release
Voltage
(31) Parking brake switch:
Open circuit, short Parking Max. 3 V
7 circuit, or hot short
circuit in wiring harness • Parking brake solenoid line
1. Turn starting switch to OFF position.
2. Disconnect connector PB.PS and connect T-adapters to female side.
3. Turn starting switch to ON position.
Parking brake switch:
20 to 30 V
Between PB.PS (female) Release
Voltage
(1) and (2) Parking brake switch:
Parking Max. 3 V

1. Turn starting switch to OFF position.


2. Disconnect connectors L62, L120, S_FA, and connect T-adapters to either
Ground fault in wiring female side.
harness 3. Remove fuse 3 in fuse box 1 (FS8).
8 Between ground and L62 (female) (8) or S_FA
(contact with ground
(female) (3) Min. 1 Mz
circuit)
Resistance Between S_FA (female) (4) and ground
Min. 1 Mz
Between S_FA (female) (6) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
Defective transmission 3. Turn starting switch to ON position.
9
controller
Between L63 (18) and Parking brake switch:
Voltage Max. 4.5 V
(31) Parking
Check parking brake oil pressure. (See "Testing and adjusting".)

Defective parking brake a Start engine and perform troubleshooting.


10 hydraulic circuit Max 2.5
Parking brake pressure Parking brake switch: MPa {25.5
Release kg/cm2 }

40-946 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to parking brake

WA470-7 40-947
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-35 Transmission cut-off mode is not selected or not released (WA380_7-FA2-


400-A-Z0-A)

Failure Transmission cut-off mode is not selected or not released.


• Defective transmission cut-off switch system
Related • Input condition (ON/OFF) from transmission cut-off switch can be checked with monitoring
information function (Code: 02214 T/M Cut Off Switch).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1, and connect T-adapters to male side.
Defective transmission Turn transmission cut-off
cut-off switch (internal Between S_RH1 (male) Max. 1 z
1 switch: ON
open circuit or short (5) and (6) Transmission cut-off
circuit) Resistance Min. 1 Mz
switch: OFF
Between ground and each of S_RH1 (male) (5) and
(6) Min. 1 Mz
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of
connector) Resistance Between L63 (female) (20) and S_RH1 (female) (6) Max. 1 z

1. Turn starting switch to OFF position.


Hot short circuit in 2. Disconnect connector S_RH1 and connect T-adapter to female side.
3 wiring harness 3. Turn starting switch to ON position.
Voltage Between S_RH1 (female) (6) and ground 7 to 9 V
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapter to either
4 female side.
(contact with ground
Between ground and L63 (female) (20) or S_RH1
circuit) Resistance (female) (6) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Insert T-adapters into connector L63.
3. Turn starting switch to ON position.
Defective transmission
5 Turn transmission cut-off
controller Max. 1 V
Between L63 (20) and switch: ON
Voltage
ground Transmission cut-off
7 to 9 V
switch: OFF

40-948 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to transmission cut-off switch

WA470-7 40-949
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-36 Transmission cut-off setting cannot be released (WA380_7-E21-400-A-Z0-A)

Failure Transmission cut-off setting cannot be released.


• Open circuit or hot short circuit of transmission cut-off set switch
Related • Input condition (ON/OFF) from transmission cut-off set switch can be checked with
information monitoring function (Code: 02214 T/M Cut Off Switch).
• If failure code [DDT4LD] is displayed, troubleshoot it first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1, and connect T-adapters to male
side.
Defective transmission cut-off Transmission cut-off
set switch Between S_RH1 Max. 1 z
1 set switch: ON
(internal open or short circuit) Resis- (male) (4) and (5) Transmission cut-off
Min. 1 Mz
tance set switch: OFF
Between ground and each of S_RH1 (male) (4)
and (5) Min. 1 Mz

1. Turn starting switch to OFF position.


Open circuit in wiring harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapters to
2 (wire breakage or defective each female side.
contact of connector) Resis- Between L63 (female) (30) and S_RH1
(female) (4) Max. 1 z
tance
1. Turn starting switch to OFF position.
2. Disconnect connector S_RH1 and connect T-adapter to female
Hot short circuit in wiring side.
3
harness 3. Turn starting switch to ON position.
Voltage Between S_RH1 (female) (4) and ground 7 to 9 V
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L63 and S_RH1, and connect T-adapter to
4 either female side.
(contact with ground circuit)
Resis- Between ground and L63 (female) (30) or
S_RH1 (female) (4) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L63.
3. Turn starting switch to ON position.
Defective transmission
5 Transmission cut-off
controller Max. 1 V
Between L63 (30) and set switch: ON
Voltage
ground Transmission cut-off
7 to 9 V
set switch: OFF

40-950 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to transmission cut-off switch

WA470-7 40-951
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-37 Directional selector (FNR) switch mode is not selected or not


released (WA380_7-FHS-400-A-Z0-A)
Failure Directional selector (FNR) switch mode is not selected or not released.
• Defective directional selector (FNR) switch mode is not selected (due to ground failure), or
the handle mode is not selected (due to open circuit.)
• The ON/OFF status of directional selector switch actuation switch can be checked with
Related
monitoring function.
information
(Code: 02214 Option FNR Switch)
• Also, you can check the mounting of right directional selector (FNR) switch in the Service
mode of the monitor.
No. Cause Procedure, measuring location, criteria and remarks
Defective directional 1. Turn starting switch to OFF position.
selector switch 2. Disconnect connector S_RH5 and connect T-adapter to male side.
1 actuation switch
(internal open or short Between S_RH5 (male) Switch: OFF Min. 1 Mz
Resistance (5) and (6)
circuit) Switch: ON Max. 1 z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and S_RH5, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between L62 (female) (27) and S_RH5 (female) (6) Max. 1 z
connector) Resistance
Between S_RH5 (female) (5) and ground Max. 1 z
Ground fault in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L62 and S_RH5, and connect T-adapter to either
3 female side.
(contact with ground
Between ground and L62 (female) (27) or S_RH5
circuit) Resistance (female) (6) Min. 1 Mz

1. Turn starting switch to OFF position.


Hot short circuit in 2. Disconnect connector S_RH5 and connect T-adapter to female side.
4 wiring harness 3. Turn starting switch to ON position.
Voltage Between S_RH5 (female) (6) and ground 7 to 9 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
Defective transmission 3. Turn starting switch to ON position.
5
controller
Between L62 (27) and Switch: OFF 7 to 9 V
Voltage
ground Switch: ON Max. 1 V

40-952 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to directional selector (FNR) switch

WA470-7 40-953
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-38 When operating engine power selection switch, engine power


selection function does not operate properly (WA380_7-E22-400-A-Z0-A)
When operating engine power selection switch, engine power selection function does
Failure not operate properly.
• If mechanical system failure code is displayed, perform troubleshooting for that code
Related information
first.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective engine power 2. Disconnect connector S_RH2 and connect T-adapters to male side.
1
selection switch Resis- Between S_RH2 Switch: OFF Min. 1 Mz
tance (male) (5) and (6) Switch: ON Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L72 and S_RH2, and connect T-adapters to
Open circuit in wiring harness each female side.
2 (wire breakage or defective Between L72 (female) (37) and S_RH2
contact of connector) Resis- (female) (6) Max. 1 z
tance
Between S_RH2 (female) (5) and ground Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L72 and S_RH2, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L72 (female) (37) or
S_RH2 (female) (6) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector S_RH2 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
harness
Voltage Between S_RH2 (female) (6) and ground 7 to 9 V
1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L72.
Defective work equipment 3. Turn starting switch to ON position.
5
controller
Between L72 (female) Switch: OFF 7 to 9 V
Voltage
(37) and ground Switch: ON Max. 1 V

40-954 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to engine power selection switch

WA470-7 40-955
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-39 Flow of loader pump does not increase from the minimum
rate (WA380_7-D51-400-A-Z0-A)
Failure Flow of loader pump does not increase from the minimum rate.
• The loader pump is set to the minimum flow rate due to the hot short in the loader pump
Related EPC solenoid circuit.
information • The current value of loader pump EPC solenoid can be checked with monitoring function.
(Code: 94500 Loader Pump EPC Current)
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Hot short circuit in 2. Disconnect connector R71, and connect T-adapter to female side.
1 wiring harness 3. Turn starting switch to ON position.
Voltage Between R71 (female) (2) and (1) Max. 4.5 V
1. Turn starting switch to OFF position.
Open or short circuit in
2 2. Disconnect connector L73, and connect T-adapter to female side.
wiring harness
Resistance Between L73 (female) (35) and (23) 5 to 10 z
Defective work If no failure is found by above checks, work equipment controller is defective.
3 equipment controller (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to loader pump EPC solenoid

40-956 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-40 ECSS function cannot be selected or cannot be released (WA380_7-E50-400-A-


Z0-A)

Failure ECSS function cannot be selected or cannot be released.


• Defective ECSS (Electronically Controlled Suspension System) operating switch system
(The ECSS function cannot be selected due to hot short, or the ECSS function cannot be
Related released due to ground fault).
information • Input condition (ON/OFF) from the ECSS switch can be checked with monitoring function
monitoring function (Code: 02214 E.C.S.S. Switch).
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective ECSS switch 2. Disconnect connector S_F4 and connect T-adapter to male side.
1
(internal open or short circuit) Resis- Between S_F4 (male) Switch: OFF Min. 1 Mz
tance (5) and (6) Switch: ON Max. 1 z
1. Turn starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors L62 and S_F4, and connect T-adapters to
each female side.
2 (wire breakage or defective Between L62 (female) (37) and S_F4 (female)
contact of connector) Resis- (5) Max. 1 z
tance
Between S_F4 (female) (6) and ground Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring harness 2. Disconnect connectors L62 and S_F4, and connect T-adapter to
3 either female side.
(contact with ground circuit)
Resis- Between ground and L62 (female) (37) or S_F4
(female) (5) Min. 1 Mz
tance
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector S_F4 and connect T-adapter to female side.
4 3. Turn starting switch to ON position.
harness
Voltage Between S_F4 (female) (5) and ground 7 to 9 V
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector L62.
Defective transmission 3. Turn starting switch to ON position.
5
controller
Between L62 (37) and Switch: OFF 7 to 9 V
Voltage
ground Switch: ON Max. 1 V

WA470-7 40-957
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to ECSS switch

40-958 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-41 None of headlamp, clearance lamp, and tail lamp lights (WA470_7-HQ1-400-A-Z0-
A)

Failure None of headlamp, clearance lamp, and tail lamp lights.


• All lamps do not light up due to an open circuit or ground fault of lamp system main circuit.
• Headlamp switch at SMALL position: The clearance lamp, tail lamp, and night lighting
lamp of machine monitor switch panel light up.
• Headlamp switch at HEAD position: The clearance lamp, tail lamp, night lighting lamp,
and headlamp light up.
Related • Input condition (ON/OFF) to machine monitor from lamp switch (clearance lamp) can be
information checked with monitoring function (Code: 04507 Night Lighting SW).
• Input condition (ON/OFF) to machine monitor from lamp switch (headlamp) can be
checked with monitoring function (Code: 04507 Head Light SW).
• Input condition (ON/OFF) to machine monitor from dimmer switch (high beam) can be
checked with monitoring function (Code: 04507 High Beam Status).
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse 11 in If fuse is blown, circuit may have ground fault, etc. (See check on cause 4.)
1
fuse box 1
1. Turn starting switch to OFF position.
2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate lamp switch and perform troubleshooting.
OFF Min. 1 Mz
Defective lamp switch Between L04 (male) (1) and (2) SMALL,
Max. 1 z
2 (internal open or short HEAD
circuit) OFF Min. 1 Mz
Resistance Between L04 (male) (1) and (3)
SMALL Min. 1 Mz
HEAD Max. 1 z
Between ground and each of L04
Always Min. 1 Mz
(male) (1), (2), and (3)
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Remove fuse 11 in fuse box 1 (FS8).
3 (wire breakage or 3. Disconnect connector L04, and connect T-adapters to female side.
defective contact of
connector) Resistance Between FS8-11 and L04 (female) (1) Max. 1 z

Ground fault in wiring 1. Turn starting switch to OFF position.


harness 2. Remove fuse 11 in fuse box 1 (FS8).
4 3. Disconnect connector L04, and connect T-adapters to female side.
(contact with ground
circuit) Between ground and fuse FS8-11 or L04 (female)
Resistance (1) Min. 1 Mz

WA470-7 40-959
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to headlamp, clearance lamp and tail lamp

40-960 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-42 Clearance lamp and tail lamp do not light up or go out (WA470_7-HQ0-400-A-Z0-A)

Failure Clearance lamp and tail lamp do not light up or go out.


• Defective switch, lamps, or wiring harness of clearance lamp and tail lamp circuits
• If the headlamp and turn signal lamp light up
• The power is supplied through fuse 12 in fuse box 1 to the circuits of the R.H. clearance
Related lamp and R.H. tail lamp.
information • The power is supplied through fuse 13 in fuse box 1 to the circuits of the L.H. clearance
lamp and L.H. tail lamp.
• Input condition (ON/OFF) to machine monitor from lamp switch (clearance lamp) can be
checked with monitoring function (Code: 04507 Night Lighting SW).
No. Cause Procedure, measuring location, criteria and remarks
If only a certain lamp does not light up, inspect it directly as the lamp may be
1 Blown lamp (bulb) blown or have poor contact.
a For the rear side, refer to cause 7.
Defective fuses 12 and If fuse is blown, circuit may have ground fault, etc. (See check on cause 5.)
2
13 in fuse box 1
1. Turn starting switch to OFF position.
2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate lamp switch and perform troubleshooting.
OFF Min. 1 Mz
Defective lamp switch Between L04 (male) (1) and (2) SMALL,
Max. 1 z
3 (internal open or short HEAD
circuit) OFF Min. 1 Mz
Resistance Between L04 (male) (1) and (3)
SMALL Min. 1 Mz
HEAD Max. 1 z
Between ground and each of L04
Always Min. 1 Mz
(male) (1), (2), and (3)
• Ground line
1. Turn starting switch to OFF position.
2. Disconnect connectors L04, LDR_L, LDR_R, COMBI (R.H. and L.H.), and
connect T-adapters to each female side.
Between R.H. COMBI (female) (B) and ground Max. 1 z
Between L.H. COMBI (female) (B) and ground Max. 1 z
Resistance
Between LDR_R (female) (C) and ground Max. 1 z
Between LDR_L (female) (C) and ground Max. 1 z
• Power supply line (input side of fuse)
1. Turn starting switch to OFF position.
2. Remove fuses 12, and 13 in fuse box 1 (FS8).
Open circuit in wiring 3. Turn starting switch to ON position.
harness 4. Lamp switch: SMALL
4 (wire breakage or Between FS8-12 and ground 20 to 30 V
defective contact of Voltage
connector) Between FS8-13 and ground 20 to 30 V
• Power supply line
1. Turn starting switch to OFF position.
2. Disconnect connectors L04, LDR_L, LDR_R, COMBI (R.H. and L.H.), and
connect T-adapters to each female side.
3. Turn starting switch to ON position.
4. Lamp switch: SMALL
Between R.H. COMBI (female) (A) and (B) 20 to 30 V
Between L.H. COMBI (female) (A) and (B) 20 to 30 V
Voltage Between LDR_R (female) (B) and (C) 20 to 30 V
Between LDR_L (female) (B) and (C) 20 to 30 V

WA470-7 40-961
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Remove fuses 12 and 13 in fuse box 1 (FS8).
3. Disconnect connectors L04, LDR_L, LDR_R, COMBI (R.H. and L.H.), and
Ground fault in wiring
connect T-adapters to each female side.
harness
5 Between L04 (female) (2) and ground Min. 1 Mz
(contact with ground
circuit) Between ground and R.H. COMBI (female) (A) or
Min. 1 Mz
Resistance LDR_R (female) (B)
Between ground and L.H. COMBI (female) (A) or
LDR_L (female) (B) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Remove fuses 12 and 13 in fuse box 1 (FS8).
3. Disconnect connectors L04, LDR_L, LDR_R, COMBI (R.H. and L.H.), and
connect T-adapters to each female side.
4. Turn starting switch to ON position.
Hot short circuit in
6 wiring harness a Headlamp switch OFF
Between L04 (female) (2) and ground Max. 1 V
Between ground and R.H. COMBI (female) (A) or
Voltage LDR_R (female) (B) Max. 1 V
Between ground and L.H. COMBI (female) (A) or
LDR_L (female) (B) Max. 1 V
Defective LED (rear If no failure is found by above checks, the LED (rear combination lamp) is
7 combination lamp) defective.

40-962 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to headlamp, clearance lamp and tail lamp

WA470-7 40-963
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-43 Both High and Low beams of headlamp do not light up or go


out (WA470_7-HQ9-400-A-Z0-A)
Failure Both "High and Low beams" of headlamp do not light up or go out.
• Defective switch, lamps, or wiring harness of headlamp (low and high beam) circuit
• If clearance lamp, tail lamp, and license-plate lamp light up and go out:
• If headlamp does not go out, remove headlamp relay. If headlamp then goes out,
Related headlamp relay is defective.
information • Input condition (ON/OFF) to machine monitor from lamp switch (headlamp) can be
checked with monitoring function (Code: 04507 Head Light SW).
• Input condition (ON/OFF) to machine monitor from dimmer switch (high beam) can be
checked with monitoring function (Code: 04507 High Beam Status).
No. Cause Procedure, measuring location, criteria and remarks
Defective fuses 14 and If fuse is blown, circuit may have ground fault, etc. (See check on cause 6.)
1
15 in fuse box 1
1. Turn starting switch to OFF position.
2. Replace headlamp relay L131 with another relay, for example, horn relay
Defective headlamp L119.
2 relay L131 3. Turn starting switch to ON position.
4. Turn the lamp switch to HEAD/OFF position.
If headlamp becomes normal, original headlamp relay (L131) is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate lamp switch and perform troubleshooting.
OFF Min. 1 Mz
Defective lamp switch Between L04 (male) (1) and (2) SMALL,
Max. 1 z
3 (internal open or short HEAD
circuit) OFF Min. 1 Mz
Resistance Between L04 (male) (1) and (3)
SMALL Min. 1 Mz
HEAD Max. 1 z
Between ground and each of L04
Always Min. 1 Mz
(male) (1), (2), and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate dimmer switch and perform troubleshooting.
Dimmer
switch: Min. 1 Mz
Between L04 (male) (5) and (6) LOW
Defective dimmer Dimmer
switch switch: Max. 1 z
4 HIGH
(internal open or short
circuit) Dimmer
Resistance switch: Max. 1 z
Between L04 (male) (5) and (7) LOW
Dimmer
switch: Min. 1 Mz
HIGH
Between ground and each of L04 Min. 1 Mz
Always
(male) (5), (6), and (7)

40-964 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


• Primary circuit of headlamp relay L131
1. Turn starting switch to OFF position.
2. Disconnect connector L04, and connect T-adapter to female side.
a Headlamp relay L131 coil resistance
200 to 400
Resistance Between L04 (female) (3) and ground
z
• Secondary circuit input of headlamp relay L131
1. Turn starting switch to OFF position.
2. Disconnect connector L131, and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between L131 (female) (3) and (2) 20 to 30 V
• R.H. headlamp line
1. Turn starting switch to OFF position.
2. Remove fuse 15 in fuse box 1 (FS8).
3. Disconnect connector L131, and connect T-adapter to female side.
4. Perform troubleshooting with dimmer switch in both high and low
positions.
a Lamp resistance is approximately 8 z
Open circuit in wiring
harness Resistance Between L131 (female) (5) and ground Approx. 8 z
• L.H. headlamp line
5 (wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Remove fuse 14 in fuse box 1 (FS8).
connector) 3. Disconnect connector L131, and connect T-adapter to female side.
4. Perform troubleshooting with dimmer switch in both high and low
positions.
a Lamp resistance is approximately 8 z
Resistance Between L131 (female) (5) and ground Approx. 8 z
a If no failure is found by above checks, this check is not required.
1.Turn starting switch to OFF position.
2.Remove fuse 11, 14, and 15 in fuse box 1 (FS8).
3.Disconnect connectors L04 and L131, and connect T-adapters to each
female side.
Between L04 (female) (3) and L131 (female) (1) Max. 1 z
Between L131 (female) (2) and ground Max. 1 z
Between fuse box FS8- 11 and L131 (female)(3) Max. 1 z
Resistance Between L131 (female) (5) and FS8-15 Max. 1 z
Between L131 (female) (5) and FS8-14 Max. 1 z
Between FS8-15 and L.H. HEAD (female) (B) Max. 1 z
Between FS8-14 and R.H. HEAD (female) (B) Max. 1 z
1. Turn starting switch to OFF position.
2. Remove fuses 14 and 15 in fuse box 1 (FS8).
3. Disconnect connectors L04, L131, HEAD (R.H. and L.H.) and connect T-
Ground fault in wiring adapters to either female side.
harness Between ground and L04 (female) (3) or L131
6 (female) (1) Min. 1 Mz
(contact with ground
circuit) Between L131 (female) (5) and ground Min. 1 Mz
Resistance
Between L.H. HEAD (female) (B) and ground Min. 1 Mz
Between R.H. HEAD (female) (B) and ground Min. 1 Mz

WA470-7 40-965
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Remove fuses 14 and 15 in fuse box 1 (FS8).
3. Disconnect connectors L04, L131, HEAD (R.H. and L.H.) and connect T-
adapters to either female side.
4. Turn starting switch to ON position.
Hot short circuit in
7 a Headlamp switch OFF
wiring harness
Between ground and L04 (female) (3) or L131
(female) (1) Max. 1 V
Voltage Between L131 (female) (5) and ground Max. 1 V
Between L.H. HEAD (female) (B) and ground Max. 1 V
Between R.H. HEAD (female) (B) and ground Max. 1 V

40-966 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to headlamp, clearance lamp, and tail lamp

WA470-7 40-967
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-44 Low beam of headlamp does not light up or go out (WA470_7-HQA-400-A-Z0-A)

Failure The headlamp "Low beam" does not light up or go out.


• Open circuit or ground fault of switch, lamp, or wiring harness of headlamp (low beam)
circuit
• If the high beam lights up (or goes out)
Related • Input condition (ON/OFF) to machine monitor from lamp switch (headlamp) can be
information checked with monitoring function (Code: 04507 Head Light SW).
• Input condition (ON/OFF) to machine monitor from dimmer switch (high beam) can be
checked with monitoring function (Code: 04507 High Beam Status).
No. Cause Procedure, measuring location, criteria and remarks
If only a certain headlamp does not light up, inspect it directly as the lamp may
1 Blown lamp (bulb)
be blown or have poor contact.
1. Turn starting switch to OFF position.
2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate dimmer switch and perform troubleshooting.
Dimmer
switch: Min. 1 Mz
Between L04 (male) (5) and (6) LOW
Defective dimmer Dimmer
switch switch: Max. 1 z
2 HIGH
(internal open or short
circuit) Dimmer
Resistance switch: Max. 1 z
Between L04 (male) (5) and (7) LOW
Dimmer
switch: Min. 1 Mz
HIGH
Between ground and each of L04
Always Min. 1 Mz
(male) (5), (6), and (7)
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L04, and HEAD (R.H. and L.H.), and connect T-
harness adapters to each female side.
3 (wire breakage or Between R.H. HEAD (female) (A) and L04 (female)
defective contact of (7) Max. 1 z
connector) Resistance
Between L.H. HEAD (female) (A) and L04 (female)
(7) Max. 1 z

Ground fault in wiring 1. Turn starting switch to OFF position.


harness 2. Disconnect connectors L04 and HEAD (R.H. and L.H.), and connect T-
4 adapters to either female side.
(contact with ground
circuit) Between ground and R.H. HEAD (female) (A), L.H.
Resistance HEAD (female) (A) or L04 (female) (7) Min. 1 Mz

40-968 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to headlamp, clearance lamp and tail lamp

WA470-7 40-969
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-45 High beam of headlamp does not light up or go out (WA470_7-HQB-400-A-Z0-A)

Failure The headlamp "High beam" does not light up or go out.


• Open circuit or ground fault of switch, lamp, or wiring harness of headlamp (high beam)
circuit
• If the low beam lights up (or goes out):
Related • Input condition (ON/OFF) to machine monitor from lamp switch (headlamp) can be
information checked with monitoring function (Code: 04507 Head Light SW).
• Input condition (ON/OFF) to machine monitor from dimmer switch (high beam) can be
checked with monitoring function (Code: 04507 High Beam Status).
No. Cause Procedure, measuring location, criteria and remarks
If only a certain headlamp does not light up, inspect it directly as the lamp may
1 Blown lamp (bulb)
be blown or have poor contact.
1. Turn starting switch to OFF position.
2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate dimmer switch and perform troubleshooting.
Dimmer
switch: Min. 1 Mz
Between L04 (male) (5) and (6) LOW
Defective dimmer Dimmer
switch switch: Max. 1 z
2 HIGH
(internal open or short
circuit) Dimmer
Resistance switch: Max. 1 z
Between L04 (male) (5) and (7) LOW
Dimmer
switch: Min. 1 Mz
HIGH
Between ground and each of L04
Always Min. 1 Mz
(male) (5), (6), and (7)
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connectors L04, and HEAD (R.H. and L.H.), and connect T-
harness adapters to each female side.
3 (wire breakage or Between R.H. HEAD (female) (C) and L04 (female)
defective contact of (6) Max. 1 z
connector) Resistance
Between L.H. HEAD (female) (C) and L04 (female)
(6) Max. 1 z

Ground fault in wiring 1. Turn starting switch to OFF position.


harness 2. Disconnect connectors L04 and HEAD (R.H. and L.H.), and connect T-
4 adapters to either female side.
(contact with ground
circuit) Between ground and R.H. HEAD (female) (C), L.H.
Resistance HEAD (female) (C) or L04 (female) (6) Min. 1 Mz

40-970 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to headlamp, clearance lamp and tail lamp

WA470-7 40-971
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-46 Front working lamp does not light up or go out (WA470_7-HR4-400-A-Z0-A)

Failure Front working lamp does not light up or go out.


• Defective switch, lamp, or wiring harness of front working lamp circuit
• If the rear working lamp lights up (or goes out)
Related • If the clearance lamp also does not light up, troubleshoot the clearance lamp first.
information • If front working lamp does not go out, remove front working lamp relay. If front working
lamp then goes out, front working lamp relay is defective.
No. Cause Procedure, measuring location, criteria and remarks
If only a certain working lamp does not light up, inspect it directly as the lamp
1 Blown lamp (bulb)
may be blown or have poor contact.
Defective fuse-8 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 6.)
2
box 2
1. Turn starting switch to OFF position.
2. Replace front working lamp relay (L127) with another relay, for example,
Defective front working horn relay (L119).
3 lamp relay (L127) 3. Turn starting switch to ON position.
4. Turn front working lamp switch ON and OFF.
If front working lamp becomes normal, original front working lamp relay L127
is defective.
1. Turn starting switch to OFF position.
Defective front working 2. Turn front working lamp switch ON and OFF, and troubleshoot.
lamp switch ON Max. 1 z
4 Between S_F1 (male) (5) and (6)
(internal open or short OFF Min. 1 Mz
circuit) Resistance
Between ground and each of S_F1
(male) (5) and (6) Continuous Min. 1 Mz
• Primary circuit of front working lamp relay L127
1. Turn starting switch to OFF position.
2. Disconnect connector S_F1, and connect T-adapters to female side.
a Coil resistance of front working lamp relay L127
200 to 400
Resistance Between S_F1 (female) (5) and ground
z
• Secondary circuit input of front working lamp relay L127
1. Turn starting switch to OFF position.
2. Disconnect connector L127, and connect T-adapters to female side.
3. Turn starting switch to ON position.
Open circuit in wiring Voltage Between L127 (female) (3) and (2) 20 to 30 V
harness • Front working lamp line
5 (wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Disconnect connector L127, and connect T-adapters to female side.
connector) a Since resistance of a working lamp is approx. 8 z and lamps are
connected in parallel, the standard value is approx. 4 z.
a If the reading is approx. 8 z one of the circuits is open. If the reading is
above 1 Mz, both circuits are open.
Resistance Between L127 (female) (5) and ground Approx. 4 z
• Input line of the switch.
1. Turn starting switch to OFF position.
2. Disconnect connector S_F1 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between S_F1 (female) (6) and (5) 20 to 30 V

40-972 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by above checks, this check is not required.
1.Turn starting switch to OFF position.
2.Remove fuse-8 in fuse box 2 (FS9).
3.Disconnect connectors S_F1, L127, C04, C05, and connect T-adapters to
Open circuit in wiring each female side.
harness Between S_F1 (female) (5) and L127 (female) (1) Max. 1 z
5 (wire breakage or Between L127 (female) (2) and ground Max. 1 z
defective contact of
connector) Between FS9-8 and L127 (female) (3) Max. 1 z
Resistance Between L127 (female) (5) and C04 (female) (1) Max. 1 z
Between L127 (female) (5) and C05 (female) (1) Max. 1 z
Between C04 (female) (2) and ground Max. 1 z
Between C05 (female) (2) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Remove fuse 8 in fuse box 2 (FS9).
3. Disconnect connectors S_F1, L127, C04, C05, and connect T-adapter to
Ground fault in wiring either female side.
harness Between ground and L127 (female) (3) or S_F1
6 (female) (6) Min. 1 Mz
(contact with ground
circuit) Between ground and S_F1 (female) (5) or L127
Resistance (female) (1) Min. 1 Mz
Between ground and L127 (female) (5), C04
(female) (1) or C05 (female) (1) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Remove fuse-8 in fuse box 2 (FS9).
3. Disconnect connectors S_F1, L127, C04, C05, and connect T-adapter to
either female side.
4. Turn starting switch to ON position.
Hot short circuit in a Front working lamp switch is OFF.
7 wiring harness Between ground and L127 (female) (3) or S_F1
(female) (6) Max. 1 V
Between ground and S_F1 (female) (5) or L127
Voltage Max. 1 V
(female) (1)
Between ground and L127 (female) (5), C04
(female) (1) or C05 (female) (1) Max. 1 V

WA470-7 40-973
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to working lamps

40-974 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-47 Rear working lamp does not light up or go out (WA470_7-HR5-400-A-Z0-A)

Failure Rear working lamp does not light up or go out.


• Defective switch, lamp, or wiring harness of rear working lamp circuit
• If the front working lamp and side working lamps (if equipped) light up (or go out)
Related • If the clearance lamp also does not light up, troubleshoot the clearance lamp first.
information • If rear working lamp does not go out, remove rear working lamp relay. If rear working lamp
then goes out, rear working lamp relay is defective.
No. Cause Procedure, measuring location, criteria and remarks
If only a certain working lamp does not light up, inspect it directly as the lamp
1 Blown lamp (bulb)
may be blown or have poor contact.
Defective fuse-9 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 6.)
2
box 2
1. Turn starting switch to OFF position.
2. Replace rear working lamp relay L128 with another relay, for example,
Defective rear working horn relay L119.
3 lamp relay (L128) 3. Turn starting switch to ON position.
4. Turn rear working lamp switch ON and OFF .
If rear working lamp becomes normal, original rear working lamp relay (L128)
is defective.
1. Turn starting switch to OFF position.
Defective rear working 2. Turn rear working lamp switch ON and OFF, and troubleshoot.
lamp switch ON Max. 1 z
4 Between S_F2 (male) (5) and (6)
(internal open or short OFF Min. 1 Mz
circuit) Resistance
Between ground and each of S_F2
(male) (5) and (6) Continuous Min. 1 Mz
• Primary side of rear working lamp relay L128
1. Turn starting switch to OFF position.
2. Disconnect connector S_F2 and connect T-adapters to female side.
a Coil resistance of rear working lamp relay L128
200 to 400
Resistance Between S_F2 (female) (5) and ground
z
• Secondary side of rear working lamp relay L128
1. Turn starting switch to OFF position.
2. Disconnect connector L128, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit in wiring Voltage Between L128 (female) (3) and (2) 20 to 30 V
harness • Front working lamp line
5 (wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Disconnect connector L128, and connect T-adapter to female side.
connector) a Since resistance of a working lamp is approx. 8 z and lamps are
connected in parallel, the standard value is approx. 4 z.
a If the reading is approx. 8 z one of the circuits is open. If the reading is
above 1 Mz, both circuits are open.
Resistance Between L128 (female) (5) and ground Approx. 4 z
• Input line of the switch.
1. Turn starting switch to OFF position.
2. Disconnect connector S_F2 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Voltage Between S_F2 (female) (6) and (5) 20 to 30 V

WA470-7 40-975
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


a If no failure is found by above checks, this check is not required.
1.Turn starting switch to OFF position.
2.Remove fuse-9 in fuse box 2 (FS9).
3.Disconnect connectors S_F2, L128, G04, G05, and connect T-adapters to
Open circuit in wiring each female side.
harness Between S_F2 (female) (5) and L128 (female) (1) Max. 1 z
5 (wire breakage or Between L128 (female) (2) and ground Max. 1 z
defective contact of
connector) Between FS9-9 and L128 (female) (3) Max. 1 z
Resistance Between L128 (female) (5) and G04 (female) (2) Max. 1 z
Between L128 (female) (5) and G05 (female) (2) Max. 1 z
Between G04 (female) (1) and ground Max. 1 z
Between G05 (female) (1) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Remove fuse-9 in fuse box 2 (FS9).
3. Disconnect connectors S_F2, L128, G04, G05, and connect T-adapter to
Ground fault in wiring either female side.
harness Between ground and L128 (female) (3) or S_F1
6 (female) (6) Max. 1 z
(contact with ground
circuit) Between ground and S_F1 (female) (5) or L128
Resistance (female) (1) Max. 1 z
Between ground and L128 (female) (5), G04
(female) (2) or G05 (female) (2) Max. 1 z

1. Turn starting switch to OFF position.


2. Remove fuse 9 in fuse box 2 (FS9).
3. Disconnect connectors S_F2, L128, G04, G05, and connect T-adapter to
either female side.
4. Turn starting switch to ON position.
Hot short circuit in a Turn rear working lamp switch to OFF position.
7 wiring harness Between ground and L128 (female) (3) or S_F1
(female) (6) Max. 1 V
Between ground and S_F1 (female) (5) or L128
Voltage Max. 1 V
(female) (1)
Between ground and L128 (female) (5), G04
(female) (1) or G05 (female) (1) Max. 1 V

40-976 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to working lamps

WA470-7 40-977
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-48 All of turn signal lamps and hazard lamps do not light up or go
out (WA470_7-HS4-400-A-Z0-A)
Failure All of turn signal lamps and hazard lamps do not light up or go out.
• Defective switch, lamps or wiring harness of turn signal lamps and hazard lamp circuits
• If turn signal lamps and hazard lamps do not go out, remove winker hazard lamp relay 2.
If turn signal lamps and hazard lamps then go out, winker hazard lamp relay 2 is
defective.
• If all turn signal lamps and hazard lamps do not flash, try another flasher unit.
Related • Input condition (ON/OFF) to machine monitor from turn signal lamp and hazard lamp
information switches (right turn signal lamp) can be checked with monitoring function (Code: 04507
Right Turn Signal).
• Input condition (ON/OFF) to machine monitor from turn signal lamp and hazard lamp
switches (left turn signal lamp) can be checked with monitoring function (Code: 04507 Let
Turn Signal).
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow If a slow-blow fuse is blown, circuit may have ground fault, etc. (See check on
1 cause 8.)
fuse
1. Turn starting switch to OFF position.
2. Replace winker hazard lamp relay 1 L111 with another relay, for example,
horn relay L119.
Defective winker hazard 3. Turn starting switch to ON position.
2 lamp relay 1 L111 4. Turn ON and OFF hazard lamp switch
5. Operate turn signal lever to right and left
If turn signal lamps become normal, original winker hazard lamp relay 1 L111
is defective.
1. Turn starting switch to OFF position.
2. Replace winker hazard lamp relay 2 L122
Defective winker hazard 3. Turn starting switch to ON position.
3 lamp relay 2 L122 4. Turn ON and OFF hazard lamp switch
5. Operate turn signal lever to right and left
If turn signal lamps become normal, original winker hazard lamp relay 2 L122
is defective.
1. Turn starting switch to OFF position.
Defective turn signal 2. Disconnect connector L04.
4 switch (Internal open or 3. Turn starting switch to ON position.
short circuit) 4. Turn ON and OFF hazard lamp switch
If turn signal lamps become normal, turn signal switch is defective.
1. Turn starting switch to OFF position.
Defective hazard lamp 2. Disconnect connector S_FB.
5 switch (internal open or 3. Turn starting switch to ON position.
short circuit) 4. Operate turn signal lever to right and left
If turn signal lamps become normal, hazard lamp switch is defective.
• Flasher unit power supply
1. Turn starting switch to OFF position.
Open circuit in wiring 2. Disconnect connector L19 and connect T-adapters to female side.
harness 1 (wire
6 breakage or defective a If check result is unusual, go to check on cause 7.
contact of connector) 3. Turn starting switch to ON position.
Voltage Between L19 (female) (2) and (1) 20 to 30 V

40-978 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Insert T-adapters into connector L19.
3. Turn starting switch to ON position.
7 Defective flasher unit 20 to 30
Vio0 V
Voltage Between L19 (female) (4) and (1)
are
repeated.

Open circuit 2 in wiring 1. Turn starting switch to OFF position.


harness 2. Disconnect connectors L111 and L19, and connect T-adapters to each
female side.
8 (wire breakage or Between L111 (female) (3) and L19 (female) (2) Max. 1 z
defective contact of
Resistance Between L19 (female) (4) and L04 (female) (9) Max. 1 z
connector)
Between L19 (female) (1) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors L111 and L19, and connect T-adapters to either
Ground fault in wiring female side.
9 harness (contact with Between ground and L111 (female) (3) or L19
ground circuit) (female) (2) Min. 1 Mz
Resistance
Between ground and L19 (female) (4) or L04
(female) (9) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L111 and L19, and connect T-adapter to either
Hot short circuit in female side.
10 wiring harness 3. Turn starting switch to ON position.
Between ground and L19 (female) (4) or L04
Voltage Max. 1 V
(female) (9)

WA470-7 40-979
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to turn signal lamp and winker lamp (hazard lamp)

40-980 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-49 Turn signal lamps do not light up or go out (WA470_7-HS6-400-A-Z0-A)

Failure Turn signal lamps do not light up or go out.


• Defective switch, lamps, or wiring harness of turn signal lamp circuit
• If the hazard lamp flashes
• If turn signal lamps do not go out, remove winker hazard lamp relay 2. If turn signal lamps
then go out, winker hazard lamp relay 2 is defective.
Related • Input condition (ON/OFF) to machine monitor from turn signal lamp and hazard lamp
information switches (right turn signal lamp) can be checked with monitoring function (Code: 04507
Right Turn Signal).
• Input condition (ON/OFF) to machine monitor from turn signal lamp and hazard lamp
switches (left turn signal lamp) can be checked with monitoring function (Code: 04507 Let
Turn Signal).
No. Cause Procedure, measuring location, criteria and remarks
If only a certain turn signal lamp does not light up, inspect it directly as the
1 Blown lamp (bulb)
lamp may be blown or have poor contact.
Defective fuse 11 in If fuse is blown, circuit may have ground fault, etc. (See check on cause 8.)
2
fuse box 2
Defective slow-blow If slow-blow fuse R06A is blown, circuit may have ground fault, etc. (See
3 check on cause 8.)
fuse
1. Turn starting switch to OFF position.
2. Replace winker hazard lamp relay 1 L111 with another relay, for example,
horn relay L119.
Defective winker hazard 3. Turn starting switch to ON position.
4 lamp relay 1 L111 4. Turn ON and OFF hazard lamp switch
5. Operate turn signal lever to right and left
If turn signal lamps become normal, original winker hazard lamp relay 1 L111
is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector L04 and connect T-adapters to male side.
3. Operate turn signal lever to right and left
Turn signal
lamp lever: Min. 1 Mz
LEFT
Turn signal
Between L04 (male) (9) and (10) lamp lever: Min. 1 Mz
NEUTRAL
Turn signal
Defective turn signal lamp lever: Max. 1 z
5 switch (internal open or RIGHT
short circuit) Turn signal
Resistance lamp lever: Max. 1 z
LEFT
Turn signal
Between L04 (male) (9) and (11) lamp lever: Min. 1 Mz
NEUTRAL
Turn signal
lamp lever: Min. 1 Mz
RIGHT
Between ground and each of L04 (male) (9), (10), Min. 1 Mz
and (11)

WA470-7 40-981
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


• Turn signal lamp power supply
1. Turn starting switch to OFF position.
2. Disconnect connector L111, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Voltage Between L111 (female) (6) and ground 20 to 30 V
1. Turn starting switch to OFF position.
2. Disconnect connectors L04, LDY_R, LDY_L, COMBI (R.H. and L.H.), and
Open circuit in wiring connect T-adapters to each female side.
harness Between L04 (female) (10) and LDY_R (female) (1) Max. 1 z
6 (wire breakage or Between L04 (female) (10) and R.H. COMBI
defective contact of (female) (C) Max. 1 z
connector)
Between L04 (female) (11) and LDY_L (female) (1) Max. 1 z
Between L04 (female) (11) and L.H. COMBI
Resistance (female) (C) Max. 1 z
Between LDY_L (female) (2) and ground Max. 1 z
Between LDY_R (female) (2) and ground Max. 1 z
Between right COMBI (female) (B) and ground Max. 1 z
Between left COMBI (female) (B) and ground Max. 1 z
1. Turn starting switch to OFF position.
2. Set battery disconnect switch to OFF position.
3. Disconnect connectors L04, L111, LDY_R, LDY_L, COMBI (R.H. and L.
H.), and connect T-adapters to each female side.
4. Remove slow blow fuse R06A.
Ground fault in wiring 5. Remove fuses 8 to 10 and 12 to 14 in fuse box 2 (FS9).
harness 6. Remove fuses 1 to 11 in fuse box 1 (FS8).
7
(contact with ground
a If fuse 11 in fuse box 2 (FS9) is blown, replace it in advance.
circuit)
Between ground and L111 (female) (6) or R06A Min. 1 Mz
Between ground and L04 (female) (10), LDY_R
Min. 1 Mz
Resistance (female) (1) or R.H. COMBI (female) (C)
Between ground and L04 (female) (11), LDY_L
(female) (1) or L.H. COMBI (female) (C) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L04, LDY_R, LDY_L, COMBI (R.H. and L.H.), and
connect T-adapters to either female side.
Hot short circuit in 3. Turn starting switch to ON position.
8 wiring harness Between ground and L04 (female) (10), LDY_R
(female) (1) or R.H. COMBI (female) (C) Max. 1 V
Voltage
Between ground and L04 (female) (11), LDY_L
(female) (1) or L.H. COMBI (female) (C) Max. 1 V

40-982 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to turn signal lamp and winker lamp (hazard lamp)

WA470-7 40-983
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-50 Hazard lamp does not light up or go out (WA470_7-HS7-400-A-Z0-A)

Failure Hazard lamp does not light up or go out.


• Defective hazard lamp or its switch
Related • If turn signal lamps flash normally
information • If hazard lamps do not go out, remove winker, hazard relay 2. If hazard lamps then go out,
winker, hazard lamp relay 2 is defective.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse 2 in fuse If fuse is blown, circuit may have ground fault. (See check on cause 6.)
1
box 1
Defective slow-blow If the slow-blow fuse is blown, circuit may have ground fault. (See check on
2 cause 7.)
fuse
1. Turn starting switch to OFF position.
2. Replace winker, hazard relay 1 L111 with another relay, for example, horn
Defective winker, relay L119.
3 hazard relay 1 L111 3. Turn starting switch to ON position.
4. Turn ON and OFF hazard lamp switch
If hazard lamps become normal, original winker, hazard relay 1 L111 is
defective.
1. Turn starting switch to OFF position.
2. Replace winker, hazard relay 2 L122
Defective winker, 3. Turn starting switch to ON position.
4 hazard relay 2 L122 4. Turn ON and OFF hazard lamp switch
If hazard lamps become normal, original winker, hazard relay 2 L122 is
defective.
1. Turn starting switch to OFF position.
2. Disconnect connector S_FB and connect T-adapter to male side.
3. Turn ON and OFF hazard switch
Defective hazard switch Hazard lamp switch: ON Max. 1 z
Between S_FB (male)
5 (internal open or short Hazard lamp switch:
(5) and (6) Min. 1 Mz
circuit) OFF
Resistance
Between ground and
each of S_FB (male) (5) Always Min. 1 Mz
and (6)

40-984 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


• Primary side GND line of relay
1. Turn starting switch to OFF position.
2. Disconnect connectors L111 and L122, and connect T-adapters to each
female side.
3. Hazard lamp switch: ON
Between L111 (female) (2) and ground Max. 1 z
Resistance
Between L122 (female) (6) and ground Max. 1 z
• Hazard lamp power supply input
1. Turn starting switch to OFF position.
2. Disconnect connectors L111 and L122, and connect T-adapters to each
female side.
3. Turn starting switch to ON position.
Between L111 (female) (5) and ground 20 to 30 V
Voltage Between L111 (female) (1) and ground 20 to 30 V
Open circuit in wiring Between L122 (female) (5) and ground 20 to 30 V
harness 1. Turn starting switch to OFF position.
6 (wire breakage or 2. Disconnect connectors L19, L122, LDY_R, LDY_L, COMBI (R.H. and L.
defective contact of H.), and connect T-adapters to each female side.
connector) Between L122 (female) (4) and LDY_L (female) (1) Max. 1 z
Between L122 (female) (4) and L.H. COMBI
(female) (C) Max. 1 z
Resistance Between L122 (female) (2) and LDY_R (female) (1) Max. 1 z
Between L122 (female) (2) and R.H. COMBI
(female) (C) Max. 1 z
Between L122 (female) (1), (3) and L19 (female) (4) Max. 1 z
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors S_FB, L111, L122, and connect T-adapters to each
female side.
Between L111 (female) (2) and S_FB (female) (5) Max. 1 z
Resistance Between S_FB (female) (6) and ground Max. 1 z
Between L122 (female) (6) and S_FB (female) (5) Max. 1 z
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to the OFF position.
3. Disconnect connectors S_FB, L111, L122, and connect T-adapters to
either female side.
Ground fault in wiring 4. Remove slow blow fuse R03.
harness 5. Remove fuses 1, and 3 to 7 in fuse box 2 (FS9).
7
(contact with ground
circuit) a If fuse 2 in fuse box 2 (FS9) is blown, replace it in advance.
Between ground and L111 (female) (1), (5) or L122
(female) (5) Min. 1 Mz
Resistance
Between ground and L111 (female) (2) or S_FB
(female) (5) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Remove fuse 8 in fuse box 2 (FS9).
3. Disconnect connectors L122, LDY_R, LDY_L, COMBI (R.H. and L.H.),
and connect T-adapters to either female side.
Hot short circuit in 4. Turn starting switch to ON position.
8 wiring harness • Hot short circuit in wiring harness of the following two systems
Between ground and L122 (female) (2), LDY_R
(female) (1), or R.H. COMBI (female) (C) Max. 1 V
Voltage
Between ground and L122 (female) (4), LDY_L
(female) (1), or L.H. COMBI (female) (C) Max. 1 V

WA470-7 40-985
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to hazard lamp

40-986 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-51 Brake lamp does not light or stays lighted (WA470_7-HT1-400-A-Z0-A)

Failure Brake lamp does not light up or stays lighted.


• Defective brake lamp or its wiring harness
Related • If brake lamp does not go out, remove brake lamp relay. If brake lamp then goes out,
information brake lamp relay is defective.
No. Cause Procedure, measuring location, criteria and remarks
Defective slow-blow If slow-blow fuse is blown, circuit may have ground fault, etc. (See check on
1 cause 8.)
fuse
Defective fuse 6 in fuse If fuse is blown, circuit may have ground fault. (See check on cause 6.)
2
box 1
1. Turn starting switch to OFF position.
Defective brake lamp 2. Replace brake lamp relay L118 with another relay, for example, horn relay
relay (L118) L119.
3 3. Turn starting switch to ON position.
(internal open or short
circuit) 4. Depress the brake pedal.
If brake lamp becomes normal, original brake lamp relay L118 is defective.
1. Turn starting switch to OFF position.
Defective brake lamp 2. Disconnect connector L09 and connect T-adapters to male side.
switch 3. Depress the brake pedal.
4
(internal open or short Between L09 (male) (1) Brake pedal: Depressed Max. 1 z
circuit) Resistance and (2) Brake pedal: Released Min. 1 Mz
Between ground and each of L09 (male) (1) and (2) Min. 1 Mz
• Brake lamp power supply
1. Turn starting switch to OFF position.
2. Disconnect connectors L118 and L09, and connect T-adapters to each
female side.
3. Turn starting switch to ON position.
Between L118 (female) (3) and ground 20 to 30 V
Voltage
Between L09 (female) (1) and ground 20 to 30 V
• Primary side of brake lamp relay L118
1. Turn starting switch to OFF position.
2. Disconnect connector L09 and connect T-adapters to female side.
a Coil resistance of brake lamp relay L118
Open circuit in wiring 200 to 400
Resistance Between L09 (female) (2) and ground
harness z
5 (wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Disconnect connectors L118, LDY_R, LDY_L, and connect T-adapters to
connector) each female side.
Between L118 (female) (5) and LDR_R (female) (A) Max. 1 z
Between L118 (female) (5) and LDR_L (female) (A) Max. 1 z
Resistance
Between LDR_L (female) (C) and ground Max. 1 z
Between LDR_R (female) (C) and ground Max. 1 z
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors L118 and L09, and connect T-adapters to each
female side.
Between L09 (female) (2) and L118 (female) (1) Max. 1 z
Resistance Max. 1 z
Between L118 (female) (2) and ground

WA470-7 40-987
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to the OFF position.
3. Disconnect connectors L09, L117, L118, LDY_R, LDY_L, and connect T-
adapters to either female side.
4. Remove slow blow fuse R06A.
Ground fault in wiring 5. Remove fuses 8 to 14 in fuse box 2 (FS9).
harness 6. Remove fuses 1 to 5, 7, and 11 in fuse box 1 (FS8).
6
(contact with ground a If fuse 6 in fuse box 1 (FS8) is blown, replace it in advance.
circuit) Between ground and L118 (female) (3) or L09
(female) (1) to L117 (female) (3) Min. 1 Mz
Between ground and L09 (female) (2) or L118
Resistance (female) (1) Min. 1 Mz
Between ground and L118 (female) (5), LDR_R
(female) (A), or LDR_L (female) (A) Min. 1 Mz

1. Turn starting switch to OFF position.


2. Disconnect connectors L09, L118, LDY_R, LDY_L, and connect T-
adapters to either female side.
Hot short circuit in 3. Turn starting switch to ON position.
7 wiring harness Between ground and L09 (female) (2) or L118
(female) (1) Max. 1 V
Voltage
Between ground and L118 (female) (5), LDR_R
(female) (A), or LDR_L (female) (A) Max. 1 V
Defective LED (rear If no failure is found by above checks, the LED (rear combination lamp) is
8 combination lamp) defective.

40-988 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to brake lamp

WA470-7 40-989
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-52 Backup lamp does not light up or does not go out (WA470_7-HU1-400-A-Z0-A)

Failure Backup lamp does not light or continues to light.


• If brake lamps do not light up, perform troubleshooting for E-51 first.
Related • If backup lamp does not go out, remove backup lamp relay. If backup lamp then goes out,
information backup lamp relay is defective.
No. Cause Procedure, measuring location, criteria and remarks
Defective backup lamp If failure code [D160KA], [D160KB], or [D160KY] is also displayed, perform
1 relay primary side troubleshooting for [D160KA], [D160KB], or [D160KY] first.
Defective directional If failure code [DF10KA] or [DF10KB] is displayed, perform troubleshooting for
2 lever system [DF10KA] or [DF10KB] first.
Defective fuse 6 in fuse If fuse is blown, circuit may have ground fault, etc. (E-51, see check on cause
3 7.)
box 1
1. Turn starting switch to OFF position.
Defective backup lamp 2. Replace backup lamp relay L117 with another relay, for example, horn
relay L117 (internal relay L119.
4 open circuit or short 3. Turn starting switch to ON position.
circuit) 4. Set directional lever in the R position.
If backup lamp becomes normal, original backup lamp relay L117 is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector R58.
Defective backup alarm 3. Turn starting switch to ON position.
5 buzzer (internal defect) 4. Set directional lever in the R position.
If backup lamp becomes normal, the backup alarm buzzer is defective.

40-990 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


• Backup lamp power supply
1. Turn starting switch to OFF position.
2. Disconnect connector L117, and connect T-adapters to female side.
3. Turn starting switch to ON position.
4. Set directional lever in the R position.
Between L117 (female) (3) and ground 20 to 30 V
Voltage
Between L117 (female) (1) and ground 20 to 30 V
• Primary circuit of backup lamp relay L117
1. Turn starting switch to OFF position.
2. Disconnect connector L62, and connect T-adapters to female side.
a Backup lamp relay L117 coil resistance
200 to 400
Resistance Between L62 (female) (19) and ground
z
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L117, LDW_R, LDW_L, and connect T-adapters to
each female side.
6 (wire breakage or
Between L117 (female) (5) and LDW_L (female) (1) Max. 1 z
defective contact of
connector) Between L117 (female) (5) and LDW_R (female)
Max. 1 z
Resistance (1)
Between LDW_L (female) (2) and ground Max. 1 z
Between LDW_R (female) (2) and ground Max. 1 z
a If no failure is found by above checks, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors L117 and L62, and connect T-adapters to each
female side.
Between L62 (female) (19) and L117 (female) (1)
• If a failure occurs, failure code [D160KA] is Max. 1 z
displayed.
Resistance
Between L117 (female) (2) and ground
• If a failure occurs, failure code [D160KA] is Max. 1 z
displayed.
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to the OFF position.
3. Disconnect connectors L117, L62, R58, LDW_R, LDW_L, RVMI, and
connect T-adapters to either female side.
Ground fault in wiring
harness Between ground and L117 (female) (5), LDW_L
7 (female) (1), LDW_R (female) (1), or R58 (female) Min. 1 Mz
(contact with ground (1)
circuit)
Resistance Between ground and L62 (female) (19) or L117
(female) (1)
Min. 1 Mz
• If a failure occurs, failure code [D160KB] is
displayed.
1. Turn starting switch to OFF position.
2. Disconnect connectors L09, L117, LDW_R, LDW_L, RVMI, and connect T-
adapters to either female side.
Hot short circuit in
8 3. Turn starting switch to ON position.
wiring harness
Between ground and L117 (female) (5), LDW_L
Voltage (female) (1), LDW_R (female) (1) or R58 (female) Max. 1 V
(1)
1. Turn starting switch to OFF position.
2. Disconnect connector L117, and connect T-adapters to female side.
Defective transmission 3. Turn starting switch to ON position.
9
controller 4. Set directional lever in the R position.
Voltage Between L117 (female) (1) and (2) 20 to 30 V

WA470-7 40-991
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


1. Turn starting switch to OFF position.
Defective rearview 2. Disconnect connector RVM1.
10 monitor (internal short 3. Turn starting switch to ON position.
circuit) 4. Set directional lever in the R position.
If backup lamp becomes normal, the rearview monitor is defective.
Defective LED (rear If no failure is found by above checks, the LED (rear combination lamp) is
11 combination lamp)
defective.

Circuit diagram related to backup lamp

40-992 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-53 Backup buzzer does not sound or continues to sound (WA470_7-KA5-400-A-Z0-A)

Failure Backup buzzer does not sound or continues to sound.


Related • If backup lamp is abnormal, perform troubleshooting for E-52 first.
information
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connector R58 and connect T-adapters to female side.
3. Turn starting switch to ON position.
Defective backup 4. Operate directional lever to troubleshoot.
buzzer
1 a If following voltages are normal and backup alarm buzzer does not operate,
(internal open or short
circuit) backup alarm buzzer may be defective.
directional lever: R 20 to 30 V
Voltage Between R58 (1) and (2) directional lever: other
Max. 1 V
than R
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors L117 and R58, and connect T-adapters to each
2 (wire breakage or female side.
defective contact of Between L117 (female) (5) and R58 (female) (1) Max. 1 z
connector) Resistance
Between R58 (female) (2) and ground Max. 1 z

WA470-7 40-993
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to backup buzzer

40-994 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-54 Front wiper does not operate (WA380_7-FG1-400-A-Z0-A)

Failure Front wiper does not operate.


• Front wiper does not operate due to the failure of front wiper motor, front wiper switch,
Related interval wiper timer, or wiring harness.
information • If the wiper does not work properly in INT only, try with another interval wiper timer.
• T-adapter is not provided for connector L31.
No. Cause Procedure, measuring location, criteria and remarks
Defective fuse-7 in fuse If fuse is blown, circuit may have ground fault, etc. (See check on cause 6.)
1
box 1
Open circuit in wiring • Ground line of front wiper motor
harness 1 (wire 1. Turn starting switch to OFF position.
2 breakage or defective 2. Disconnect connector C12, and connect T-adapters to female side.
contact of connector) Resistance Between C12 (female) (3) and ground Max. 1z
• Front wiper motor input voltage
1. Turn starting switch to OFF position.
2. Disconnect connector C12, and connect T-adapters to female side.
3. Turn starting switch to ON position.
4. Operate the front wiper switch and perform troubleshooting.
a If the following voltage is normal but front wiper does not operate, front
wiper motor is defective.
Between C12 (female)
Defective front wiper Power supply 20 to 30 V
(6) and ground
3 motor
Front wiper switch: Lo 20 to 30 V
(internal defect) 0 V o 20 to
Between C12 (female)
Voltage 30 Vo0V
(2) and ground Front wiper switch: INT
are
repeated*
Between C12 (female)
Front wiper switch: Hi 20 to 30 V
(1) and ground
a If wiper switch is turned OFF while wiper is operating, voltage is applied
between C12 (5) and ground until the wiper motor stops.
1. Turn starting switch to OFF position.
2. Disconnect connector L21, and connect T-adapters to male side.
Front wiper switch: Lo Max. 1z
Between L21 (male) (7)
and (5) Front wiper switch: INT,
Min. 1 Mz
Hi
Front wiper switch: Hi Max. 1z
Between L21 (male) (7)
Defective front wiper and (4) Front wiper switch: INT,
4 Min. 1 Mz
switch (internal failure) Lo
Resistance Between L21 (male) (7) Front wiper switch: INT Max. 1z
and (2) Front wiper switch: Lo, Hi Min. 1 Mz
Between L21 (male) (3) Front wiper switch: INT Max. 1z
and (5) Front wiper switch: Lo, Hi Min. 1 Mz
Between ground and each of L21 (male) (2), (3), Min. 1 Mz
(4), (5), and (7)

WA470-7 40-995
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


• Checks related to INT operation
a If no failure is found in INT operation, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors L21 and L31, and connect T-adapter to female
side of L21.
3. Remove fuse 7 in fuse box 1 (FS8).
Between L31 (female) (1) and ground Max. 1z
Between fuse box 1 (FS8) (7) and L31 (female)(3) Max. 1z
Resistance
Open circuit 2 in wiring Between L21 (female) (2) and L31 (female) (4) Max. 1z
harness Between L21 (female) (3) and L31 (female) (5) Max. 1z
5 (wire breakage or • Front wiper motor related checks
defective contact of
a If each input voltage checked for cause 3 is normal, this check is not
connector)
required.
1. Turn starting switch to OFF position.
2. Disconnect connectors C12 and L21, and connect T-adapters to each
female side.
3. Remove fuse-7 in fuse box 1 (FS8).
Between fuse box 1 (FS8) (7) and C12 (female) (6) Max. 1z
Between L21 (female) (4) and C12 (female) (1) Max. 1z
Resistance
Between L21 (female) (5) and C12 (female) (2) Max. 1z
Between L21 (female) (7) and FS8-7 Max. 1z
1. Turn starting switch to OFF position.
2. Disconnect connectors C12, C15, L21, L31, CL27, and connect T-
adapters to female side of either C12 or L21.
3. Remove fuse-7 in fuse box 1 (FS8).
Between ground and L21 (female) (3) or L31
(female) (5) Min. 1 Mz
Ground fault in wiring
Between ground and L21 (female) (5) or C12
6 harness (contact with Min. 1 Mz
(female) (2)
ground circuit)
Between ground and L21 (female) (7) or C12
Resistance (female) (6) Min. 1 Mz
Between ground and L21 (female) (4) or C12
(female) (1) Min. 1 Mz
Between ground and L21 (female) (2) or L31
(female) (4) Min. 1 Mz
Defective interval wiper
7 If no failure is found by above checks, interval wiper timer is defective.
timer (internal defect)

40-996 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to wiper

WA470-7 40-997
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-55 Rear wiper does not operate (WA470_7-FG2-400-A-Z0-A)

Failure Rear wiper does not operate.


• Rear wiper does not operate due to failure of rear wiper motor, rear wiper switch, or wiring
Related harness.
information • If front wiper does not operate, perform troubleshooting for E-54 first.
• T-adapter is not prepared for connector L31.
No. Cause Procedure, measuring location, criteria and remarks
Open circuit in wiring • Ground line of rear wiper motor
harness 1 (wire 1. Turn starting switch to OFF position.
1 breakage or defective 2. Disconnect connector C15 and connect T-adapters to female side.
contact of connector) Resistance Between C15 (female) (4) and ground Max. 1 z
• Rear wiper motor input voltage
1. Turn starting switch to OFF position.
2. Disconnect connector C15 and connect T-adapters to female side.
3. Turn starting switch to ON position.
4. Operate the rear wiper switch and perform troubleshooting.
Defective rear wiper a If voltage measured below is normal but rear wiper does not operate, rear
2 motor wiper motor is defective.
(internal defect) Between C15 (female)
Power supply 20 to 30 V
(1) and ground
Voltage
Between C15 (female)
Rear wiper switch: ON 20 to 30 V
(2) and ground
a If wiper switch is turned OFF while wiper is operating, voltage is applied
between C15 (3) and ground until the wiper motor stops.
1. Turn starting switch to OFF position.
2. Disconnect connector L21 and connect T-adapters to male side.
Defective rear wiper Between L21 (male) (7) Rear wiper switch: ON Max. 1 z
switch and (9) Rear wiper switch: OFF Min. 1 Mz
3
(internal defect) Resistance Between L21 (male) (8) Rear wiper switch: OFF Max. 1 z
and (9) Rear wiper switch: ON Min. 1 Mz
Between ground and each of L21 (male) (7), (8),
and (9) Min. 1 Mz
• Front wiper motor related checks
a If each input voltage checked for cause 2 is normal, this check is not
required.
Open circuit 2 in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors C15 and L21, and connect T-adapters to each
4 (wire breakage or female side.
defective contact of 3. Remove fuse 7 in fuse box 1 (FS8).
connector) Between FS8-7 and C15 (female) (1) Max. 1 z
Between L21 (female) (7) and C15 (female) (1) Max. 1 z
Resistance
Between L21 (female) (8) and C15 (female) (3) Max. 1 z
Between L21 (female) (9) and C15 (female) (2) Max. 1 z
1. Turn starting switch to OFF position.
2. Disconnect connectors C12, C15, L21, L31, CL27, and connect T-
Ground fault in wiring adapters to female side of either L21 or C15.
harness 3. Remove fuse 7 in fuse box 1 (FS8).
5
(contact with ground Between ground and L21 (female) (8) or C15
circuit) (female) (3) Min. 1 Mz
Resistance
Between ground and L21 (female) (9) or C15
(female) (2) Min. 1 Mz

40-998 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to wiper

WA470-7 40-999
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-56 Window washer does not operate (WA470_7-FH0-400-A-Z0-A)

Failure Window washer does not operate.


• Window washer does not operate due to the failure of window washer motor, switch, timer
(front system only), or wiring harness.
Related • Perform following troubleshooting when wiper operates normally. (If wiper does not
information operate normally, perform troubleshooting for E-54 and E-55 first.)
• Check that front wiper (Hi, Lo, INT) and rear wiper operate normally.
• T-adapter is not prepared for connectors L31, R43, R45, D08, and D09.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
Defective front washer 2. Disconnect connector R43 and connect T-adapters to male side.
1 motor (internal failure) Between R43 (male) (1) and (2) 3 to 10 z
Resistance
Between R43 (male) (1) and ground Min. 1 Mz
Defective rear washer 1. Turn starting switch to OFF position.
motor 2. Disconnect connector R45 and connect T-adapters to male side.
2
Between R45 (male) (1) and (2) 3 to 10 z
(internal defect) Resistance
Between R45 (male) (1) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector L21 and connect T-adapters to male side.
Front wiper washer
Between L21 (male) (7) switch: ON Max. 1 z
Defective front wiper
3 and (6) Front wiper washer
switch (internal failure) Min. 1 Mz
Resistance switch: OFF
Between L21 (male) (3)
Front wiper switch: OFF Max. 1 z
and (5)
Between L21 (male) (6) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connector L21 and connect T-adapters to male side.
Defective rear wiper Rear wiper washer
4 switch Between L21 (male) (7) switch: ON Max. 1 z
(internal defect) Resistance and (10) Rear wiper washer
Min. 1 Mz
switch: OFF
Between L21 (male) (10) and ground Min. 1 Mz
1. Turn starting switch to OFF position.
2. Disconnect connectors D08 and D09.
Between D08 (male) (2) (+) and (1) (-) Continuity
Defective diode No
5 Between D08 (male) (2) (-) and (1) (+)
(internal defect) continuity
Continuity Between D09 (male) (2) (+) and (1) (-) Continuity
No
Between D09 (male) (2) (-) and (1) (+) continuity

40-1000 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

No. Cause Procedure, measuring location, criteria and remarks


• Window washer motor line
1. Turn starting switch to OFF position.
2. Disconnect connectors L21, R43, R45, and connect T-adapters to female
side of L21.
Between R43 (female) (2) and ground Max. 1 z
Between R45 (female) (2) and ground Max. 1 z
Open circuit in wiring Resistance
harness Between L21 (female) (6) and R43 (female) (1) Max. 1 z
6 (wire breakage or Between L21 (female) (10) and R45 (female) (1) Max. 1 z
defective contact of • Front wiper operation related checks
connector) a If front wiper operates when front window washer is activated, this check is
not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors L21 and L31, and connect T-adapter to female
side of L21.
Resistance Between L31 (female) (2) and L21 (female) (6) Max. 1 z
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors L21, L31, R43, R45, D08, D09, and connect T-
harness adapters to female side of L21.
7 Between ground and L21 (female) (6), R43
(contact with ground Min. 1 Mz
(female) (1) or L31 (female) (2)
circuit) Resistance
Between ground and L21 (female) (10) or R45
(female) (1) Min. 1 Mz

Defective interval wiper a If no failure is found by above checks and the front wiper does not operate
8 timer (internal defect) when the front window washer is activated, the interval wiper timer is
defective.

WA470-7 40-1001
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to window washer system

40-1002 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-57 Fuel feed pump does not operate or stop automatically (WA470_7-FHY-400-A-Z0-
A)

Failure Fuel feed pump does not operate or stop automatically.


Related
information
No. Cause Procedure, measuring location, criteria and remarks
Insufficient battery
1 Battery charge level may be insufficient. Check the battery.
charge level
Defective fuses No. 1 If fuse 1 or 15 in fuse box 2 is blown, circuit probably has ground fault.
2 (Perform troubleshooting for E-5.)
and 15 in fuse box 2
1. Turn battery disconnect switch to OFF position.
Open circuit in wiring
2. Disconnect connector E28 and connect T-adapters to female side.
harness
3. Turn battery disconnect switch to ON position.
(drive power supply Voltage Between E28 (female) (3) and (10) 20 to 30 V
3 system)
(wire breakage or 1. Turn battery disconnect switch to OFF position (to shut off continuous
defective contact of power supply)
connector) 2. Disconnect connector E28 and connect T-adapters to female side.
Resistance Between E28 (female) (10) and ground Max. 1 z
1. Turn battery disconnect switch to OFF position (to shut off continuous
Ground fault in wiring power supply)
harness 2. Disconnect connector E28 and connect T-adapters to female side.
4 3. Remove fuse 1 in fuse box 2 (FS9).
(contact with ground
circuit) Between E28 (female) (1) and ground Min. 1 Mz
Resistance
Between E28 (female) (3) and ground Min. 1 Mz
1. Turn battery disconnect switch to OFF position.
2. Disconnect connector E28 and connect T-adapters to female side.
3. Turn battery disconnect switch to ON position.
Defective fuel feed 4. Fuel feed pump switch ON
5 pump timer switch
controller Voltage Between E28 (female) (1) and (12) 20 to 30 V
• If output voltage is inappropriate though lamp flashes or if lamp does not
flash though no failure is found in checks on causes 1 to 4, fuel feed pump
is defective.
Defective fuel feed If fuel feed pump does not stop automatically, fuel feed pump switch may be
pump switch (pump defective.
6 malfunctions or does (Turn toggle switch to OFF position to stop pump operation, then replace
not stop automatically) switch.)
• Lamp flashes but power supply to pump is stopped in approx. 5 seconds.
Overload of fuel feed
7 pump a * If pump is overloaded, power supply is automatically cut off for protection
of circuit (priming pump switch is automatically restored).
1. Turn battery disconnect switch to OFF position.
2. Disconnect connector E29 and connect T-adapters to male side.
Internal defect of fuel
8 Between E29 (male) (1) and (2) 1 to 3 z
feed pump
Resistance Between E29 (male) (1) and pump body Min. 1 Mz
Between E29 (male) (2) and pump body Min. 1 Mz

WA470-7 40-1003
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

Circuit diagram related to fuel feed pump

40-1004 WA470-7
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

E-58 KOMTRAX system does not operate properly (WA500_7-F50-400-A-Z0-A)

Failure KOMTRAX system does not operate normally.


• Perform following troubleshooting if administrator of KOMTRAX system requests to check
Related whether failure occurs in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all results of troubleshooting on service menu display of machine monitor.
No. Cause Procedure, measuring location, criteria and remarks
1. Turn starting switch to ON position.
Defective 2. Display "Terminal status" screen.
1
communication 1 Monitoring
Check item: Station set-up check Complete
display
1. Turn starting switch to ON position.
2. Display "GPS & Communication Status" screen.
N ###.##.## (Latitude)
Defective positioning by Monitoring
2 Check item: Positioning E ###.##.## (Longitude)
GPS display
Positioning in Progress
If latitude and longitude are not displayed within 5 minutes under the open
sky, contact KOMTRAX service hot line.
1. Turn starting switch to ON position.
2. Display "GPS & Communication Status" screen.
Defective Monitoring "Satellite in View" or "No
3 communication display Check item: Communication
Satellite in View"
environment If Communication Status does not display "Satellite in view" within 15 minutes
under the open sky, check whether the connector of TC330 or the antenna on
top of cab is properly connected.
1. Turn starting switch to ON position.
Defective 2. Display "GPS & Communication Status" screen.
4
communication 2 Monitoring Check item: Number of message(s)
0 to 60 (normally 0)
display not yet sent

a Select "Terminal Status" from "KOMTRAX settings" in service menu of machine monitor.

WA470-7 40-1005
40 Troubleshooting
Troubleshooting of electrical system (E-mode)

a Select "GPS & Communication Status" from "KOMTRAX settings" in service menu of machine monitor.

40-1006 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-


3840-001-A-02-A)

Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)

(Rev. 2011/03)

a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5

WA470-7 40-1007
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

System chart of hydraulic and mechanical systems (WA470-PM10-054-K-01-A)

40-1008 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

WA470-7 40-1009
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Power train system chart

40-1010 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Failure mode and cause table (WA470-5340-40D-A-00-A)

Power train component Brake component


Component causing failure

Pressure reducing valve of accumulator charge valve


Transmission charge pump main relief valve

Troubleshooting No.
Torque converter relief valve

Transmission valve (ECMV)


Transmission charge pump

Transmission clutch (*)


Transmission breather

Lockup clutch ECMV

Brake pedal linkage


Last chance filter

Fan control pump


Torque converter

Slack adjuster
Lockup clutch
Transmission

Brake piston
Brake valve
Failure

Machine does not move off. q q q q q q q q H-1

Torque converter lockup clutch is not disengaged (engine stalls). q q H-2


Power train system

Torque converter lockup clutch is not engaged. q q q q H-3


Travel speed is slow, bucket thrust force is weak, gradability is low,
q q q q q q q q q q q H-4
or gear speed does not shift.
Large shocks are made when machine starts or gear is shifted. q q q q q q H-5

Machine starts or gear speed shifts with long time lag. q q q q q q H-6

Torque converter oil temperature is high. q q q q q q q q H-7

Machine does not turn. q H-8

Turning response is poor. q H-9


Steering
system

Steering wheel is heavy to turn. q H-10

Machine sways or large shocks are made while machine turns. q H-11

Turning radius differs between right and left turns. H-12

Wheel brakes do not work or they are weak. q q q q q H-13

Wheel brakes are not released or drag.


system

q q q q H-14
Brake

Parking brake does not work or it is weak. H-15

Parking brake is not released or drags. H-16

Boom does not rise. q H-17

Boom moves slow or boom lacks lifting force. q H-18

Rising boom slows down at certain height. H-19


Lift cylinders do not serve to hold bucket on ground (bucket rises off
q H-20
ground).
Work equipment system and

Hydraulic drift of boom is large. H-21


hydraulic component

Boom moves up and down during operation. q H-22

Bucket does not tilt back. q H-23

Bucket moves slow or bucket lacks tilt back force. q H-24

Bucket decelerates during tilt-back operation. q H-25

Bucket cylinder does not hold bucket on ground. q H-26

Hydraulic drift of bucket is large. H-27


Bucket tilts back and forth during carrying load (work equipment
q H-28
valve in "HOLD").
Boom and bucket control levers do not move smoothly and heavy to H-29
move.

WA470-7 40-1011
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Power train component Brake component


Component causing failure

Pressure reducing valve of accumulator charge valve


Transmission charge pump main relief valve

Troubleshooting No.
Torque converter relief valve

Transmission valve (ECMV)


Transmission charge pump

Transmission clutch (*)


Transmission breather

Lockup clutch ECMV

Brake pedal linkage


Last chance filter

Fan control pump


Torque converter

Slack adjuster
Lockup clutch
Transmission

Brake piston
Brake valve
Failure

Operating work equipment causes engine speed to lower


Work equipment system and

q H-30
significantly or engine to stall.
hydraulic component

Large shocks are made when work equipment starts to move and
q H-31
stops.
When single work equipment is relieved hydraulically, other work
q H-32
equipment moves.
E.C.S.S. (travel damper) does not work and machine pitches and
H-33
bounces.
Bucket does not stop at the position which is set with remote bucket
H-34
positioner
Fan system

Fan speed is abnormal (too high or low, or fan does not rotate). q H-35

Unusual noise is heard from around fan. H-36

40-1012 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Brake component Steering component


Component causing failure

Check valve (between last chance filter and

Parking brake emergency release valve

Steering valve (overload relief valve)


Steering valve (main relief valve)

Steering valve (unload valve)


Parking brake solenoid valve

Accumulator charge valve


 parking brake solenoid)

Steering valve (spool)


Brake disc and plate

Troubleshooting No.
Flow control valve
Brake accumulator

Steering cylinder
Steering pump
Parking brake

Stop valve
Orbitrol
Failure

Machine does not move off. q q q q q H-1

Torque converter lockup clutch is not disengaged (engine stalls). H-2


Power train system

Torque converter lockup clutch is not engaged. H-3


Travel speed is slow, bucket thrust force is weak, gradability is low,
q H-4
or gear speed does not shift.
Large shocks are made when machine starts or gear is shifted. q H-5

Machine starts or gear speed shifts with long time lag. q H-6

Torque converter oil temperature is high. H-7

Machine does not turn. q q q q q q q q q H-8

Turning response is poor. q q q q q q q q H-9


Steering
system

Steering wheel is heavy to turn. q q q q q q q H-10

Machine sways or large shocks are made while machine turns. q q q q q q q q H-11

Turning radius differs between right and left turns. q H-12

Wheel brakes do not work or they are weak. q q q H-13

Wheel brakes are not released or drag.


system

q H-14
Brake

Parking brake does not work or it is weak. q q H-15

Parking brake is not released or drags. q q q q H-16

Boom does not rise. H-17

Boom moves slow or boom lacks lifting force. H-18

Rising boom slows down at certain height. H-19


Lift cylinders do not serve to hold bucket on ground (bucket rises off
H-20
ground).
Hydraulic drift of boom is large. H-21

Boom moves up and down during operation. H-22

Bucket does not tilt back. H-23


Work equipment system and

Bucket moves slow or bucket lacks tilt back force. H-24


hydraulic component

Bucket decelerates during tilt-back operation. H-25

Bucket cylinder does not hold bucket on ground. H-26

Hydraulic drift of bucket is large. H-27


Bucket tilts back and forth during carrying load (work equipment
H-28
valve in "HOLD").
Boom and bucket control levers do not move smoothly and heavy to
H-29
move.
Operating work equipment causes engine speed to lower
H-30
significantly or engine to stall.
Large shocks are made when work equipment starts to move and
H-31
stops.
When single work equipment is relieved hydraulically, other work
H-32
equipment moves.
E.C.S.S. (travel damper) does not work and machine pitches and
H-33
bounces.
Bucket does not stop at the position which is set with remote bucket H-34
positioner

WA470-7 40-1013
Fan
system

Failure
mode)

40-1014
40 Troubleshooting

Unusual noise is heard from around fan.


Fan speed is abnormal (too high or low, or fan does not rotate).
Component causing failure

Brake disc and plate

Parking brake
Troubleshooting of hydraulic and mechanical system (H-

Parking brake solenoid valve

Check valve (between last chance filter and

 parking brake solenoid)


Brake component

Parking brake emergency release valve

Accumulator charge valve

Brake accumulator

Steering pump

Orbitrol

Steering cylinder

Stop valve

Flow control valve

Steering valve (spool)


Steering component

Steering valve (main relief valve)

Steering valve (overload relief valve)

Steering valve (unload valve)

Troubleshooting No.
H-36
H-35

WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Work equipment and hydraulic component


Component causing failure

Work equipment valve (main relief valve)


Transmission output shaft speed sensor

Boom control valve (load check valve)


Transmission oil temperature sensor

Work equipment valve (unload valve)


Radiator fan motor (relief valve)

Troubleshooting No.
Bucket control valve (spool)
Boom control valve (spool)
Transmission controller
Hydraulic tank strainer

Work equipment pump

Pump suction piping


Engine
Failure

PT-
O
Machine does not move off. q q H-1

Torque converter lockup clutch is not disengaged (engine stalls). H-2


Power train system

Torque converter lockup clutch is not engaged. H-3


Travel speed is slow, bucket thrust force is weak, gradability is low,
q q q H-4
or gear speed does not shift.
Large shocks are made when machine starts or gear is shifted. q q q q H-5

Machine starts or gear speed shifts with long time lag. q q q H-6

Torque converter oil temperature is high. q q q H-7

Machine does not turn. q q q H-8

Turning response is poor. q q H-9


Steering
system

Steering wheel is heavy to turn. H-10

Machine sways or large shocks are made while machine turns. H-11

Turning radius differs between right and left turns. H-12

Wheel brakes do not work or they are weak. q H-13

Wheel brakes are not released or drag.


system

H-14
Brake

Parking brake does not work or it is weak. H-15

Parking brake is not released or drags. H-16

Boom does not rise. q q q q q q q q H-17

Boom moves slow or boom lacks lifting force. q q q q q q q H-18

Rising boom slows down at certain height. H-19


Lift cylinders do not serve to hold bucket on ground (bucket rises off
H-20
ground).
Hydraulic drift of boom is large. q q H-21

Boom moves up and down during operation. H-22

Bucket does not tilt back. q q q q q q q H-23


Work equipment system and

Bucket moves slow or bucket lacks tilt back force. q q q q q q H-24


hydraulic component

Bucket decelerates during tilt-back operation. H-25

Bucket cylinder does not hold bucket on ground. H-26

Hydraulic drift of bucket is large. q H-27


Bucket tilts back and forth during carrying load (work equipment
H-28
valve in "HOLD").
Boom and bucket control levers do not move smoothly and heavy to
H-29
move.
Operating work equipment causes engine speed to lower
q q q H-30
significantly or engine to stall.
Large shocks are made when work equipment starts to move and
q H-31
stops.
When single work equipment is relieved hydraulically, other work
q q H-32
equipment moves.
E.C.S.S. (travel damper) does not work and machine pitches and
q q H-33
bounces.
Bucket does not stop at the position which is set with remote bucket
H-34
positioner
Fan speed is abnormal (too high or low, or fan does not rotate).
system

q q q H-35
Fan

Unusual noise is heard from around fan. q H-36

WA470-7 40-1015
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Work equipment and hydraulic component


Component causing failure

Pilot circuit (between EPC valve and work equipment control valve)
Shut off valve (for pilot circuit of work equipment valve)

Cooling component and exterior parts around fan


Accumulator selector valve for travel damper
Boom suction valve (cylinder head end)

PC-EPC valve (work equipment pump)


LS-EPC valve (work equipment pump)
Radiator fan direction selector valve

PC valve (work equipment pump)

LS valve (work equipment pump)


Radiator fan valve (relief valve)
Accumulator for travel damper

Travel damper solenoid valve


Bucket overload relief valve

Travel damper charge valve

Air conditioner components


PC valve (steering pump)
LS valve (steering pump)

Bucket control lever

Troubleshooting No.
Boom control lever
Bucket EPC valve
Boom EPC valve
Bucket cylinder
Lift cylinder

Failure

Machine does not move off. H-1

Torque converter lockup clutch is not disengaged (engine stalls). H-2


Power train system

Torque converter lockup clutch is not engaged. H-3


Travel speed is slow, bucket thrust force is weak, gradability is low,
H-4
or gear speed does not shift.
Large shocks are made when machine starts or gear is shifted. H-5

Machine starts or gear speed shifts with long time lag. H-6

Torque converter oil temperature is high. H-7

Machine does not turn. H-8

Turning response is poor. q q H-9


Steering
system

Steering wheel is heavy to turn. H-10

Machine sways or large shocks are made while machine turns. H-11

Turning radius differs between right and left turns. H-12

Wheel brakes do not work or they are weak. H-13

Wheel brakes are not released or drag.


system

H-14
Brake

Parking brake does not work or it is weak. H-15

Parking brake is not released or drags. H-16

Boom does not rise. q q q H-17

Boom moves slow or boom lacks lifting force. q q q q q q H-18

Rising boom slows down at certain height. q H-19


Work equipment system and

Lift cylinders do not serve to hold bucket on ground (bucket rises off
hydraulic component

q q q H-20
ground).
Hydraulic drift of boom is large. q H-21

Boom moves up and down during operation. q q q q H-22

Bucket does not tilt back. q q q q q H-23

Bucket moves slow or bucket lacks tilt back force. q q q q q q q H-24

Bucket decelerates during tilt-back operation. q H-25


H-26
Bucket cylinder does not hold bucket on ground. q q q q

40-1016 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Work equipment and hydraulic component


Component causing failure

Pilot circuit (between EPC valve and work equipment control valve)
Shut off valve (for pilot circuit of work equipment valve)

Cooling component and exterior parts around fan


Accumulator selector valve for travel damper
Boom suction valve (cylinder head end)

PC-EPC valve (work equipment pump)


LS-EPC valve (work equipment pump)
Radiator fan direction selector valve

PC valve (work equipment pump)

LS valve (work equipment pump)


Radiator fan valve (relief valve)
Accumulator for travel damper

Travel damper solenoid valve


Bucket overload relief valve

Travel damper charge valve

Air conditioner components


PC valve (steering pump)
LS valve (steering pump)

Bucket control lever

Troubleshooting No.
Boom control lever
Bucket EPC valve
Boom EPC valve
Bucket cylinder
Failure Lift cylinder

Hydraulic drift of bucket is large. q q H-27


Bucket tilts back and forth during carrying load (work equipment
q q q q H-28
valve in "HOLD").
Work equipment system and

Boom and bucket control levers do not move smoothly and heavy to
q q q q H-29
hydraulic component

move.
Operating work equipment causes engine speed to lower
q q q q H-30
significantly or engine to stall.
Large shocks are made when work equipment starts to move and
q q q q q H-31
stops.
When single work equipment is relieved hydraulically, other work
q H-32
equipment moves.
E.C.S.S. (travel damper) does not work and machine pitches and
q q q q H-33
bounces.
Bucket does not stop at the position which is set with remote bucket
H-34
positioner
Fan speed is abnormal (too high or low, or fan does not rotate).
system

q q H-35
Fan

Unusual noise is heard from around fan. q H-36

WA470-7 40-1017
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

(*) Clutches to be used


F R 1st 2nd 3rd 4th
In auto shift
q
mode
N
In manual
q q q q
shift mode
F1 q q
Ge-
F2 q q
ar
spe- F3 q q
ed F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

40-1018 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-1 Machine does not move off (WA470_7-BH0-400-A-Z0-A)

Failure Machine does not move off at all gear speeds.


• Check that transmission oil level is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
15SGLH, 15SHL1, or 15SHLH).
Related • Check drive shaft, etc. for abnormalities.
information • Check that parking brake is surely released.
• Torque converter oil pressure can be checked with monitoring function. (Monitoring code:
32601 (Input pressure), 32603 (Output pressure))
• Engine speed can be checked with monitoring function. (Monitoring code: 01001)
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
1 transmission charge Check strainer for clogging.
pump
Air sucked in on suction
2 side of transmission Check suction piping for cracks, etc.
charge pump
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
3 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26.0 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (fatigue of spring) and internal defect (defective valve seat).
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Torque converter 0.1 to 0.88 MPa
input pressure Brake OFF
Improper torque {1.0 to 9.0 kg/cm2}
4 converter pressure Torque converter 0.06 to 0.71 MPa
(relief valve) output pressure Brake OFF
{0.6 to 7.1 kg/cm2}
When pressure cannot be adjusted to normal level, check relief valve for
malfunction (fatigue of spring) and internal defect (defective valve seat).
• If torque converter output pressure is below standard value, oil cooler may
be broken.
a Be ready with engine stopped, then perform troubleshooting during torque
converter stall operation.
Defective torque Economy mode
5 ON 1,710 ± 100 rpm
converter Torque converter switch
stall speed Power mode 1,785 ± 100 rpm
ON
switch

WA470-7 40-1019
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Output pressure of F 2.06 ± 0.15 MPa
F1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of R 2.06 ± 0.15 MPa
R1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of 2.35 ± 0.15 MPa
F1
1st clutch ECMV {24 ± 1.5 kg/cm2}
Defective gear speed Gear speed
6 2.35 ± 0.15 MPa
clutch ECMV Output pressure of
F2
2nd clutch ECMV {24 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F3
3rd clutch ECMV {23.5 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F4
4th clutch ECMV {23.5 ± 1.5 kg/cm2}
* Combination of two gear speed clutches determines gear speed. Check
combination of two clutches to be used for selection of gear speed by
referring to Table 1.
• If measured pressure is below standard value in check on cause (6), oil
Defective gear speed may leak through clutch seal ring.
7
clutch • If measured pressure is normal in check on cause (6), clutch may slip.
• If measured pressure is unusual in check on cause (3) and main relief
Defective transmission valve is normal, disconnect transmission charge pump outlet hose, crank
8 charge pump engine, and check that oil flows out.
• Check line filter for foreign materials such as metal particles.
Internal defect of • If no failure is found by checks on causes (1) to (8), transmission may
9
transmission have internal defect.
Clogged last chance If no failure is found by check on cause (3) but lockup clutch pressure is low or
10 “0“, check last chance filter for clogging.
filter
Malfunction of check Check check valve between last chance filter and parking brake solenoid for
11 sticking.
valve
Malfunction of parking If turning release valve does not release parking brake, check release valve
12 brake emergency spool for sticking.
release valve
a Be ready with engine stopped, then perform troubleshooting with engine at
low idle.
0 MPa
Output pressure of ON
Malfunction of parking Parking brake {0 kg/cm2}
13 parking brake
brake solenoid valve switch 2.32 MPa
solenoid valve OFF
{23.5 kg/cm2}
If oil pressure is not developed with parking brake switch at OFF position,
check solenoid valve spool for sticking.
• If no failure is found by check on cause (13), parking brake may be
defective.
14 Defective parking brake Check parking brake for worn disc, deformed spring, etc.
Thickness of parking brake disc Min. 2.97 mm

40-1020 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

Table 1
Clutches to be used
F R 1st 2nd 3rd 4th
In auto shift
q
mode
N
In manual
q q q q
shift mode
F1 q q
Gear speed

F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.

WA470-7 40-1021
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-2 Torque converter lockup clutch is not disengaged (engine


stalls) (WA470_7-AD1-400-A-Z0-A)
Failure Torque converter lockup clutch is not disengaged (engine stalls).
• Check that transmission oil level is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (DXH1KA, DXH1KB, or DXH1KY)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
When torque converter lockup
Malfunction of lockup 1.66 ± 0.15 MPa
1 clutch is engaged
clutch ECMV Output pressure of (Manual lockup switch: ON) {17.0 ± 1.5 kg/cm2}
lockup clutch ECMV
When torque converter lockup 0 MPa
clutch is disengaged {0 kg/cm2}
2 Defective lockup clutch If measured pressure is normal in check on cause (1), lockup clutch may be
seized.

40-1022 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-3 Torque converter lockup clutch is not engaged (WA470_7-F11-400-A-Z0-A)

Failure Torque converter lockup clutch is not engaged.


• Check that transmission oil level is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (DXH1KA, DXH1KB, or DXH1KY)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
1 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26.0 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (setting of spring) and internal defect (defective valve seat).
Clogged last chance If no failure is found by check on cause (1) but lockup clutch pressure is low or
2 "0", check last chance filter for clogging.
filter
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
When torque converter lockup
Malfunction of lockup 1.66 ± 0.15 MPa
3 clutch is engaged
clutch ECMV Output pressure of (Manual switch: ON) {17.0 ± 1.5 kg/cm2}
lockup clutch ECMV
When torque converter lockup 0 MPa
clutch is disengaged {0 kg/cm2}
If measured pressure is normal in check on cause (3), lockup clutch may have
worn.
4 Defective lockup clutch
If measured pressure is unusual but ECMV is normal, sealing of lockup clutch
piston may be defective.

WA470-7 40-1023
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-4 Travel speed is slow, bucket thrust force is weak, gradability is low,
or gear speed does not shift (WA470_7-D20-400-A-Z0-A)
Travel speed is slow, bucket thrust force is weak, gradability is low, or gear speed does not
Failure
shift.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
Related 15SGLH, 15SHL1, or 15SHLH).
information • Check that wheel brake or parking brake is not dragged.
• Torque converter oil pressure can be checked with monitoring function. (Monitoring code:
32601 (Input pressure), 32603 (Output pressure))
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
1 transmission charge Check strainer for clogging.
pump
Air sucked in on suction
2 side of transmission Check suction piping for cracks, etc.
charge pump
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
3 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (fatigue of spring) and internal defect (defective valve seat).
Clogged last chance If no failure is found by check on cause (3) but lockup clutch pressure is low or
4 "0", check last chance filter for clogging.
filter
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Torque converter 0.1 to 0.88 MPa
input pressure Brake OFF
Improper torque {1.0 to 9.0 kg/cm2}
5 converter pressure Torque converter 0.06 to 0.71 MPa
(relief valve) output pressure Brake OFF
{0.6 to 7.1 kg/cm2}
When pressure cannot be adjusted to normal level, check relief valve for
malfunction (fatigue of spring) and internal defect (defective valve seat).
• If torque converter output pressure is below standard value, oil cooler may
be broken.
a Be ready with engine stopped, then perform troubleshooting during torque
converter stall operation.
Defective torque Economy mode
6 ON 1,710 ± 100 rpm
converter Torque converter switch
stall speed Power mode 1,785 ± 100 rpm
ON
switch

40-1024 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Output pressure of F 2.06 ± 0.15 MPa
F1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of R 2.06 ± 0.15 MPa
R1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of 2.35 ± 0.15 MPa
F1
1st clutch ECMV {24 ± 1.5 kg/cm2}
Defective gear speed Gear speed
7 2.35 ± 0.15 MPa
clutch ECMV Output pressure of
F2
2nd clutch ECMV {24 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F3
3rd clutch ECMV {23.5 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F4
4th clutch ECMV {23.5 ± 1.5 kg/cm2}
* Combination of two gear speed clutches determines gear speed. Check
combination of two clutches to be used for selection of gear speed by
referring to Table 1.
• If measured pressure is below standard value in check on cause (7), oil
Defective gear speed may leak through clutch seal ring.
8
clutch • If measured pressure is normal in check on cause (7), clutch may slip.
a Be ready with engine stopped, then perform troubleshooting with engine
Lockup clutch running at 2,000 rpm.
9
Malfunction of ECMV Output pressure of 1.66 ± 0.15 MPa
Lockup switch ON
lockup clutch ECMV {17 ± 1.5 kg/cm2}
• If measured pressure is below standard value in check on cause (9),
Slippage of lockup clutch piston seal ring or ring groove may wear.
10
clutch • If measured pressure is normal in check on cause (9), clutch may slip.
• If measured pressure is unusual in check on cause (3) and main relief
Defective transmission valve is normal, disconnect power train pump outlet hose, crank engine,
11 charge pump and check that oil flows out.
• Check line filter for foreign materials such as metal particles.
Clogged transmission Check breather for clogging.
12
breather
Internal defect of If no failure is found by checks on causes (1) to (12), transmission may have
13
transmission internal defect.
• If no failure is found by checks on causes (1) to (13) and torque converter
14 Lowered engine output stall speed is below standard value (power mode: 1785 rpm), engine
performance may lower.
Table 1
Clutches to be used
F R 1st 2nd 3rd 4th
In auto shift
q
mode
N
In manual
q q q q
shift mode
F1 q q
Gear speed

F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

WA470-7 40-1025
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.

40-1026 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-5 Large shock is made when machine starts or gear is shifted (WA470_7-C10-
400-A-Z0-A)

Failure Large shock is made when machine starts or gear is shifted.


• It is difficult to determine whether shock you feel is large or small. so, regard shocks as
large in following cases.
1. When you feel that shock increases significantly and suddenly
2. When you feel that shock is larger than that of other machines of same model
• Check that transmission oil level is normal.
Related • If any failure code is displayed, perform trouble shooting for that failure code first.
information 15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
15SGLH, 15SHL1, 15SHLH, DGF1KA, or DGF1KB)
• Check that drive shaft, etc. are normal.
• Engine speed can be checked with monitoring function. (Monitoring code: 01001)
• Clutch fill time can be checked with monitoring function. (Monitoring code: 41802 (1st),
41803 (2nd), 41804 (3rd), 41805 (4th), 41806(R), 41808 (F))
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
1 transmission charge Check strainer for clogging.
pump
Air sucked in on suction
2 side of transmission Check suction piping for cracks, etc.
charge pump
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
3 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (setting of spring) and internal defect (defective valve seat).
If no failure is found by check on cause (3) but lockup clutch pressure is low or
Clogged last chance
4 “0“, check last chance filter for clogging.
filter

WA470-7 40-1027
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Output pressure of F 2.06 ± 0.15 MPa
F1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of R 2.06 ± 0.15 MPa
R1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of 2.35 ± 0.15 MPa
F1
1st clutch ECMV {24 ± 1.5 kg/cm2}
Gear speed
Defective gear speed Output pressure of 2.35 ± 0.15 MPa
5 F2
clutch ECMV 2nd clutch ECMV {24 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F3
3rd clutch ECMV {23.5 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F4
4th clutch ECMV {23.5 ± 1.5 kg/cm2}
• Pressure control valve spool may malfunction due to trapped dirt, or fill
switch or solenoid may malfunction.
* Combination of two gear speed clutches determines gear speed. Check
combination of two clutches to be used for selection of gear speed by
referring to Table 1.
• If measured pressure is low in check on cause (5), oil may leak through
Defective gear speed clutch seal ring.
6
clutch • If measured pressure is normal in check on cause (5), clutch may slip.
• If gear speed clutch is normal in check on cause (5), sealing of parking
7 Defective parking brake brake piston may be defective.
• If measured pressure is unusual in check on cause (3) and main relief
Defective transmission valve is normal, disconnect transmission charge pump outlet hose, crank
8 charge pump engine, and check that oil flows out.
• Check line filter for foreign materials such as metal particles.
Internal defect of • If no failure is found by checks on causes 1 to 8, transmission may have
9
transmission internal defect.
Defective transmission • If no failure is found by checks on causes 1 to 9, transmission controller
10 may be defective.
controller
Table 1
Clutches to be used
F R 1st 2nd 3rd 4th
In auto shift
q
mode
N
In manual
Q Q Q Q
shift mode
F1 q q
Gear speed

F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.

40-1028 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-6 Machine starts or gear speed shifts with long time lag (WA470_7-C60-400-A-Z0-A)

Failure Machine starts or gear speed shifts with long time lag.
• Check that transmission oil level is normal.
• If any failure code is displayed, perform trouble shooting for that failure code first.
Related 15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
information 15SGLH, 15SHL1, 15SHLH, DGF1KA, or DGF1KB)
• Check that drive shaft, etc. are normal.
• Engine speed can be checked with monitoring function. (Monitoring code: 01001)
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
If unusual noise is heard from charge pump or transmission oil filter when
1 transmission charge
transmission oil temperature is low, check strainer for clogging.
pump
Air sucked in on suction
2 side of transmission Check suction piping for cracks, etc.
charge pump
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
3 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (setting of spring) and internal defect (defective valve seat).
Clogged last chance If no failure is found by check on cause (3) but lockup clutch pressure is low or
4 “0“, check last chance filter for clogging.
filter
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Output pressure of F 2.06 ± 0.15 MPa
F1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of R 2.06 ± 0.15 MPa
R1
clutch ECMV {21 ± 1.5 kg/cm2}

Output pressure of 2.35 ± 0.15 MPa


F1
1st clutch ECMV {24 ± 1.5 kg/cm2}
Gear speed
Defective gear speed
5
clutch ECMV Output pressure of 2.35 ± 0.15 MPa
F2
2nd clutch ECMV {24 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F3
3rd clutch ECMV {23.5 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F4
4th clutch ECMV {23.5 ± 1.5 kg/cm2}
• Pressure control valve spool may malfunction due to trapped dirt, or fill
switch or solenoid may malfunction.
* Combination of two gear speed clutches determines gear speed. Check
combination of two clutches to be used for selection of gear speed by
referring to Table 1.
• If no failure is found by check on cause (5) and any gear speed causes
Malfunction of parking
6 long time lag, sealing of parking brake piston may be defective.
brake

WA470-7 40-1029
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


• If measured pressure is low in check on cause (5), oil may leak through
Defective gear speed clutch seal ring.
7
clutch • If measured pressure is normal in check on cause (5), clutch may slip.
• If measured pressure is unusual in check on cause (3) and main relief
Defective transmission valve is normal, disconnect transmission charge pump outlet hose, crank
8 charge pump engine, and check that oil flows out.
• Check line filter for foreign materials such as metal particles.
Internal defect of • If no failure is found by checks on causes 1 to 8, transmission may have
9
transmission internal defect.
Table 1
Clutches to be used
F R 1st 2nd 3rd 4th
In auto shift
q
mode
N
In manual
q q q q
shift mode
F1 q q
Gear speed

F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a Clutch fill time can be checked with monitoring function.


Monitoring code: 41802 (1st)
41803 (2nd)
41804 (3rd)
41805 (4th)
41806 (R)
41808 (F)
a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.

40-1030 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-7 Torque converter oil temperature is high (WA470_7-AM0-400-A-Z0-A)

Failure Torque converter oil temperature is high.


• Check that transmission oil level is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(15SAL1, 15SALH, 15SBL1, 15SBLH, 15SEL1, 15SELH, 15SFL1, 15SFLH, 15SGL1,
15SGLH, 15SHL1, 15SHLH, DGT1KA, or DGT1KB)
• Check that parking brake is surely released.
Related • Measure torque converter oil temperature actually and compare it with that displayed by
information using monitoring function to determine whether oil temperature sensor is normal.
(Monitoring code: 30100)
• Torque converter oil pressure can be checked with monitoring function. (Monitoring code:
32601 (Input pressure), 32603 (Output pressure))
• Engine speed can be checked with monitoring function. (Monitoring code: 01001)
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
1 transmission charge Check strainer for clogging.
pump
Air sucked in on suction
2 side of transmission Check suction piping for cracks, etc.
charge pump
Clogged transmission Check breather for clogging.
3
breather
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 2,000 rpm.
2.32 ± 0.2 MPa
Defective main relief Low idle
4 valve of transmission {23.5 ± 2 kg/cm2}
Main relief pressure Engine speed
charge pump 2.55 ± 0.2 MPa
2,000 rpm
{26 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (setting of spring) and internal defect (defective valve seat).
a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Torque converter 0.1 to 0.88 MPa
input pressure Brake OFF
Improper torque {1.0 to 9.0 kg/cm2}
5 converter pressure Torque converter 0.06 to 0.71 MPa
(relief valve) output pressure Brake OFF
{0.6 to 7.1 kg/cm2}
When pressure cannot be adjusted to normal level, check relief valve for
malfunction (setting of spring) and internal defect (defective valve seat).
• If torque converter output pressure is low, oil cooler may be broken.
a Be ready with engine stopped, then perform troubleshooting with torque
converter at stall.
Defective torque Economy mode
6 ON 1、710 ± 100 rpm
converter Torque converter switch
stall speed Power mode 1、785 ± 100 rpm
ON
switch

WA470-7 40-1031
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine
running at 2,000 rpm.
Output pressure of F 2.06 ± 0.15 MPa
F1
clutch ECMV {21 ± 1.5 kg/cm2}
Output pressure of R 2.06 ± 0.15 MPa
R1
clutch ECMV {21 ± 1.5 kg/cm2}

Output pressure of 2.35 ± 0.15 MPa


F1
1st clutch ECMV {24 ± 1.5 kg/cm2}
Gear speed
Defective gear speed
7 Output pressure of 2.35 ± 0.15 MPa
clutch ECMV F2
2nd clutch ECMV {24 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F3
3rd clutch ECMV {23.5 ± 1.5 kg/cm2}
Output pressure of 2.30 ± 0.5 MPa
F4
4th clutch ECMV {23.5 ± 1.5 kg/cm2}
• Pressure control valve spool may malfunction due to trapped dirt, or fill
switch or solenoid may malfunction.
* Combination of two gear speed clutches determines gear speed. Check
combination of two clutches to be used for selection of gear speed by
referring to Table 1.
• If measured pressure is low in check on cause (7), oil may leak through
Defective gear speed clutch seal ring.
8
clutch • If measured pressure is high in check on cause (7), clutch may slip.
• If measured pressure is unusual in check on cause (3) and main relief
valve is normal, disconnect transmission charge pump outlet hose, crank
Defective transmission engine, and check that oil flows out.
9 charge pump • Check whether hydraulic oil flows into transmission case due to broken
pump shaft seal.
• Check line filter for foreign materials such as metal particles.
Internal defect of • If no failure is found by checks on causes 1 to 9, transmission may have
10
transmission internal defect.
• If no failure is found by checks on causes 1 to 10, engine performance
Defective engine
11 system may lower. Perform troubleshooting by referring to "S mode"
troubleshooting.
Table 1
Clutches to be used
F R 1st 2nd 3rd 4th
In auto shift
q
mode
N
In manual
q q q q
shift mode
F1 q q
Gear speed

F2 q q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

a When manual shift mode is selected, speed clutch (marked with q) for current gear speed, to which gear
shift lever is set, remains engaged.
• When transmission is at NATURAL, operating gear shift lever does not switch engaged clutches.

40-1032 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-8 Machine does not turn (WA470_7-L10-400-A-Z0-A)

Failure Machine does not turn.


• Check that oil level in hydraulic tank is normal.
• Check that frame lock bar is removed.
• Check that steering shaft is not damaged.
Related • Check that steering stop valve is properly adjusted.
information • Steering pump pressure can be checked with monitoring function. (Monitoring code:
95302)
• Fan speed can be checked with monitoring function. (Monitoring code: 10009)
No. Cause Procedure, measuring location, criteria and remarks
When machine does not turn to either side, if work equipment or cooling fan
1 Defective PTO also malfunctions, PTO may be defective.
Air sucked in on suction
2 Check suction piping for cracks, etc.
side of steering pump
Defective strainer of
3 Check steering pump strainer for clogging.
steering pump
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of 3.72 ± 0.2 MPa
4 accumulator charge Steering wheel NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve
• Output pressure of accumulator charge valve is source pressure for
Orbitrol.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
5 Defective Orbitrol Pressure must be
Output pressure of applied while
Steering wheel Operation
Orbitrol steering wheel is
operated.
a Be ready with engine stopped, then perform troubleshooting with engine at
Defective relief valve of low idle.*
6 steering valve Steering control 1.15 to 1.55 MPa
Steering wheel NEUTRAL
pressure {11.7 to 15.3 kg/cm2}
If measured pressure is abnormally high in check on cause (6), flow control
Defective flow control spool may malfunction.
7 spool
Check spool for sticking.
When measured pressure is normal in check on cause (6), if oil pressure is
not applied to steering cylinder while steering wheel is operated, steering
8 Defective steering spool spool may malfunction.
Check spool for sticking.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective steering main 24.5 (+1.23/-2.45)
9 Steering main relief Steering MPa
relief valve Relief
pressure cylinder {250 (+12.5/-25) kg/
cm2}
• If measured relief pressure is unusual, adjust main relief valve.
If measured relief pressure of either side is low in check on cause (9),
Defective overload relief overload relief valve may be defective.
10
valve Replace the assembly because it cannot be adjusted when it is installed to
actual machine.
When no failure is found by check on cause (10), if machine turn only to one
side or steering wheel is too heavy to turn to one side, stop valve may be
11 Defective stop valve
defective.

WA470-7 40-1033
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective steering If measured relief pressure is below standard value in check on cause (9),
12 cylinder
disconnect hydraulic hose from steering cylinder head end, set frame lock bar,
and extend that steering cylinder to relieve it hydraulically. If oil flows out of
cylinder, piston ring of steering cylinder is defective.
• If measured pressure is unusual in check on cause (9) and main relief
valve is normal, disconnect steering pump outlet hose, crank engine, and
Defective steering
13 pump check that oil flows out.
• Check return filter and suction strainer for foreign materials such as metal
particles.
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (4), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
14 pump Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-35
Fan speed is abnormal".
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

40-1034 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-9 Turning response is poor (WA470_7-L30-400-A-Z0-A)

Failure Turning response is poor.


• Check that oil level in hydraulic tank is normal.
• Check that steering shaft is not damaged.
General • Check that steering stop valve is properly adjusted.
information • Steering pump pressure can be checked with monitoring function. (Monitoring code:
95302)
• Fan speed can be checked with monitoring function. (Monitoring code: 10009)
No. Cause Procedure, measuring location, criteria and remarks
When machine does not turn to either side, if work equipment or cooling fan
1 Defective PTO also malfunctions, PTO may be defective.
Air sucked in on suction
2 Check suction piping for cracks, etc.
side of steering pump
Defective strainer of
3 Check steering pump strainer for clogging.
steering pump
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of 3.72 ± 0.2 MPa
4 accumulator charge Steering wheel NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve
• Output pressure of accumulator charge valve is source pressure for
Orbitrol.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
5 Defective Orbitrol Pressure must be
Output pressure of developed while
Steering wheel Operation
Orbitrol steering wheel is
operated.
a Be ready with engine stopped, then perform troubleshooting with engine at
Defective relief valve of low idle.
6 steering valve Steering control 1.15 to 1.55 MPa
Steering wheel NEUTRAL
pressure {11.7 to 15.3 kg/cm2}
If measured pressure is abnormally high in check on cause (6), flow control
Defective flow control spool may malfunction.
7 spool
Check spool for sticking.
When measured pressure is normal in check on cause (6), if oil pressure is
not applied to steering cylinder while steering wheel is operated, steering
8 Defective steering spool spool may malfunction.
Check spool for sticking.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective steering main 24.5 (+1.23/-2.45)
9
relief valve Steering main relief Steering MPa
pressure cylinder Relief
{250 (+12.5/-25) kg/
cm2}
If measured relief pressure of either side is low in check on cause (9),
Defective overload relief overload relief valve may be defective.
10
valve Replace the assembly because it cannot be adjusted when it is installed to
actual machine.
When no failure is found by check on cause (9), if machine turn only to one
11 Defective stop valve side or steering wheel is too heavy to turn to one side, stop valve may be
defective.
Check PC valve for sticking of spool and fatigue of spring. If any failure is
12 Malfunction of PC valve found, replace it.
Check LS valve for sticking of spool and fatigue of spring. If any failure is
13 Malfunction of LS valve found, replace it.

WA470-7 40-1035
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine at
Defective steering high idle.*
14 cylinder If measured relief pressure is low, disconnect hydraulic hose from steering
cylinder head end, and relieve steering cylinder hydraulically at its stroke end.
If oil flows out from cylinder, cylinder piston ring is defective.
• If measured pressure is unusual in check on cause (9) and main relief
valve is normal, disconnect steering pump outlet hose, crank engine, and
Defective steering
15 pump check that oil flows out.
• Check return filter and suction strainer for foreign materials such as metal
particles, etc.
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (4), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
16 pump Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-35
Fan speed is abnormal".
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

40-1036 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-10 Steering wheel is heavy to turn (WA470_7-LQ0-400-A-Z0-A)

Failure Steering wheel is heavy to turn.


• Check that oil level in hydraulic tank is normal.
• Check that steering shaft is not damaged.
• Check that steering stop valve is properly adjusted.
Related • Check that inflation pressure is normal.
information • If machine does not turn smoothly, perform troubleshooting for H-8 and H-9.
• Steering pump pressure can be checked with monitoring function. (Monitoring code:
95302)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
full speed.
Defective charge valve Output pressure of 3.72 ± 0.2 MPa
1 accumulator charge Steering wheel NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve
• Output pressure of accumulator charge valve is source pressure for
Orbitrol.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
2 Defective Orbitrol Pressure must be
Output pressure of developed while
power steering Steering wheel Operated
steering wheel is
control unit operated.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
24.5 (+1.23/-2.45)
Defective steering main
3 Steering main relief Steering MPa
relief valve Hydraulic relief
pressure cylinder {250 (+12.5/-25) kg/
cm2}
• If measured relief pressure is unusual, adjust main relief valve.
When no failure is found by check on cause (3), if machine turn only to one
4 Defective stop valve side or steering wheel is heavy and hard to turn only to one side, stop valve
may be defective.
Malfunction of steering
5 • Check them after disconnecting steering shaft from Orbitrol.
wheel or steering shaft
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (4), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
6 Torque converter oil temperature:
pump Fan speed 1,300 ± 200 rpm
Min. 105°C
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-35
Fan speed is abnormal".
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1037
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-11 Machine sways or large shocks are made while machine


turns (WA470_7-L54-400-A-Z0-A)
Failure Machine sways or large shocks are made while machine turns.
• Check that steering shaft is not damaged.
• Check that play of steering wheel is normal.
General • Check that inflation pressure is normal.
information • Steering pump pressure can be checked with monitoring function. (Monitoring code:
95302)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of 3.72 ± 0.2 MPa
1 accumulator charge Steering wheel NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve
• Output pressure of accumulator charge valve is source pressure for
Orbitrol.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
2 Defective Orbitrol Pressure must be
Output pressure of developed while
Steering wheel Operation
Orbitrol steering wheel is
operated.
a Be ready with engine stopped, then perform troubleshooting with engine at
Defective relief valve of low idle.*
3 steering valve Steering control 1.15 to 1.55 MPa
Steering wheel NEUTRAL
pressure {11.7 to 15.3 kg/cm2}
If measured pressure is abnormally high in check on cause (3), flow control
Defective flow control spool may malfunction.
4 spool
Check spool for sticking.
When measured pressure is normal in check on cause (3), if oil pressure is
not applied to steering cylinder while steering wheel is operated, steering
5 Defective steering spool spool may malfunction.
Check spool for sticking.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective steering main 24.5 (+1.23/-2.45)
6 Steering main relief Steering MPa
relief valve Relief
pressure cylinder {250 (+12.5/-25) kg/
cm2}
• If measured relief pressure is unusual, adjust main relief valve.
If measured relief pressure of either side is low in check on cause (6),
Defective overload relief overload relief valve may be defective.
7
valve Replace valve assembly because valve cannot be adjusted when it is
installed to machine.
If machine sways to either side or large shock is made while machine turns,
stop valve may be defective.
8 Defective stop valve
If large shock is made when steering cylinder reaches its stroke end, stop
valve may be defective.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective steering If measured relief pressure is below standard value in check on cause (6),
9 cylinder disconnect hydraulic hose from steering cylinder head end, set frame lock bar,
and extend that steering cylinder to relieve it hydraulically. If oil flows out of
cylinder, piston ring of cylinder is defective.

40-1038 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


• If measured output pressure of accumulator charge valve is below
standard value in check on cause (4), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
10 pump Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-36
Fan speed is abnormal".
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1039
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-12 Turning radius differs between right and left turns (WA380_7-L90-400-A-Z0-A)

Failure Turning radius differs between right and left turns.


Related • Check that stopper bolt for stop valve is not loosened.
information
No. Cause Procedure, measuring location, criteria and remarks
Improper adjustment of a Adjust installed positions of stopper bolts for steering stop valves
1 steering stop valve (right and left).

a For adjustment procedure of stopper bolt, see k Take care not to loosen stopper bolt
Testing and adjusting, "Testing and adjusting (1) excessively so that it does not
stopper bolt". press spool.
(Reference) Adjustment procedure of stopper
bolt for stop valve

4. Turn machine back more than 10 degrees


and stop engine.
5. Loosen stopper bolt (1) further 8.5 turns
1. Set stopper bolt (1) to its minimum length.
(approx. 15 mm), and fix it with lock nut (3).
6. Adjust both right and left stopper bolts by
applying procedures of steps (1) to (5).

2. Run engine at low idle, and turn steering


wheel slowly so that stopper bolt contacts
frame end.
3. Under condition in step (2), loosen stopper
bolt (1) until its head contacts end face of
spool of stop valve (2).

40-1040 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-13 Wheel brakes do not work or are weak (WA470_7-FL8-400-A-Z0-A)

Failure Wheel brakes do not work or they are weak.


• Check that hydraulic oil level is normal.
• Check that play of brake pedal is normal.
• Check that inflation pressure is normal.
Related • Brake pressure can be checked with monitoring function. (Monitoring code: 41201)
information • Brake cut-off operating pressure can be checked with monitoring function. (Monitoring
code: 41203)
• Fan speed can be checked with monitoring function. (Monitoring code: 10009)
No. Cause Procedure, measuring location, criteria and remarks
Air sucked in on suction
1 side of cooling fan Check suction piping for cracks, etc.
pump
Air mixed in brake Bleed air from brake circuit. For details, see Testing and adjusting "Bleeding
2
circuit air from wheel brake circuit".
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Charge valve cut-in pressure
5.9 (+0.98/-0.5) MPa
Defective accumulator (When brake pressure caution
3 charge valve {60 (+10/-5) kg/cm2}
Charge valve lamp goes out)
operating pressure Charge valve cut-out pressure 9.8 (+1.5/-0.5) MPa
(When brake pressure switches {100 (+15/-5) kg/
from rising to lowering) cm2}
a Be ready with engine stopped, then perform troubleshooting with engine
stopped.
Count number of times
Number of times
depressing brake pedal required
Defective brake depressing brake Min. 5 times
4 until brake pressure caution lamp
accumulator pedal
goes out.
If brakes went out immediately after engine is stopped, accumulator may be
short of charged gas or its sealing may be defective.
(Reference) Charged gas pressure: 3.4 ± 0.10 MPa {35 ± 1.0 kg/cm2 }
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
5 Defective brake valve
Brake actuating Min. 4.2 MPa
Brake pedal depressed
pressure {Min. 42.7 kg/cm2}
• If measured pressure is below standard value in check on cause (5), brake
piston seal ring or ring groove may be defective.
• If measured pressure is normal in check on cause (5), brake disc may slip.
6 Defective wheel brake Protrusion of shaft
(See Testing and adjusting,
Wear of disc Max. 2.4 mm
"Testing wear of wheel brake
disc".)
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (3), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 90 °C
Defective cooling fan
7 Torque converter oil temperature:
pump Fan speed 1,300 ± 200 rpm
Min. 100 °C
Hydraulic oil temperature: Min. 90
°C
• If fan speed is below standard value, perform troubleshooting for “H-34
Fan speed is abnormal“.
If large depressing effort is required for brake pedal or brakes work with time
8 Defective slack adjuster
lag, slack adjuster may be defective.

WA470-7 40-1041
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

40-1042 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-14 Wheel brakes are not released or drag (WA470_7-E63-400-A-Z0-A)

Failure Wheel brakes are not released or drag.


• Check that brake pedal returns completely.
Related • Check that parking brake is released completely.
information • Brake pressure can be checked with monitoring function. (Monitoring code: 41201)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
0 MPa
When brake pedal is released
Brake valve {0 kg/cm2}
operating pressure Min. 4.2 MPa
1 Defective brake valve When brake pedal is depressed
{Min. 42.7 kg/cm2}
If brake pressure is developed when brake pedal is released, brake valve
spool may be stuck.
Release brake pedal, remove oil from air bleeder, and check whether circuit
pressure lowers and brakes are released.
When air bleeder at wheel portion is loosened, if oil flows out and brake is
2 Defective slack adjuster
released, slack adjuster may be defective.
• Jack up four wheels and put axles onto the stands. (Engine stopped)
3 Defective wheel brake Release parking brake and rotate the tires to check if there is any tire not
rotate smoothly.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1043
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-15 Parking brake does not work or it is weak (WA470_7-FPR-400-A-Z0-A)

Failure Parking brake does not work or it is weak.


• Check that oil level in hydraulic tank is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (2F00MA or DDB6L4)
• Check that parking brake has not been released mechanically.
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
low idle.
0 MPa
ON
Defective parking brake Parking brake Parking brake {0 kg/cm2}
1
solenoid valve pressure switch Min. 2.32 MPa
OFF
{Min. 23.5 kg/cm2}
If oil pressure is developed with parking brake switch at ON position, check
solenoid valve spool for locking.
• If no failure is found by check on cause (1), parking brake may be
defective.
2 Defective parking brake Check parking brake for worn disc, deformed spring, etc.
Thickness of parking brake disc Min. 2.97 mm

40-1044 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-16 Parking brake is not released or drags (including emergency


release system) (WA470_7-E73-400-A-Z0-A)
Failure Parking brake is not released or drags.
• Check that oil level in hydraulic tank is normal.
Related • If any failure code is displayed, perform troubleshooting for that failure code first.
information (DDB6L4)
• Check that parking brake is automatically applied when engine is stopped.
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
low idle.
0 MPa
ON
Malfunction of parking Parking brake Parking brake {0 kg/cm2}
1
brake solenoid valve pressure switch Min. 2.32 MPa
OFF
{Min. 23.5 kg/cm2}
If oil pressure is not developed with parking brake switch at OFF position,
check solenoid valve spool for locking.
If turning release valve does not release parking brake, release valve may
Malfunction of parking malfunction.
2 brake emergency
(For release procedure, see Testing and adjusting, "Release procedure of
release valve
parking brake".)
If parking brake becomes hard to release immediately after engine is stopped,
Defective rear brake accumulator may be short of charged gas.
3
accumulator
(Reference) Charged gas pressure: 3.4 ± 0.10 MPa {35 ± 1.0 kg/cm2 }
a Be ready with engine stopped, then perform troubleshooting with engine
running at low idle and 1,900 rpm.
23.2 ± 0.2 MPa
Defective main relief Low idle
4 valve of transmission {23.5 ± 2.0 kg/cm2}
Main relief pressure Engine Speed
charge pump 2.55 ± 0.2 MPa
1,900 rpm
{26 ± 2.0 kg/cm2}
When pressure cannot be adjusted to normal level, check main relief valve for
malfunction (setting of spring) and internal defect (defective valve seat).
Malfunction of check Check check valve between last chance filter and parking brake solenoid for
5 locking.
valve
• If no failure is found by checks on causes (1) to (5), parking brake may be
defective.
6 Defective parking brake Check parking brake for worn disc, deformed spring, etc.
Thickness of parking brake disc Min. 2.97 mm

WA470-7 40-1045
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-17 Boom does not rise (WA470_7-M60-400-A-Z0-A)

Failure Boom does not rise.


• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DB90KK, DB92KK, DB95KX, DK59L8, DW4PKA, DW4PKB, DW4PKY, DW4QKY,
DW4RKY, DW4SKY, DWM1KY, DXA1KY, or DXHKKY)
• Check that lever stroke of boom control lever is correct.
Related • Check that engine high idle speed is normal with monitoring function. (Monitoring code:
information 01001)
(Engine high idle speed: 2,120 to 2,220 rpm)
For measuring procedure, see "Testing engine speed" in "Testing and adjusting".
• Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
1 Defective PTO If bucket does not move and boom does not rise, PTO may be defective.
Defective strainer of
2 work equipment pump Check strainer for clogging.
Air sucked in on suction
3 side of work equipment Check suction piping for cracks, etc.
pump
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
4 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for boom control valve (RAISE and LOWER).
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of boom high idle.*
5
RAISE EPC valve Output pressure of Boom control 2.94 ± 0.2 MPa
RAISE
EPC valve lever {30.0 ± 1.6 kg/cm2}
If output pressures of all EPC valves including boom (RAISE) control EPC
Malfunction of shut off valve are below standard value in check on cause (5), shut off valve may
6 valve (for pilot circuit of malfunction.
work equipment valve)
Check shut off valve spool for sticking.
a Be ready with engine stopped, then perform troubleshooting with engine at
Defective unload valve high idle.*
7 of work equipment
valve Unload valve relief Work equipment 1.72 to 3.43 MPa
pressure NEUTRAL
control lever {17.5 to 35 kg/cm2}
a Be ready with engine stopped, then perform troubleshooting with engine at
full speed. (For measuring procedure, see Testing and adjusting, "Testing
work equipment oil pressure".)
Defective work
34.3 (+1.8/-4.4) MPa
8 equipment main relief Work equipment
valve Lift cylinder Relief {350 (+18/-45) kg/
main relief pressure
cm2}
If relief pressure is not increased to normal level after main relief valve is
adjusted, unload valve may remain opened.
When no failure is found by checks on causes (4) and (7), if main circuit
Malfunction of boom pressure at boom RAISE operation does not rise above relief pressure of
9 control valve spool unload valve, work equipment valve spool may malfunction.
Check spool for sticking.
Boom control valve
When no failure is found by checks on cause (8), check load check valve for
10 Malfunction of load sticking.
check valve

40-1046 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
11 Defective lift cylinder If measured relief pressure is below standard value in check on cause (8),
disconnect hydraulic hose from lift cylinder head end and relieve it
hydraulically at its stroke end. If oil flows out of cylinder, piston ring of cylinder
is defective.
• If measured pressure is unusual in check on cause (8) and main relief
valve is normal, disconnect work equipment pump outlet hose, crank
Defective work
12 engine, and check that oil flows out.
equipment pump
• Check return filter and suction strainer for foreign materials such as metal
particles.
Check PC valve for sticking of spool and fatigue of spring. If any failure is
13 Malfunction of PC valve found, replace it.
Check LS valve for sticking of spool and fatigue of spring. If any failure is
14 Malfunction of LS valve found, replace it.
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (4), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
15 pump Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-34
Fan speed is abnormal".
Malfunction of suction While boom can be raised when it is unloaded, if it can not be raised in
16 safety valve in lift digging or loading operation, or if hydraulic drift of boom is large, boom bottom
cylinder bottom circuit suction safety valve may malfunction.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1047
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-18 Boom moves slow or boom lacks lifting force (WA470_7-D56-400-A-Z0-A)

Failure Boom moves slow or boom lacks lifting force.


• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DK59KA, DK59KY, DK59L8, DK5AKA, DK5AKY, or DXA1KY)
• Check that lever stroke of boom control lever is correct.
Related • Check that engine high idle speed is normal with monitoring function. (Monitoring code:
information 01001)
(Engine high idle speed: 2,120 to 2,220 rpm)
For measuring procedure, see "Testing engine speed" in "Testing and adjusting".
• Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
1 Check work equipment pump strainer for clogging.
work equipment pump
Air sucked in on suction
2 side of work equipment Air may be sucked in. Check suction piping of work equipment pump.
pump
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
3 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for boom control valve (RAISE and LOWER).
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of boom high idle.*
4
RAISE EPC valve Output pressure of Boom control 2.94 ± 0.16 MPa
RAISE
EPC valve lever {30.0 ± 1.6 kg/cm2}
If output pressures of all EPC valves including boom (RAISE) control EPC
Malfunction of shut off valve are below standard value in check on cause (4), shut off valve may
5 valve (for pilot circuit of malfunction.
work equipment valve)
Check shut off valve spool for sticking.
a Be ready with engine stopped, then perform troubleshooting with engine at
Defective unload valve high idle.*
6 of work equipment Boom and
valve Unload valve relief 1.72 to 3.43 MPa
pressure bucket control NEUTRAL
levers {17.5 to 35 kg/cm2}

a Be ready with engine stopped, then perform troubleshooting with engine at


high idle. (For measuring procedure, see Testing and adjusting, "Testing
work equipment oil pressure".)
Defective work
7 equipment main relief 34.3 (+1.8/-4.4) MPa
Work equipment
valve Lift cylinder Relief {350 (+18/-45) kg/
main relief pressure
cm2}
If relief pressure is not increased to normal level after main relief valve is
adjusted, unload valve may remain opened.
Defective charge valve If no failure is found by check on cause (7) but relief pressures of boom and
8 of travel damper bucket are below standard value, travel damper charge valve may be
defective.
When no failure is found by checks on causes (4) and (6), if main circuit
Malfunction of boom pressure at boom RAISE operation does not rise above relief pressure of
9 control valve spool unload valve, work equipment valve spool may malfunction.
Check spool for sticking.
Boom control valve
When no failure is found by checks on cause (8), check load check valve for
10 Malfunction of load sticking.
check valve

40-1048 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


Check PC valve for sticking of spool and fatigue of spring. If any failure is
11 Malfunction of PC valve found, replace it.
Check LS valve for sticking of spool and fatigue of spring. If any failure is
12 Malfunction of LS valve found, replace it.

a Be ready with engine stopped, then perform troubleshooting with engine at


high idle.*
13 Defective lift cylinder If measured relief pressure is below standard value, disconnect hydraulic
hose from lift cylinder head end, and relieve lift cylinder hydraulically at its
stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
• If measured pressure is unusual in check on cause (7) and main relief
valve is normal, disconnect work equipment pump outlet hose, crank
Defective work
14 equipment pump engine, and check that oil flows out.
• Check return filter and suction strainer for foreign materials such as metal
particles.
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (3), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
15 pump Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-35
Fan speed is abnormal".
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1049
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-19 Rising boom slows down at certain height (WA470_7-D52-400-A-Z0-A)

Failure Rising boom slows down at certain height.


Related • Check booms and lift cylinders for visible deformation.
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective lift cylinder Lift cylinder tube may bulge or cylinder may have internal damage.
a When boom RAISE remote positioner is enabled, if boom control lever is held in detent position to allow
boom to exceed target stop angle, rising boom decelerates temporarily and then accelerates.
(Reference)
For other failure symptoms while boom is rising, see "H-18 Boom moves slow or boom lacks lifting force".

40-1050 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-20 Lift cylinders do not serve to hold bucket on ground (WA470_7-A83-400-A-Z0-A)

Failure Lift cylinders do not serve to hold bucket on ground (bucket rises off ground).
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DB90KK, DB92KK, DB95KX, DK59L8, DW4PKY, DW4QKA, DW4QKB, DW4QKY,
DW4RKY, DW4SKY, DWM1KY, DXA1KY, DXHJKY, or DXHKKY)
• If failure symptom of "Boom moves slow" or "Boom lacks lifting power" also appears,
Related perform troubleshooting for "H-18" as well.
information • Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
• Boom control lever stroke can be checked with monitoring function. (Monitoring code:
42104)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
1 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for boom control valve (RAISE and LOWER).
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Defective suction-safety Relief pressure Lift cylinder {350 (+18/-45) kg/
2 hydraulic relief
valve cm2}
If only boom LOWER relief pressure is low, suction safety valve may
malfunction.
Replace suction safety valve assembly.
Stroke to
Lever strike of boom Boom control LOWER
Defective boom control control lever Min. -74%
3 lever position
lever
a Stroke means lever travel to point just before detent position.
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of boom high idle.*
4
LOWER EPC valve Output pressure of Boom control 1.91 ± 0.15 MPa
LOWER
EPC valve lever {19.5 ± 1.5 kg/cm2}
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
5 Defective lift cylinder If measured relief pressure is below standard value, disconnect hydraulic
hose from lift cylinder head end, and relieve lift cylinder hydraulically at its
stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1051
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-21 Hydraulic drift of boom is large (WA470_7-MS1-400-A-Z0-A)

Failure Hydraulic drift of boom is large.


• If any failure code is displayed, perform troubleshooting for that failure code first.
Related (DK59KA, DK59L8, or DW4QKY)
information • Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Defective suction safety Relief pressure Lift cylinder {350 (+18/-45) kg/
1 hydraulic relief
valve cm2}
If only boom LOWER relief pressure is low, suction safety valve may
malfunction.
Replace suction safety valve assembly.
Defective sealing of When boom is raised and hydraulic hose is disconnected from lift cylinder
2 main spool of boom head end, if oil does not flow out of cylinder and lift cylinder drifts hydraulically,
control valve sealing of spool may be defective.
When boom is raised and hydraulic hose is disconnected from lift cylinder
Defective seating of head end, if oil does not flow out of cylinder and lift cylinder drifts hydraulically,
3
check valve load check valve at the lift cylinder bottom end may be seated defectively.
a Raise boom, stop engine, and then perform troubleshooting.
4 Defective lift cylinder When boom is raised and hydraulic hose is disconnected from lift cylinder
head end, if oil flows out of cylinder, piston ring of cylinder is defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

40-1052 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-22 Boom moves up and down during operation (WA470_7-M70-400-A-Z0-A)

Boom moves up and down during operation. (When machine is performing digging or leveling
Failure work with boom control lever set in "HOLD" position, bucket and boom move up and down
along ground.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DK59KA, DK59KY, DK59L8, DW4PKY, or DW4QKY)
Related • Work equipment pump pressure can be checked with monitoring function. (Monitoring
information code: 94700)
• Check hydraulic drift of boom, and check that machine body is raised off ground by using
lift cylinders. If any failure is found, see troubleshooting for H-20 and H-21 respectively.
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
34.3 (+1.8/-4.4) MPa
Boom LOWER
Relief pressure Lift cylinder {350 (+18/-45) kg/
hydraulic relief
Defective suction safety cm2}
1 valve at lift cylinder If only boom LOWER relief pressure is low, suction safety valve may
head side malfunction.
Move boom several times to allow lift cylinders to move over their whole
strokes. After that, if machine body is raised off ground by using lift cylinders,
cause of this failure is vacuum generated in cylinder. If this symptom occurs
repeatedly, valve seat of suction valve may be defective.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
2 Defective lift cylinder If measured relief pressure is below standard value in check on cause (1),
disconnect hydraulic hose from lift cylinder head end, and relieve lift cylinder
hydraulically at its stroke end. If oil flows out of cylinder, cylinder piston ring is
defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1053
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-23 Bucket does not tilt back (WA470_7-M80-400-A-Z0-A)

Failure Bucket does not tilt back.


• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DB90KK, DB92KK, DB95KX, DK5BL8, DW4PKY, DW4QKY, DW4RKA, DW4RKB,
DW4RKY, DW4SKY, DWM1KY, DXA1KY, DXHJKY, or DXHKKY)
• Check that lever stroke of bucket control lever is correct.
Related • Work equipment pump pressure can be checked with monitoring function. (Monitoring
information code: 94700)
• Check that engine high idle speed is normal with monitoring function. (Monitoring code:
01001)
(Engine high idle speed: 2,120 to 2,220 rpm)
For measuring procedure, see "Testing engine speed" in "Testing and adjusting".
No. Cause Procedure, measuring location, criteria and remarks
1 Defective PTO If boom does not move and bucket does not tilt back, PTO may be defective.
Defective strainer of
2 work equipment pump Check strainer for clogging.
Air sucked in on suction
3 side of work equipment Check suction piping for cracks, etc.
pump
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
4 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for bucket control valve (TILT and DUMP).
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of bucket high idle.*
TILT BACK EPC valve Output pressure of Bucket control 3.1 ± 0.17 MPa
Tilt control
EPC valve lever {31.5 ± 1.7 kg/cm2}
If output pressures of all EPC valves including bucket (TILT) control EPC
Malfunction of shut off valve are below standard value in check on cause (5), shut off valve may
6 valve (for pilot circuit of malfunction.
work equipment valve)
Check shut off valve spool for sticking.
a Be ready with engine stopped, then perform troubleshooting with engine at
Defective unload valve high idle.*
7 of work equipment
valve Unload valve relief Work equipment 1.72 to 3.43 MPa
pressure NEUTRAL
control lever {17.5 to 35 kg/cm2}
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle. (For measuring procedure, see Testing and adjusting, "Testing
Defective suction safety work equipment oil pressure".)
8 valve at bucket control
valve on tilt side 32.4 (+1.6/-4.3) MPa
Set pressure of Bucket TILT
Bucket cylinder {330 (+16/-43) kg/
safety valve relief
cm2}
When no failure is found by checks on causes (5) and (7), if main circuit
Bucket control valve pressure at bucket TILT BACK operation does not rise above relief pressure
9 of unload valve, work equipment valve spool may malfunction.
Malfunction of spool
Check spool for sticking.
Bucket control valve When no failure is found by checks on cause (8), check load check valve for
10 Malfunction of load sticking.
check valve

40-1054 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


a Be ready with engine stopped, then perform troubleshooting with engine at
Defective bucket high idle.*
11 cylinder If measured relief pressure is below standard value, disconnect hydraulic
hose from bucket cylinder head end, and relieve bucket cylinder hydraulically
at its stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
• If measured pressure is unusual in check on cause (8) and main relief
valve is normal, disconnect work equipment pump outlet hose, crank
Defective work
12 engine, and check that oil flows out.
equipment pump
• Check return filter and suction strainer for foreign materials such as metal
particles.
Check PC valve for sticking of spool and fatigue of spring. If any failure is
13 Malfunction of PC valve found, replace it.
Check LS valve for sticking of spool and fatigue of spring. If any failure is
14 Malfunction of LS valve found, replace it.
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (4), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
15 pump Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-35
Fan speed is abnormal".
Malfunction of suction While bucket can tilt back when it is unloaded, if bucket cannot tilt back in
16 safety valve in bucket digging or scooping operation, or if hydraulic drift of bucket is large, bucket
cylinder bottom circuit bottom suction safety valve may malfunction.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1055
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-24 Bucket moves slow or lacks tilt-back force (WA470_7-D85-400-A-Z0-A)

Failure Bucket moves slow or bucket lacks tilt back force.


• Check that oil level in hydraulic tank is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DK5BKA, DK5BKY, DK5BL8, DK5CKA, DK5CKY, or DXA1KY)
• Check that lever stroke of bucket control lever is correct.
Related • Work equipment pump pressure can be checked with monitoring function. (Monitoring
information code: 94700)
• Check that engine high idle speed is normal with monitoring function. (Monitoring code:
01001)
(Engine high idle speed: 2,120 to 2,220 rpm)
For measuring procedure, see "Testing engine speed" in "Testing and adjusting"
No. Cause Procedure, measuring location, criteria and remarks
Defective strainer of
1 Check strainer for clogging.
work equipment pump
Air sucked in on suction
2 side of work equipment Check suction piping for cracks, etc.
pump
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
3 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for bucket control valve (TILT and DUMP).
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of bucket high idle.*
4
TILT BACK EPC valve Output pressure of Bucket 3.1 ± 0.17 MPa
TILT
EPC valve Control lever {31.5 ± 1.7 kg/cm2}
If output pressures of all EPC valves including bucket (TILT) control EPC
Malfunction of shut off valve are below standard value in check on cause (4), shut off valve may
5 valve (for pilot circuit of malfunction.
work equipment valve)
Check shut off valve spool for locking.
a Be ready with engine stopped, then perform troubleshooting with engine at
Defective unload valve high idle.*
6 of work equipment
valve Unload valve relief Work equipment 1.72 to 3.43 MPa
pressure NEUTRAL
control lever {17.5 to 35 kg/cm2}
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle. (For measuring procedure, see Testing and adjusting, "Testing
Defective suction safety work equipment oil pressure".)
7 valve at bucket control
valve on tilt side 32.4 (+1.8/-4.4) MPa
Set pressure of Bucket TILT
Bucket cylinder {330 (+18/-45) kg/
suction safety valve relief
cm2}
Defective charge valve If no failure is found by check on cause (7) but relief pressures of boom and
8 of travel damper bucket are below standard value, travel damper charge valve may be
defective.
If only bucket TILT back relief pressure is below standard value in check on
Malfunction of suction cause (7), suction safety valve in cylinder bottom circuit may be defective.
9 safety valve in bucket Replace it with suction safety valve in bucket cylinder head circuit, and check
cylinder bottom circuit whether failure symptom changes (it cannot be adjusted when it is installed to
machine).
Bucket control valve
When no failure is found by checks on cause (8), check load check valve for
10 Malfunction of load sticking.
check valve

40-1056 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks


When no failure is found by checks on causes (4) and (7), if main circuit
Bucket control valve pressure at bucket TILT BACK operation does not rise above relief pressure
11 of unload valve, work equipment valve spool may malfunction.
Malfunction of spool
Check spool for sticking.
Check PC valve for sticking of spool and fatigue of spring. If any failure is
12 Malfunction of PC valve found, replace it.
Check LS valve for sticking of spool and fatigue of spring. If any failure is
13 Malfunction of LS valve found, replace it.

a Be ready with engine stopped, then perform troubleshooting with engine at


Defective bucket high idle.*
14 cylinder If measured relief pressure is below standard value, disconnect hydraulic
hose from bucket cylinder head end, and relieve bucket cylinder hydraulically
at its stroke end. If oil flows out of cylinder, cylinder piston ring is defective.
• If measured pressure is unusual in check on cause (8) and main relief
valve is normal, disconnect work equipment pump outlet hose, crank
Defective work
15 equipment pump engine, and check that oil flows out.
• Check return filter and suction strainer for foreign materials such as metal
particles, etc.
• If measured output pressure of accumulator charge valve is below
standard value in check on cause (3), cooling fan pump may be defective.
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
Defective cooling fan
16 pump Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
• If fan speed is below standard value, perform troubleshooting for "H-34
Fan speed is abnormal".
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1057
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-25 Bucket decelerates during tilt-back operation (WA470_7-D82-400-A-Z0-A)

Failure Bucket decelerates during tilt-back operation.


Related • Check bucket and bucket cylinder for visible deformation.
information
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket
1 cylinder Bucket cylinder tube may bulge or cylinder may have internal damage.
(Reference)
For other failure symptoms while operating bucket, see "H-24 Bucket moves slow or bucket lacks tilt-back
force".

40-1058 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-26 Bucket cylinder does not hold bucket on ground (WA470_7-A85-400-A-Z0-A)

Failure Bucket cylinder does not hold bucket on ground.


• If any failure code is displayed, perform troubleshooting for that failure code first.
(DB90KK, DB92KK, DB95KX, DK5BL8, DW4PKY, DW4QKY, DW4RKY, DW4SKA,
DW4SKB, DW4SKY, DWM1KY, DXA1KY, DXHJKY, or DXHKKY)
• Check that lever stroke of bucket control lever is correct.
Related • If failure symptom of "Bucket moves slow" or "Bucket lacks tilt-back force" also appears,
information perform troubleshooting for "H-24" as well.
• Bucket control lever stroke can be checked with monitoring function. (Monitoring code:
42106)
• Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
Defective bucket control Bucket control
1 Control lever stroke HOLD o DUMP Max. -95 %
lever lever
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
2 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for bucket control valve (TILT and DUMP).
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle. (For measuring procedure, see Testing and adjusting, "Testing
work equipment oil pressure".)
Defective suction safety 34.3 (+1.8/-4.4) MPa
Relief pressure Bucket cylinder Bucket DUMP
3 valve at bucket control relief {350 (+18/-45) kg/
valve on dump side cm2}
If only bucket DUMP relief pressure is below standard value, suction safety
valve in bucket DUMP circuit may malfunction.
Replace valve assembly because valve cannot be adjusted when it is
installed to machine.
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of bucket high idle.*
4
DUMP EPC valve Output pressure of Bucket control 2.75 ± 0.14 MPa
DUMP
EPC valve lever {28 ± 1.4 kg/cm2}
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective bucket If measured relief pressure is below standard value in check on cause (3),
5 cylinder disconnect hydraulic hose from bucket cylinder head end, and relieve bucket
cylinder hydraulically at its stroke end. If oil flows out of cylinder, cylinder
piston ring is defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1059
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-27 Hydraulic drift of bucket is large (WA470_7-MS2-400-A-Z0-A)

Failure Hydraulic drift of bucket is large.


• If any failure code is displayed, perform troubleshooting for that failure code first.
Related (DK5BKA, DK5BL8, or DW4SKY)
information • Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
full speed. (For measuring procedure, see Testing and adjusting, "Testing
work equipment oil pressure".)
Defective suction safety 32.4 (+1.8/-4.4) MPa
1
valve Relief pressure Bucket cylinder TILT back side {330 (+18/-45) kg/
relief
cm2}
If only relief pressure of bucket TILT back side is below standard value, valve
seat of suction safety valve in TILT back circuit may be defective.
Defective sealing of When boom is raised and hydraulic hose is disconnected from bucket cylinder
2 main spool of bucket head end, if oil does not flow out of cylinder and bucket cylinder drifts
control valve hydraulically, sealing of spool may be defective.
a Raise boom, stop engine, and then perform troubleshooting.
Defective bucket
3 If oil flows out of cylinder when boom is raised, and hydraulic hose is
cylinder
disconnected from bucket cylinder head side, piston ring of cylinder is
defective.

40-1060 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-28 Bucket tilts back and forth during carrying load (work equipment
valve in HOLD) (WA470_7-M90-400-A-Z0-A)
Failure Bucket tilts back and forth during carrying load (work equipment valve in HOLD).
• If any failure code is displayed, perform troubleshooting for that failure code first.
(DK5BKA, DK5BKY, DK5BL8, DW4RKY, or DW4SKY)
Related • Check pins and bushings of work equipment linkage for "play" (unusual noise).
information • Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle. (For measuring procedure, see Testing and adjusting, "Testing
work equipment oil pressure".)
Malfunction of suction 34.3 (+1.8/-4.4) MPa
safety valve in bucket Relief pressure Bucket cylinder Bucket DUMP
1 relief {350 (+18/-45) kg/
cylinder circuit on head cm2}
side.
If only relief pressure on bucket DUMP side is below standard value, suction
safety valve on bucket DUMP circuit may malfunction.
Replace valve assembly because valve cannot be adjusted when it is
installed to machine.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective bucket If measured relief pressure is below standard value in check on cause (1),
2 cylinder disconnect hydraulic hose from bucket cylinder head end, and relieve bucket
cylinder hydraulically at its stroke end. If oil flows out of cylinder, cylinder
piston ring is defective.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1061
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-29 Boom and bucket control levers do not move smoothly and are
heavy to move (WA470_7-LS1-400-A-Z1-A)
Failure Boom and bucket control levers do not move smoothly and are heavy to move.
Related
information
No. Cause Procedure, measuring location, criteria and remarks
When lever
From HOLD to moves (to short Max. 17.1 N {1.8
RAISE of detent kgf}
position)
When lever 4.9 to 30.5 N
From RAISE to passes through
HOLD detent position (0.5 to 3.1 kgf)
When lever
Defective boom control
1 Lever control effort From HOLD to moves (to short Max. 17.1 N {1.8
lever of detent kgf}
LOWER
position)
When lever
From LOWER passes through Max. 30.3 N {3.1
to FLOAT kgf}
detent position
When lever 4.9 to 30.5 N
From FLOAT to passes through
HOLD detent position (0.5 to 3.1 kgf)
From HOLD to When lever Max. 26.6 N {2.7
DUMP moves kgf}
When lever
From HOLD to moves (to short Max. 17.1 N {1.8
Defective bucket control of detent kgf}
2 Lever control effort TILT
lever position)
When lever 4.9 to 30.5 N
From TILT to passes through
HOLD detent position (0.5 to 3.1 kgf)

40-1062 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-30 Operating work equipment causes engine speed to lower


significantly or engine to stall (WA470_7-FT6-400-A-Z0-A)
Failure Operating work equipment causes engine speed to lower significantly or engine to stall.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(AA10NX, B@BCNS, DXA1KA, or DXA1KB)
• Check that engine speed is normal with monitoring function. (Monitoring code: 01001)
Related (Engine low idle speed: 825 ± 25 rpm, engine high idle speed: 2,170 ± 50 rpm) (For
information measuring procedure, see "Testing engine speed" in "Testing and adjusting".)
• Work equipment pump pressure can be checked with monitoring function. (Monitoring
code: 94700)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
1 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure for work
equipment pump EPC valve.
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.. (For measuring procedure, see Testing and adjusting, "Testing
Defective work work equipment oil pressure".)
2 equipment main relief
valve 34.3 (+1.8/-4.4) MPa
Work equipment Bucket TILT
Bucket cylinder {350 (+18/-45) kg/
main relief pressure relief
cm2}
Check PC valve for sticking of spool and fatigue of spring. If any failure is
Malfunction of PC valve found, replace it.
Check LS valve for sticking of spool and fatigue of spring. If any failure is
4 Malfunction of LS valve found, replace it.
• If measured oil pressure is unusual in check on cause (2) and main relief
Defective work valve is normal, work equipment pump may be defective.
5 equipment pump • Check return filter and suction strainer for foreign materials such as metal
particles.
• If no failure is found by checks on causes (1) to (5), engine performance
Defective engine
6 may lower. Perform troubleshooting by referring to "S mode"
system
troubleshooting.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1063
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-31 Large shocks are made when work equipment starts to move and
stops (WA470_7-FT3-400-A-Z0-A)
Failure Large shocks are made when work equipment starts to move and stops.
• Boom control lever stroke (expressed in percentage) can be checked with monitoring
function. (Monitoring code: 42104)
• Input signal (voltage) from boom lever potentiometer (main) can be checked with
Related monitoring function. (Monitoring code: 42000)
information • Input signal (voltage) from bucket lever potentiometer (main) can be checked with
monitoring function. (Monitoring code: 42002)
• Bucket control lever stroke (expressed in percentage) can be checked with monitoring
function. (Monitoring code: 42106)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
Defective charge valve Output pressure of All control levers 3.72 ± 0.2 MPa
1 accumulator charge (including NEUTRAL
of accumulator {38 ± 2.0 kg/cm2}
valve steering wheel)
• Output pressure of accumulator charge valve is source pressure of pilot
pressure for work equipment control valve (boom and bucket).
• Pilot circuit between EPC valve and work equipment control valve may be
2 Clogged pilot circuit clogged with dirt, etc.
Check pilot circuit of work equipment that causes large shock.
Malfunction of main • If abnormally large shock is made, main spool may not move smoothly.
3 spool of control valve After releasing remaining pressure, check main spool for jerky motion.
Boom control RAISE 44.5 ± 4.4 mm
Control lever stroke
Boom control lever LOWER Min. 31.2 mm
4
Defective lever Check that lever is not caught or it does not become heavy to move while
operating it.
Be ready with starting switch at OFF position, and then turn starting switch to
ON position to perform troubleshooting.
Lever in
2.4 to 2.6 V
NEUTRAL
RAISE
(just before the 3.38 to 4.04 V
Boom lever detent position)
5
Defective potentiometer Voltage from Boom control RAISE
potentiometer lever 3.90 to 4.40 V
(Detent position)
LOWER
(just before the 0.96 to 1.62 V
detent position)
FLOAT 0.6 to 1.10 V
Bucket control DUMP 44.5 ± 4.4 mm
Control lever stroke
Bucket control lever Tilt control 44.5 ± 4.4 mm
6
Defective lever Check that lever is not caught or it does not become heavy to move while
operating it.
Be ready with starting switch at OFF position, and then turn starting switch to
ON position to perform troubleshooting.
Lever in
2.4 to 2.6 V
NEUTRAL
Bucket lever Tilt control
7 (just before the 3.38 to 4.04 V
Defective potentiometer Voltage from Bucket control
potentiometer lever detent position)
Tilt control
3.90 to 4.40 V
(Detent position)
Full DUMP 0.60 to 1.10 V

40-1064 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

No. Cause Procedure, measuring location, criteria and remarks

For boom RAISE a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
8 Malfunction of EPC
Output pressure of Boom control 2.94 ± 0.16 MPa
valve RAISE
EPC valve lever {30.0 ± 1.6 kg/cm2}

For boom LOWER a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
9 Malfunction of EPC
Output pressure of Boom control 1.99 ± 0.14 MPa
valve LOWER
EPC valve lever {20.3 ± 1.4 kg/cm2}

For bucket TILT a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
10 Malfunction of EPC
Output pressure of Bucket control 3.1 ± 0.17 MPa
valve TILT
EPC valve lever {31.5 ± 1.7 kg/cm2}

For bucket DUMP a Be ready with engine stopped, then perform troubleshooting with engine at
high idle.*
11 Malfunction of EPC
Output pressure of Bucket control 2.75 ± 0.14 MPa
valve DUMP
EPC valve lever {28 ± 1.4 kg/cm2}
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1065
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-32 When certain work equipment stalls hydraulically, other work


equipment moves (WA380_7-FT4-400-A-Z0-A)
Failure When single work equipment is relieved hydraulically, other work equipment moves.
Related ―
information
No. Cause Procedure, measuring location, criteria and remarks
• After releasing remaining pressure from hydraulic tank and control
Malfunction of main spool of valve, check that pressure releasing port of main spool of work
1
control valve equipment that moves by itself is not clogged with foreign materials.

40-1066 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-33 E.C.S.S. (travel damper) does not work and machine pitches and
bounces (WA470_7-CG1-400-A-Z0-A)
Failure E.C.S.S. (travel damper) does not work and machine pitches and bounces.
• If any failure code is displayed, perform troubleshooting for that failure code first.
(D192KA, D192KB, D192KY, DLT3KA, or DLT3LC)
Related • Transmission output shaft speed can be checked with monitoring function. (Monitoring
information code: 31400)
• Output command value (ON/OFF) to travel damper solenoid can be checked with
monitoring function. (Monitoring code: 03705)
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine at
low idle.
Defective ECSS Approx. 12.3 MPa
1 accumulator charge Charge relief Boom control RAISE (*) {Approx. 125 kg/
relief valve pressure lever
cm2}
(*) While raising boom slowly with engine running at low speed, measure
stabled charge pressure.
If no failure is found by check on cause (1) and travel damper does not work
Defective ECSS (travel at all, travel damper solenoid valve may be defective.
2 damper) solenoid valve
Check solenoid valve spool for seizure and locking.
Defective ECSS If no failure is found by checks on causes (1) and (2), and travel damper does
3 accumulator selector not work at all, ECSS accumulator selector valve may be defective.
valve Check selector valve spool for seizure and locking.
a Be ready with engine stopped, then perform troubleshooting with engine
stopped.
Approx. 2.94 MPa
Nitrogen gas charged pressure {Approx. 30.0 kg/
Defective ECSS
4 cm2}
accumulator
If nitrogen gas charged pressure drops immediately, sealing of accumulator
may be defective.
Nitrogen gas charged pressure varies depending on outside air temperature.
Check charged pressure by referring to Testing and adjusting section.
While displaying monitoring screen of transmission output shaft speed on
Defective transmission machine monitor, drive machine on flat road at F1 or F2 gear speed with
5 output shaft speed engine at low speed. Increase engine speed gradually and check that
sensor transmission output shaft speed indicated on monitoring screen increases as
engine speed increases (travel speed shall be 5 km/h and above).
Defective transmission If no failure is found by checks on causes (1) to (5), transmission controller
6 may be defective.
controller

WA470-7 40-1067
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-34 Bucket does not stop at the position which is set with remote
bucket positioner (WA470_7-M91-400-A-Z0-A)
Failure Bucket does not stop at the position which is set with remote bucket positioner
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related (DKA1KA, DKA1KY, DKA0KA, DKA0KY, or DKA0L0)
information • Check pins and bushings of work equipment linkage for "play" (unusual noise).
No. Cause Procedure, measuring location, criteria and remarks
a Be ready with engine stopped, then perform troubleshooting with engine
stopped.
Lower the work equipment to the
ground, remove sensor cover (1)
Total clearance of and (2), bolt (3), and washer (4),
Defective ECSS (a) and (b) Max. 1.5 mm
and measure the clearance
1 accumulator charge between lock boss (5) and the
relief valve hole.
Rotation lock may be worn by friction if clearances (a) and (b) of rotation lock
of bell crank pin are large. (As a result, bucket angle sensor becomes
inaccurate)
Perform repair of the actual machine according to 50. Disassembly and
assembly, "Repair of bell crank pin rotation lock".

40-1068 WA470-7
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-35 Fan speed is abnormal (too high or low, or fan does not
rotate) (WA470_7-FTP-400-A-Z0-A)
Failure Fan speed is abnormal (too high or low, or fan does not rotate).
• When engine is started for first time after hydraulic oil replacement, fan may temporarily
rotates at higher speed but this is normal.
• If any failure code is displayed, perform troubleshooting for that failure code first.
Related (DW7BKA, DW7BKB, DW7BKY, DLM3KA, DLM3LC, LA00L3, DX16KA, DX16KB,
information DB16KY, DGT1KA, DGT1KB, or DGH2KX)
• Engine speed can be checked with monitoring function. (Monitoring code: 01001)
• Radiator fan speed can be checked with monitoring function. (Monitoring code: 10009)
No. Cause Procedure, measuring location, criteria and remarks
a For measuring procedure, see "Testing engine speed" in "Testing and
adjusting".
1 Defective engine speed Engine low idle 825 ± 25 rpm
Engine speed
Engine high idle 2,170 ± 50 rpm
If engine speed is not increased to specification, perform troubleshooting for
"S-5 Engine runs rough or is unstable".
a Perform troubleshooting with engine at high idle.
Coolant temperature: Min. 95°C
2 Defective fan speed Torque converter oil temperature:
Fan speed Min. 105°C 1,300 ± 200 rpm
Hydraulic oil temperature: Min.
95°C
Defective PTO (fan
3 Fan pump drive of PTO may be defective.
pump drive)
a Be ready with engine stopped, then perform troubleshooting with engine at
Malfunction of
high idle.*
4 accumulator charge
valve (relief valve) Fan motor drive Fan adjustment mode: 100% 14.3 ± 2.1 MPa
pressure Hydraulic oil temperature: 50°C {146 ± 22 kg/cm2}
If pressure does not reach specified value after relief valve is adjusted in
5 Defective fan pump check on cause (4), fan pump may have internal defect.
Check strainer of self-pressure reducing valve inlet for metal particles.
a Be ready with engine stopped, then perform troubleshooting with engine at
full speed and fan in reverse rotation mode.
Fan reverse Fan adjustment mode: 100% 1.98 to 3.04 MPa
solenoid output
Malfunction of fan motor pressure Hydraulic oil temperature: 50°C {20.2 to 31.0 kg/cm2}
6 (direction selector
valve) a Release remaining pressure from hydraulic tank and piping, and then
perform troubleshooting with engine stopped.
• Check direction selector valve spool in valve body for seizure or sticking.
(Spool shall move smoothly and shall not be caught.)
• Take direction selector spool from valve body, and check it for defects and
dirt.
If no failure is found by checks on causes (1) to (6), fan motor may have
7 Defective fan motor
internal defect.
*: This means the accelerator pedal is fully depressed. (There is no need to operate the work equipment lock
switch or to lower the boom to the minimum position.)

WA470-7 40-1069
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)

H-36 Unusual noise is heard from around fan (WA470_7-FTQ-400-A-Z0-A)

Failure Unusual noise is heard from around fan.


Related
information
No. Cause Procedure, measuring location, criteria and remarks
Defective installation of Check fan and fan motor for rattling due to loose installation.
1
fan and fan motor
2 Interference with shroud Check fan for interference with shroud.
Internal defect of fan If no failure is found by checks on causes 1 and 2, fan motor may have
3
motor internal defect.

40-1070 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)

Information mentioned in troubleshooting table (S mode) (PC400-5170-010-A-00-A)

(Rev. 2011/04 125T4)

a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment

1. Gauze filter for feed pump


a This figure shows the location of gauze filter (1) for the feed pump explained in this manual.

WA470-7 40-1071
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-1 When starting switch is turned to START position, engine is not


cranked (PC400-A26-400-A-Z0-A)
Failure When starting switch is turned to START position, engine is not cranked
• See E mode (E-1) for troubleshooting the electrical system.
Related information • If any failure code is displayed, carry out troubleshooting for it first.

No. Cause Detail of work, remarks Remedy


Defective starting circuit wiring • When starting switch is turned to START
Diagnose and take
1 system position, starting motor pinion is not pushed
remedies for E-1
out
• Grating noise is heard from starting motor
pinion
(When starting switch is turned to START
position, starting motor pinion is pushed
out)
• Starting motor pinion disengages during
operation
(When starting switch is turned to START
Defective starting motor position, starting motor pinion is pushed Diagnose and take
2 (safety relay section) out) remedies for E-1
• Ratting noise is heard and starting motor
does not turn.
(When starting switch is turned to START
position, starting motor pinion is pushed
out)
(Reference: Rattling noise is caused when
starting motor pinion is repeatedly pushed
out and pulled in.)
• If grating noise is heard from starting motor
3 Broken flywheel ring gear pinion and the starting motor does not Replace if damaged
crank, visually check the flywheel ring gear.
• Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
Cracked EGR cooler antifreeze flows out Replace EGR cooler
4 (Reference: coolant in exhaust and drain water from
gas) a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.

40-1072 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-2 The engine cranks but exhaust smoke does not come out (PC400-A27-400-A-Z0-
A)

Failure The engine cranks but exhaust smoke does not come out
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
7 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
8 Defective supply pump when checking common rail pressure on Replace supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
• When priming pump is operated, no
9 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze • Gauze filter is clogged Clean or replace
10 gauze filter
filter
• Common rail pressure does not go down Loosen injection piping
when when pressure is checked with and high pressure
Improper bleeding of common
11 rail or injection piping monitoring function and then stopped piping mounting nuts
(Code: 36400 Common rail pressure) on common rail and
(pressure will not decrease if air is present) bleed air

WA470-7 40-1073
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-3 Fuel is injected but engine does not start (incomplete combustion,
engine seems to start but does not) (PC400-A28-400-A-Z0-A)
Fuel is injected but engine does not start (incomplete combustion, engine seems to start
Failure but does not)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• Specific gravity of electrolyte and voltage of Add electrolyte or
1 Defective battery
battery are low charge battery
• When fuel tank is inspected, it is found to
2 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
3 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
4 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
5
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
6 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
7 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
• When priming pump is operated, no
8 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze Clean or replace
9 • Gauze filter is clogged
filter gauze filter
• Air cleaner dust indicator is at a caution Test and adjust air
10 Clogged air cleaner element
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor heater
does not indicate properly
• Check valve clearance
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve Replace valve or
12 Worn valves or rocker arms clearance") rocker arm
• While engine is running, unusual noise is
heard around cylinder head
• Testing compression pressure
Replace piston ring or
13 Defective piston ring (Reference: See Testing and adjusting,
piston
"Testing compression pressure")
Defective injector • When a certain cylinder is cut out, engine
speed does not change
14 (clogged injector, defective Replace Injector
(Note: see "Handling cylinder cutout mode
injection) operation" section of Testing and adjusting)
• Since this is an internal defect, Replace engine
15 Defective engine controller troubleshooting cannot be performed. controller.

40-1074 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-4 Engine startability is poor (PC400-A10-400-A-Z0-A)

Failure Engine startability is poor.


• If any failure code is displayed, carry out troubleshooting for it first.
• The common rail fuel injection system (CRI) controls the fuel injection timing
Related information electrically. Accordingly, even if the engine is cranked properly, the engine may not
start until the crankshaft rotates two turns under the most disadvantageous
condition. This phenomenon does not mean a problem, however.
No. Cause Detail of work, remarks Remedy
• Specific gravity of electrolyte and voltage of Add electrolyte or
1 Defective battery
battery are low charge battery
• When fuel tank is inspected, it is found to
2 Insufficient fuel in tank be empty Add fuel
• Non-specified fuel is being used.
• Fuel suitable for ambient temperature is not
used Use proper fuel
Improper fuel used (Reference: When engine starts in warm specified in Operation
3
temperatures but not in low temperatures) and Maintenance
• Wax is found when clear bowl of fuel Manual
prefilter is checked (milky)
Flush air breather hole
Air breather hole in fuel tank
4 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
5 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
6
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
7 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
8 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
9 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
when checking common rail pressure on Replace supply pump
10 Defective supply pump
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
Clogging of feed pump gauze Clean or replace
11 • Gauze filter is clogged
filter gauze filter
• Air cleaner dust indicator is at a caution Check, clean air
12 Clogged air cleaner element
level cleaner element
• During pre-heating operation, intake air
heater mount is cold
• When engine is preheated or when Replace intake air
13 Defective intake air heater
temperature is low, preheating monitor heater
does not indicate properly

WA470-7 40-1075
40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Detail of work, remarks Remedy


• Remove EGR cooler inlet and outlet gas
piping and check if coolant containing
Cracks in EGR cooler antifreeze flows out Replace EGR cooler
14 (Reference: coolant in exhaust and drain water from
gas) a Water can normally be condensed in the engine cylinders
exhaust gas, so make sure the water is
coolant or not.
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
15 Defective injector • When a certain cylinder is cut out, engine Replace injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
• Since this is an internal defect, Replace engine
16 Defective engine controller troubleshooting cannot be performed. controller.
• Measure the compression pressure (see
standard values table)
(Reference: See Testing and adjusting,
Defective contact of valve with "Testing compression pressure") Correct or replace
17 • Test the valve clearances
valve seat valve or valve seat
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance")
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
(Reference: See Testing and adjusting,
"Testing exhaust gas color".) Replace piston ring or
18 Defective piston ring • Measure the compression pressure (see piston
standard values table)
(Reference: See Testing and adjusting,
"Testing compression pressure")
• Check piston rings and piston ring grooves

40-1076 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-5 Engine does not pick-up smoothly (PC400-A30-400-A-Z0-A)

Failure Engine does not pick up smoothly


Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
Check leakage from common rail pressure
limiter according to "Measuring fuel delivery,
return and leakage" in "Testing and adjusting".
7 Defective common rail Replace common rail
a Common rail is normal if the leakage from
common rail pressure limiter is Max.10
(CC/min)
a Check "Defective common rail" described
above first.
If the pressure doesn't rise during cranking
Defective supply pump when checking common rail pressure on Replace supply pump
8
machine monitor, the supply pump is
defective.
a Common rail pressure can be checked with
monitoring function. (Code: 36400 (MPa))
Clogging of feed pump gauze Clean or replace
9 • Gauze filter is clogged
filter gauze filter
• If Crankcase Pressure High Error (failure
code: CA555) is still displayed after KCCV
Abnormally high crankcase filter element is replaced, blow-by pressure Perform
10 pressure may be high due to seizure or damage of troubleshooting for
KVGT (see Testing and adjusting, "Testing cause 10 and after.
blow-by pressure")
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
11 Defective injector • When a certain cylinder is cut out, engine Replace injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
12 Seized or broken KVGT Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
• When engine is cranked, Unusual noise is
13 Incorrect valve clearance generated around cylinder head Adjust valve clearance
• Check valve clearance

WA470-7 40-1077
40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Detail of work, remarks Remedy


(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance")
• Since this is an internal defect, Replace engine
14 Defective engine controller troubleshooting cannot be performed. controller.
• Measure the compression pressure (see
standard values table)
(Reference: See Testing and adjusting,
Defective contact of valve with "Testing compression pressure") Correct or replace
15 • Test the valve clearances
valve seat valve or valve seat
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance")
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
(Reference: See Testing and adjusting,
"Testing exhaust gas color".) Replace piston ring or
16 Defective piston ring • Measure the compression pressure (see piston
standard values table)
(Reference: See Testing and adjusting,
"Testing compression pressure")
• Check piston rings and piston ring grooves

40-1078 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-6 Engine stops during operation (WA500-AF0-400-A-Z0-A)

Failure Engine stops during operation


Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Performing air
is performed, air comes out bleeding operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
• When priming pump is operated, no
7 Defective priming pump Replace priming pump
resistance is felt or it is heavy
Clogging of feed pump gauze Clean or replace
8 • Gauze filter is clogged
filter gauze filter
• See Testing and adjusting, "Checking fuel Replace supply pump
9 Defective supply pump
delivery, return rate and leakage" and pressure limiter
Defective air intake hose
• Visually check the air intake hose for Replace air intake
10 (from air cleaner to KVGT damage hose
inlet)
• Check the intake manifold for internal Replace air intake
11 Defective air intake manifold damage manifold
Defective boost piping and
connections Correct or replace
12 • Air flows out from boost piping
(from KVGT outlet to air intake boost piping
manifold)
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
13 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat shield plate)
• Check valves and rocker arms
Replace valve or
14 Damaged valve or rocker arm (Unusual noise is heard and engine
stopped suddenly) rocker arm
• Metallic powders are found in oil drained
from oil pan
• Remove oil pan and check pistons and
Broken or seized piston or Replace piston or
15 connecting rod connecting rods
connecting rod
(Reference: Unusual noise is heard and
engine stopped suddenly, or stopped after
overheating)
• Metallic powders are found in oil drained
Broken or seized crankshaft from oil pan Replace crankshaft
16 main bearing • Remove oil pan and check crankshaft main main bearing
bearing
• Check engine controller power supply
Correct engine
Defective engine controller wiring
17 power supply wiring controller power
(Reference: See Troubleshooting, Failure
supply wiring
Code [CA343].)

WA470-7 40-1079
40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Detail of work, remarks Remedy


Defective starting switch Diagnose and take
18 wiring • Check starting switch wiring
remedies for E-1
Malfunction of hydraulic • See H mode, "H-2 Torque converter lockup Diagnose and take
19 system clutch is not disengaged (engine stalls)" remedies for H-2

40-1080 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-7 Engine runs rough or is unstable (PC400-A40-400-A-Z0-A)

Failure Engine runs rough or is unstable


Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Bleeding air from fuel system")
• Check for leaks from boost system (KVGT Correct or replace
7 Leakage in boost system outlet to aftercooler, aftercooler to air intake parts around boost
manifold) piping
Clogging of feed pump gauze Clean or replace
8 • Gauze filter is clogged
filter gauze filter
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
9 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor

WA470-7 40-1081
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-8 Engine lacks power (PC400-A60-400-A-Z0-A)

Failure Engine lacks power


Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel tank is inspected, it is found to
1 Insufficient fuel in tank be empty Add fuel
Flush air breather hole
Air breather hole in fuel tank
2 • Air breather hole in fuel tank cap is clogged in fuel tank cap and
cap is clogged
clean surrounding area
• Check used hours of fuel filter. If used
3 Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
may be clogged element

Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
4
drained
• When air bleeding operation for fuel system Perform air bleeding
is performed, air comes out operation
5 Air in fuel piping system
(Reference: See Testing and adjusting, Correct or replace fuel
"Bleeding air from fuel system") piping
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Check fuel circuit for leaking")
• See Testing and adjusting, "Checking fuel Replace supply pump
7 Defective supply pump
delivery, return rate and leakage" and pressure limiter
Clogging of feed pump gauze Clean or replace
8 • Gauze filter is clogged
filter gauze filter
Clogged air cleaner element Check, clean air
9 • Air cleaner dust indicator in caution level
cleaner element
• Check air cleaner and airflow screen for Correct or replace air
10 Defective air cleaner
deformation cleaner
Defective air intake hose
• Visually check the air intake hose for Replace air intake
11 (from air cleaner to KVGT damage hose
inlet)
• Check the intake manifold for internal Replace air intake
12 Defective air intake manifold damage manifold
Defective boost piping and
connections Correct or replace
13 • Air flows out from boost piping
(from KVGT outlet to air intake boost piping
manifold)
Improperly installed boost • Air leaks from boost pressure sensor Correct mounting of
14 pressure sensor mounting boost pressure sensor
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
15 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat shield plate)
16 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
Check intake and exhaust
system • Measure boost pressure
Correct or replace
17 (KVGT outlet to air intake (Reference: See Testing and adjusting,
defective parts
manifold, exhaust manifold to "Testing boost pressure")
KDPF inlet)
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
18 Seized or broken KVGT Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)

40-1082 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Detail of work, remarks Remedy


• Open the exhaust color inspection hole in
front of KDPF, check the exhaust gas (refer
Excessive soot accumulation standard value table) Clean or replace
19
in KDPF (Note: see "Measuring exhaust gas color" KDPF
section of Testing and adjusting
• KDPF clogging - check exhaust pressure Clean or change
20 Defective KDPF
before KDPF KDPF
• When engine is cranked, Unusual noise is
generated around cylinder head
• Check valve clearance
21 Incorrect valve clearance Adjust valve clearance
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance")
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
22 Defective injector • When a certain cylinder is cut out, engine Replace injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
• Since this is an internal defect, Replace engine
23 Defective engine controller
troubleshooting cannot be performed. controller.
• Measure the compression pressure (see
standard values table)
(Reference: See Testing and adjusting,
Defective contact of valve with "Testing compression pressure") Correct or replace
24 • Test the valve clearances
valve seat valve or valve seat
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance")
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
(Reference: See Testing and adjusting,
"Testing exhaust gas color".) Replace piston ring or
25 Defective piston ring
• Measure the compression pressure (see piston
standard values table)
(Reference: See Testing and adjusting,
"Testing compression pressure")
• Check piston rings and piston ring grooves

WA470-7 40-1083
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-9 KDPF gets clogged in a short time (PC400-AH5-400-A-Z0-A)

Failure KDPF gets clogged in a short time


Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Use proper fuel
Improper fuel used • Non-specified fuel is being used. specified in Operation
1
and Maintenance
Manual
Foreign material in fuel • Rust and water are found when fuel tank is Replace fuel
2
drained
• Check air cleaner and airflow screen for Correct or replace air
3 Defective air cleaner
deformation cleaner
Defective exhaust pipes • Check exhaust pipes for damage and
exhaust gas leakage
4 (from exhaust manifold to Replace exhaust pipes
(Check heat insulation cover and soot on
KDPF inlet) heat shield plate)
Correct charge (boost)
Defective mounting of charge • Air leakage from mounting part of charge
5 pressure sensor
(boost) pressure sensor (boost) pressure sensor
mounting
Defective boost piping and
connections Correct or replace
6 • Air flows out from boost piping
(From KVGT outlet to air boost piping
intake manifold)
• KDPF clogging - check exhaust pressure Clean or change
7 Defective KDPF
before KDPF KDPF
8 Gas leakage from EGR piping • Gas leaks from EGR piping Replace EGR piping
• Unusual noise is heard from KVGT
• Check if KVGT shaft rotates
9 KVGT seized or broken Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
10 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
• Too much fuel is returned when flow is
checked
(Reference: See Testing and adjusting, Correct or replace fuel
11 Defective fuel return piping
"Checking fuel delivery, return rate and return piping
leakage")
• Check fuel return piping for clogging
• Replace sensor and check if problem is
Defective mass air flow and corrected Replace mass air flow
12 temperature sensor (Failure code may not be issued if the and temperature
sensor is covered with dust.) sensor
• When engine is cranked, Unusual noise is
generated around cylinder head
• Check valve clearance Adjust valve clearance
13 Incorrect valve clearance
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance".

40-1084 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

No. Cause Detail of work, remarks Remedy


• Measure the compression pressure (see
standard values table).
(Reference: See Testing and adjusting,
Defective contact of valve with "Testing compression pressure".) Correct or replace
14
valve seat • Test the valve clearances valve or valve seat
(Reference: For details, see Testing and
adjusting, "Testing and adjusting valve
clearance".
• Open the exhaust gas color measuring hole
before the KDPF and check the color of the
exhaust gas.
(Reference: See Testing and adjusting,
"Testing exhaust gas color".) Replace piston ring or
15 Defective piston ring • Measure the compression pressure (see piston
standard values table).
(Reference: See Testing and adjusting,
"Testing compression pressure".)
• Check piston rings and piston ring grooves

WA470-7 40-1085
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-10 Engine oil consumption is excessive (PC400-B10-400-A-Z0-A)

Failure Engine oil consumption is excessive


Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Dust sucked in from intake • When intake piping between air cleaner Clean or replace
1 system and engine is removed, dust is found intake piping
inside.
• Measured blowby pressure exceeds
standard value.
• Blow-by pressure is still high after KCCV
filter element is replaced Replace or correct
2 Broken or worn piston ring
• Measure the compression pressure (see piston ring
standard values table).
(Reference: See Testing and adjusting,
"Testing compression pressure".)
Oil leakage from KCCV oil • Check for oil leaks from KCCV oil return Correct or replace oil
3 return piping piping piping
External leakage of oil from
4 engine • Check for oil leaks Correct oil leaks

Oil leakage from oil filter Reinstall or replace oil


5 • Check for oil leaks from oil filter
filter
Correct or replace oil
6 Oil leakage from oil piping • Check for oil leaks from oil piping
piping
7 Oil leakage from oil drain plug • Check for oil leaks from oil drain plug Retighten oil drain plug
Correct or replace oil
8 Oil leakage from oil pan • Check for oil leaks from oil pan
pan
Correct or replace
9 Oil leakage from cylinder head • Check for oil leaks from cylinder head
cylinder head
• Oil level in clutch chamber or damper Correct or replace rear
10 Worn or damaged rear oil seal
chamber on machine is low. oil seal
• KVGT blower inlet and outlet, and turbine
outlet are dirty with oil.
11 Oil leakage from KVGT • Check if KVGT shaft rotates Replace KVGT
(Move KVGT vanes with hand in axial and
radial directions to judge)
• Oil in coolant
• Remove oil cooler and check for external oil
12 Oil leakage from oil cooler leaks Replace oil cooler
• Check for leaks by applying air pressure to
oil cooler
Oil leakage from EGR valve • When EGR valve is removed, outlet port is
13 Replace EGR valve
stem found to be dirty with oil.
• Check valve guide and stem seal
• Remove cylinder head. Check inside
Worn or damaged valve guide, diameter of guide, and check stem seal for Replace valve guide
14
stem seal damages. and stem seal
(Reference: See "Maintenance standard".)

40-1086 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-11 Engine oil becomes contaminated early (PC400-B20-400-A-Z0-A)

Failure Engine oil becomes contaminated quickly.


Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
2
and Maintenance
Manual.
• Check exhaust gas color at location just Perform
Black exhaust gas color
upstream of KDPF. troubleshooting for "S-
3 checked at location just
(Reference: See Testing and adjusting, 9 Exhaust gas is
upstream of KDPF
"Testing exhaust color".) black".
• Measured blowby pressure exceeds
standard value. Perform following
4 Excessive blowby gas
• Blowby pressure is still high after KCCV checks.
filter element is replaced.
• Rotate KVGT shaft and check for play.
Defective KVGT seal on (Move KVGT vanes with hand in axial and Replace KVGT.
5
turbine side radial directions to make judgement.)
• Remove EGR valve and check stem seal,
guide, and stem.
6 Worn EGR valve guide Replace EGR valve.
• When EGR valve is remove, outlet port is
dirty with oil.
• Check oil level for excessive refilling.
7 Excessive refilling of oil (If oil level is excessive, oil will reach high Refill with oil to correct
temperatures and early deteriorates.) oil level.
• Visually check oil cooler element for
contamination. Clean or replace oil
8 Dirty oil cooler element
(Contaminated oil cooler element can cooler element.
increased oil temperature.)
• Measured blowby pressure exceeds
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
9 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
Standard value table).
(Reference: See Testing and adjusting,
"Testing compression pressure".)
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide
10 guide or stem seal diameter of guide and stem seal for
damage. and stem seal.
(Reference: See "Maintenance standards".)

WA470-7 40-1087
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-12 Fuel consumption is excessive (PC400-B70-400-A-Z0-A)

Failure Fuel consumption is excessive


Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Replace injector
• Test spill rate from injector
Too much fuel is spilled from (Reference: See Testing and adjusting, There may be
1 injector "Checking fuel delivery, return rate and excessive dust in fuel.
leakage") Confirm quality control
of fuel.
• Check fuel return piping for clogging
Correct or replace fuel
2 Clogged fuel return piping (Injection rate increased due to clogged fuel
return piping
return piping)
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
3 Defective injector • When a certain cylinder is cut out, engine Replace injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
Fuel leakage from inside • Check for increased oil level
4 Correct defective parts
cylinder head • Check for smell of diesel fuel
• Check for increased engine oil level and
Fuel leakage from feed pump smell of diesel fuel Replace feed pump oil
5
oil seal • Check feed pump oil seal seal
6 Fuel leakage to outside • Check for fuel leakage to outside of engine. Correct defective parts
7 Fuel leakage from fuel doser • Check fuel doser for fuel leaks Replace fuel doser

40-1088 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)

Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block

WA470-7 40-1089
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-14 Oil pressure drops (PC400-10D-400-A-Z0-A)

Failure Oil pressure drops


• If any failure code is displayed, carry out troubleshooting for it first.
Related information • Confirm if machine has been operated on a slope steeper than specified in the
Operation and Maintenance Manual.
No. Cause Detail of work, remarks Remedy
• Oil level in oil pan is low
1 Lack of oil in oil pan • Oil pressure monitor indicates low oil Add oil
pressure when operating on slopes
Defective oil pressure sensor, Replace oil pressure
• Check oil pressure sensor, wiring harness,
2 wiring harness sensor, wiring harness,
and connector
or connector
If oil is contaminated
with fuel, carry out
• Perform oil analysis and check for fuel in oil
3 Fuel in oil troubleshooting for "S-
• Engine oil smells of diesel fuel
15 Fuel mixes into
engine oil"
If oil is contaminated
• Perform oil analysis and check for water in with water, carry out
4 Water in oil oil troubleshooting for "S-
• Oil is milky 16 Water mixes into
engine oil (milky)"
• Check oil filter
(Reference: Oil filter has been used beyond
5 Clogged oil filter the specified period, oil heavily Replace oil filter
deteriorated, etc.)
• Water in oil can cause oil filter blockage
6 Clogged oil strainer • Check oil strainer Clean oil strainer
Crushed or clogged hydraulic Replace hydraulic
7 • Hydraulic piping is crushed or clogged
piping piping
• Check oil pump
8 Defective oil pump (worn or damaged gear) Replace oil pump
• Oil pump rotation is heavy or it has play
Defective regulator valve • Check valve spring for fatigue or damage Replace regulator
9
valve
• Valve and spring of oil pump relief valve is Replace oil pump relief
10 Defective oil pump relief valve fatigued, damaged. valve
Cracks in oil pump suction • Check around oil pump suction piping Replace oil pump
11 piping (cracked piping) suction piping
Defective seal between oil
12 pump and oil pump suction • Check seal Replace seal
piping
Replace boost oil
13 Defective boost oil pump • Check boost oil pump
pump
Defective boost oil pump relief • Check boost oil pump relief valve for fatigue Replace boost oil
14 or damage on valve and spring pump relief valve
valve
Oil leakage from EGR Replace EGR
15 hydraulic piping • Check EGR hydraulic piping
hydraulic piping
• Check main journal bearing
Replace main journal
16 Worn main journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
• Check pin journal bearing
Replace pin journal
17 Worn pin journal bearing • Metallic powders are found in oil drained
bearing
from oil pan
Worn idler bushing, damaged Replace idler bushing
18 idler gear • Check idler bushing and idler gear
or idler gear
Breakage or falling off of Replace piston cooling
19 piston cooling nozzle • Check piston cooling nozzle
nozzle

40-1090 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A)

Failure Fuel mixes into engine oil (smells of diluted diesel fuel)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When exhaust manifold is touched
immediately after starting engine,
temperature of some cylinders is low
1 Defective injector • When a certain cylinder is cut out, engine Replace Injector
speed does not change
(Reference: See Testing and adjusting,
"Handling of cylinder cut-out operation".)
Fuel leakage from injector or
2 • Check injector or O-ring Replace injector O-ring
O-ring (spill circuit)
Defective seal between
• Check seal between injector and injection
3 injector and injection piping, Repair or replace
piping, and check injection piping for cracks
cracks in injection piping
• Confirm that fuel no longer mixes into oil
4 Defects in supply pump Replace supply pump
after supply pump is replaced

WA470-7 40-1091
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-16 Water mixes into engine oil (milky) (PC400-B32-400-A-Z0-A)

Failure Water mixes into engine oil (milky)


• If oil mixes into the coolant, perform troubleshooting for "S-13 Oil mixes into coolant"
• If any failure code is displayed, carry out troubleshooting for it first.
When engine starting and stopping is frequently repeated in low outside
temperatures, the KCCV may cause condensation of water vapor in the blow-by gas
Related information leading to milky oil or emulsification inside the engine, but this is normal. This is not
a problem if coolant is not leaking.
If coolant leakage is suspected by such as drop of coolant level in a short time, carry
out the following troubleshooting procedures.
No. Cause Detail of work, remarks Remedy
• Coolant containing antifreeze flows out
when EGR cooler inlet and outlet gas
piping are removed.
(Make sure the water is coolant or not. It
may be condensate water)
1 Cracks in EGR cooler Replace EGR cooler
(Reference: If cracks are found in the EGR
cooler, this may be caused by low coolant
level in the cooling system. When replacing
the EGR cooler, check for leaks from
coolant system piping and radiator.)
• Check oil cooler element and O-ring
Damaged oil cooler element or Replace oil cooler
2 • Pressure-tightness test of oil cooler shows
O-ring element or O-ring
oil leakage
Leakage from water pump • Check for leaks from water pump Replace water pump
3
mechanical seal mechanical seal mechanical seal
Clogged water pump drain • Check water pump drain hole Clean water pump
4
hole drain hole
Replace cylinder head
Broken cylinder head or • Disassemble engine and check cylinder
5 or cylinder head
cylinder head gasket head and cylinder head gasket
gasket
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
6
block or pitting in cylinder block

40-1092 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-17 Coolant temperature rises too high (overheating) (PC400-AL0-400-A-Z0-A)

Failure Coolant temperature rises too high (overheating).


Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Clogged radiator core • Check radiator core for clogging, and check
1 Clean radiator core.
fin for crush.
• Thermostat does not open at cracking
temperature.
2 Malfunction of thermostat a Thermostat cracking temperature: 76.5 ± 2 Replace thermostat.
°C
(Full open temperature: 90 °C)
• Error related to coolant temperature is Replace coolant
Defective coolant temperature temperature sensor,
3 displayed, but measured value of radiator
gauge monitor or wiring
coolant temperature is normal.
harness.
Perform
Increased fuel injection rate • Fuel injection rate is high. troubleshooting for "S-
4
12 Fuel consumption is
excessive".
5 Low coolant level • Check coolant level. for lowering. Refill with coolant.
Replace coolant
6 Leakage of coolant • Check water leakage from coolant piping.
piping.
• Visually check water pump.
(Check shaft seal for water leakage,
7 Breakage of water pump Replace water pump.
impeller for damage, and shaft for
breakage.)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
against fresh air amount) • Check mass air flow and temperature
8 and temperature
caused by defective mass air sensor.
sensor.
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount
• Check air cleaner and rectifying wire net for Repair or replace air
9 against fresh air amount)
deformation. cleaner.
caused by air cleaner
deformation
Defective cylinder head or • Check radiator coolant for excessive Perform
10 cylinder head gasket bubbles and spurt back. troubleshooting for "S-
13 Oil is in coolant".
• Open exhaust color inspection hole that is
just upstream of KDPF, and check exhaust
gas.
(Reference: See Testing and adjusting,
"Testing exhaust color".) Replace piston ring or
11 Defective piston ring • Measure compression pressure (see piston.
Standard value table).
(Reference: See Testing and adjusting,
"Testing compression pressure".)
• Check piston ring and piston ring groove.

WA470-7 40-1093
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-18 Unusual noise is heard (PC400-BA1-400-A-Z0-A)

Failure Unusual noise is heard.


• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
• Exhaust gas leaks from piping between
cylinder head and exhaust manifold,
Exhaust gas leakage from between exhaust manifold and KVGT, or Repair or replace
1 piping between KVGT outlet and KDPF. defective parts.
• Exhaust gas leaks from EGR piping or air
intake piping.
Vibration of exhaust piping or • Visually check for vibration. Check and retighten
2 piping brackets.
exhaust bellows
• Check whether KVGT shaft rotates.
3 Seized or broken KVGT (Move KVGT vanes with hand in axial and Replace KVGT.
radial directions to make judgement.)
Clean or replace
4 Internal damage of KDPF • Check inside of KDPF.
KDPF.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
5 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
• Check valve clearance.
6 Incorrect valve clearance (Reference: See Testing and adjusting, Adjust valve clearance.
"Testing and adjusting valve clearance".)
Seized pin bushing, front Repair or replace
7 bearing, or main bearing • Check for metal particles in oil pan.
damaged parts.
• If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder Replace piston ring or
8 • Measure compression pressure (see
liner cylinder liner.
Standard value table).
(Reference: See Testing and adjusting,
"Testing compression pressure".)
• Overhaul engine and check valves and Replace valve or
9 Damaged valve or rocker arm rocker arm parts. rocker arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.

40-1094 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-19 Vibration is excessive (HM300_3-BC0-400-A-Z0-A)

Failure Vibration is excessive.


• If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Related Unusual noise is heard", too.
information • If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
• Visually check engine mounting bolts for
Loose engine mounting bolts Retighten bolts or
1 looseness and cushions for cracks and
or defective cushions replace cushions.
hardening.
• Visually check viscous damper for Replace engine
2 Damaged engine damper
discoloration. damper.
Defective output shaft or • Check output shaft for damage and damper Replace defective
3 internal defect of damper parts.
for internal defect.
Misalignment and facial
runout at connection between • Measure misalignment and facial runout at Replace defective
4 engine and hydraulic pump connection from engine to output shaft. parts.
are out of standard range.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
• When engine is run in cylinder cutout mode
5 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
(Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
Worn main bearing or • If metal particles are found in oil pan or oil Repair or replace
6 connecting rod bearing filter, overhaul engine. damaged parts.
• If metal particles are found in oil pan or oil Repair or replace
7 Stuck valve or rocker arm filter, open cylinder head cover and check damaged parts.
valves and rocker arms.
• If metal particles are found in oil pan or oil
Replace camshaft
8 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings.
bushings.

WA470-7 40-1095
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-20 Air cannot be bled from fuel circuit (PC400-A29-400-A-Z0-A)

Failure Air cannot be bled from fuel circuit


Related information • If any error code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
• When fuel feed pump switch is turned ON,
1 Insufficient fuel in tank pump operating sound is heard. Add fuel
• Even when fuel feed pump switch is turned
2 Low battery charge level Charge battery
ON, pump operating sound is not heard.
• Check drain valve of fuel prefilter for
Loose drain valve of fuel
3 loosening Close drain valve
prefilter
(Air leaking in due to loose drain valve)
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
4
may be clogged element
• When air bleeding operation for fuel system
is performed, air comes out Correct or replace fuel
5 Air in fuel piping system
(Reference: See Testing and adjusting, piping
"Bleeding air from fuel system")
• Fuel is leaking from fuel piping
Leakage from fuel piping Correct or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts
"Checking fuel system for leakage")
• With fuel feed pump switch ON, voltage to
Replace fuel feed
7 Malfunction of fuel feed pump fuel feed pump is generated but pump does
pump
not operate.
• With fuel feed pump switch ON, voltage to
Malfunction of fuel feed pump Replace fuel feed
8 fuel feed pump is not generatedLamp does
switch pump switch
not light up.
Defective wiring harness of
fuel feed pump and fuel feed • Check wiring harness Replace wiring
9
pump switch harness

40-1096 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-21 Active regeneration is executed frequently (PC400-AQ0-400-A-Z0-A)

Failure Active regeneration is executed frequently.


Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
Long-term machine operation
Perform Regeneration
with engine at low to medium • Soot can accumulate if machine does not
1 for Service to burn
speeds (exhaust temperature perform heavy-duty work.
away soot completely.
does not rise)
• Open exhaust color inspection hole being Perform
just upstream of KDPF, and check exhaust troubleshooting for "S-
2 Defective exhaust gas color gas (see Standard value table). 9 Exhaust gas is black
(Reference: See Testing and adjusting, (KDPF gets clogged in
"Testing exhaust color".) a short time)".
• If regeneration frequency does not return to
Plugged KDOC resulting from normal after remedies for cause 2 are taken,
3 Clean KDOC.
bad exhaust color KDOC is plugged.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
4
and Maintenance
Manual.
• If regeneration frequency does not return to
Plugged KCSF due to use of
5 normal after remedies for cause 4 are taken, Clean or replace
improper oil KCSF.
KCSF is plugged.
Perform
Coolant leaking into exhaust troubleshooting for "S-
6 system • Check for low coolant level. 16 Water mixes into
engine oil (milky)".
Plugged KCSF due to coolant Clean or replace
7 leaking into exhaust system • Check KCSF inlet for plugging.
KCSF.
Use proper fuel
specified in Operation
8 Improper fuel used • Fuel other than specified one is used.
and Maintenance
Manual.
• KDOC is deteriorated by high sulfur content.
Deteriorated KDOC due to (If regeneration frequency does not return to
9 use of improper fuel Replace KDOC.
normal after remedies for causes 1 to 8 are
taken, KDOC is deteriorated.)
• If regeneration frequency is not improved
10 Plugged KDOC after remedies on causes 1 to 9, KDOC is Clean KDOC.
blocked.
11 Damaged KDOC • Check KDOC for damage. Replace KDOC.

WA470-7 40-1097
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-22 Active regeneration takes a long time (PC400-AQ1-400-A-Z0-A)

Failure Active regeneration takes a long time


• If any failure code is displayed, carry out troubleshooting for it first.
Related information • Since the time required for manual stationary regeneration depends on the
accumulated soot level, see failure code CA2639.
No. Cause Detail of work, remarks Remedy
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature:
approximately 250°C or below and KVGT
Replace the whole
solenoid current: approximately 1000 mA
KVGT (including
1 Malfunction of KVGT remain unchanged after performing
hydraulic actuator and
regeneration for service, KVGT is defective.
KVGT position sensor).
(Since the time required for manual stationary
regeneration depends on the accumulated soot
level, see failure code CA2639. )
• Open the exhaust gas color measuring hole Carry out
before the KDPF and check the color of the troubleshooting for "S-
2 Exhaust gas color is bad exhaust gas (see standard value table). 9 Exhaust gas is black
(Reference: See Testing and adjusting, (KDPF gets clogged in
"Testing exhaust gas color".) a short time)"
Defective regeneration due to
3 soot accumulation in fuel • Check fuel doser Clean fuel doser
doser
Bad exhaust color causing • If regeneration time is not improved after
4 KDOC face plugging remedies on cause 2, KDOC is blocked. Clean KDOC
Carry out
Coolant leaking into exhaust troubleshooting for "S-
5 system • Check for low coolant level 16 Water mixes into
engine oil (milky)"
KCSF plugged due to coolant
6 • Check KCSF for plugging Clean KCSF
leaking into exhaust system
Use proper fuel
Improper fuel used • Non-specified fuel is being used. specified in Operation
7
and Maintenance
Manual
• KDOC deteriorated by high sulfur content
KDOC deterioration due to (If regeneration time is not improved after
8 Replace KDOC
improper fuel used remedies on causes 1 to 6, KDOC is
deteriorated.)
• If regeneration duration does not return to
9 Plugged KDOC normal after remedies for causes 1 to 7 are Clean KDOC
taken, KDOC is plugged
10 Damaged KDOC • Check KDOC for damage Replace KDOC

40-1098 WA470-7
40 Troubleshooting
Troubleshooting of engine (S-mode)

S-23 White smoke is exhausted during active regeneration (PC400-AQ2-400-A-Z0-A)

Failure White smoke is exhausted during active regeneration.


• White smoke may be observed for a short time immediately after engine is started in cold
Related weather or during regeneration, but this is normal.
information • If any failure code is displayed, perform troubleshooting for that code first.
No. Cause Point to check, remarks Remedy
Perform
Coolant leaking into exhaust troubleshooting for "S-
1 system • Check for low coolant level. 16 Water mixes into
engine oil (milky)".
Plugged KDOC due to • If white smoke problem is not resolved after
coolant leaking into exhaust remedies for cause 1 are taken, KDOC is Clean or replace
2
system plugged. KDOC.
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
3
and Maintenance
Manual.
• KDOC is deteriorated by high sulfur content.
Deteriorated KDOC due to (If white smoke problem is not resolved after
4 Replace KDOC.
use of improper fuel remedies for causes 1 to 3 are taken, KDOC
is deteriorated.)
• If white smoke problem is not resolved after
5 Plugged KDOC remedies for causes 1 to 4 are taken, KDOC Clean KDOC.
is plugged.
6 Damaged KDOC • Check KDOC for damage. Replace KDOC.
7 Damaged KCSF • Check KCSF for damage. Replace KCSF.

WA470-7 40-1099
40 Troubleshooting
Troubleshooting of engine (S-mode)

40-1100 WA470-7
SHOP MANUAL

WHEEL LOADER
WA470-7
Model Serial Number

WA470-7 10001 and up

50 Disassembly and assembly


7 50 Disassembly and assembly

WA470-7 50-1
50 Disassembly and assembly
Table of contents

Table of contents (ALL-0310-002-A-00-A)


50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-17
Engine and cooling system ........................................................................................................ 50-47
Removal and installation of supply pump assembly............................................................... 50-47
Removal and installation of injector assembly....................................................................... 50-53
Removal and installation of fuel doser assembly ................................................................... 50-61
Removal and installation of cylinder head assembly.............................................................. 50-63
Removal and installation of engine hood assembly ............................................................... 50-77
Removal and installation of grille assembly .......................................................................... 50-79
Removal and installation of cooling system assembly............................................................ 50-82
Removal and installation of radiator core assembly ............................................................... 50-85
Removal and installation of aftercooler................................................................................. 50-87
Removal and installation of hydraulic oil cooler ..................................................................... 50-90
Removal and installation of power train oil cooler assembly ................................................... 50-92
Removal and installation of engine assembly ....................................................................... 50-96
Removal and installation of engine front oil seal .................................................................. 50-102
Removal and installation of engine rear oil seal................................................................... 50-105
Removal and installation of cooling fan and cooling fan motor assembly ............................... 50-110
Removal and installation of KDPF assembly....................................................................... 50-112
Disassembly and assembly of KDPF assembly .................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-126
Removal and installation of KVGT assembly....................................................................... 50-128
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly...................... 50-133
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly..................... 50-134
Removal and installation of air cleaner assembly ................................................................ 50-136
Removal and installation of air conditioner compressor belt ................................................. 50-138
Removal and installation of alternator belt .......................................................................... 50-139
Removal and installation of fuel tank assembly ................................................................... 50-140
Power train............................................................................................................................. 50-143
Removal and installation of torque converter and transmission assembly.............................. 50-143
Disassembly and assembly of transmission assembly......................................................... 50-148
Disassembly and assembly of torque converter assembly ................................................... 50-178
Disassembly and assembly of transmission clutch pack assembly ....................................... 50-185
Removal and installation of front axle assembly .................................................................. 50-208
Removal and installation of rear axle assembly................................................................... 50-210
Disassembly and assembly of axle housing assembly......................................................... 50-215
Disassembly and assembly of differential assembly ............................................................ 50-225
Steering system...................................................................................................................... 50-244
Removal and installation of steering valve assembly ........................................................... 50-244
Brake system ......................................................................................................................... 50-246
Removal and installation of brake charge valve assembly.................................................... 50-246
Removal and installation of parking brake disc and plate ..................................................... 50-247
Undercarriage and frame......................................................................................................... 50-250
Removal and installation of center hinge pin ....................................................................... 50-250
Removal and installation of counterweight assembly ........................................................... 50-258
Removal and installation of full-length fender assembly ....................................................... 50-260
Hydraulic system .................................................................................................................... 50-261
Removal and installation of hydraulic tank assembly ........................................................... 50-261
Removal and installation of control valve assembly ............................................................. 50-264
Removal and installation of steering pump and power train pump assembly .......................... 50-267
Removal and installation of work equipment pump and cooling fan pump assembly............... 50-269
Disassembly and assembly of hydraulic cylinder assembly.................................................. 50-271

50-2 WA470-7
50 Disassembly and assembly
Table of contents

Work equipment ..................................................................................................................... 50-278


Removal and installation of work equipment assembly ........................................................ 50-278
Cab and its attachments .......................................................................................................... 50-283
Removal and installation of operator's cab and floor frame assembly.................................... 50-283
Removal and installation of operator's cab glass (stuck window glass).................................. 50-287
Removal and installation of operator's seat assembly.......................................................... 50-295
Removal and installation of seat belt .................................................................................. 50-297
Removal and installation of air conditioner unit assembly..................................................... 50-298
Removal and installation of air conditioner compressor assembly......................................... 50-303
Removal and installation of air conditioner condenser assembly .......................................... 50-305
Electrical system .................................................................................................................... 50-307
Removal and installation of machine monitor assembly ....................................................... 50-307
Removal and installation of engine controller assembly ....................................................... 50-308
Removal and installation of work equipment controller assembly.......................................... 50-309
Removal and installation of transmission controller assembly .............................................. 50-311
Removal and installation of monitor controller assembly ...................................................... 50-312
Removal and installation of mass air flow and temperature sensor ....................................... 50-314
Removal and installation of KOMTRAX terminal assembly .................................................. 50-315

WA470-7 50-3
50 Disassembly and assembly
General information on disassembly and assembly

General information on disassembly and assembly (ALL-3851-001-A-00-A)

How to read this manual (ALL-0320-011-A-00-A)


(Rev.2010.10)

Removal and installation of TTTT assembly • Common tools that are necessary for installation
Special tools are described as [1], [2] ... etc. and their part
• Special tools which are necessary for removal or numbers, part names and quantities are not
installation of assemblies are described as described.
A1•••X1 etc. and their part numbers, part names, • Marks shown in the installation section are
necessities, and quantities are described in the explained below.
special tool list. k: This mark indicates safety-related
• Marks used in the column of necessity are precautions which must be followed when
explained below. performing the work.
t: Tools are not substituted, must always be
equipped (used). a : This marks gives guidance or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tool. 4 : This mark shows the weight of a part or
• For details and the sketches of the special tools, the assembled parts for a device.
see "special tool list" and "sketches of special
tools". 2 : This mark indicates a specific coating
Removal agent to be used.
• In the removal section, the work procedures, 3 : This mark indicates the specified
precautions and know-how to do the work and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark indicates the amount of oil or
• Common tools that are necessary for the coolant to be added.
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities Disassembly and assembly of TTTT assembly
are not described. Special tools
• Marks used in the removal section are explained • Special tools which are necessary for
below. disassembly and assembly of assemblies are
described as A1•••X1 etc. and their part
k: This mark indicates safety-related numbers, part names, necessities, and
precautions which must be followed when quantities are described in the special tool list.
performing the work. • Marks used in the column of necessity are
explained below.
a : This mark gives guidance or precautions when t: Tools are not substituted, must always be
performing the work. equipped (used).
[*1]: This mark indicates that instructions or q: Tools extremely useful if available or tools
precautions for the assembly installation work are that can be substituted with commercially
given in the installation section. available tool.
• For details and the sketches of the special tools,
6 : This mark shows the amount of oil or see "special tool list" and "sketches of special
coolant to be drained. tools".
Disassembly
4 : This mark shows the weight of a part or • In the disassembly section, the work
the assembled parts for a device. procedures, precautions and know-how to do
Installation the work, and the amount of oil and coolant to be
• Unless otherwise instructed the installation of drained are described.
assemblies is to be made in the reverse order to • Common tools that are necessary for the
removal. disassembly work are indicated as [1], [2] ... etc.
• Instructions and precautions for assembly and their part numbers, part names, and
installation are shown with [*1] mark in the quantities are not described.
removal section, identifying which step the • Marks used in the disassembly section are
instructions are intended for. explained below.

50-4 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

k: This mark indicates safety-related


precautions which must be followed when
performing the work.

a : This marks gives guidance or precautions


when performing the work.

6 : This mark shows the amount of oil or


coolant to be drained.

4 : This mark shows the weight of a part or


the assembled parts for a device.
Assembly
• In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
• Common tools that are necessary for the
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
• Marks used in the assembly section are
explained below.
k: This mark indicates safety-related
precautions which must be followed when
performing the work.

a : This mark gives guidance or precautions when


performing the work.

4 : This mark shows the weight of a part or


the assembled parts for a device.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.

5 : This mark indicates the amount of oil or


coolant to be added.

WA470-7 50-5
50 Disassembly and assembly
General information on disassembly and assembly

Coating materials list (ALL-3540-071-A-00-A)


(Rev.2012.08)

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

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20g polypropylene, tetrafluoroethylene, and
Polyethylene vinyl chloride), rubber, metal, and non-
LT-1B 790-129-9050 (2 pcs. container metal parts which require immediate
contained)
and strong adhesion.
• Features: Resistance to heat and
50 g Polyethylene chemicals
LT-2 790-129-9180
container • Use to fix and seal bolts and plugs.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 (Set of adhesive Can
Hardener: plastics.
and hardener)
500 g
250 g Polyethylene • Use to seal plugs for blank holes.
LT-4 790-129-9040
container
• Heat-resistant seal used to repair
Holtz MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
50 g Polyethylene • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 • Use mainly to bond metals, rubbers,
container
plastics, and woods.
• Instantaneous adhesive
• Quick-curing type (max. strength is
Aron Alpha 201 2g Polyethylene
790-129-9130 obtained after 30 minutes)
container
• Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 g Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
• Features: Resistance to heat and
Polyethylene chemicals
Loctite 648-50 79A-129-9110 50 cc • Use for fitted portions used at high
container
temperatures.

50-6 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Liquid gasket
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal various thread portions,
Polyethylene pipe joints, and flanges.
LG-5 790-129-9080 1 kg
container • Use to seal taper plugs, elbows, and
nipples for hydraulic piping.
• Features: Silicon-based heat and
cold-resistant sealant
200 g • Use to seal thread portions and flange
LG-6 790-129-9160 Tube
surface.
• Use to seal oil pan, final drive case,
etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and
cold-resistant, vibration-resistant,
ThreeBond 419-15-18131 100 g Tube impact-resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
ThreeBond 790-129-9310 200 g Tube clamped by bolts, gaps in the weld
1206D which must be caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission
case and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine

Molybdenum disulfide lubricant


Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
LM-P 09940-00040 200 g Tube portions, and thread portions.
• Use to lubricate linkages, bearings,
etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, pins and bolts of various
links, etc.

WA470-7 50-7
50 Disassembly and assembly
General information on disassembly and assembly

Seizure prevention compound


Komatsu code Part No. Capacity Container Main features and applications
• Feature: Seizure and galling
prevention compound with metallic
LC-G super-fine-grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.

Grease
Komatsu code Part No. Capacity Container Main features and applications
SYG2-400LI-A
G2-LI SYG2-16LI • Lithium grease with extreme pressure
G0-LI (*) SYGA-16CNLI Various Various lubrication performance, general
*: For cold regions SYG0-400LI-A(*) purpose type
SYG0-16CNLI(*)
• Use for parts under heavy load.
Caution:
• Do not use this grease for rolling
Molybdenum SYG2-400M 400 g x 10 Bellows-type bearings like swing circle bearings,
disulfide grease SYG2-400M-A 400 g x 20 container etc. and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work
equipment pins only when
installing them, but do not use it
afterward.
Hyper White
SYG2-400T • Higher seizure resistant, heat
Grease Bellows-type
SYG2-16CNT 400 g resistant and water resistant than
G2-T container molybdenum disulfide grease.
SYG0-400T(*) 16 kg • Not conspicuous on machine since
G0-T (*) Can
SYG0-16CNT(*) color is white.
*: For cold regions
Bio grease
G2-B SYG2-400B
SYGA-16CNB 400 g Bellows-type • Since this grease is biodegradable in
G2-BT (*) container short period, it has less impact on
*: For use at high SYG2-400BT(*) 16 kg microorganisms, animals, and plants.
Can
temperature and SYGA-16CNBT(*)
under high load
• Silicone grease with wide usable
temperature range, high resistance to
G2-S thermal-oxidative degradation and
— 200 g Tube performance to prevent deterioration
ThreeBond 1855 of rubber and plastic parts
• Use for oil seals of the transmission,
etc.
• Urea (organic system) grease with
heat resistance and long life.
Enclosed type.
G2-U-SENS
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
grease
damper.
Caution: Do not mix it with lithium
grease.

50-8 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Primer
Komatsu code Part No. Capacity Container Main features and applications
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
Primer 580 Super 20 ml (Effective period: 4 months after
container
manufacture)
417-926-3910
• Use as primer for cab glass
Sunstar Glass Glass surface.
20 ml

For adhering cab glass


Primer 580 Super container (Effective period: 4 months after
manufacture)
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
22M-54-27230 20 ml (Effective period: 4 months after
Primer 435-95 container
manufacture)
• Use as primer for black ceramic-
coated glass surface and for hard
Sunstar Glass polycarbonate-coated surface.
22M-54-27240 150 ml Steel can
Primer 435-41 (Effective period: 4 months after
manufacture)
• Use as primer for sash (Almite)
Sunstar Sash Glass (Effective period: 4 months after
22M-54-27250 20 ml
Primer GP-402 container manufacture)

Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use "S" in high temperature
season and "W" in low
Sunstar Penguin
For adhering cab glass

Polyethylene temperature season as adhesive


Seal 580 Super 417-926-3910 320 ml for glass.
container
"S" or "W" (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.
Sika Japan, Polyethylene (Effective period: 6 months after
20Y-54-39850 310 ml
Sikaflex 256HV container manufacture)
Ecocart • Use as adhesive for glass.
Sunstar Penguin
22M-54-27210 320 ml (Special (Effective period: 6 months after
Super 560
container) manufacture)

Caulking material
Komatsu code Part No. Capacity Container Main features and applications
• Use to seal joints of glass parts.
Sunstar Penguin Polyethylene
For adhering cab glass

417-926-3920 320 ml (Effective period: 4 months after


Seal No.2505 container manufacture)
• Use to seal front window.
Sekisui Silicone Polyethylene (Effective period: 6 months after
20Y-54-55130 333 ml
Sealant container manufacture)
• Use to seal glass-to-glass joint.
GE Toshiba Translucent white seal.
Silicones 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL 381 manufacture)

WA470-7 50-9
50 Disassembly and assembly
General information on disassembly and assembly

Special tools list (WA470-3530-061-A-00-A)

a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t: Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tools.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification.
a Tools marked with Q in the Sketch column have the sketches. (See "Sketches of special tools")

New/Redesign
Necessity

Sketch
Details of work and

Q'ty
Work Symbol Part No. Part name
remarks

Removal and 1 795-630-5500 Standard puller t 1


installation of supply Removal of gear and
2 01010-81090 Bolt t 2
pump assembly shaft
3 01643-31032 Washer t 2
Removal and
installation of supply
pump assembly Removal and installation
4 6212-82-0110 Wrench t 1
Removal and of KCCV ventilator
installation of supply
pump assembly
Tightening of cylinder
5 790-331-1110 Wrench q 1
head bolts
Removal and 793T-601-1410 Bracket t 1 N Q
installation of cylinder Installation of exhaust
01011-81040 Bolt t 2
head assembly 6 tube between KVGT and
01643-31032 Washer t 2 KDPF
01580-01008 Nut t 2
Removal and
installation of engine
front oil seal Seal puller Removal of engine front
7 795-931-1100 assembly q 1
Removal and A seal and rear seal
installation of engine
front oil seal
Removal and 8 795T-521-1140 Push tool t 1 Q
Installation of engine
installation of engine 9 01010-61650 Bolt t 3
front oil seal
front oil seal 10 01643-31645 Washer t 9
1 795T-401-1310 Push tool t 1 Q
2 795T-401-1320 Guide bolt t 3 Q
3 795T-601-1310 Push tool t 1 N Q
11
Removal and 4 795T-401-1330 Push tool t 1 N Q
t Installation of engine
installation of engine 5 795T-401-1340 Guide 1 Q
rear oil seal
rear oil seal 6 795T-401-1350 Spacer t 1 Q
1 01010-61660 Bolt t 1
12
2 01010-61640 Bolt t 1
13 01643-31645 Washer t 1
Removal and Adjusting the installed
installation of KDPF 14 J4000-01650 Bolt q 1 position of KDPF
assembly assembly

50-10 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

New/Redesign
Necessity

Sketch
Details of work and

Q'ty
Work Symbol Part No. Part name
remarks

Removal and 15 795T-621-2820 Push tool t 1 Q


installation of KVGT Installation of exhaust
A
assembly 16 795T-621-2810 Installer t 1 Q connector
Disassembly and 793T-607-1550 Bracket t 1 N Q
assembly of 01051-62240 Bolt t 1
transmission
Removal and installation
assembly 1 of ring
Removal and 01643-32260 Washer t 1
installation of parking
brake disc and plate
793T-607-1260 Plate t Q
01016-51645 Bolt t 1 Removal of transfer
2
01016-51690 Bolt t 1 shaft 1 and inner race
01010-81245 Bolt t 4
3 793T-607-1570 Plate t 1 N Q Removal and installation
4 790-102-1891 Nut wrench t 1 of PTO gear nut
793T-607-1220 Lifting tool t 1 Q Removal and installation
5 of F and 1st clutch pack
793-607-1230 Pin t 1 assembly
793T-607-1280 Lifting tool t 2 Q
01016-31245 Bolt t 4
01580-11210 Nut t 4 Removal and installation
of R and 2nd clutch pack
01017-30250 Bolt t 2
6 assembly and 3rd and
01643-32060 Washer t 4 4th clutch pack
01580-12016 Nut t 4 assembly
793T-607-1290 Bar t 1 Q
B 04530-11628 Eyebolt t 1
793T-607-1310 Plate t 1 Q
Disassembly and
assembly of 793T-607-1520 Push tool t 1 N Q Removal of transfer
transmission 7 2989-01-1220 Bolt t 1 shaft 2 and transfer gear
assembly 01643-33080 Washer t 1 2
01017-31420 Bolt t 8
793T-607-1330 Bracket t 1 Q
793T-607-1340 Plate t 1 Q
8 Layout of transfer gear 2
01010-80820 Bolt t 2
01643-30823 Washer t 2
793T-607-1350 Bolt t 1 Q Installation of transfer
9
04530-11018 Eyebolt t 1 shaft 2
793T-607-1560 Sleeve t 1 N Q
Installing spacer to
10 01017-51630 Bolt t 1 transfer gear 1
01643-31645 Washer t 1
Press fit of outer races
11 790-201-2660 Plate q 1 into F and 1st clutch
shaft cage
Press fit of transfer shaft
12 792-135-3360 Plate q 1 1 bearing into case
13 792-822-1430 Plate q 1 Press fit of outer races
for transfer gear 2 into
14 790-201-2860 Spacer q 1 case

WA470-7 50-11
50 Disassembly and assembly
General information on disassembly and assembly

New/Redesign
Necessity

Sketch
Details of work and

Q'ty
Work Symbol Part No. Part name
remarks

15 792T-227-1110 Push tool t 1 Q Press fit of bearing into


16 792T-423-1230 Push tool t 1 Q transfer shaft 2
17 790-201-2680 Plate q 1 Press fit of outer race on
the rear side of output
18 794T-425-1110 Push tool t 1 Q shaft
Press fit of output shaft
19 793T-615-1810 Push tool t 1 N Q
bearing (small)
Press fit of output shaft
20 791T-630-2410 Push tool t 1 Q bearing (large)
Press fit of outer race on
21 790-201-2220 Plate q 1 the front side of output
shaft
Press fit of input shaft
22 790-201-2160 Plate q 1 bearing into case
Press fit of input shaft
23 793T-607-1420 Push tool t 1 Q
inner races
Press fit of outer races
24 793T-623-1170 Push tool t 1 Q into PTO cage

Disassembly and 25 790-445-3810 Push tool t 1 Press fit of PTO bearing


assembly of B Press fit of input shaft
26 790-201-2860 Spacer q 1
transmission cover
assembly 790-101-5401 Push tool kit q 1
790-101-5421 • Grip 1 Press fit of input shaft
27 spacer
790-101-5441 • Plate 1
01010-51240 • Bolt 1
Press fit of input shaft
28 790-434-1470 Push tool q 1 bearing (large)
793T-607-1430 Push tool t 1 Q Press fit of oil and dust
29 790-101-5421 Grip t 1 seals on the front side of
01010-51240 Bolt t 1 output shaft
Press fit of dust seal on
30 793T-607-1140 Spacer t 1 Q the front side of output
shaft
793T-607-1440 Push tool t 1 Q Press fit of oil and dust
31 790-101-5421 Grip t 1 seals on the rear side of
01010-51240 Bolt t 1 output shaft
Press fit of dust seal on
32 793T-607-1450 Spacer t 1 Q the rear side of output
shaft
790-501-5000 Unit repair stand q 1
Fixing torque converter
33 790-901-2110 Bracket q 1 assembly
793T-613-1510 Plate q 1 N Q
Disassembly and Removal and installation
34 792-213-1110 Wrench t 1
assembly of torque B of stator shaft locknut
converter assembly Removal of stator shaft
35 790-201-2650 Plate q 1 and bearing
Removal of boss and
36 790-201-2740 Spacer q 1 bearing ring

50-12 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

New/Redesign
Necessity

Sketch
Details of work and

Q'ty
Work Symbol Part No. Part name
remarks

Removal of bearing and


37 790-201-2660 Plate q 1 housing
Assembly of turbine and
38 792T-415-1410 Spacer q 1 Q
case
Disassembly and Press fit of bearing into
assembly of torque 39 790-201-2750 Spacer q 1 housing
converter assembly
Press fit of bearing into
40 790-201-2680 Plate q 1 guide
41 790-201-2220 Plate q 1 Removal of stator shaft
42 791-830-1770 Push tool q 1 into bearing
Commercially
Puller q 1
available Removal of F and R
43 790-101-2501 Push puller t 1 clutch bearings and
790-101-3201 Bearing puller t 1 spacers
790-201-1310 Plate t 1
Commercially t 1
Puller Removal of 1st clutch
44 available
bearing
790-201-1410 Plate t 1
790-101-2510 Block t 1
790-101-2520 Screw t 1
t Removal and installation
791-112-1180 Nut 1
45 of 1st and 2nd clutch
790-101-2540 Washer t 1 snap rings
790-101-2450 Adapter t 1
B
790-201-2860 Spacer t 1
790-101-3501 Puller t 1 Removal of 2nd clutch
46 bearing and hub
790-201-1320 Plate t 1
Disassembly and Installation of seal ring
assembly of 47 793-415-1170 Seal holder t 1
to 3rd piston
transmission clutch Press fit of spacer into
pack assembly 48 793T-607-1420 Push tool q 1 Q
3rd clutch
Installation of seal ring
49 793T-607-1370 Seal holder t 1 Q to 4th piston
Press fit of bearing into
2nd and 4th clutches
50 796T-467-2160 Push tool t 1 Q Press fit of bearing and
spacer into R clutch
t 1 Operation check of
51 799-301-1500 Oil leak tester
clutch
Installation of seal ring
52 793T-607-1380 Seal holder t 1 Q to 1st and 2nd pistons
Press fit of inner races
53 792T-446-1150 Push tool t 1 Q
into 2nd clutch
Installation of seal ring
54 793T-607-1390 Seal holder t 1 Q to F and R pistons
Press fit of bearing into
55 795-102-2730 Collar t 1 1st clutch

WA470-7 50-13
50 Disassembly and assembly
General information on disassembly and assembly

New/Redesign
Necessity

Sketch
Details of work and

Q'ty
Work Symbol Part No. Part name
remarks

1 790-501-5000 Unit repair stand q 1


Fixing differential
D1 2 790-901-2110 Bracket q 1 assembly
3 790T-901-3440 Plate q 1 Q
Removal of cage
D2 793T-622-2570 Eyebolt t 2 N Q
assembly
Removal of cage and
D3 790-201-2730 Spacer q 1 pinion gear
1 793T-615-1730 Spacer q 1 Q Press fit of outer races
D4 into cage
2 790-201-2770 Spacer q 1
1 790-201-2780 Spacer q 1 Press fit of outer races
D5
2 793T-623-1210 Spacer q 1 N Q into cage
1 796-765-1110 Push tool t 1 Press fit of bearing into
D6 pinion gear
2 790-201-2750 Spacer t 1
1 796-765-1110 Push tool t 1 Press fit of bearing into
D7
2 792T-413-1120 Push tool t 1 Q pinion gear
Measurement of starting
D8 79A-264-0021 Push-pull scale q 1 torque
Disassembly and 1 793T-622-1310 Push tool t 1 Q
assembly of Press fit of oil seal into
D9 2 790-101-5421 Grip t 1
differential assembly cage
3 01010-51240 Bolt t 1
1 793T-622-1310 Push tool t 1 Q
2 793T-622-1320 Spacer t 1 Q Press fit of dust seal into
D10 cage
3 790-101-5421 Grip t 1
4 01010-51240 Bolt t 1
t 1 Press fit of bearing into
D11 793T-622-1360 Push tool Q
case and cover
1 793T-622-2560 Wrench t 1 N Q Measurement of
D12 differential torque under
2 01316-10616 Bolt t 2
no load
Press fit of outer races
D13 793T-615-1730 Spacer q 1 Q into bearing carrier
799-101-5230 Adapter t 1
1
07002-11423 O-ring t 1
D14 Check for oil leakage.
2 793-605-1001 Brake tester t 1
3 790-101-1102 Hydraulic pump t 1
Checking operation of
D15 799-301-1500 Oil leak tester kit t 1
piston
Commercially t 1
1 Puller
D16 available Removal of ring gear
2 790-201-1410 Plate t 1
Disassembly and 1 793T-622-2520 Block t 1 N Q
assembly of axle 2 790-101-2520 Screw t 1
housing assembly 3 791-112-1180 Nut t 1 Removal of axle shaft
D17 and bearing
4 790-101-2540 Washer t 1
5 790-101-2620 Leg t 2
6 790-101-2570 Plate t 4

50-14 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

New/Redesign
Necessity

Sketch
Details of work and

Q'ty
Work Symbol Part No. Part name
remarks

7 790-101-2560 Nut t 2
8 790-101-2740 Adapter t 2
Removal of axle shaft
D17 9 790-201-1410 Plate t 1 and bearing
10 790-101-2102 Puller assembly t 1
11 790-101-1102 Hydraulic pump t 1
1 790-101-2800 Bearing puller t 1
Removal of axle shaft
D18 2 793T-622-2530 Bolt t 2 Q bearing
3 01643-32060 Washer t 2
Disassembly and Press fit of outer races
assembly of axle D19 793T-622-2540 Spacer q 1 Q into axle housing
housing assembly Press fit of outer races
D20 793T-622-2550 Spacer q 1 Q into axle housing
1 793T-622-1330 Push tool t 1 Q Press fit of oil seal and
D21
2 793T-622-1340 Spacer t 1 Q bearing into axle shaft
1 793T-622-1370 Support t 2 Q Adjusting the installed
D22 position of oil seal
2 01010-50830 Bolt t 6
Press fit of axle shaft
D23 793T-622-2510 Spacer t 1 Q into bearing
D24 793T-622-1510 Holder t 1 Q Selection of shims
Disassembly and
assembly of axle
housing assembly Measurement of starting
D25 79A-264-0021 Push-pull scale q 1 torque
Disassembly and
assembly of
differential assembly
1 790-101-2300 Push puller t 1
2 793-520-2370 Push tool t 1
3 793-520-2350 Push tool t 1
Removal and t
4 793-520-2540 Guide 1 Installation of upper
installation of center E1
5 793-520-2360 Bar t 2 hinge pin
hinge pin
6 791-112-1180 Nut t 2
7 790-101-1102 Hydraulic pump t 1
8 790-101-2102 Puller (30 ton) t 1
1 790-502-1003 Repair stand t 1 Disassembly and
F1 assembly of hydraulic
2 790-101-1102 Hydraulic pump t 1 cylinder assembly
Socket
For steering cylinder
F2 790-302-1280 (width across flats: t 1
piston nut
55 mm)
1 790-330-1100 Wrench assembly t 1 For steering cylinder
Disassembly and F3
2 790-102-2304 Wrench assembly t 1 cylinder head
assembly of hydraulic
cylinder assembly 1 790-102-4300 Wrench assembly t 1 For lift cylinder and
F4 bucket cylinder piston
2 790-102-4310 Pin t 1
1 790-720-1000 Expander t 1
2 796-720-1650 Ring t 1
F5 3 07281-01029 Clamp t 1 For piston ring assembly
4 796-720-1680 Ring t 1
5 07281-01589 Clamp t 1

WA470-7 50-15
50 Disassembly and assembly
General information on disassembly and assembly

New/Redesign
Necessity

Sketch
Details of work and

Q'ty
Work Symbol Part No. Part name
remarks

1 790-201-1500 Push tool kit t 1


2 790-101-5021 • Grip 1
3 01010-50816 • Bolt 1
F6 For cylinder dust seal
4 790-201-1570 • Plate 1
5 790-201-1990 Plate t 1
Disassembly and
6 790-201-1660 • Plate 1
assembly of hydraulic
cylinder assembly 1 790-201-1702 Push tool kit t 1
2 790-101-5021 • Grip 1
3 01010-50816 • Bolt 1 For cylinder head
F7 bushing
4 790-201-1761 • Push tool 1
5 790-201-1930 • Push tool 1
6 790-201-1851 • Push tool 1
Removal and 1 793-498-1120 Clear plate t 2
installation of X2 2 793-498-1130 Plate t 2 Installation of operator's
operator's cab glass Magnet t 2
3 793-498-1110 cab glass
(adhered window
glass) X3 793-498-1210 Lifter (suction cup) t 2

50-16 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Sketches of special tools (WA470-3531-066-A-00-A)

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A6: Bracket

A8: Push tool

WA470-7 50-17
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A11-1: Push tool

A11-2: Guide bolt

50-18 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A11-3: Push tool

A11-4: Push tool

WA470-7 50-19
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A11-5: Guide

A11-6: Spacer

50-20 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A15: Push tool

A16: Installer

WA470-7 50-21
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B1: Bracket

B2: Plate

50-22 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B3: Plate

B5: Lifting tool

WA470-7 50-23
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B6: Lifting tool

B6: Bar

50-24 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B7: Plate

B7: Push tool

WA470-7 50-25
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B8: Bracket

B8: Plate

50-26 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B9: Bolt

B10: Sleeve

WA470-7 50-27
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B15: Push tool

B16: Push tool

50-28 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B18: Push tool

B19: Push tool

WA470-7 50-29
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B20: Push tool

B23: Push tool

50-30 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B24: Push tool

B29: Push tool

WA470-7 50-31
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B30: Spacer

B31: Push tool

50-32 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B32: Spacer

B33: Plate

WA470-7 50-33
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B38: Spacer

B48: Push tool

50-34 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B49: Seal holder

B50: Push tool

WA470-7 50-35
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B52: Seal holder

B53: Push tool

50-36 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
B54: Seal holder

D1-3: Plate

WA470-7 50-37
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D2: Eyebolt

D4-1 and D13: Spacer

50-38 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D5-2: Spacer

D7-2: Push tool

WA470-7 50-39
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D9-1 and D10-1: Push tool

D10-2: Spacer

50-40 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D11: Push tool

D12-1: Wrench

WA470-7 50-41
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D17-1: Block

D18-2: Bolt

50-42 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D19: Spacer

D20: Spacer

WA470-7 50-43
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D21-1: Push tool

D21-2: Spacer

50-44 WA470-7
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D22-1: Support

D23: Spacer

WA470-7 50-45
50 Disassembly and assembly
General information on disassembly and assembly

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
D24: Holder

50-46 WA470-7
50 Disassembly and assembly
Engine and cooling system

Engine and cooling system (ALL-R401-001-K-00-A)

Removal and installation of supply pump assembly (WA470-AD70-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

1 795-630-5500 Standard puller t 1


2 01010-81090 Bolt t 2
A
3 01643-31032 Washer t 2
4 6212-82-0110 Wrench t 1

k Place the machine on a level ground, and


turn the parking brake switch to ON position.
3. Remove case (6) of KCCV ventilator. [*1]
k Set the frame lock bar to LOCK position, and 4. Remove oil filler pipe (7).
chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling battery
disconnect switch".)
5. Disconnect fuel hose (8).
a When removing or installing fuel piping, be 6. Remove overflow valve (9). [*2]
careful that foreign matter does not enter in it. If 7. Remove cover (10).
any dirt or dust sticks the parts of the fuel system, 8. Remove bolt (11), loosen bolt (12), and slide
clean it off thoroughly with clean fuel. cover (13) to the right side.
Removal (WA470-AD70-520-K-00-A) a Bolts (12) cannot be removed.
1. Open full-length fender (1) and side cover (2). 9. Remove joint bolt (14). [*3]
10.Remove all the clamps of fuel tube (15), and
slide fuel tube (15).

2. Disconnect connectors PCV1 (3), PCV2 (4) and


G (5).

WA470-7 50-47
50 Disassembly and assembly
Engine and cooling system

17.Remove the supply pump lower brackets (26)


and (27).

11.Remove joint bolt (16), and disconnect fuel tube


(17). [*4]
12.Remove joint bolt (18), and disconnect fuel tube 18.Remove rubber cover (28) on the front side of
(19). [*4] the engine.
a Identify the installation positions of joint bolts
(16) and (18).
13.Remove fuel tube (20). [*5]

19.Rotate the crankshaft forward (in the direction of


the arrow) by using crank pulley mounting bolt
(29), and align the center point (a) between "2.5
14.Remove lubrication tube (21) and bracket (21- TOP" and "3.4 TOP" stamp lines on damper (30)
1). with pointer (31).
15.Remove fuel spray prevention caps (22) and a At this time, the stamp line of "1.6 TOP" is
(23). almost at the bottom.
16.Remove high-pressure fuel pipes (24) and (25).
• Width across flats of crank pulley mounting
bolt: 24 mm

50-48 WA470-7
50 Disassembly and assembly
Engine and cooling system

23.Loosen nut (35) by approximately 2 turns.

24.Install tools A1, A2, and A3.


25.Tighten the center bolt of tool A1, and separate
supply pump drive gear (36) from shaft (37).
26.Remove A1, A2, and A3, and remove nut (35).
27.To prevent supply pump drive gear (36) from
falling off, install A1, A2, and A3 again.

20.Open cover (32).

21.Remove cover (33). [*6]

28.Remove mounting bolts (38) (4 pieces), and


remove supply pump assembly (39).

22.Check that the supply pump drive gear forcing


tap is aligned with cover mounting bolt hole (34)
as described above. If it is not aligned with the
bolt hole, rotate the crankshaft 1 more turn.

WA470-7 50-49
50 Disassembly and assembly
Engine and cooling system

Installation (WA470-AD70-720-K-00-A)

a Observe the following about fuel high-pressure


pipes.
k KOMATSU recommend to use the Komatsu
genuine fuel high-pressure pipe clamps and
observe the tightening torque indicated.

k Do not bend the fuel high-pressure pipe to


correct before installing.

k Before installing the fuel high-pressure pipe,


check it for the following.
3. Finger-tighten mounting bolts (38) (4 pieces).
If the fuel high-pressure pipe has any defect,
replace it with a new one since fuel may leak. a When reusing mounting bolt (38), apply the
adhesive (LT-2) to the threaded part.
• Check that the taper seal portion of the
connection (portion (a): 2 mm area from 2 Mounting bolt (38):
the tip-end) is free from visually Adhesive (LT-2)
recognizable longitudinal slits (b) or 4. Remove tools A1, A2 and A3.
spotty dents (c). 5. Check that shaft key (40) of the supply pump is
• Make sure that part (d) (end of taper seal: aligned with the keyway of the drive gear, and
2 mm from the tip-end) is free from steps then install nut (35).
which can be felt by your fingernail.
(Namely, this portion must be free from 3 Mounting nut (35):
fatigue.) 176 to 196 Nm {18 to 20 kgm}
6. Install brackets (26) and (27) by finger-tightening
the bolt.

1. When supply pump assembly (39) is the state


shown in the figure, make sure that shaft key
(40) faces directly above.
2. Install supply pump assembly (39), aligning shaft
key (40) with keyway (a) on the gear.

50-50 WA470-7
50 Disassembly and assembly
Engine and cooling system

17.Fasten clamps (47) and (48) to the specified


torque.
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
18.Tighten mounting bolts (49) of bracket (21-1) to
the specified torque.
19.Tighten mounting bolts (50) of bracket (45) to
the specified torque.
20.Tighten mounting bolts (51) of bracket (46) to
the specified torque.
21.Tighten bolt (52) to the specified torque.
22.Install lubrication tube (21) to the specified
torque.
3 Joint bolt
(cylinder block side):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
(Supply pump side):
7.9 to 12.7 Nm {0.8 to 1.3 kgm}
23.Tighten mounting bolts (53) of bracket (43) to
the specified torque.
24.Tighten mounting bolts (54) of bracket (44) to
the specified torque.

7. Fasten fuel high-pressure pipes (24) and (25) by


hands.
8. Install the preceding fuel high-pressure pipe
clamp and bracket by finger-tightening the bolt.
9. Fasten lubrication tube (21) by hands.
10.Tighten sleeve nuts of fuel high-pressure pipes
(24) and (25) to the specified torque.
3 Sleeve nut
(both common rail side and supply
pump side):
39.2 to 44.1 Nm {4 to 4.5 kgm}
11.Tighten supply pump mounting bolts (38) to the
specified torque.
3 Mounting bolt (38):
59 to 74 Nm {6.0 to 7.5 kgm}
12.Tighten the mounting bolts (2 pieces) of bracket
(26) at supply pump side to the specified torque.
3 Supply pump side mounting bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
13.Tighten bolts (41) and (42) in this order to the
specified torque.
14.Install fuel spray prevention caps (22) and (23).
a Install the cap with its slit facing as follows. 25.Perform the subsequent installation in the
• Fuel spray prevention cap (22): reverse order to removal.
Cylinder block side [*1]
• Fuel spray prevention cap (23): Downward a Tighten case (6) fully by hands, and retighten it
15.Install brackets (43), (44), (45), (46) and (21-1) by 1/15 to 2/15 turns (1 to 2 ribs of ring) by using
by finger-tightening the bolt. tool A4.
16.Fasten clamps (47) and (48) by hands.

WA470-7 50-51
50 Disassembly and assembly
Engine and cooling system

3 Case (6) (reference value):


36.6 to 44.7 Nm {3.7 to 4.6 kgm}

[*2]
3 Overflow valve (9):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*3]
3 Joint bolt (14):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
[*4]
a Install joint bolts (16) and (18) while confirming
discrimination mark put at disassembly.
3 Joint bolts (16) and (18):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*5]
3 Joint bolt of fuel tube (20) (supply pump
side):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
3 Joint bolt of fuel tube (20) (fuel filter
side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*6]
3 Cover (33) mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}
• Air bleeding
Bleed air in the fuel system. For details, see
Testing and adjusting, "Bleeding air in circuit".
• Checking for fuel leakage
Check for fuel leakage. For details, see Testing
and adjusting, "Testing fuel circuit for leakage".

50-52 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of injector assembly (WA470-AE60-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

A4 6212-82-0110 Wrench t 1

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.
5. Remove case (3) of KCCV ventilator, fuel filter
k Lower the work equipment to the ground, (4), fuel prefilter (5), and oil filter (6). [*1]
and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling battery
disconnect switch".)

a When removing or installing fuel piping, be


careful not to let foreign matter enter. If any dirt
or dust sticks on the parts of the fuel system,
clean it off thoroughly with clean fuel. 6. Disconnect following connectors and move the
wiring harness.
Removal (WA470-AE60-520-K-00-A) • G(7)
1. Remove the KDPF assembly. For details, see • PCV1(8)
"Removal and installation of KDPF assembly". • PCV2(9)
2. Remove the air cleaner assembly. For details, • POIL(10)
see "Removal and installation of air cleaner • SEGR(11)
assembly". • EGR-SOL(12)
3. Remove clamps (1) (3 places). • VGT-SOL(13)
• PCCV(14)
• PIM(15)

4. Sling and remove bracket (2).

4 Bracket (2):
40 kg

WA470-7 50-53
50 Disassembly and assembly
Engine and cooling system

9. Remove spill tube (23-1). [*2]


10.Disconnect fuel injector connectors (24) (6
places).
a Disconnect fuel injector connectors
according to the following procedure.
1) Apply flat-head screwdriver [1] to stepped
part (a) and push stopper (b).
2) Move flat-head screwdriver [1] in direction x
to disconnect connector (c).

• VGT-REV(16)
• SVGT(17)
• PDOSER(18)
• SOV1(19)
• SOV2(20)
7. Remove bracket (21).
8. Remove tubes (22) and (23).

11.Remove mounting bolts (26) of bracket (25).


12.Remove bracket (27) and clamp inside.
13.Remove fuel high-pressure pipe clamps (28) (4
pieces) and (29) (6 pieces).

50-54 WA470-7
50 Disassembly and assembly
Engine and cooling system

19.Remove mounting bolts (38) to remove rocker


arm and shaft assembly (39).
a Loosen lock nuts (40), and then loosen
adjustment screws (41) thoroughly so that
excessive force does not apply to the push
rods when the rocker arms are installed.

14.Remove fuel spray prevention caps (30) and


(31) (6 pieces each).
a Figure shows the state without surrounding
parts for explanation. (Mixing connector does
not need to be removed.)
15.Remove fuel high-pressure pipes (32) (6
pieces). 20.Remove injector assembly (42).
16.Remove cylinder head covers (33) (6 pieces). a Before removing the injector, record the
cylinder number to be removed and the
character string (M) listed on the QR code
tab (Q) on the injector as a set.
a Read character string (M) in the order of the
arrow shown in the figure.
a Be sure to check that the recorded character
string is correct.
a Do not damage and remove QR code tab (Q)
attached to the injector head.
(Reference: The QR code or character string
indicates the compensation value for fuel
17.Loosen nut (34) (2 pieces) thoroughly. injection of the injector, which is specific to
each injector.)
a Loosen the nuts alternately.
18.Remove mounting bolt (36) of holder (35) and
then reposition injector harness (37) out of the
way.

WA470-7 50-55
50 Disassembly and assembly
Engine and cooling system

Installation (WA470-AE60-720-K-00-A)

a Wash off and remove dirt and dust attached on


the parts near harness connectors to prevent
them from entering connectors.
a Use clean engine oil when applying engine oil to
O-rings and lubricated portions.
1. When replacing the injector assembly or engine
controller assembly, write the character string
into the engine controller according to the
following procedure. For details, see Testing and
adjusting, "Writing compensation values at
replacement of injector and engine controller".
1) Remove mounting bolt (44) of holder (43). 1) Note the number of cylinder to which a new
injector is installed and character string (M)
listed on the QR code tab at the top of the
injector as a set.
a Read character string (M) in the order
indicated by the arrow in the figure.
a Be sure to check that the noted character
string is correct.
2) Write the noted character string into the
engine controller.
a Be sure to write the noted character string
into the cylinder number column of the
2) Insert "L" shaped bar [1] into inlet connector cylinder to which the injector is installed.
(a) of the injector, and then pry up injector a If the character strings are not written
assembly (42). correctly, the engine may not operate
a Never grip the solenoid valve at the top of normally.
the fuel injector with pliers, etc. to pull out (Reference: The QR code or character
the injector. string indicates the difference of
3) Remove injector assembly (42) and holder compensation value for fuel injection of
(43) as a unit. the injector, which is specific to each
injector.)

50-56 WA470-7
50 Disassembly and assembly
Engine and cooling system

insertion portion, and lightly tighten it so that


it matches to inlet connector (c).
a Lightly tighten sleeve nut on the common
rail side.
6) Tighten holder (43) to the specified torque.
a While pulling the pipe of high-pressure
fuel pipe in the opposite direction of the
injector, tighten mounting bolt (44).
3 Holder mounting bolt (44):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
a Separate high-pressure fuel pipe after
tightening holder.

2. Install the injector assembly according to the


following procedure.
1) Check that the injector assembly mounting
bore in the cylinder head is free from dust.
2) Install gasket (45) and O-rings (46) and (47)
to injector assembly (42).
a Install O-ring (46) to groove (a). Do not
install it to groove (b).
2 O-ring:
Engine oil
3) Insert holder (43) to injector assembly (42),
then insert it further into the injector
assembly mounting hole.
a Refer to the cylinder number recorded
when removed it, install the correct
injector.
a Be careful not to damage QR code tab
attached to the top of the injector
assembly (42) and do not remove it.
a Align inlet connector (c) with high-
pressure fuel pipe insertion portion of the
rocker housing.
4) Install the spherical washer (48) to bolt (44)
and lightly tighten holder (43).
2 Spherical washer (48):
Engine oil
5) Insert sleeve nut (49) of the high-pressure
fuel pipe to the high-pressure fuel pipe

WA470-7 50-57
50 Disassembly and assembly
Engine and cooling system

3. Install locker arm and shaft assembly according 5. Install the O-ring and cylinder head cover (33).
to the following procedure.
a Installing the O-ring without a twist.
1) Set rocker arm and shaft assembly (39).
3 Mounting bolt:
a Install the rocker arm shaft (50) with its
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
larger mounting hole end down and with
its ball plug (51) side facing to front of
engine.
2) Check that the ball of adjustment screw (41)
is fitted in push rod socket (52) and tighten
mounting bolt (38).
a Clean the oil hole of mounting bolt (38)
and install it.
3 Mounting bolt (38):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3) Adjust the valve clearance. For details, see
Testing and adjusting, "Testing and adjusting
valve clearance". 6. Install the high-pressure fuel pipes according to
the following procedure.

k KOMATSU recommends to use the


Komatsu genuine high-pressure fuel pipe
clamps and observe the tightening torque
indicated.

k Do not bend the fuel high-pressure pipe


to correct before installing.

k Before installing the fuel high-pressure


pipe, check it for the following.
4. Install the injector harness (37) according to the If the high-pressure fuel pipe has any
following procedure. defect, replace it with a new one since
1) Tighten holders (35) with bolts (36). fuel may leak.
• Check that the taper seal portion of the
3 Bolt (36): connection (portion (a): 2 mm area
27 to 34 Nm {2.8 to 3.5 kgm} from the tip-end) is free from visually
2) Set the harness terminal to the top of the recognizable longitudinal slits (b) or
injector and tighten 2 nuts (34) alternately. spotty dents (c).
3 Nut (34): • Be sure that part (d) (2 mm from the
tip-end) is free from steps which can
2.0 to 2.4 Nm {0.2 to 0.24 kgm} be felt by your fingernail. (Namely, this
portion must be free from fatigue.)

50-58 WA470-7
50 Disassembly and assembly
Engine and cooling system

1) Finger-tighten sleeve nuts of fuel high-


pressure fuel pipe (32).
a Loosen all clamps of the high-pressure
fuel pipe.
2) Tighten sleeve nut of high-pressure fuel pipe
(32) to the specified torque.
3 Sleeve nut (for both sides):
39.2 to 44.1 Nm {4 to 4.5 kgm}
3) Install fuel spray prevention caps (30) and
(31) to each high-pressure fuel pipe.
a When installing the cut-out portion, face it
as follows.
• Fuel spray prevention cap (31):
Downward
• Fuel spray prevention cap (30): Toward
cylinder block
4) Finger-tighten all the following clamps and
brackets.
• Clamps (29) (6 pieces)
• Bracket (53) (5 pieces)
• Brackets (54) and (27)
5) Fasten clamp (29) to the specified torque.
3 Mounting bolt:
7. Perform the subsequent installation in the
11.8 to 14.7 Nm {1.2 to 1.5 kgm} reverse order of removal.
6) Install brackets (53) and (54) to the specified [*1]
torque.
7) Finger-tighten four clamps (28). a Tighten case (3) of KCCV ventilator until it
8) Finger-tighten clamp (55) and bracket (27) cannot be rotated by hands and then use tool
and install it to the specified torque. A4 to retighten it by 1/15 to 2/15 turn (1 to 2
threads of ring rib).
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm} 3 Case (3) (reference value):
9) Install bracket (27) to the specified torque. 36.6 to 44.7 Nm {3.7 to 4.6 kgm}
10)Install clamp (28) to the specified torque.
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

WA470-7 50-59
50 Disassembly and assembly
Engine and cooling system

a After the packing contacts the seal surface,


tighten the filters (4) to (6) as follows.
• Fuel filter (4): 3/4 turn
• Fuel pre-filter (5): 1/2 to 3/4 turn
• Oil filter (6): 3/4 to 1 turn
2 Packing: Engine oil
[*2]
3 Joint bolt of spill tube (23-1):
9.8 to 12.7 Nm {1.0 to 1.3 kgm}
• Air bleeding
Bleed air in the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
• Checking for fuel leakage
Check for fuel leakage. For details, see
Testing and adjusting, "Testing fuel circuit for
leakage".

50-60 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of fuel doser assembly (WA470-A9H6-924-K-00-A)

k Place the machine on a level ground and turn


the parking brake switch to ON position.

k Set the frame lock bar to LOCK position and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF Installation (WA470-A9H6-720-K-00-A)


position, and remove the key. (For details,
see Testing and adjusting, "Handling battery 1. Install heat insulator (10) to fuel doser assembly
disconnect switch".) (8).
2. Insert bolts (7) into fuel doser assembly (8),
Removal (WA470-A9H6-520-K-00-A) install gasket (9) to the fuel doser assembly, and
then install them to the exhaust connector.
1. Open full-length fender (1), and side cover (2).
3 Bolt (7) (width across flats 8 mm):
8.5 to 9.5 Nm {0.87 to 0.97 kgm}
a Bolt (7), gasket (9) and heat insulator (10) to
be used must be new ones.

2. Disconnect connector DOSER (3).


3. Remove clamps (4) (3 pieces).
4. Disconnect fuel hose (5). [*1]
5. Disconnect coolant hose (6). [*2]
6. Remove bolts (7) (2 pieces) (8 mm of width
across flats), and remove fuel doser assembly
a Install gasket (9) so that its stepped portion
(8).
becomes convex against the exhaust
connector.

3. Perform subsequent installation in the reverse


order of removal.

WA470-7 50-61
50 Disassembly and assembly
Engine and cooling system

[*1]
3 Sleeve nut of fuel hose (5):
14.7 ± 4.9 Nm {1.5 ± 0.5 kgm}
[*2]
3 Joint bolt of coolant hose (6):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
a After installing the fuel doser assembly, run the
engine at low idle for approximately 3 minutes.
Then stop the engine and check the fuel doser
for water and fuel circuits for leakage.

50-62 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of cylinder head assembly (WA470-A100-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

5790-331-1110 Wrench q 1
793T-601-1410 Bracket t 1
A 01011-81040 Bolt t 2
6
01643-31032 Washer t 2
01580-01008 Nut t 2

k Place the machine on a level ground, and


turn the parking brake switch to ON position. 6. Remove tubes (3) and (4). [*1]

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of 7. Remove the following connectors, and remove
battery disconnect switch".) the wiring harness.
• G (5)
Removal (WA470-A100-520-K-00-A)
• PCV1 (6)
1. Drain the coolant. • PCV2 (7)
• POIL (8)
6 Radiator: 75 l
2. Remove engine hood assembly. For details, see
"Removal and installation of engine hood
assembly".
3. Remove the KDPF assembly. For details, see
"Removal and installation of KDPF assembly".
4. Remove clamps (1) (3 pieces).

• VGT-SOL (9)

5. Sling bracket (2), and remove it.

4 Bracket (2):
40 kg

WA470-7 50-63
50 Disassembly and assembly
Engine and cooling system

• SEGR (10) 9. Remove tubes (23) and (24). [*2]


• EGR-SOL (11) 10.Remove brackets (25) and oil filter (26) together
as a unit.

• INJ (12)
• DOSER (13) 11.Disconnect hose (27), and remove fuel prefilter
• PAMB (14) (28). [*3]
• SVGT (15) 12.Remove fuel tubes (29) and (30). [*4]
• VGT-REV (16) 13.Remove filter head assembly (31).
• PDOSER (17)
• SOV1 (18)
• PCCV (19)

14.Remove tube (32).


15.Remove fuel tube (33). [*5]
16.Remove dosing valve (34). [*6]
8. Remove covers (20) to (22). 17.Remove fuel tube (35). [*6]
18.Remove fuel tube (36). [*7]
19.Remove fuel tubes (37) and (38). [*8]
a To disconnect fuel tube (38) on the priming
pump side, remove joint bolt (40) with nut
(39) fixed.

50-64 WA470-7
50 Disassembly and assembly
Engine and cooling system

24.Remove air conditioner compressor belt (47).


For details, see "Removal and installation of air
conditioner compressor belt". [*11]
25.Remove the clamp of tubes (44) and (45).
26.Disconnect connector E10 (50), and tilt air
conditioner compressor (51) forward.

27.Disconnect terminal E07B (52). [*12]


28.Remove the clamp and move the wiring harness
(53).

20.Remove filter head (41), and fuel filter (42)


together as a unit.

29.Remove tubes (54) and (55). [*13]


30.Remove EGR valve assembly (56).

21.Disconnect hose (43). [*9]


22.Remove the clamp and joint bolt of tubes (44)
and (45). [*10]
23.Remove KCCV assembly (46).

31.Remove bracket (57).

WA470-7 50-65
50 Disassembly and assembly
Engine and cooling system

4 Mixing connector (63):


40 kg

32.Disconnect hose (58) on the aftercooler side.


[*14]
33.Remove mounting bolts (59) to (61) (2 pieces
each) of air intake connector. 36.Remove oil filler pipe (64).
37.Remove the injector assembly. For details, see
"Removal and installation of injector assembly".

38.Remove tube clamp (65) at the rear of the air


intake manifold.
39.Disconnect connector TIM (66).

34.Remove clamp (62).

40.Remove mounting bolts (24 pieces), and


remove air intake manifold (67). [*15]

4 Air intake manifold (67):


30 kg

35.Sling mixing connector (63), and remove it.

50-66 WA470-7
50 Disassembly and assembly
Engine and cooling system

41.Remove exhaust tube (68). [*16] 47.Remove covers (81) and (82).

42.Disconnect connector DOSER (69), and remove


the clamp of the wiring harness.
43.Remove the clamp of tubes (70) and (71).
44.Loosen clamp (72), and remove hose (73),
connector (74) and bracket (75) together as a
unit. [*17]

48.Remove brackets (83) and (84). [*20]

45.Remove hose (76). [*18]


46.Remove tube (77), hose (78) and brackets (79)
and (80) together as a unit. [*19]

49.Remove tubes (85) to (88). [*21]


a To remove tube (88), remove joint bolts (88-
1).

WA470-7 50-67
50 Disassembly and assembly
Engine and cooling system

50.Remove tubes (89) and (90). [*22] 55.Remove bracket (97).


56.Remove tubes (98) and (99). [*23]
57.Remove tube (100). [*24]
58.Remove tube (101). [*25]

51.Remove tube (91).

59.Remove cover (102).

52.Remove EGR cooler assembly (92).

60.Disconnect hoses (103) to (105), and remove


tubes (106) to (108). [*26]
61.Remove tube (109). [*27]

53.Remove clamp (93), and remove bracket (94).


54.Remove clamp (95), and remove bracket (96).

50-68 WA470-7
50 Disassembly and assembly
Engine and cooling system

65.Remove tube (115). [*30]


66.Remove brackets (116) to (120).

62.Remove clamps (110) and (111), and remove


bracket (112). [*28]
67.Remove head cover (121).
a The head cover has been already removed
in "Removal and installation of injector
assembly". Note that it has been installed
loosely to prevent foreign material from
entering.

63.Sling the KVGT assembly and exhaust manifold.


64.Remove the exhaust manifold mounting bolt,
and then remove KVGT assembly (113) and
exhaust manifold (114) together as a unit. [*29]

4 KVGT assembly and exhaust


manifold:
68.Remove push rod (122). [*31]
55 kg 69.Remove crossheads (123). [*32]

WA470-7 50-69
50 Disassembly and assembly
Engine and cooling system

a Install the cylinder head assembly aligning its


dowel hole to the dowel pin.
2. Tighten the cylinder head mounting bolts.
1) Check the mounting bolts on following
conditions. If any bolt meets either condition,
do not use it but replace it with a new one.
• The number of tightening times reaches 6
times (5 punch marks).
• Stem length (a) of bolt: 171.4 mm or
above

70.Remove rocker housing (124). [*33]

2) Tighten the mounting bolts from 1 to 6 in


order.

71.Remove mounting bolts, sling cylinder head 2 Cylinder head mounting bolt
assembly (125), and remove it. (threaded part and seat surface):
Molybdenum disulphide lubricant
4 Cylinder head assembly (125): (LM-P) or engine oil
20 kg 3 Cylinder head mounting bolt:
1st time: 98 ± 9.8 Nm {10 ± 1 kgm}
2nd time: 166.6 to 176.4 Nm {17 to
18 kgm}
(Target: 176.4 Nm {18 kgm})
3rd time: By using tool A5,
retighten the bolt by 90 to 120
degrees.
(Target: 120 degrees)

Installation (WA470-A100-720-K-00-A)

1. Install the cylinder head assembly.


a Place the cylinder head gasket on the
cylinder block after checking that the cylinder
head mounting face on the cylinder block
and the inside of each cylinder is free from
dust or foreign matters.
a When installing the cylinder head gasket,
check that the grommets do not peel off or
are not lost.

50-70 WA470-7
50 Disassembly and assembly
Engine and cooling system

3 Hose clamp:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*2]
a Install tubes (23) and (24) according to the
following procedure.
1. Tighten the mounting bolts of the oil filter bracket
lightly.
2. Install tubes (23) and (24), and tighten bolt (A)
and (B) lightly.
3. Tighten bolts (B) and (A) in this order to the
specified torque.
4. Tighten the mounting bolts of the oil filter bracket
a If tool A5 is not used, put mark (b) on to the specified torque.
cylinder head and bolt with paint etc., and 5. Install cushion (C) and fasten clamp (D).
retighten bolt by 90 to 120 degrees a Install cushion (C) so that slit position (a)
(target 120 degrees). faces outside of clamp (D).
3) After tightening, put a punch mark (c) on
each bolt head to indicate the number of
tightening.
a When a new bolt is used, do not put a
punch mark on its head.

4) Tighten cylinder head auxiliary bolt (7).


3 Cylinder head mounting auxiliary
bolt (7):
58.8 to 73.5 Nm {6.0 to 7.5 kgm}

[*3]
a After the packing touches the seal surface,
tighten fuel prefilter (28) by 1/2 to 3/4 turns.
2 Packing: Engine oil
[*4]
a Install tubes (29) and (30) according to the
following procedure.
1. Loosen elbow (A) at filter head side and elbow
(B) at merge-divider block side in advance.
3. Perform the subsequent installation in the
2. Install tubes (29) and (30), and fasten the sleeve
reverse order to removal.
nuts on both ends.
[*1]

WA470-7 50-71
50 Disassembly and assembly
Engine and cooling system

3 Sleeve nut:
43 to 47 Nm {4.4 to 4.8 kgm}
3. Secure elbows (A) and (B) to prevent them from
rotation, and tighten the nuts.
3 Nut:
84 to 132 Nm {8.5 to 13.5 kgm}

a Tighten the overflow valve at supply side of fuel


tube (35) to the following torque.
3 Overflow valve:
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
[*7]
3 Joint bolt of fuel tube (36) (supply pump
side):
14.8 to 19.6 Nm {1.5 to 2.0 kgm}
3 Joint bolt of fuel tube (36) (fuel filter
side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*8]
3 Joint bolts at dosing valve side of fuel
tubes (37) and (38):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolt of fuel tube (37) (fuel filter side
[*5] and aggregate block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolts of fuel tube (33) (both sides):
7.8 to 9.8 Nm {0.8 to 1.0 kgm} a Tighten joint bolt (40) at priming pump side of
fuel tube (38) with nut (39) secured.
[*6]
3 Joint bolt (40):
a Tighten joint bolts (A) and (B) to the following
torque. 11.6 to 13.6 Nm {1.2 to 1.4 kgm}

3 Joint bolt (A) (M10 x 1.0):


9.8 to 12.7 Nm {1.0 to 1.3 kgm}
3 Joint bolt (B) (M12 x 1.5):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}

[*9]
3 Hose clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}

50-72 WA470-7
50 Disassembly and assembly
Engine and cooling system

[*10]
3 Joint bolt of tubes (44) and (45) (cylinder
block side):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Joint bolt of tubes (44) and (45) (KCCV
side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*11]
a Adjust the air conditioner compressor belt
tension. For details, see Testing and adjusting,
"Testing and adjusting air conditioner
compressor belt tension". [*15]
[*12] a Tighten the intake manifold mounting bolts in the
3 Terminal E07B(52): order shown in the figure.
5.88 to 7.84 Nm {0.6 to 0.8 kgm} 3 Air intake manifold mounting bolt:
[*13] 59 to 74 Nm {6.0 to 7.5 kgm}
3 Joint bolt of tube (54) (both ends):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Tube (55) joint bolt:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 Sleeve nut of tube (55):
24 to 27 Nm {2.4 to 2.7 kgm}
[*14]
a Install the hose and clamp at aftercooler side in
the dimensions as follows.
• Dimensions (a) and (b): 10 mm
• Dimension (c): 75 mm [*16]
• Angle (d): 35 degrees
a Install exhaust tube (68) according to the
3 Clamp: following procedure.
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} 1. Remove plug (A).

a Install the hose and clamp at intake connector 2. Install tool (A6) to exhaust connector (B).
side in the dimensions as follows. 3. Install exhaust tube (68) to exhaust connector
(B) loosely.
• Dimension (e): 75 mm
• Dimensions (f) and (g): 10 mm 2 Thread part of bolt at exhaust
connector side:
3 Clamp:
Seizure prevention compound (LC-G)
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

WA470-7 50-73
50 Disassembly and assembly
Engine and cooling system

4. Tighten bolts and nuts (C) (2 pieces) of KDPF 3 Clamp of hose :


side flange lightly. 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
5. Tighten nuts (D) (4 pieces) of flange at exhaust
connector side to the specified torque.
3 Nut (D):
78.5 to 88.3 Nm {8 to 9 kgm}
6. Remove tool A6.
7. Tighten plug (A) to the specified torque.
2 Threaded part of plug (A):
Seizure prevention compound (LC-G)
3 Plug (A):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}

a Install hose and clamp at aftercooler side in the


dimensions as follows.
• Dimension (d): 75 mm
• Dimensions (e) and (f): 10 mm

[*17]
a Set clamp (72) to level, adjust the direction of
clamp, and tighten it to the following torque.
3 Clamp (72):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*19]
a Install clamps (2 pieces) of hose (78) with its
screws to be same direction.
3 Clamp of hose (78):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*18]
a Install clamps (both ends) of hose with its
screws to be opposite direction (shifted by 180
degrees).
a Install hose and clamp at KVGT side in the
dimensions as follows.
[*20]
• Dimensions (a) and (b): 10 mm
• Dimension (c): 75 mm a Apply seizure prevention compound (LC-G) to
mounting bolts (A) of bracket (83).

50-74 WA470-7
50 Disassembly and assembly
Engine and cooling system

3 Mounting bolt (A): 2 Mounting bolt of bracket (112):


68.6 to 73.5 Nm {7 to 7.5 kgm} Seizure prevention compound (LC-G)
[*29]
a Install the exhaust manifold according to the
following procedure.
1. Install ring (114-4) to intermediate manifold (114-
1).
2 Both ends (a) of intermediate manifold
(114-1):
Heat-resistant sealant (HOLTS MH705
or equivalent)
2. Install manifolds (114-2) and (114-3) to
intermediate manifold (114-1).
3. Set the exhaust manifolds with the gasket to the
[*21]
intermediate manifold, and then finger-tighten all
3 Tube (85) mounting bolts (both ends): mounting bolts 2 or 3 threads.
59 to 74 Nm {6 to 7.5 kgm} 4. Tighten mounting bolts (A), (B), and (C) to the
specified torque, and then tighten other
3 Joint bolts (88-1): mounting bolts.
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Mounting bolt:
[*22]
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
3 Joint bolt of tubes (89) and (90):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*23]
3 Joint bolt of tubes (98) and (99):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Sleeve nut of tubes (98) and (99):
24 to 27 Nm {2.4 to 2.7 kgm}
[*24]
3 Tube (100) joint bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*25]
3 Tube (101) joint bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Sleeve nut of tube (101):
24 to 27 Nm {2.4 to 2.7 kgm}
[*26]
3 Hoses (103) and (104) and tube (106) joint
bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Sleeve nut of hose (105):
14.7 ± 4.9 Nm {1.5 ± 0.5 kgm} [*30]
[*27] 3 Tube (115) joint bolt:
3 Sleeve nut of tube (109): 9.8 to 12.7 Nm {1.0 to 1.3 kgm}
24 to 27 Nm {2.4 to 2.7 kgm} [*31]
[*28]
a Check that the tip of push rod is fitted in the
socket of cam follower securely.

WA470-7 50-75
50 Disassembly and assembly
Engine and cooling system

[*32]
a Adjust the crosshead according to the following
procedure.
1. Loosen lock nut (126) and back off adjustment
screw (127).
2. While pressing the top of crosshead (123) lightly,
tighten adjustment screw (127).
3. When adjustment screw (127) touches the valve
stem, tighten it further by 20 degrees.
4. With the adjustment screw in this position,
tighten lock nut (126).
2 Crosshead guide and top of
crosshead:
Engine oil
3 Lock nut (126):
58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}

[*33]
3 Rocker housing mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}
• Adjust the valve clearance. For details, see
Testing and adjusting, "Adjusting valve
clearance".
• Refilling of coolant (radiator)
Refill with the coolant to the specified level
through the water filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.

5 Radiator:
75 l

50-76 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of engine hood assembly (WA470-H540-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 5. Disconnect hose (4).


position, and remove the key. (For details, a Install a plug to the hose connection portion.
see Testing and adjusting, "Handling battery
disconnect switch".)

Removal (WA470-H540-520-K-00-A)

1. Remove the air cleaner assembly For details,


see "Removal and installation of air cleaner
assembly".
2. Remove cover (1).
a Remove the cover on the other side as well.

6. Remove the mounting bolts of cover (5).


a Do not remove cover (5) at this time.

3. Remove cover (2).

7. Sling the engine hood assembly.


8. Remove mounting bolts (6) (4 pieces) on the
hydraulic oil side.

4. Remove clamp (3).

WA470-7 50-77
50 Disassembly and assembly
Engine and cooling system

9. Remove mounting bolts (7) and (8). Installation (WA470-H540-720-K-00-A)

a Remove the mounting bolts on the other side • Perform installation in the reverse order of
as well. removal.

10.Sling engine hood assembly (9), and remove it.

4 Engine hood assembly:


300 kg
11.Remove cover (5).

50-78 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of grille assembly (WA470-H54E-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 3. Remove cover (3).


position, and remove the key. (For details, a Install the cover to prevent foreign matter
see Testing and adjusting, "Handling battery from entering air cleaner inlet (A) and KDPF
disconnect switch".) outlet (B).
Removal (WA470-H54E-520-K-00-A)

1. Remove caps (1) (8 pieces) of the engine upper


cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows.
a Do not remove the bolts marked with e.
(Otherwise the door hinge is removed and
adjustment during installation process
becomes difficult.)

4. Pull out frame (4) downward and remove it.

2. Sling and remove cover (2).

4 Cover (2):
70 kg 5. Open full-length fender (5) on the right and left
side of the machine body, and then open side
cover (6).

WA470-7 50-79
50 Disassembly and assembly
Engine and cooling system

6. Remove frame (7) on the left side of the 12.Remove mounting bolt (13) at the top of the
machine body. engine hood.
7. Remove clamp (8).
a Remove them on the other side in the same
8. Remove the mounting bolts of cover (9).
way.

9. Disconnect connector GR1 (10).


13.Open the grille at the rear of the machine body,
and remove mounting bolt (14).

10.Remove frame (11) on the right side of the


machine body.
14.Remove mounting bolt (15) at the bottom of the
11.Disconnect hose (12).
grille assembly.
a Remove them on the other side in the same
way.

50-80 WA470-7
50 Disassembly and assembly
Engine and cooling system

4 Grille assembly:
130 kg

15.Remove cover (16).


16.Remove clamp (17).

Installation (WA380-H54E-720-K-00-A)

• Perform installation in the reverse order to


removal.

17.Disconnect connectors R59 (18) and R89 (19).

18.Remove cap (20).

19.Sling grille assembly (21), and remove it.

WA470-7 50-81
50 Disassembly and assembly
Engine and cooling system

Removal and installation of cooling system assembly (WA470-B000-924-K-00-A)

k Place the machine on a level ground, and 7. Remove brackets (5) and (6).
turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details, 8. Disconnect hose (7) on the right side of the
see Testing and adjusting, "Handling battery machine.
disconnect switch".)

Removal (WA470-B000-520-K-00-A)

1. Drain the coolant.

6 Radiator:
75 l
2. Remove the grille assembly. For details, see
"Removal and installation of grille assembly".
3. Remove the aftercooler. For details, see
"Removal and installation of aftercooler."
4. Disconnect radiator lower hose (1). [*1]
5. Disconnect hose (2) from hydraulic oil cooler
piping. 9. Remove clamp (8) on the left side of the
machine.

10.Disconnect radiator upper hoses (9) and (10).


[*2]

6. Disconnect hoses (3) and (4).

50-82 WA470-7
50 Disassembly and assembly
Engine and cooling system

a Install hose and the clamp in the dimensions as


follows.
• Dimensions (a) and (b): 10 mm
• Dimension (c): 65 mm
• Dimension (d): 5 mm
• Dimension (e): 8.8 mm
• Dimension (f): 53 mm
2 Hose insertion portion (both ends):
Liquid gasket (LG-10)
3 Clamp of hose (both end):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
11.Remove stay (11) and plates (12) at the bottom
of the fan guard.

[*2]
12.Remove the mounting bolts(3 pieces each) on
a When installing the clamps of hose (9), set the
the right and left, sling cooling system assembly
screws 180 degrees apart from each other in the
(13), and remove it.
dimensions as follows.
4 Cooling system assembly (13): • Dimension (a): 55.5 mm
• Dimension (b): 9 mm
400 kg • Dimension (c): 5 mm
2 Hose (9) insertion portion:
Liquid gasket (LG-10)
3 Clamp of hose:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

Installation (WA470-B000-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
a When installing the clamps of hose, set the
screws 180 degrees apart from each other, in
a Install hose (10) and the clamp in the
the direction as follows.
dimensions as follows.
• Radiator side: Toward the bottom
• Dimension (d): 12.5 mm
• Power train oil cooler side: Toward the top
• Dimension (e): 24 mm

WA470-7 50-83
50 Disassembly and assembly
Engine and cooling system

• Refilling of coolant (radiator)


Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.

5 Radiator:
75 l

50-84 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of radiator core assembly (WA470-B222-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 8. Sling radiator core assembly (13), and remove it.
position, and remove the key. (For details, a Remove the assembly on the other side in
see Testing and adjusting, "Handling battery the same way.
disconnect switch".)
4 Radiator core assembly (13):
Removal (WA470-B222-520-K-00-A)
40 kg
1. Remove the cooling system assembly (1) and
stably place it on block [1]. For details, see
"Removal and installation of cooling system
assembly".
2. Remove hoses (2) and (3). [*1]

Installation (WA470-B222-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
3. Disconnect hoses (4) to (6), and then remove
joint (7). a Install hose (3) and the clamp in the dimensions
4. Remove hose (8). [*2] as follows.
5. Remove plates (9) and (10). • Dimension (a): 28 mm
6. Remove bolt (11). • Dimension (b): 5 mm
3 Clamp:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

7. Remove mounting bolts (12).

WA470-7 50-85
50 Disassembly and assembly
Engine and cooling system

[*1] [*2]
a When installing the clamps of hoses (2) and (8),
set the screws 180 degrees apart from each
other, in the direction as follows.
• Hose (2): Toward the bottom
• Hose (8): Toward the top
a Install hoses (2), (8) and their clamps in the
dimensions as follows.
a The figure shows an example of hose (8). Note
that the dimensions are the same as those of
hose (2).
• Dimensions (a) and (d): 9 mm
• Dimensions (b) and (c): 4 mm
• Dimensions (e) and (f): 53.5 mm
2 Insertion portion (both ends) of hoses (2)
and (8):
Liquid gasket (LG-10)
3 Clamps (both ends) of hoses (2) and (8):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

50-86 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of aftercooler (WA470-A9A0-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 3. Remove air conditioner condenser assembly (1).
position, and remove the key. (For details, For details, see "Removal and installation of air
see Testing and adjusting, "Handling battery conditioner condenser assembly".
disconnect switch".) a Do not disconnect hoses (2) and (3)
4. Remove cover (4) and move air conditioner
Removal (WA470-A9A0-520-K-00-A)
condenser assembly (1) toward the engine side.
1. Remove caps (A) (8 pieces) of the engine upper
cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows.
a Do not remove the bolts marked with e.
(Otherwise, the door hinge is removed and
adjustment during installation process
becomes difficult.)

5. Remove bracket (1–1).

2. Sling cover (B), and remove it.

4 Cover (B):
70 kg

6. Disconnect hose (5). [*1]


7. Disconnect hose (6). [*2]

WA470-7 50-87
50 Disassembly and assembly
Engine and cooling system

Installation (WA470-A9A0-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
a When installing the clamps of hose, set the
screws 180 degrees apart from each other.
a Install hose and the clamp in the dimensions
as follows.
• Dimension (d): 75 mm
• Dimensions (e) and (f): 10 mm

8. Sling aftercooler (7), and remove mounting bolts 3 Clamp:


(4 pieces). 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
9. Slide aftercooler (7) to the left side of the
machine body, and place it on block [1]
temporarily.
10.Sling aftercooler (7) from the outside of the
engine hood again, and remove it.

4 Aftercooler:
25 kg

[*2]
a Install hose and the clamp in the dimensions
as follows.
• Dimensions (a) and (b): 10 mm
• Dimension (c): 75 mm
• Angle (d): 35 degrees
3 Clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

50-88 WA470-7
50 Disassembly and assembly
Engine and cooling system

WA470-7 50-89
50 Disassembly and assembly
Engine and cooling system

Removal and installation of hydraulic oil cooler (WA470-B8P0-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 7. Disconnect hose (11).


position, and remove the key. (For details,
see Testing and adjusting, "Handling battery
disconnect switch".)

Removal (WA470-B8P0-520-K-00-A)

1. Drain the hydraulic oil.

6 Hydraulic tank:
173 l
2. Open full-length fender (1) and side cover (2).
a Perform the same work on the opposite side.

8. Remove clamp (12).

3. Remove mounting bolt (3), and move case (4).


4. Disconnect hoses (5) and (6) on the cooling fan
motor side. 9. Remove mounting bolt (13) and remove
5. Remove clamp (7). hydraulic piping flange bolt (14).
6. Remove bolts (8) to (10), and move the bracket a Remove them on the other side in the same
and piping together as a unit. way. The positions of the mounting bolt and
of the hydraulic piping flange bolt on the
opposite side must be turned upside down.

50-90 WA470-7
50 Disassembly and assembly
Engine and cooling system

10.Pull out hydraulic oil cooler (15) from the right


side of the machine, and remove it.

Installation (WA470-B8P0-720-K-00-A)

• Perform installation in the reverse order of


removal.
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Hydraulic tank:
173 l

WA470-7 50-91
50 Disassembly and assembly
Engine and cooling system

Removal and installation of power train oil cooler assembly (WA470-B850-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 5. Open full-length fender (3) on the right and left
position, and remove the key. (For details, side of the machine body, and then open side
see Testing and adjusting, "Handling battery cover (4).
disconnect switch".)

Removal (WA470-B850-520-K-00-A)

1. Drain the coolant.

6 Radiator: 75 l
2. Drain the power train oil.

6 Transmission case: 65 l
3. Remove caps (1) (8 pieces) of the engine upper
cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows. 6. Disconnect hose (5). [*1]
a Do not remove the bolts marked with e. 7. Remove covers (6) to (8).
(Otherwise, the door hinge is removed and 8. Remove bolts (9) to (11) and move the bracket
adjustment during installation process and piping together as a unit.
becomes difficult.) 9. Disconnect hose (11-1).

4. Sling cover (2), and remove it.

4 Cover (1):
70 kg

50-92 WA470-7
50 Disassembly and assembly
Engine and cooling system

10.Remove bracket (12) (2 pieces) mounting bolts, 17.Remove mounting bolts (21).
and remove receiver drier (13). 18.Remove the clamps of hoses (22) and (23), and
11.Remove clamp (14), and disconnect hose (15). pull out power train oil cooler assembly (24) from
12.Disconnect hose (16). the hose. [*3]
13.Remove clamp (17), and move hose (16).
14.Disconnect hose (18).

19.Sling power train oil cooler assembly (24), and


place it on the left side of the machine body
15.Disconnect hose (19). temporarily.
16.Remove hose (20). [*2] 20.Sling power train oil cooler assembly (24) from
the outside of the engine hood, and remove it.

4 Power train oil cooler assembly (24):


30 kg

WA470-7 50-93
50 Disassembly and assembly
Engine and cooling system

a Install hose and the clamp in the dimensions as


follows.
• Dimensions (a) and (b): 10 mm
• Dimension (c): 65 mm
• Dimension (d): 5 mm
• Dimension (e): 8.8 mm
• Dimension (f): 53 mm
2 Hose insertion portion (both ends):
Liquid gasket (LG-10)
3 Clamp of hose (both end):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

Installation (WA470-B850-720-K-00-A)
[*3]
• Perform installation in the reverse order of
removal. a When installing the clamps of hose (22), set the
[*1] screws 180 degrees apart from each other.

a When installing the clamps of hose, set the a Install hose (22) and the clamp in the
screws 180 degrees apart from each other. dimensions as follows.
• Dimensions (a) and (b): 10 mm
a Install hose and the clamp in the dimensions as
• Dimension (c): 65 mm
follows.
• Dimension (d): 75 mm 2 Hose (22) insertion portion:
• Dimensions (e) and (f): 10 mm Liquid gasket (LG-10)
3 Clamp of hose (22):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*2]
a When installing the clamps of hose, set the
screws 180 degrees apart from each other, in • Refilling of oil
the direction as follows. Refill with oil to the specified level through the oil
• Radiator side: Toward the bottom filler port. Run the engine to circulate the power
• Power train oil cooler side: Toward the top

50-94 WA470-7
50 Disassembly and assembly
Engine and cooling system

train oil through the system. Then check the oil


level again.

5 Transmission case:
65 l
• Refilling with coolant
Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.

5 Radiator: 75 l

WA470-7 50-95
50 Disassembly and assembly
Engine and cooling system

Removal and installation of engine assembly (WA470-A000-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 5. Remove clamp (6) on the front right of the fuel
position, and remove the key. (For details, tank.
see Testing and adjusting, "Handling battery 6. Remove mounting bolt (7) of drain hose.
disconnect switch".)

Removal (WA470-A000-520-K-00-A)

1. Drain the coolant.

6 Radiator:
75 l
2. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
assembly".
3. Disconnect connectors ER2 (1), ER1 (2) and
ER3 (3) at the bottom of the hydraulic tank on
the left side of the machine body.
7. Disconnect hose (8). [*1]

4. Disconnect terminals (4) and (5) and remove the 8. Disconnect connector E28 (9).
harness clamp on the side of the engine on the 9. Remove fuel feed pump (10) and bracket (10)
left side of the machine body. together as a unit.
10.Remove cover (11).

50-96 WA470-7
50 Disassembly and assembly
Engine and cooling system

11.Disconnect fuel hoses (12) and (13). 16.Disconnect hose (21) and ground cable (22).

12.Remove clamps (14) and (15). 17.Disconnect hose (23).

13.Remove clamps (16) and (17). 18.Disconnect connector CAN1 (24) on the side of
14.Disconnect hose (18). the engine on the right side of the machine.

15.Disconnect terminal E07A (19) and connector 19.Disconnect hoses (25) to (27). [*2]
ER4 (20).

WA470-7 50-97
50 Disassembly and assembly
Engine and cooling system

23.Remove cover (32).

24.Sling damper (33), remove mounting bolts (6


pieces), and remove it. [*3]

4 Damper (33):
15 kg

20.Remove bracket (28).

25.Remove plate (34).

21.Remove upper clamp (29) between the engine


and transmission.
22.Remove U-bolt (30), and remove bracket (31).

50-98 WA470-7
50 Disassembly and assembly
Engine and cooling system

26.Disconnect terminals E02 (35) and E04 (36), 32.Sling the engine assembly.
and remove the harness clamp. 33.Remove connection bolts (42) (12 pieces)
between the engine and transmission.

27.Remove air conditioner compressor belt (37).


For details, see "Removal and installation of air 34.Remove engine mount mounting bolts (43) (2
conditioner compressor belt". pieces). [*4]
28.Remove the clamps of hoses (38) and (39).
29.Disconnect connector E10 (40).
30.Remove air conditioner compressor (41), and fix
it on the machine body side.

35.Sling engine assembly (44) and remove it.


a Check that all wiring and pipes are
disconnected.
31.Set jack [1] under the transmission. a When removing wiring and pipes, be careful
to prevent interference with the parts of the
a This prevents the transmission from lowering
machine body.
during separation of the engine assembly.
4 Engine assembly (44):
1,600 kg

WA470-7 50-99
50 Disassembly and assembly
Engine and cooling system

Installation (WA470-A000-720-K-00-A) [*2]


• Perform installation in the reverse order of a When installing the clamps (both ends) of hose
removal. (25), set the screws 180 degrees apart from
[*1] each other.
a For the aftercooler side of hose, install the hose 3 Clamp of hose (25) (both end):
and clamp on in the dimensions as follows.
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
• Dimensions (a) and (b): 10 mm
• Dimension (c): 75 mm a Install hose (25) and the clamp on KVGT side in
• Angle (d): 35 degrees the dimensions as follows.
3 Clamp: • Dimension (a) and (b): 10 mm
• Dimension (c): 75 mm
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

a Install hose (25) and clamp on the aftercooler


a For the air intake connector side of hose, install side in the dimensions as follows.
the hose and clamp on in the dimensions as
follows. • Dimension (d): 75 mm
• Dimension (e) and (f): 10 mm
• Dimension (e): 75 mm
• Dimensions (f) and (g): 10 mm
3 Clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

50-100 WA470-7
50 Disassembly and assembly
Engine and cooling system

a When installing the clamps of hose (26), set the a Install hose (27) and the clamp on the engine
screws 180 degrees apart from each other. side in the dimensions as follows.
a Install hose (26) and the clamp in the • Dimension (d): 58 mm
dimensions as follows. • Dimension (e): 5 mm
• Dimension (f): 10 mm
• Dimension (a): 10 mm
• Dimension (b): 7 mm
• Dimension (c): 60 mm
2 Hose (26) insertion portion:
Liquid gasket (LG-10)
3 Clamp of hose (26):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*3]
3 Damper (33) mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*4]
a Install cushion (45) of the engine mount portion
with its mark (a) facing to the outside of machine
body.
a When installing the clamps (both ends) of hose
(27), set the screws 180 degrees apart from 3 Engine mount mounting bolt:
each other. 455 to 565 Nm {46.5 to 58 kgm}
2 Hose (27) insertion portion (both ends):
Liquid gasket (LG-10)
3 Clamp of hose (27):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
a Install hose (27) and the clamp on the radiator
side in the dimensions as follows.
• Dimension (a): 55.5 mm
• Dimension (b): 9 mm
• Dimension (c): 5 mm

• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Radiator:
75 l

WA470-7 50-101
50 Disassembly and assembly
Engine and cooling system

Removal and installation of engine front oil seal (WA470-A350-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

7 795-931-1100 Seal puller assembly q 1


8 795T-521-1140 Push tool t 1
A
9 01010-61650 Bolt t 3
10 01643-31645 Washer t 9

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling battery 5. Sling damper (4), remove mounting bolts (6
disconnect switch".) pieces), and remove it. [*1]

Removal (WA470-A350-520-K-00-A) 4 Damper (4):


1. Remove the aftercooler. For details, see 15 kg
"Removal and installation of aftercooler."
2. Remove cover (1).

6. Sling crank pulley (5), remove mounting bolts (6


pieces), and remove it. [*2]
3. Remove air conditioner compressor belt (2). For
details, see "Removal and installation of air 4 Crank pulley (5):
conditioner compressor belt". 15 kg
4. Remove alternator belt (3). For details, see
"Removal and installation of alternator belt".

50-102 WA470-7
50 Disassembly and assembly
Engine and cooling system

7. Remove engine front oil seal (6).


Installation (WA470-A350-720-K-00-A)
a Before removal, tap engine front oil seal (6)
to unstick it. 1. Install engine front oil seal (6) according to the
following procedure.
a Be careful not to damage the oil seal contact
surfaces on front cover (7) and crankshaft a Before installation, check that end surfaces
(8). and oil seal lip sliding surface of the
crankshaft and the front cover are free from
a If it is difficult to remove engine front oil seal flaws, burrs, rust, etc.
(6), remove it according to the following
1) Set engine front oil seal (6) to front cover (7),
procedure.
and then use a plastic hammer to install the
1) Drill several holes about 3 mm in diameter in seal until oil seal lip (a) fits on to crankshaft
engine front oil seal (6). (8).
a Remove all the chips. a Install the engine front oil seal (6) in the
2) Change the tip part of tool A7 to the drill type direction as shown in the figure.
one. Insert it to the hole as described above.
3) Pull slide hammer [SH] of tool A7 forward, a Tap evenly on all around engine front oil
and remove engine front oil seal (6) by using seal (6) to press fit it in place while using
impact power of the hammer. care not to deform the seal.

a Perform this work evenly at several a Take care not to let oil seal lip (a) get
places so that engine front oil seal (6) is caught on crankshaft (8).
not tilted. 2 Engine front oil seal (8) (50 to 80 %
of lip space volume):
Grease (G2-LI)

• Tool A7

2) Install tool A8 and tighten them evenly until


tool A9 (bolt) (3 pieces) hit. Press-fit engine
front oil seal (6) to front cover (7).
a Do not install tool A10 (washer) to tool A9
(bolt).

WA470-7 50-103
50 Disassembly and assembly
Engine and cooling system

3) Remove tool A9 (bolt) (3 pieces) and install


tool A10 (washer) (3 pieces) to those tools
A9 (bolt) respectively.
4) Install tools A9 (bolt) (3 pieces) again and
tighten them evenly until the end face of tool
A8 hits the end face of front cover (7). Press-
fit engine front oil seal (6).
a Press fit depth (b) between engine front
oil seal (6) and end face of front cover (7):
16 (+1/0) mm

a Press fit depth (c) between engine front


oil seal (6) and end face of crankshaft (8):
9.2 (+1/0) mm

2. Perform subsequent installation in the reverse


order of removal.
[*1]
3 Damper (4) mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*2]
3 Crank pulley (5) mounting bolt:
M14: 157 to 196 Nm {16 to 20 kgm}
M16: 245 to 309 Nm {25 to 31.5 kgm}

50-104 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of engine rear oil seal (WA470-A510-924-K-00-A)

a Special tools

Necessity
Q'ty
Symbol Part No. Part name

Seal puller
7 795-931-1100 assembly q 1
1 795T-401-1310 Push tool t 1
2 795T-401-1320 Guide bolt t 3
3 795T-601-1310 Push tool t 1
11
4 795T-401-1330 Push tool t 1
A 5 795T-401-1340 Guide t 1
4. Remove rear oil seal (4) according to the
6 795T-401-1350 Spacer t 1 following procedure.
Bolt: (M16 x 2.0,
1 01010-61660 stem length: 60) t 1 1) Slightly tap rear oil seal (4) to unstick it from
12 flywheel housing (5).
Bolt: (M16 x 2.0,
2 01010-61640 stem length: 40) t 1
13 01643-31645 Washer (t = 4.5) t 1

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and 2) If the seal is sleeved, cut sleeve (7), and
stop the engine. remove it by using a chisel and a hammer.

k Turn the battery disconnect switch to OFF a Be careful not to damage crankshaft (6).
position, and remove the key. (For details, 3) Hang the tip of tool A7 on the metal ring of
see Testing and adjusting, "Handling of rear oil seal (4), and remove the seal by
battery disconnect switch".) using impact power of slide hammer (SH).
(Perform this work evenly so that the rear oil
Removal (WA470-A510-520-K-00-A) seal is not tilted.)
1. Remove the engine assembly. For details, see a Do not use a drill as metal chips may
"Removal and installation of engine assembly". enter the engine.
2. Sling flywheel (1), and install guide bolt [1]. a If any chips are generated, remove them
3. Remove mounting bolt (2), pull out flywheel (1), completely.
and remove it. [*1]
• Tool A7
4 Flywheel (1):
30 kg

WA470-7 50-105
50 Disassembly and assembly
Engine and cooling system

a Seal type is double seal (Inside of a Clean, degrease, and dry the contacting
flywheel housing is wet). surface against flywheel housing (5).
a The left one in the following figure shows a Before installing rear oil seal (4), ensure that
the standard oil supply seal and the right the end corner and lip sliding surface of the
one shows the sleeved seal. crankshaft, and flywheel housing (5) are free
from scratches, burrs, sharp fins, rust, etc.
a When installing rear oil seal (4), do not apply
oil or grease to the crankshaft and seal lip
surface (around the crankshaft). Thoroughly
wipe off oil or grease from the crankshaft.

Installation (WA470-A510-720-K-00-A)

1. Install the rear oil seal according to the following


procedure.
a When installing rear oil seal (4), check the
wear of the crankshaft and select "standard
seal (A)" or "sleeved seal (B)". 1) Installation of standard oil seal

a If the wear depth of the shaft is 10 mm or less a Before installing the oil seal, check that
and no scratch is present, install "standard the end corner and oil seal lip sliding
seal (A)". Otherwise, install "sleeved seal surface of the crankshaft and the housing
(B)". are free from scratches, sharp fins, burrs,
rust, etc.
• (8): Inner plastic tube/installation guide
• (7): Sleeve a When installing the oil seal, do not apply
oil or grease to the crankshaft and seal lip.
a Do not remove inner plastic tube/installation Thoroughly wipe off oil or grease from the
guide (8) before installing rear oil seal (4). crankshaft.
a Handle sleeve (7) and rear oil seal (4) as an a Never remove the inner plastic tube of the
assembly and never separate them from standard seal of spare part just before
each other. installation.
a The left one in the following figure shows the 1] Install tool A11-1 to the rear end of
standard seal and the right one shows the crankshaft, and screw in tool A11-2 (3
sleeved seal. pieces) lightly.
a At this stage, tool A11-2 has a little
play.

50-106 WA470-7
50 Disassembly and assembly
Engine and cooling system

a Be careful not to damage the seal lip


surface when removing inner plastic
tube (4a).

2] Insert tool A11-5 into tool A11-1, adjust


the position of tool A11-1 so that the
centers of crankshaft (6) and tool A11-1
are aligned, and then tighten tool A11-2 to
secure them. 7] Attach tool A12-1 (bolt: stem length 60
mm) and tool A13 to tool A11-3, and
insert tool A11-6 (spacer) to tool A12-1.
8] Put tool A11-3 on tool A11-1, and install
them guided by tool A11-2.

3] Remove tool A11-5, and check the


centers of crankshaft (6) and tool A11-1
are aligned
4] Apply the larger inside diameter side "a"
of inner plastic tube (4a) to the end of tool
A11-1.
a Take care not to put the wrong end.

9] Tighten tool A12-1 (bolt: stem length 60


mm) fully until it stops, and insert the
seal.
10]Remove tool A11-3 and remove tool A11-
6 (spacer).
5] Put both of your hands to the metal ring of
11]Exchange tool A12-1 (bolt: stem length
seal (4) and push in the seal evenly
6] After pushing in seal (4), remove inner 60 mm) with tool A12-2 (bolt: stem length
plastic tube (4a). 40 mm), and install tool A11-3 again.
a Install tool A11-3 without tool A11-6
(spacer).

WA470-7 50-107
50 Disassembly and assembly
Engine and cooling system

12]Tighten tool A12-2 (bolt: stem length 40


mm) fully until it stops, and insert the
seal.
13]After inserting the seal, remove tool A11-
3, tool A11-2 and tool A11-1.
a Wipe off the dirt in the sealant applied
to periphery of the seal.

2] Insert tool A11-5 into tool A11-1, adjust


the position of tool A11-1 so that the
centers of crankshaft (6) and tool A11-1
are aligned, and then tighten tool A11-2 to
secure them.

3] Remove tool A11-5, and check the


centers of the crankshaft and tool A11-1
are aligned
2) Installation of sleeved oil seal
4] Apply liquid gasket to inside of sleeve of
a Before installing the oil seal, check that sleeved seal, and insert sleeved seal (4)
the end corner and oil seal lip sliding to tool A11-1.
surface of the crankshaft and the housing
a When inserting the seal, place
are free from scratches, sharp fins, burrs,
chamfered side (4b) of sleeve to the
rust, etc.
end of tool A11-1.
a When installing the oil seal, do not apply
2 Inside surface of sleeve:
oil or grease to the crankshaft and gap
between sleeve (4b) and seal lip. Liquid gasket (LG-7)
Thoroughly wipe off oil or grease from the
crankshaft.
a Handle seal (4) and sleeve (4b) as
assembled state, and never remove seal
(4) from sleeve (4b).
1] Install tool A11-1 to the rear end of
crankshaft, and screw in tool A11-2 (3
pieces) lightly.
a At this stage, tool A11-2 has a little
play.

5] Attach tool A12-1 (bolt: stem length 60


mm) and tool A13 to tool A11-4, and

50-108 WA470-7
50 Disassembly and assembly
Engine and cooling system

insert tool A11-6 (spacer) to tool A12-1


(bolt: stem length 60 mm).
6] Put tool A11-4 on tool A11-1, and install
them guided by tool A11-2.

2. Perform subsequent installation in the reverse


order to removal.
[*1]
a Tighten the flywheel (1) mounting bolts in the
numerical order shown in the figure.
2 Threaded part of flywheel (1) mounting
bolt:
Engine oil
3 Flywheel (1) mounting bolt
1st time: 147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time: 289.1 ± 19.6 Nm {29.5 ± 2.0
kgm}

7] Tighten tool A12-1 (bolt: stem length 60


mm) fully until it stops, and insert the
seal.
8] Remove tool A11-4 and remove spacer
A11-6.
9] Exchange tool A12-1 (bolt: stem length
60 mm) with tool A12-2 (bolt: stem length
40 mm), and install tool A11-4 again.
10]Tighten tool A12-2 (bolt: stem length 40
mm) fully until it stops, and insert the
seal.
11]After inserting the seal, remove tool A11- a By using dial gauge [2], measure the facial
4, tool A11-2 and tool A11-1. runout and radial runout.

a Wipe off the dirt in the sealant applied • Facial runout: Max. 0.17 mm
to periphery of the seal. • Radial runout: Max. 0.13 mm

WA470-7 50-109
50 Disassembly and assembly
Engine and cooling system

Removal and installation of cooling fan and cooling fan motor


assembly (WA470-B5L0-924-K-00-A)
k Place the machine on a level ground, and
turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 6. Remove guard (10).


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-B5L0-520-K-00-A)

1. Drain the hydraulic oil.

6 Hydraulic tank: 173l l


2. Open grille (1), and remove cover (2).

7. Remove lock plate (11) and nut (12). [*1]


8. Tighten nut (12) by 2 to 3 turns to install it
loosely.

3. Disconnect connectors R59 (3) and R89 (4).


4. Disconnect hoses (5) to (7).

9. Separate cooling fan (13) from the cooling fan


motor by using puller [1].

5. Pull lever (8) downward, and open cooling fan


assembly (9).

50-110 WA470-7
50 Disassembly and assembly
Engine and cooling system

Installation (WA470-B5L0-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
a Install lock plate (11) and nut (12) according to
the following procedure.
1. Tighten nut (12) to the following torque.
3 Nut (12):
132 to 157 Nm {13.5 to 16 kgm}
2. Retighten sleeve nut (12).
10.Remove nut (12) to remove cooling fan (13).
a Align the positions of mounting bolt holes (a)
on both faces of lock plate (11) so that
retightening of nut (12) can be done with
minimum volume.
3. Tighten the mounting bolt of lock plate (11).

11.Remove connector (14) from the bracket.


12.Remove upper mounting bolts (2 pieces) (15)
and install guide bolt [2].
13.Remove lower mounting bolts (2 pieces) (15),
and pull out cooling fan motor assembly (16).
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Hydraulic tank: 173l


l

WA470-7 50-111
50 Disassembly and assembly
Engine and cooling system

Removal and installation of KDPF assembly (WA470-A9H0-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

A14 4000-01650 Bolt q 1

k Place the machine on a level ground and turn


the parking brake switch to ON position.

k Set the frame lock bar to LOCK position and


chock the wheels.
2. Sling cover (2), and remove it.
k Lower the work equipment to the ground,
and set the work equipment lock switch to 4 Cover (2):
LOCK.
70 kg
k Turn the starting switch to OFF position, and
stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling battery
disconnect switch".)

k Since KDPF is heated to 500°C or above,


start the work after KDPF cools down.

k Check for any accumulated combustibles


(dry leaves, twigs, etc.) on the KDPF, and
remove them if they are accumulated. 3. Remove cover (3).
a Install the cover to prevent foreign matter
k The KDPF will break if dropped or bumped.
from entering air cleaner inlet (A) and KDPF
Handle it with care. Do not reuse a damaged
outlet (B).
part.

k Keep the record for each KDPF unit to check


the service life, and never use the KDPF
exceeding its service life.

Removal (WA470-A9H0-520-K-00-A)

1. Remove eight caps (1) of the engine upper


cover and eight inner bolts.
a Remove the caps and bolts indicated by the
arrows.
a Do not remove the bolts marked with ▲.
(Otherwise, the door hinge is removed and 4. Pull out frame (4) downward and remove it.
adjustment during installation process
becomes difficult.)

50-112 WA470-7
50 Disassembly and assembly
Engine and cooling system

5. Open full-length fender (5) on the right and left 8. Remove tube (10).
side of the machine body, and then open side 9. Remove mounting bolts (11) (8 pieces) of KDPF
cover (6). assembly bracket.

6. Remove covers (7) and (8) on the the right and 10.Disconnect connectors E25 (12) and E26 (13) at
left sides of the engine. the top of KDPF assembly.

11.Remove KDPF assembly (14) and bracket


together as a unit.

4 KDPF assembly (14) and bracket:


115 kg

7. Remove bolts (9) (4 pieces) on the inlet side of


KDPF.

WA470-7 50-113
50 Disassembly and assembly
Engine and cooling system

12.Place the KDPF assembly on a level ground. 2. Tighten bolts (16) (4 pieces).
13.Remove exhaust pipe (15).

3. Install U-bolt (17).


14.Sling the KDPF assembly.
a Use a plastic hammer, etc. to tap the top of
15.Remove bolts (16) (4 pieces) and U-bolt (17).
the U-bolt to eliminate the clearance between
16.Sling KDPF assembly (14), and remove
U-bolt and KDPF assembly.
brackets (18) and (19).
4. Install washer (20) and tighten nuts (21) evenly.
4 KDPF assembly (14): 3 Nut (21):
75 kg 14.7 to 34.3 Nm {1.5 to 3.5 kgm}
5. Tighten four lock nuts (22) evenly.
3 Nut (22):
21 to 49 Nm {2.1 to 5.0 kgm}
6. Check that distances (a) between tip end of U-
bolt (17) and nut (22) are even on both sides.
7. Rotate nut (21) lightly in the loosening direction.

Installation (WA470-A9H0-720-K-00-A)

1. Sling KDPF assembly (14) and lower it to


brackets (18) and (19).

4 KDPF assembly (14):


75 kg
8. Install exhaust pipe (15).

50-114 WA470-7
50 Disassembly and assembly
Engine and cooling system

a At this time, check that bellows portion (A) of


pipe (23) is not deformed.

9. Install KDPF assembly (14) and bracket together


as a unit.

4 KDPF assembly (14) and bracket:


115 kg

13.If the above clearance (b) exceeds the standard


value, adjust it according to the following
procedure.
10.Tighten eight mounting bolts (11) of KDPF
1) Push the KDPF assembly by hands to adjust
assembly bracket lightly.
the position in the lateral and vertical
directions.
2) Loosen bolt (16) and nuts (21) and (22) insert
tool A14 to the position in the figure to adjust
the position in the vertical direction.
3) After the adjustment, proceed with steps 2 to
7 again.
4) Remove tool A14.

11.Tighten bolts (9) (4 pieces) on the inlet side of


KDPF lightly.
2 Threaded portion of bolt (9):
Seizure prevention compound (LC-G)
12.Check that clearance (b) between the flanges is
in the following dimensions.
a Measure clearance (b) at 4 positions on each
flange surface in total. 14.Tighten bolts (9) (4 pieces) on the inlet side of
KDPF to the specified torque.
• Clearance (b): Max. 2 mm (including
gasket thickness) 3 Bolt (9):
78.5 to 88.3 Nm {8.0 to 9.0 kgm}

WA470-7 50-115
50 Disassembly and assembly
Engine and cooling system

15.Tighten mounting bolts (11) (8 pieces) of KDPF


assembly bracket to the specified torque.
16.Install tube (10).

17.Connect connectors E25 (12) and E26 (13) at


the top of the KDPF assembly.

18.Perform subsequent installation in the reverse


order of removal.

50-116 WA470-7
50 Disassembly and assembly
Engine and cooling system

Disassembly and assembly of KDPF assembly (WA470-A9H0-926-K-00-A)

k Since KDPF and KDOC are heated to 500°C


or above, be careful not to get burn injury.

k Stop the engine, wait until piping around the


engine cools down, then remove the KDPF.

k When cleaning, replacing, or disposing the


KDPF or KCSF, use a dust mask during the
work to prevent inhaling accumulated soot,
ash, mat material or powder of precious
metals inside the KDPF.

k When installing KCSF, be careful about its


installed direction.

k Handle the KDPF with care since an impact


on it, for instance, dropping it, causes it to
damage. And be sure not to use a damaged
part.

k Keep record of each KDPF unit to control its


service life, and never use a KDPF after its
service life has elapsed.

a Since the V-clamp and band used for the KDPF


are made of stainless steel, avoid using an
impact wrench for removal and installation of
nuts. Otherwise threaded portions can be
damaged.
a When removing a gasket or band, prepare new
ones at hand.
a In the following procedures, the size of some
tools to be used is expressed in both units of min
and inch, however, general tools are available
for them.
Disassembly (WA470-A9H0-530-K-00-A)

1. Preparation
1) Use lifting tool [1] to lift KDPF assembly (1). 2) Mark at 3 points (a), (b), and (c) of each body
Place blocks [2] to 4 places under it to connection.
support the assembly securely. • (A): Connection between inlet and KDOC
• (B): Connection between KDOC and
4 KDPF assembly (1): KCSF
70 kg • (C): Connection between KCSF and
a Place block [2] at a position where it does outlet
not touch the piping and bands of the a These marks are required to facilitate
KDPF. angle adjustment of KDPF inlet and outlet
a Place cloth or the like on the supporting flanges in assembly work.
portion of block [2] to prevent damage on • (2): Inlet body
the KDPF. • (3): KDOC body
• (4): KCSF body
a Dimensions of blocks [2] are shown in the • (5): Outlet body
following figure.

WA470-7 50-117
50 Disassembly and assembly
Engine and cooling system

a Disconnect connector (10) according to


the following procedure.
1] Slide the lever of the connector in the
direction of the arrow to unlock.

2] While pressing the knob on the upper


portion of the connector, pull out the
connector in the direction of the arrow.

2. KDOC inlet and outlet temperature sensors


1) Put a match mark for each installed position
of harness clip band (6), and harness clamps
(7) and (8).
2) Disconnect harness clip band (6), and
harness clamps (7) and (8).
• Width across flats of harness clamp
mounting bolt: 14 mm 5) Loosen mounting nut (12) and remove
3) Disconnect KDOC inlet temperature sensor KDOC inlet temperature sensor (13).
connector (9) from TEMP1 of temperature
• Width across flats of mounting nut (12):
sensor consolidation box (11).
14 mm
4) Disconnect KDOC outlet temperature sensor
connector (10) from TEMP2 of temperature a To remove temperature sensor (13), hold
sensor consolidation box (11). metal portion (d) and pull it straight in the
direction of the arrow.

50-118 WA470-7
50 Disassembly and assembly
Engine and cooling system

a When removing the temperature sensor,


pull the sensor straight until it completely
comes out of the mounting hole of KDPF.
(The sensor is inserted in KDPF
approximately 100 mm.)
6) Loosen mounting nut (12a) and remove
KDPF outlet temperature sensor (14).
• Width across flats of mounting nut (12a):
14 mm
a To remove temperature sensor (14), hold
metal portion (d) and pull it straight in the
direction of the arrow.
a When removing the temperature sensor, a Disconnect connector (17) according to
pull the sensor straight until it completely the following procedure.
comes out of the mounting hole of KDPF. 1] Slide the lever of the connector in the
(The sensor is inserted in KDPF direction of the arrow to unlock.
approximately 100 mm.)

2] While pressing the knob on the upper


portion of the connector, pull out the
connector in the direction of the arrow.

3. KDPF outlet temperature sensor


1) Remove harness clip (16) from bracket (15).
3) Loosen mounting nut (18) and remove KDPF
• Width across flats of mounting bolt: 14 outlet temperature sensor (19).
mm
2) Disconnect extension harness connector • Width across flats of mounting nut (18):
(17) of the KDPF outlet temperature sensor 14 mm
from TEMP3 of temperature sensor a To remove temperature sensor (19), hold
consolidation box (11). metal portion (d) and pull it straight in the
direction of the arrow.

WA470-7 50-119
50 Disassembly and assembly
Engine and cooling system

a When removing the temperature sensor,


pull the sensor straight until it completely
comes out of the mounting hole of KDPF.
(The sensor is inserted in KDPF
approximately 100 mm.)

5) Loosen nuts on the body side of the


differential pressure sensor piping.
• Width across flats of nut (24) of pipe (25):
11/16 in. (17.46 mm)
• Width across flats of nut (26) of pipe (27):
4. Remove the differential pressure sensor pipings 5/8 in. (15.88 mm)
and the differential pressure sensor in the 6) Disconnect connectors (22) and (23) for
following procedure. differential pressure sensor pipes (25) and
(27).
1) Remove clamp (20).
• Width across flats of clamp (20) mounting a While pressing lock (f) on the fitting of the
bolt: 10 mm connector, pull out the connector in the
2) Remove clamp (21). direction of the arrow.
• Width across flats of clamp (21) mounting a Lock (f) of the fitting of differential
bolt: 14 mm pressure sensor pipe (22) is located on
3) By using the tool (long socket), remove band its back.
(28). 7) Remove differential pressure sensor (31)
and sensor table (29) as a unit.
a Put match marks on band (28) before
removing them. a When removing the differential pressure
• Width across flats of band (28) tightening sensor (31), take extreme care since it
nut: 7/16 in. (11.1 mm) breaks easily.

a Band (28) is made of stainless steel,


accordingly never use an impact wrench
for tightening. (The threaded portion may
be damaged.)
a Discard band (28) because reuse of the
band is not allowed.
4) Bind sensor table (29) by using string, etc. to
fix it.

50-120 WA470-7
50 Disassembly and assembly
Engine and cooling system

2] Remove mounting bolt (32) and remove


temperature sensor consolidating box
(11) from sensor table (29).
• Width across flats of mounting bolt
(32): 10 mm

5. Body
a Before removing each body, record the
mounting position of each harness bracket.
1) Place blocks [2] at 4 places under them to
support the assembly securely.
2) Remove mounting bolts (33) (12 pieces) at
8) Remove differential pressure sensor pipes each connection between bodies, and then
(25) and (27). remove backup plate (34) and hangers (36)
and (37).
a To remove differential pressure sensor
• Width across flats of mounting bolt (33):
pipes (25) and (27), vertically pull them
14 mm
out because those pipes are inserted in
3) Remove harness bracket (38).
the KCSF and outlet body.
4) Disconnect inlet body (2), KDOC body (3),
KCSF body (4), and outlet body (5).
a Support KDOC body (3) with your hand
because its lower part is not supported
with blocks [2].
5) Remove gaskets (35) from between the
bodies.
a Discard gaskets (35) because reuse of the
gaskets is not allowed.

9) Remove mounting bolt (30) and remove


differential pressure sensor (31) from sensor
table (29).
• Width across flats of mounting bolt (30):
10 mm
10)When replacing temperature sensor
consolidating box (11), remove it according
to the following procedure.
1] Disconnect all of the temperature sensor
connectors from temperature sensor Assembly (WA470-A9H0-710-K-00-A)
consolidation box (11).
1. Body

WA470-7 50-121
50 Disassembly and assembly
Engine and cooling system

1) Place blocks [2] at 4 places under the bodies


to support the assembly securely.
a Use the blocks used at disassembly.
2) Set inlet body (2), KDOC body (3), KCSF
body (4), and outlet body (5).
3) Set them by aligning match marks (a), (b),
and (c) made at disassembly.
a If they are assembled with match marks
displaced, the flanges of KDPF inlet and
outlet are installed at wrong angle,
causing defective installation of exhaust
pipe to the inlet and slanted installation of
tail pipe to the outlet. a The figure shows the view from the inlet side
4) Install gaskets (35) between the bodies. (upstream side).
a Use new gaskets (35). *1: Bolt that tightens also hanger
5) Install backup plate (34), hangers (36) and *2: Bolt that tightens also harness bracket
(37), and harness bracket (38). (A): Connection between inlet and KDOC
6) Install and lightly tighten mounting bolts (33a),
(B): Connection between KDOC and KCSF
(33b), and (33c), 12 bolts each at connection
between the bodies. (C): Connection between KCSF and outlet

a Install mounting bolts (33a), (33b), and


(33c) from the direction shown in the
following figure.
• Install mounting bolts (33a) and (33b)
from the upstream side.
• Install mounting bolt (33c) from the
downstream side.
7) Tighten mounting bolts (33a), (33b), and
(33c) to the specified torque.
• Width across flats of mounting bolts (33a),
(33b), and (33c): 14 mm
2 Mounting bolts (33a), (33b), and
(33c):
Seizure prevention compound
(LC-G)
3 Mounting bolts (33a), (33b), and
(33c):
59 to 74 Nm {6.0 to 7.6 kgm}

a Installed positions of backup plates (34a) and


(34b) are shown in the following figure.
a Install backup plates while aligning lower flat
part (h) of each backup plate not to cause a
step.

50-122 WA470-7
50 Disassembly and assembly
Engine and cooling system

1] Set sensor table (29) to the installed


position.
2] By using the tool (long socket), partially
tighten band (28).
• Width across flats of band (28)
tightening nut: 11.1 mm {7/16 inch}
a Once the band is tightened, folding marks
are made on it by the edges of fixed parts.
Since the folding marks can loose the
band, replace the band with a new one.
a The nut of band (28) is to be tightened to
the specified torque after the KDPF
differential pressure sensor pipe is
installed.

2. Install the differential pressure sensor pipings


and the differential pressure sensor in the
following procedure.
1) When temperature sensor consolidating box
(11) is replaced, install it according to the
following procedure.
1] Install remove temperature sensor
consolidation box (11) to sensor table
(29).
• Width across flats of mounting bolt
(32): 10 mm
3 Mounting bolt (32):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
2] Install all the temperature sensor
connectors to temperature sensor 3. KDPF differential pressure sensor pipe
consolidating box (11). 1) Temporarily assemble the following.
2) When the KDPF differential pressure sensor • (27): Differential pressure sensor Lo pipe
is replaced, install it according to the • (25): Differential pressure sensor Hi pipe
following procedure. • (20): Clamp
1] Install sensor table (29) to KDPF • (21): Clamp
differential pressure sensor (31). 2) Install pipe connectors (22) and (23) to the
• Width across flats of mounting bolt differential pressure sensor in the direction
(30): 10 mm indicated as arrows.

3 Mounting bolt (30): a Check that locking sound is heard when


pipe connectors (22) and (23) are
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
inserted.
2] Install the KDPF differential pressure
3) Position differential pressure sensor pipes
sensor pipe.
(25) and (27), and check that they are not
3) When the KCSF is replaced, install the
unnecessarily stressed.
sensor table according to the following
4) Tighten band (28) to the specified torque.
procedure.

WA470-7 50-123
50 Disassembly and assembly
Engine and cooling system

• Width across flats of band (28) tightening


nut: 11.1 mm {7/16 inch}
3 Nut of band (28):
6.3 to 8.3 Nm {0.64 to 0.85 kgm}
a Band (28) is made of stainless steel,
accordingly never use an impact wrench
for tightening. (The threaded portion may
be damaged.)
5) Tighten differential pressure sensor Lo pipe
mounting nut (26) to the specified torque.
• Width across flats of mounting nut (26):
15.88 mm {5/8 inch}
3 Mounting nut (26):
13.6 to 19.0 Nm {1.39 to 1.94 kgm}
6) Tighten differential pressure sensor Hi pipe
mounting nut (24) to the specified torque.
• Width across flats of mounting nut (24):
17.46 mm {11/16 inch}
3 Mounting nut (24):
24.5 to 36.5 Nm {2.5 to 3.7 kgm}
7) Fasten clamp (21) to the specified torque.
• Width across flats of mounting bolt: 14
mm 4. KDPF outlet temperature sensor
1) Install KDPF outlet temperature sensor (19).
3 Mounting bolt:
• Width across flats of mounting nut: 14
11.8 to 26.0 Nm {1.1 to 2.7 kgm}
mm
8) Fasten clamp (20) to the specified torque.
• Width across flats of mounting bolt: 10 3 Mounting nut:
mm 24 to 36 Nm {2.45 to 3.67 kgm}
3 Mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

2) Install harness clip (16) to bracket (15).


• Width across flats of mounting bolt: 14
mm
3 Mounting bolt:
11.8 to 26.0 Nm {1.1 to 2.7 kgm}
3) Connect extension harness connector (17) of
the KDPF outlet temperature sensor to
TEMP3 of temperature sensor consolidation
box (11).

50-124 WA470-7
50 Disassembly and assembly
Engine and cooling system

a Installed positions of KDOC inlet


temperature sensor (13), outlet
temperature sensor (14), harness clip
band (6), and harness clamps (7) and (8)
are shown in the following figure.
(Installed positions of the clamps are for
reference.)

5. KDOC inlet and outlet temperature sensors


1) Install KDOC outlet temperature sensor (14).
• Width across flats of mounting nut (12a):
14 mm
3 Mounting nut (12a):
24 to 36 Nm {2.45 to 3.67 kgm}
2) Install KDOC inlet temperature sensor (13).
• Width across flats of mounting nut (12):
14 mm
3 Mounting nut (12):
24 to 36 Nm {2.45 to 3.67 kgm}

3) Connect KDOC outlet temperature sensor


connector (10) to TEMP2 of temperature
sensor consolidation box (11).
4) Connect KDOC inlet temperature sensor
connector (9) to TEMP1 of temperature
sensor consolidation box (11).
5) Place harness clip band (6) to the position
marked at disassembly, and bind the
harnesses.
a Use a new harness clip band.
6) Place harness clamps (7) and (8) to the
positions marked at disassembly, and install
them to the bracket.
• Width across flats of mounting bolt: 14
mm
3 Mounting bolt:
11.8 to 26.0 Nm {1.1 to 2.7 kgm}

WA470-7 50-125
50 Disassembly and assembly
Engine and cooling system

Removal and installation of KCCV assembly (WA470-A180-924-K-00-A)

k Place the machine on a level ground, and 8. Remove mounting bolts (4 pieces), and remove
turn the parking brake switch to ON position. KCCV assembly (9).

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".) Installation (WA470-A180-720-K-00-A)

• Perform installation in the reverse order to


Removal (WA470-A180-520-K-00-A)
removal.
1. Drain the coolant. [*1]
3 Clamp of hose (5):
6 Radiator: 75 l
2. Open full - fender (1) and side cover (2). 3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
a When check valve (A) at the bottom of hose (5)
is removed, install it with following direction.
• (a): KCCV ventilator side (gray)
• (b): Cylinder block side (black)

3. Remove cover (3).

[*2]
3 Clamp of blowby hose (6):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
[*3]
3 Joint bolt of tubes (7) and (8) (KCCV
side):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
4. Disconnect connector PCCV (4).
3 Joint bolt of tubes (7) and (8) (cylinder
5. Disconnect hose (5). [*1]
block side):
6. Disconnect blowby hoses (6) (2 pieces) on the
tube side. [*2] 24.5 to 34.3 Nm {2.5 to 3.5 kgm}
7. Remove the joint bolt and clamp of tubes (7) and • Refilling with coolant
(8). [*3] Refill with the coolant to the specified level
through the coolant filler port. Run the engine to

50-126 WA470-7
50 Disassembly and assembly
Engine and cooling system

circulate the coolant through system. Then


check the coolant level again.

5 Radiator: 75 l

WA470-7 50-127
50 Disassembly and assembly
Engine and cooling system

Removal and installation of KVGT assembly (WA470-AA10-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

15 795T-621-2820 Push tool t 1


A
16 795T-621-2810 Installer t 1

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels. 4. Open full-length fender (1) and side cover (2).

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-AA10-520-K-00-A)
5. Remove heat insulation cover (3).
1. Drain the coolant. 6. Remove cover (4) and bracket (5).

6 Radiator: 75 l
2. Remove caps (A) (8 pieces) of the engine upper
cover and inner bolts (8 pieces).
a Remove the caps and bolts indicated by the
arrows.
a Do not remove the bolts marked with e.
(Otherwise, the door hinge is removed and
adjustment during installation process
becomes difficult.)

7. Disconnect connectors SVGT (6) and VGT-REV


(7).

3. Sling cover (B) and remove it.

4 Cover (B): 70 kg

50-128 WA470-7
50 Disassembly and assembly
Engine and cooling system

8. Disconnect connector DOSER (8), and remove


all the harness clamps.
9. Remove all the clamps of tubes (9) to (11).

17.Remove joint bolt (22). [*5]


18.Remove tube (23).

10.Disconnect hoses (12) to (14).

19.Remove fuel doser assembly (24). For details,


see "Removal and installation of fuel doser
assembly".
11.Disconnect hose (15) on the air cleaner side. [*1]
20.Remove U-bolt (25).
12.Remove the clamp of hose (16). [*2]
21.Remove bracket (26).
13.Remove bracket (17).
22.Loosen the clamp of hose (27), and pull out tube
14.Remove air intake connector (18) and hoses
(28). [*6]
(15) and (16) together as a unit.

23.Remove joint bolt (29). [*7]


15.Remove bolts (20) (4 pieces) of the flange of
24.Remove all the clamps of tubes (30) and (31).
tube (19). [*3]
Loosen the sleeve nut on the front cover side.
16.Remove bracket (21). [*4]
[*7]
25.Remove tubes (32) and (33). [*8]

WA470-7 50-129
50 Disassembly and assembly
Engine and cooling system

3 Clamp of hose:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

26.Remove mounting bolts (2 pieces) and nuts (2


pieces). Sling KVGT assembly (34) and remove
it. Place it on the blocking tool [1] temporarily.
[*9]
[*2]
27.Sling KVGT assembly (34) again from outside of
the engine hood, and remove it. a Install hose and clamp in the dimension as
follows.
4 KVGT assembly: 35 kg • Dimensions (a) and (c): 10 mm
• Dimension (b): 43 mm
3 Clamp of hose:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3]
2 Bolt (20):
Seizure prevention compound (LC-G)
3 Bolt (20):
78.5 to 88.3 Nm {8 to 9 kgm}
[*4]

Installation (WA470-AA10-720-K-00-A)
2 Mounting bolt of bracket (21):
Seizure prevention compound (LC-G)
• Perform installation in the reverse order to
removal. 3 Mounting bolt of bracket (21):
[*1] 68.6 to 73.5 Nm {7.0 to 7.5 kgm}
a Install hose and clamp in the dimension as [*5]
follows.
3 Joint bolt (22):
• Dimension (a): 40 mm
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
• Dimension (b): 10 mm
[*6]

50-130 WA470-7
50 Disassembly and assembly
Engine and cooling system

a Install clamps (both ends) of hose (27) with its 2. By using tool A15, install seal (37) to oKVGT
screws to be same direction. housing (36).
3 Clamp of hose (27): a Drive in tool A15 until it touches flange
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} surface (c) of KVGT housing (36).
a Clearance (d) between KVGT housing (36)
and seal (37) becomes following dimension.
• Clearance (d): 3 mm

[*7]
3 Joint bolt (29):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3. Install bracket (21).
3 Sleeve nut at front cover side of tubes
(30) and (31): a Lightly tighten the mounting bolts.
24 to 27 Nm {2.4 to 2.7 kgm} 2 Mounting bolt of bracket (21):
[*8] Seizure prevention compound (LC-G)
3 Sleeve nut of tube (32): 4. Install plug (38) to exhaust connector (35).
24 to 27 Nm {2.4 to 2.7 kgm} 3 Plug (38):
3 Tube (32) joint bolt: 2.9 to 5.9 Nm {0.3 to 0.6 kgm}
5. Install seal ring (39) to exhaust connector (35).
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*9] a Install seal ring (39) with its stamp mark (R)
facing the KVGT housing.
2 KVGT assembly (34) mounting bot and 6. Fix tool A16 to exhaust connector (35) with bolt
nut: [1].
Seizure prevention compound (LC-G) 7. Install exhaust connector (35) to KVGT housing
(36).
3 KVGT assembly (34) mounting bot and
nut: a Push in tool A16 until its end face touches
68.6 to 73.5 Nm {7 to 7.5 kgm} flange surface (c) of KVGT housing (36).
8. Fix KVGT housing (36) and tool A16 with bolt
a When exhaust connector (35) is removed, install [2].
it according to the following procedure.
a Check that dimensions (e) and (f) are the
following value.
• Dimension (e): 129 mm
• Dimension (f): 19 mm
9. Tighten bolt (40).
10.Tighten the mounting bolts of bracket (21) to the
specified torque.
3 Mounting bolt of bracket (21):
68.6 to 73.5 Nm {7.0 to 7.5 kgm}
11.Remove tool A16.

1. Install the KVGT assembly.

WA470-7 50-131
50 Disassembly and assembly
Engine and cooling system

• Refilling with coolant


Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.

5 Radiator: 75 l

50-132 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of EGR (Exhaust Gas Recirculation) valve


assembly (WA470-A9K1-924-K-00-A)
k Place the machine on a level ground, and
turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 5. Remove connecting bolts (9) (4 pieces) from
position, and remove the key. (For details, tube (8).
see Testing and adjusting, "Handling of 6. Remove mounting bolts (2 pieces), and remove
battery disconnect switch".) EGR valve assembly (10).

Removal (WA470-A9K1-520-K-00-A)

1. Open full-length fender (1), and side cover (2).


a Perform the same work on the opposite side.

Installation (WA470-A9K1-720-K-00-A)

• Perform installation in the reverse order to


removal.
[*1]
2. Remove cover (3).
3 Tube (6) joint bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
3 Tube (7) joint bolt:
34.3 to 44.1 Nm {3.5 to 4.5 kgm}
3 Tube (7) sleeve nut:
24 to 27 Nm {2.4 to 2.7 kgm}

3. Disconnect connectors SEGR (4) and EGR-SOL


(5).
4. Remove tubes (6) and (7). [*1]

WA470-7 50-133
50 Disassembly and assembly
Engine and cooling system

Removal and installation of EGR (Exhaust Gas Recirculation) cooler


assembly (WA470-A9L0-924-K-00-A)
k Place the machine on a level ground, and
turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 5. Remove tubes (6) and (7). [*2]
position, and remove the key. (For details, 6. Remove tubes (8) to (10). [*3]
see Testing and adjusting, "Handling of a To remove tube (9), remove the upper joint
battery disconnect switch".) bolt.
Removal (WA470-A9L0-520-K-00-A)

1. Drain the coolant.

6 Radiator: 75 l
2. Open full-length fender (1), and side cover (2).

3. Remove heat insulation plates (3) and (4).

7. Remove connecting bolts (12) (4 pieces) from


tube (11).
8. Remove EGR cooler assembly (13).

4. Remove tube (5). [*1]

50-134 WA470-7
50 Disassembly and assembly
Engine and cooling system

Installation (WA470-A9L0-720-K-00-A)

• Perform installation in the reverse order to


removal.
[*1]
3 Tube (5) mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}
[*2]
3 Joint bolt of tubes (6) and (7):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*3]
3 Upper joint bolt of tube (9):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
• Refilling with coolant
Refill with the coolant to the specified level
through the coolant filler port. Run the engine to
circulate the coolant through system. Then
check the coolant level again.

5 Radiator: 75 l

WA470-7 50-135
50 Disassembly and assembly
Engine and cooling system

Removal and installation of air cleaner assembly (WA470-A910-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 6. Remove band (7), and remove air cleaner
position, and remove the key. (For details, assembly (8). [*2]
see Testing and adjusting, "Handling battery
disconnect switch".)

Removal (WA470-A910-520-K-00-A)

1. Open full-length fender (1), and side cover (2).


a Perform the same work on the opposite side.

2. Disconnect connector R93 (3).


3. Disconnect hose (4).
4. Disconnect hose (5). [*1]

Installation (WA470-A910-720-K-00-A)

• Perform installation in the reverse order to


removal.
[*1]
a Install the hose and clamp at KVGT side in the
dimension as follows.
• Dimension (a): 10 mm
• Dimension (b): 40 mm
5. Remove cover (6). 3 Clamp of hose (both ends):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

50-136 WA470-7
50 Disassembly and assembly
Engine and cooling system

[*2]
a Install the clamp so that inlet (A) of air cleaner is
not caught by seal (9).

a Install air cleaner assembly (8) so that band (7)


and dust outlet port (B) are following
dimensions.
• Dimension (c): 25 mm
• Angle (d): 15 degrees
3 Band (7):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

WA470-7 50-137
50 Disassembly and assembly
Engine and cooling system

Removal and installation of air conditioner compressor belt (WA470-AT50-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-AT50-520-K-00-A)

1. Open full-length fender (1) and the side cover


(2).

Installation (WA470-AT50-720-K-00-A)

• Perform installation in the reverse order of


removal.
a Adjust the belt tension. For details, see Testing
and adjusting, "Testing and adjusting air
conditioner compressor belt tension".
2. Insert the starting switch key into lock (3) to
release it, and open covers (4) and (5).

3. Loosen bolts (6) and (7).


4. Loosen nut (8) and bolt (9), and slide air
conditioner compressor (10) in the direction
indicated by the arrow.
5. Remove air conditioner compressor belt (11).

50-138 WA470-7
50 Disassembly and assembly
Engine and cooling system

Removal and installation of alternator belt (WA470-AKM4-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-AKM4-520-K-00-A)

1. Remove air conditioner compressor belt. For


details, see "Removal and installation of air
conditioner compressor belt".
2. Open full-length fender (1) and side cover (2).

Installation (WA470-AKM4-720-K-00-A)

• Perform installation in the reverse order to


removal.
a Adjust the belt tension. For details, see Testing
and adjusting, "Testing and adjusting alternator
belt tension".

3. Insert the starting switch key into lock (3) to


release it, and open cover (4).
4. Remove cover (5) and handrail (6).
5. After loosening bolts (7) and (8), loosen locknut
(9).
6. Loosen adjustment nut (10), and move
alternator (11) in the direction of the arrow.
7. Remove alternator belt (12).

WA470-7 50-139
50 Disassembly and assembly
Engine and cooling system

Removal and installation of fuel tank assembly (WA470-AD10-924-K-00-A)

k Place the machine on a level ground and turn


the parking brake switch to ON position.

k Set the frame lock bar to LOCK position and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 4. Disconnect fuel hoses (4) and (5).
position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

a When removing and installing the fuel piping,


take extreme care not to allow foreign matters to
enter the fuel piping. If dust, etc. sticks to any
part, wash that part thoroughly with clean fuel.
a Note the connector numbers and installed
positions of the wirings and hoses before
disconnecting them.
a When disconnecting wiring and hoses, be
careful not to damage or deform them by 5. Disconnect fuel hose (6) on the right front side of
tightening clips and clamps. Remove clips and the fuel tank.
clamps in advance if they may damage wiring or
hoses.
Removal (WA470-AD10-520-K-00-A)

1. Drain fuel.

6 Fuel tank (when the tank is full):


380 l
2. Open full-length fender (1), and side cover (2).
a Perform the same work on the opposite side.

6. Remove plate (7) and step (8).


a Remove the mounting bolts on the other side
in the same way.
7. Remove engine oil drain port (9).
8. Remove coolant drain port (10).

3. Remove cover (3).

50-140 WA470-7
50 Disassembly and assembly
Engine and cooling system

11.Remove all the clamps of hose (13).


12.Remove breather (14), and move it toward the
fuel tank side.

13.Sling fuel tank assembly (15) by using belt sling


[1] and wire [2], and support it by using jack [3].
14.Remove mounting bolt (16) (1 pieces each) on
the right and left side and mounting bolt (17).
Slowly lower the crane and jack [3]. [*1]
a Check that all harnesses and pipes are
disconnected.
a Remove coolant drain hose clamp (18) on
the left side in the process of lowering the
9. Disconnect connector R33 (11) on the left side of
fuel tank assembly.
the fuel tank, and remove the harness clamp.
4 Fuel tank assembly (15): 210 kg
15.Lower the crane and jack until the bottom of the
fuel tank assembly is in parallel with the ground.
16.Place fuel tank assembly on pallet jack, etc. and
pull it out of the machine.

10.Remove coolant drain hose clamps (12) (2


pieces) on the left side of the fuel tank.
a Remove another clamp in the process of
removing the fuel tank assembly.

WA470-7 50-141
50 Disassembly and assembly
Engine and cooling system

Installation (WA470-AD10-720-K-00-A)

• Perform installation in the reverse order to


removal.
[*1]
3 Mounting bolts (16) and (17):
785 to 980 Nm {80 to 100 kgm}

50-142 WA470-7
50 Disassembly and assembly
Power train

Power train (ALL-C100-001-K-00-A)

Removal and installation of torque converter and transmission


assembly (WA470-R406-924-K-00-A)
k Place the machine on a level ground, and
turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 9. Remove tube (2).


position, and remove the key. (For details, 10.Disconnect hoses (3) and (4), and remove block
see Testing and adjusting, "Handling of (5).
battery disconnect switch".)

Removal (WA470-R406-520-K-00-A)

1. Drain the hydraulic oil.

6 Hydraulic tank: 173l l


2. Drain the transmission oil.

6 Transmission case: 65 l
3. Remove full-length fender assembly. For details,
see "Removal and installation of full-length
fender assembly".
4. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood 11.Remove the cover on the right side of the
assembly". machine body and disconnect hose (6).
5. Remove the hydraulic tank assembly. For details, 12.Disconnect ground cable (6-1).
see "Removal and installation of hydraulic tank
assembly".
6. Remove the operator's cab and floor frame
assembly. For details, see "Removal and
installation of operator's cab and floor frame
assembly".
7. Remove all piping connected to the pump. For
details, see "Removal and installation of steering
lubrication pump and power train pump
assembly".
8. Remove all piping connected to the pump. For
details, see "Removal and installation of work
equipment pump and cooling fan pump
13.Remove tube (7). [*1]
assembly".
14.Remove the clamp (8), and move harnesses (9)
a Remove bracket (1). and (10).

WA470-7 50-143
50 Disassembly and assembly
Power train

18.Disconnect hose (17).


19.Remove the mounting bolt of block (18) and
move it.

15.Remove bracket (11), and move the


corresponding piping.

20.Remove brackets (19) to (21).


a To remove bracket (21) ,disconnect
connector R100A (22).

16.Remove cover (12) on the right side of the


machine body.
a Remove the cover on the rear side as well.

17.Disconnect hoses (13) to (16).


21.Remove clamps (23) and (24).
22.Remove clamps (25) and (26), and the bracket
immediately beneath them.

50-144 WA470-7
50 Disassembly and assembly
Power train

23.Remove clamp (27).


24.Disconnect hoses (28) and (29).

28.Set blocks [1] under the flywheel housing.


a The figure shows the state without the torque
25.Remove rear drive shaft (30) and center drive converter and transmission assembly for
shaft (31). [*2] illustration purposes.
a Make a matchmark on the coupling and drive a Using block [1] prevents the combined part
shaft, and then remove them. on the engine side from lowering during
26.Remove oil filler pipe (32). separation of the torque converter and
27.Remove drain port (33) on the left side of the transmission assembly.
machine body.

29.Sling the torque converter and transmission


assembly.
30.Remove transmission mount bracket (34).
1) Remove right and left engine mount bolts
(35). [*3]
2) Remove mounting bolts (36) (2 pieces) on
the upper side of left and right transmission
mount brackets (34) and bolt (37). [*4]
3) Use jack [2] to raise the bottom surface of the
transmission to the position where mounting

WA470-7 50-145
50 Disassembly and assembly
Power train

bolts (2 pieces) on the lower side of left and


right transmission mount brackets (34) can
be removed.
4) Remove mounting bolts (2 pieces) on the
lower side and remove left and right
transmission mount brackets (34). [*5]

33.Sling and remove the torque converter and


transmission assembly (40).

4 Torque converter and transmission


assembly (40):
1,500 kg

Installation (WA470-R406-720-K-01-A)

• Perform installation in the reverse order of


removal.
[*1]
2 Hose insertion portion of tube (7):
Liquid gasket (LG-9)
3 Hose clamp of tube (7):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
a Tighten drive shaft mounting bolts according to
31.Remove U-bolt (38). the following procedure.
32.Remove connecting bolts (39) (12 pieces)
1. Check that the mating yoke and the seat of the
between the engine and torque converter.
drive shaft spider are free from rust, foreign
material (masking material), bruise, etc.
2. Set the yoke key slot in the vertical position,
place the drive shaft on the lower part of the
faucet joint portion, and insert the key into the
key slot.
3. Lightly tighten upper and lower bolts (4 pieces
each) until the spider contacts the seat of the
yoke.

50-146 WA470-7
50 Disassembly and assembly
Power train

a Use a plastic (or copper) hammer to tap them


for contacting if fit of keyway portion and
faucet joint is hard. (Do not use a hard metal
hammer since it can damage the cross
bearing)
3 Mounting bolt of drive shaft (30) and
(31):
98 to 123 Nm {10 to 12.5 kgm}
[*3]
3 Engine mounting bolt (35):
455 to 565 Nm {46.5 to 58 kgm}
[*4]
3 Transmission mounting bolt (37):
455 to 565 Nm {46.5 to 58 kgm}
[*5]
a Adjust the clearance (a) between the
transmission mount bracket and front and rear
stopper bolt (41) to the following value, and
tighten lock nut (42).
• Clearance (a): 2 mm

• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Hydraulic tank: 173l l


Transmission case: 65 l
• Air bleeding
Bleed air from each part. For details, see Testing
and adjusting.

WA470-7 50-147
50 Disassembly and assembly
Power train

Disassembly and assembly of transmission assembly (WA470-CF00-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Necessity
Part No. Part name
bol
Sym-

Q'ty
Part No. Part name
bol
25 790-445-3810 Push tool t 1
793T-607-1550 Bracket t 1 26 790-201-2860 Spacer q 1
1 01051-62240 Bolt t 1 790-101-5401 Push tool kit q 1
01643-32260 Washer t 1 790-101-5421 • Grip 1
27
793T-607-1260 Plate t 1 790-101-5441 • Plate 1
01016-51645 Bolt t 1 01010-51240 • Bolt 1
2 28 790-434-1470 Push tool q 1
01016-51690 Bolt t 1
01010-81245 Bolt t 4 B 793T-607-1430 Push tool t 1
3 793T-607-1570 Plate t 1 29 790-101-5421 Grip t 1
4 790-102-1891 Nut wrench t 1 01010-51240 Bolt t 1
793T-607-1220 Lifting tool t 1 30 793T-607-1140 Spacer t 1
5 793T-607-1440 Push tool t 1
793-607-1230 Pin t 1
793T-607-1280 Lifting tool t 2 31 790-101-5421 Grip t 1
01016-31245 Bolt t 4 01010-51240 Bolt t 1
01580-11210 Nut t 4 32 793T-607-1450 Spacer t 1
01017-30250 Bolt t 2 Disassembly (WA470-CF00-530-K-00-A)
6
01643-32060 Washer t 4
a Be careful not to damage parts during
01580-12016 Nut t 4
disassembly (also during transporting and
793T-607-1290 Bar t 1
storing them).
04530-11628 Eyebolt t 1
If you damaged a part and the damage is
793T-607-1310 Plate t 1
repairable, repair it before assembly.
793T-607-1520 Push tool t 1
7 t If the damage is not repairable (when the repair
2989-01-1220 Bolt 1
can affect part's dimension, precision, surface
01643-33080 Washer t 1
roughness, etc.), replace the part with a new one.
B 01017-31420 Bolt t 8
t 1. Place the torque converter and transmission
793T-607-1330 Bracket 1
assembly on a level place, and stabilize it by
793T-607-1340 Plate t 1
8 using block, etc.
01010-80820 Bolt t 2 2. Remove steering pump and power train pump
01643-30823 Washer t 2 assembly (A).
793T-607-1350 Bolt t 1
9
04530-11018 Eyebolt t 1 4 Steering pump and power train pump
793T-607-1560 Sleeve t 1 assembly:
10 01017-51630 Bolt t 1 85 kg
01643-31645 Washer t 1
11 790-201-2660 Plate q 1
12 792-135-3360 Plate q 1
13 792-822-1430 Plate q 1
14 790-201-2860 Spacer q 1
15 792T-227-1110 Push tool t 1
16 792T-423-1320 Push tool t 1
17 790-201-2680 Plate q 1
18 794T-425-1110 Push tool t 1
19 793T-615-1810 Push tool t 1
20 791T-630-2410 Push tool t 1
21 790-201-2220 Plate q 1
22 790-201-2160 Plate q 1 3. Remove work equipment pump and cooling fan
23 793T-607-1420 Push tool t 1 pump assembly (B).
24 793T-623-1170 Push tool t 1

50-148 WA470-7
50 Disassembly and assembly
Power train

4 Work equipment pump and cooling


fan pump assembly:
160 kg

3) Disconnect hose (6) and remove flange (7).

4. Remove emergency steering pump and motor


assembly (1) and bracket (2).

4) Remove tube (8) and filter assembly (9).

5. Disconnect all the connectors, and remove the


wiring harnesses.
a For details of the connectors, see
Troubleshooting, "Connector list and layout".
6. Piping, sensor and ECMV assembly
1) Remove tube (3).

5) Remove tubes (10) and (10a).


6) Remove transmission output shaft speed
sensor (11).

2) Remove tube (4) and gauge (5).

7) Remove transmission oil temperature sensor


(12).

WA470-7 50-149
50 Disassembly and assembly
Power train

8) Remove torque converter outlet pressure 12)By using guide bolt [2], remove R ECMV
sensor (13) and torque converter oil assembly (20), 2nd ECMV assembly (21),
temperature sensor (13-1). 3rd ECMV assembly (22), block (23), and
9) Remove tube (14). filter (24) together with plate (25).

10)By using guide bolt [1], remove L/C ECMV 13)Remove transmission input shaft speed
assembly (15-1), F ECMV assembly (15), 1st sensor (26).
ECMV assembly (16), and 4th ECMV
assembly (17) together with plate (18).

7. Coupling and strainer


1) remove coupling (27) and strainer (28).
11)Remove torque converter inlet pressure
sensor (19-1) and main relief valve (19).

50-150 WA470-7
50 Disassembly and assembly
Power train

8. Preparation for removal of rear and 2nd clutch


4) Install tool B2.
pack assembly
a At this time, install the tool for removing the R
and 2nd clutch pack assembly.
1) Remove cage (29).

9. Disconnection of front case and rear case


1) Place the torque converter and transmission
assembly on a level place with the torque
converter side up and stabilize it by using
2) Remove holder (30) and plate (31). blocks, etc.
2) Sling rear case (32) and remove the
connecting bolts between the front case and
the rear case.
3) By using forcing screw [3] (M12 x 1.75),
separate the front case and the rear case.
4) Sling and remove rear case assembly (32).

3) Install the bolt (M20 x 2.5) of tool B2 to


transfer shaft 1 (68).

10.Disconnection of torque converter assembly


a When removing the bearing outer races from
the front case and the rear case, take
extreme care not to damage the cases.
If any portion is scratched, modify it smoothly.

WA470-7 50-151
50 Disassembly and assembly
Power train

1) Place the assembly with the torque converter


side of the rear case up on a level place and
stabilize it by using blocks, etc.
2) Remove the mounting bolts of housing (33).
3) By using forcing screw [4] (M12 x 1.75),
separate the housing and the rear case.
4) Sling and remove housing (33).

9) Remove bolts (39) (10 pieces).


a Remove cover (40) when necessary.
a Install bolt (M10 x 1.5) to the forcing tap to
remove.

5) Turn over the rear case and stabilize it by


using blocks, etc.
6) Remove snap ring (34), then remove bearing
(35).

10)Sling and remove rear case (41) and


separate torque converter assembly (41a).
a The shape of torque converter assembly
shown in the figure is different from the
real one.

7) Install bolts [5] (M10 x 1.5) to the tapped


holes and remove spacer (36).

a For disassembly and assembly procedure of


torque converter assembly, see
"Disassembly and assembly of torque
8) Remove thrust plate (37) and snap ring (38). converter assembly".
11.PTO assembly
a Disassemble the right and left PTO
assemblies in the same procedure.

50-152 WA470-7
50 Disassembly and assembly
Power train

1) Remove the mounting bolts of PTO


assembly (42).
2) By using forcing screws [7] (M12 x 1.75),
sling and remove PTO assembly (42).

12.Rear case
Remove outer races (50), (51), and (52) from the
rear case.
a When removing the bearing outer races from
3) By using tool B3, fix gear (43). the front case and the rear case, be careful
4) By using tool B4, remove nut (44).
not to damage the cases.
If any portion is scratched, modify it smoothly.

5) Remove cage (45) and bearing (46).


6) Remove bearing (47) from gear (43).
13.Input shaft and gear
1) Remove input shaft (53).
2) Remove seal ring (54), thrust bearing (55),
thrust plate (56), and inner race (57) from
input shaft (53).

7) Remove outer races (48) and (49) and snap


ring (45a) from cage (45).

WA470-7 50-153
50 Disassembly and assembly
Power train

3) Remove gear (58). 2) By using tool B5, sling and remove F and 1st
clutch assembly (64).

4) Remove inner race (58a) from gear (58).


3) Install tool B6 to R and 2nd clutch pack
assembly (65) and 3rd and 4th clutch pack
assembly (66), then sling them.
4) While tightening the bolt installed in the
center of tool B2 in Step 8-4), sling and
remove R/2nd clutch pack assembly (65)
and 3rd/4th clutch pack assembly (66).
a Remove them by separating inner race
(67) and transfer shaft 1 (68).
2 Threaded portion and end face of
center bolt of tool B2:
Molybdenum disulfide lubricant
5) Remove bearing (60) from front case (59).

14.Clutch pack assembly


1) Remove seal rings (61), (62), and (63) from
each clutch pack assembly.

50-154 WA470-7
50 Disassembly and assembly
Power train

5) Loosen bolts (74) (4 pieces) and bolts (75)


a For the disassembly and assembly (12 pieces) gradually and evenly to remove.
procedure of the clutch pack assembly, see 6) Remove cover (76).
"Disassembly and assembly of transmission
clutch pack assembly".
15.Parking brake
1) Remove coupling (69).

7) Remove springs (77) and (78).


8) By using eyebolt (M12 x 1.75), remove piston
(79).

2) Remove the mounting bolts of cage (71).


3) By using forcing screws [8] (M12 x 1.25),
remove cage (71).

9) Remove O-rings (80) and (81) and backup


rings (82) and (83) from piston (79).

4) Remove dust seal (72) and oil seal (73) from


cage (71).

WA470-7 50-155
50 Disassembly and assembly
Power train

13)Remove spacer (90).


14)Install bolts (M10 x 1.5) to the tapped holes
and remove hub (91).
15)Remove plate (92).

10)By using tool B1, push spacer (84) to


remove ring (85).

16)Remove the mounting bolts of retainer (93).


17)By using forcing screws [12], remove
retainer (93).

11)Install bolts [11] (M8 x 1.25) to the tapped


holes and remove spacer (86).

18)Remove outer race (94) from retainer (93).

12)Remove plates (87) (7 pieces), springs (88)


(6 pieces), and discs (89) (6 pieces).

19)Remove shims (95).

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50 Disassembly and assembly
Power train

a When removing the bearing outer races


from the front case and the rear case, be
careful not to damage the cases.
If any portion is scratched, modify it
smoothly.

20)Sling and remove housing (96).

16.Transfer shaft 2 and transfer gear 2


1) Remove the mounting bolts of cage (105).
2) By using forcing screws [13] (M12 x 1.75),
remove cage (105).

21)Install eyebolts (M22 x 1.5) to the tapped


holes of the shaft and sling and remove shaft
and gear assembly (97).

3) Remove outer race (106) from cage (105).


a When removing the bearing outer races
from the cage, take extreme care not to
damage the cage.
If any portion is scratched, modify it
smoothly.
22)Remove bearing (99), spacer (100), gear
(101), and bearing (102) from shaft (98)

4) Remove shims (107).


5) Remove snap ring (107a) and plate (107b).
23)Remove cover (103) and outer race (104).

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50 Disassembly and assembly
Power train

6) Install tool B7 to transfer shaft 2 (108) and


transfer gear 2 (109).

17.Transfer gear 1

7) Tighten the outside bolts of tool B7 to a Transfer shaft 1 is removed together with the
separate and remove transfer shaft 2 (108) R and 2nd clutch pack assembly.
from transfer gear 2 (109). a When removing the bearing outer races from
a Tighten all the outside bolts evenly. the front case and the rear case, take
extreme care not to damage the cases.
2 Threaded portion and end face of
If any portion is scratched, modify it smoothly.
outside bolt:
1) Remove inner race (112) and bearing (113).
Molybdenum disulfide lubricant
8) Remove bearings (108a) and (108b) from a After removing bearing (113), remove the
transfer shaft 2 (108). remaining plate [a component part of
9) Move transfer gear 2 (109) sideways to bearing (113)].
remove.
10)Remove outer race (111) from front case
(110).
a When removing the bearing outer races
from the front case and the rear case,
take extreme care not to damage the
cases.
If any portion is scratched, modify it
smoothly.

2) Remove transfer gear 1 (114).

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50 Disassembly and assembly
Power train

3) Remove spacer (115) from transfer gear 1


2) Remove outer race (120) from cage (118).
(114).
a When removing the bearing outer races
from the cage, take extreme care not to
damage the cage.
If any portion is scratched, modify it
smoothly.

4) Remove snap ring (116), then remove


bearing (118) from front case (117).

19.Retainer
1) Remove retainer (121) from front case (117).
2) Remove dust seal (122) and oil seal (123)
from retainer (121).

18.Cage
1) Remove cage (118) and shim (119) from
front case (117).

Assembly (WA470-CF00-710-K-00-A)

a Before assembly, remove all liquid gasket


sticking to the mating face of the case.
a Clean all parts and check them for dirt or
damage before assembling.

WA470-7 50-159
50 Disassembly and assembly
Power train

a Press-fit the outer race and inner race of each a Part b:


bearing until they are seated on the case or Fill 40 to 60% of the clearance between
shaft, and check the feeler gauge (thickness: the main lip of oil seal (123) and the lip of
0.05 mm) cannot be inserted. dust seal (122), and the clearance
a After installing each bearing, drip at least 6 cc of between the dust seal and the oil seal
power train oil (TO10) to them and rotate them at with grease (G2-S or G2-LI).
least 10 turns. a Part c:
a When expansion-fit a bearing, drip at least 6 cc Grease may protrude into the clearance
of power train oil (TO10) to it and rotate it at least between the oil seal and the dust seal.
10 turns before cooling it in dry ice. Note, however, that excessively applied
grease can be mistaken for oil leakage.
a Check that snap ring is fitted to the groove
securely.
1. Retainer
1) Thinly apply liquid gasket (LG-5) to the oil
seal fitting face of retainer (121).
2) By using tool B31, press fit oil seal (123) to
retainer (121).
a Dimension (a) becomes 18.9 ± 0.2 mm.

5) Install retainer (121) to front case (117).

3) By using tools B31 and B32, press-fit dust


seal (122).
a Dimension (b) becomes 9.9 ± 0.2 mm.

2. Cage
1) By using tool B11, press fit outer race (120)
to cage (118).
2 Inner periphery of outer race:
Power train oil (TO10)

4) Apply and fill grease as shown in the


following figure.
a Part a:
Apply grease (G2-S or G2-LI) to the lip
ends (3 places).

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50 Disassembly and assembly
Power train

2 Inner periphery of outer race:


Power train oil (TO10)

2) Install shim (119) and cage (118) to front


case (117) loosely.
2 Periphery of O-ring: 2) By using tool B13, press fit outer race (106)
Grease (G2-LI) to cage (105).
a Set the total thickness of shim (119) to be 2 Inner periphery of outer race:
2.2 to 2.5 mm. Power train oil (TO10)
a After completion of assembly of
transmission assembly, adjust shim (119).

3) By using tools B15 and B16, press-fit


bearings (108a) and (108b) to transfer shaft
3. Bearing for transfer shaft 1 2 (108).
4) Apply oil to bearings (108a) and (108b) and
1) Install snap ring (116) to front case (117).
rotate the bearing at least 10 turns to spread
2) By using tool B12, press-fit bearing (118).
the oil.
2 Bearing:
Power train oil (TO10)

4. Transfer shaft 2 and transfer gear 2


1) By using tools B13 and B14, press fit outer
race (111) to front case (110).

WA470-7 50-161
50 Disassembly and assembly
Power train

5) Install tool B8 to transfer gear 2 (109). 11)Set heated transfer gear 2 (109) and tool B8
6) Heat transfer gear 2 (109) with tool B8 as a set in the front case (110).
installed in a heating cabinet.
k Do not hold transfer gear 2 (109) and
a Heat at temperature below 145°C for at
least 2 hours. tool B8 with bare hands.
2 Inner periphery of gear:
Power train oil (TO10)
12)Check that the inside faces of transfer gear 2
(109) and outer race (111) are aligned each
other.
13)Insert transfer shaft 2 (108) slowly into
transfer gear 2 (109).
a Insert the shaft until it stops.
a Once the shaft is positioned, do not raise
it. (At the moment when the shaft is
raised, the temperature difference
between the shaft and gear is lost and
7) Install tool B9 to transfer shaft 2 (108). they may be fixed together)
8) Refrigerate transfer shaft 2 (108) with tool B9 14)Check that level difference (b) between
installed in a freezer for at least 1 hour. transfer shaft 2 (108) and transfer gear 2
9) Refrigerate plate (107b) in the freezer. (109) is in the following range by using a
a The refrigerating time of the plate may be depth gauge.
shorter than that of transfer shaft 2 (108). • Dimension (b): -0.4 to 0.4 mm
10)Check that the temperature difference a If dimension (b) is out of the standard
between transfer gear 2 (109) and transfer value, separate the shaft and gear
shaft (108) is at least 140°C. immediately. Eliminate the cause, and
then repeat the procedure from step 6).
15)Leave the shaft and gear as they are for at
least 20 minutes until their temperature
decreases to the normal temperature.
16)Rotate transfer shaft 2 (108) to check that it
is press fitted to transfer gear 2 (109) (the
shaft and gear do not slip on each other).
a Do not raise transfer shaft 2 (108).
17)Remove tools B8 and B9.

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50 Disassembly and assembly
Power train

5. Parking brake
1) By using tools B17 and B18, press fit outer
race (104) to the front case.
2 Inner periphery of outer race:
Power train oil (TO10)
2) Install cover (103).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}

18)Install plate (107b) and snap ring (107a).

19)Install cage (105) lightly.


a After adjusting the shims in the following
step 5-9), fasten cage (105) to the
specified torque.
2 Periphery of O-ring:
Grease (G2-LI)

3) Install gear (101) and spacer (100) to shaft


(98).
a When installing gear (101), direct the side
of the tapped holes downward.
4) By using tools B19 and B20, press fit
bearings (99) and (102) to shaft (98).

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50 Disassembly and assembly
Power train

2 Bearings (99) and (102): 6) Sling down and install housing (96).
Power train oil (TO10) 2 Periphery of O-ring:
Grease (G2-LI)

7) By using tool B13, press fit outer race (94) to


retainer (93).
2 Inner periphery of outer race:
Power train oil (TO10)

5) Install eyebolts (M22 x 1.5) to the tapped


holes of the shaft and sling down and install
the shaft and gear assembly (97).

8) Adjust the shim of the output shaft according


to the following procedure.
1] Install retainer (93) without installing shim
(95).
3 Mounting bolt:
9.80 ± 0.98 Nm {1 ± 0.1 kgm}
2] Rotate shaft (98) 10 turns each clockwise
and counterclockwise, and then check

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50 Disassembly and assembly
Power train

that the tightening torque of the mounting 5] to 7] until the value is in the preceding
bolt of retainer (93) has not changed. range.
a If the tightening torque has changed a If the shim thickness is increased by
0.98 Nm {0.1 kgm} or more, repeat 0.1 mm, the rotating torque changes
steps 1] and 2]. -5.88 to -1.96 Nm {-0.60 to -0.20
kgm}.

9) Adjust the shim of the transfer 2 shaft


according to the following procedure.
1] Install cage (105) without installing shim
(107).
2 Periphery of O-ring:
Grease (G2-LI)
3 Mounting bolt:
9.80 ± 0.98 Nm {1 ± 0.1 kgm}
2] Rotate shaft (98) 10 turns each clockwise
and counterclockwise, and then check
3] Loosen the mounting bolts of retainer that the tightening torque of the mounting
(93) and measure rotating torque (A) of bolt of cage (105) has not changed.
shaft (98) by using torque wrench [22].
4] Remove retainer (93) and select and a If the tightening torque has changed
install shims for shim (95) so that their 0.98 Nm {0.1 kgm} or more, repeat
total thickness is as follows. steps 1] and 2].
• Set shim thickness (mm): 3] Measure clearance (c) at equally spaced
0.15, 0.20, 0.50 3 places on the periphery and calculate
• Total shim thickness (mm): the average value.
1.3 (+0.25 / -0.45) a If the difference between the
5] Tighten retainer (93) to the following maximum and minimum ones of the 3
torque. measured values is larger than 0.15
3 Mounting bolt: mm, the bearing may not be installed
properly or there may be another
98.0 to 122.5 Nm {10 to 12.5 cause. So inspect and modify it.
kgm} 4] Loosen the mounting bolts of cage (105).
6] By using torque wrench [22], measure 5] Select and install shims for shim (107) so
rotating torque (B) of shaft (98). that their total thickness is the average
7] Check that value (B - A) obtained by clearance (c) obtained in step 3] plus
subtracting rotating torque (A) from 0.15 to 0.21 mm.
rotating torque (B) is as follows. 6] Tighten cage (105) mounting bolt.
• B - A = 0.49 to 2.94 Nm {0.05 to 0.3
kgm} 3 Mounting bolt:
8] If value (B - A) is out of the preceding 98.0 to 122.5 Nm {10 to 12.5
range, increase or decrease the kgm}
thickness of shim (95) and repeat steps 7] By using torque wrench [22], measure
rotating torque (C) of shaft (98).

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50 Disassembly and assembly
Power train

8] Check that value (C - B) obtained by


subtracting rotating torque (B) measured
in step 8)-6] from rotating torque (C) is as
follows.
• C - B = 0.49 to 2.94 Nm {0.05 to 0.3
kgm}
9] If value (C - B) is out of the preceding
range, increase or decrease the
thickness of shim (107) and repeat steps
6] to 8] until the value is in the preceding
range.
a If the shim thickness is increased by
0.1 mm, the rotating torque changes
-6.86 to -1.96 Nm {-0.70 to -0.20
kgm}.

13)Install bolts [11] (M8 x 1.25) to the tapped


holes and install spacer (86).
2 Periphery of O-ring:
10)Install plate (92). Grease (G2-LI)
a Direct the side having level difference
down when installing.
11)Install hub (91) and spacer (90).
2 Both end faces of hub and spacer:
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LM-
G)

14)By using tool B1, push spacer (84) to install


ring (85).

12)Install plates (87) (7 pieces), springs (88) (6


pieces), and discs (89) (6 pieces).
a Install these parts in the order shown in
the figure and take care that springs (88)
are not caught.

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50 Disassembly and assembly
Power train

15)Install O-rings (80) and (81) and backup


rings (82) and (83) to piston (79).
2 Outside faces of O-ring and
backup ring:
Grease (G2-LI)

18)Install cover (76).


19)Tighten bolts (75) (12 pieces) and bolts (74)
(4 pieces) gradually and evenly.
a Check that the dowel pin on the cover
side is aligned with the hole on the piston.
16)By using eyebolts (M12 x 1.75), install piston 3 Mounting bolt:
(79) to housing (96).
98 to 123 Nm {10 to 12.5 kgm}
a At this time, align matchmarks (a) on the
housing side and piston side.

20)Thinly apply liquid gasket (LG-5) to the oil


seal fitting face of cage (71).
21)By using tool B29, press-fit oil seal (73).
a Dimension (a) becomes 19 ± 0.2 mm.

17)Install springs (77) and (78).

22)By using tools B29 and B30, press-fit dust


seal (72).
a Dimension (b) becomes 10 ± 0.2 mm.

WA470-7 50-167
50 Disassembly and assembly
Power train

25)Install coupling (69).


23)Apply and fill grease as shown in the
following figure. 2 Mounting bolt:
a Part a: Adhesive (LT-2)
Apply grease (G2-S or G2-LI) to the lip 3 Mounting bolt:
ends (3 places). 662 to 829 Nm {67.5 to 84.5 kgm}
a Part b:
Fill 40 to 60% of the clearance between
the main lip of oil seal (73) and the lip of
dust seal (72) and the clearance between
the dust seal and the oil seal with grease
(G2-S or G2-LI).
a Part c:
Grease may protrude into the clearance
between the oil seal and the dust seal.
Note, however, that excessively applied
grease can be mistaken for oil leakage.

6. Clutch pack assembly


1) Turn over the front case.
2) By using tool B6, install R and 2nd clutch
pack assembly (65) and 3rd and 4th clutch
pack assembly (66) simultaneously to the
front case.

24)Install cage (71).


2 Periphery of O-ring:
Grease (G2-LI)

3) By using tool B5, install F, 1st clutch pack


assembly (64).

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50 Disassembly and assembly
Power train

4) Install seal rings (61), (62), and (63) to each 3) Install gear (58).
clutch pack assembly.
a Check that the height difference between
a When installing seal rings (61) for the F the meshed 3 gears is 3 mm or less.
and 1st clutch pack and seal rings (63) for If the position of gear (140) is higher, F
the R and 2nd clutch pack, check that and 1st clutch pack assembly (64) may
there are oil grooves on their sides. be stopped at the faucet joint portion.
2 Periphery of seal ring:
Grease (G2-LI)

4) By using tool B23, press-fit inner race (57) to


input shaft (53).
7. Input shaft and gear
1) By using tool B21, press fit bearing (60) to
front case (59).
2 Bearing:
Power train oil (TO10)

5) Install thrust plate (56), thrust bearing (55),


and seal rings (54).
a When installing seal rings (54), check that
there are oil grooves on its sides.
2 Periphery of seal ring:
2) By using push tool B22, press-fit inner race Grease (G2-LI)
(58a) to gear (58).

WA470-7 50-169
50 Disassembly and assembly
Power train

6) Install input shaft (53).


1) Install snap ring (45a) to cage (45).
2) By using tool B24, press fit outer races (48)
and (49) to cage (45).
2 Inner periphery of outer race:
Power train oil (TO10)

8. Rear case
By using tool B13, press fit outer races (50), (51),
and (52) to the rear case.
a Press fit bearing outer race (50) for the taper
roller bearing to the portion where there is
identification hole (a). 3) By using tool B25, press fit bearing (47) to
2 Inner periphery of outer race: gear (43).
Power train oil (TO10) 2 Bearing:
Power train oil (TO10)
4) Install cage (45) and bearing (46).
2 Bearing:
Power train oil (TO10)
5) Finger-tighten nut (44).
a Direct the chamfered side down.
6) Rotate gear (43) at least 10 turns to spread
oil.

9. PTO assembly
a Assemble the right and left PTO assemblies
in the same procedure.
a When installing inner race and outer race of
the bearing, check that their manufacturing
numbers and match symbols (A) or (B) are
the same.

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50 Disassembly and assembly
Power train

7) By using tool B3, fix gear (43). 2) By using tool B26, press fit cover (40) and
8) By using tool B4, tighten nut (44). tighten bolts (39) (10 pieces).
2 Nut: 2 Mounting bolt:
Adhesive (LT-2) Adhesive (LT-2)
3 Nut: 3 Mounting bolt:
392.3 to 441.3 Nm {40 to 45 kgm} 98 to 123 Nm {10 to 12.5 kgm}

9) Install PTO assembly (42).


2 Periphery of O-ring:
Grease (G2-LI)

3) Install snap ring (38) and thrust plate (37).

10.Installation of torque converter assembly


1) Sling and lower rear case (41) onto torque
converter assembly (41a).
a The shape of torque converter shown in
the figure is different from the real one.

WA470-7 50-171
50 Disassembly and assembly
Power train

6) Turn over the rear case and stabilize it by


using blocks, etc.
7) By using guide bolts [17], install housing
(33).
2 Periphery of O-ring:
Grease (G2-LI)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}

4) By using tool B27, install spacer (36).

11.Joint of front case and rear case


a Secure the front case with its mating surface
level.
5) By using tool B28, press fit bearing (35) and a Sling down the rear case with its mating
install snap ring (34). surface level. (If front case and rear case are
jointed while they are slung inclined, inner
2 Bearing:
parts may be damaged.)
Power train oil (TO10)
1) Apply liquid gasket to the mating faces of the
front case and rear case as shown in the
following figure.
a (A) indicates that there are forcing taps on
the mating case.
2 Mating face of case:
Liquid gasket (LG-8)

2) By using guide bolts [18], sling and lower


rear case (32) to install.
3 Connecting bolt:
98 to 123 Nm {10 to 12.5 kgm}

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50 Disassembly and assembly
Power train

2 Bearing:
Power train oil (TO10)
6) Remove cage (29).

12.Transfer gear 1, bearing, and cage


1) Place the assembly with the front case side
up on a level place and stabilize it by using
blocks, etc.
2) Install transfer gear 1 (114) to transfer shaft 1 7) By using plate [20] (outside diameter: 100
(68). mm, thickness: approximately 10 mm) and
3) By using tool B10, install spacer (115) to bolt [21] (M20 x 2.5, stem length:
transfer gear 1 (114). approximately 70 mm), press fit inner race
(112) and spacer (31).
2 Both end surfaces of spacer and
end surface (a part) of transfer
gear 1 (114):
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LM-
G)

8) Install holder (30).


2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
4) Install bearing inner ring (130).
a This is a component part of bearing (113).
a When installing this part, direct the side of
the rounded end corner down.
2 Both end faces of bearing inner
ring:
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LM-
G)
5) Fasten cage (29) with bolts [19] (M12 x 1.5,
stem length: 80 to 40 mm) until it touches the
front case, then press fit bearing (113). 9) Install cage (29).

a At this time, do not fit the O-ring to cage 2 Periphery of O-ring:


(29). Grease (G2-LI)

WA470-7 50-173
50 Disassembly and assembly
Power train

10)If value (E - D) is out of the preceding range,


increase or decrease the thickness of shim
(119) and repeat steps 7] to 9] until the value
is in the preceding range.
a If the shim thickness is increased by 0.1
mm, the rotating torque changes -5.88 to
-1.96 Nm {-0.60 to -0.20 kgm}.

13.Adjustment of shims of F and 1st shafts


1) Install cage (118) without installing shim
(119).
2 Periphery of O-ring:
Grease (G2-LI)
3 Mounting bolt:
9.80 ± 0.98 Nm {1 ± 0.1 kgm}
2) Rotate the F and 1st shafts 10 turns each 11)Check that the F and 1st shaft have no end
clockwise and counterclockwise, and then play.
check that the tightening torque of the a Install a bolt (M12 x 1.75, stem length:
mounting bolt of cage (118) has not changed. Min. 140 mm) to each shaft and measure
a Install bolts (M12 x 1.75) to the F and 1st end play by using a dial gauge.
shafts, and rotate them. 12)Install cover (131).

a If the tightening torque has changed 0.98 2 Periphery of O-ring:


Nm {0.1 kgm} or more, repeat steps 1) Grease (G2-LI)
and 2).
3) Measure clearance (d) at equally spaced 3
places on the periphery and calculate the
average value.
a If the difference between the maximum
and minimum ones of the 3 measured
values is larger than 0.15 mm, the
bearing may not be installed properly or
there may be another cause. So inspect
and modify it.
4) Loosen the mounting bolts of cage (118).
5) By using torque wrench [22], measure
rotating torque (D).
6) Select and install shims for shim (119) so that 14.Coupling and strainer
their total thickness is average clearance (d) 1) Place the torque converter and transmission
obtained in step 3) plus 0.18 to 0.24 mm. assembly on a level place and stabilize it by
7) Tighten cage (118) mounting bolt. using block, etc.
3 Mounting bolt: 2) Install coupling (27) and strainer (28).
98.0 to 122.5 Nm {10 to 12.5 kgm}
8) By using torque wrench [22], measure
rotating torque (E) of the F and 1st shafts.
9) Check that value (E - D) obtained by
subtracting rotating torque (D) measured in
step 5) from rotating torque (E) is as follows.
• E - D = 0.49 to 2.94 Nm {0.05 to 0.3 kgm}

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50 Disassembly and assembly
Power train

3 Torque converter inlet pressure


sensor:
29.4 to 34.3 Nm {3.0 to 3.5 kgm}

15.Piping, sensor and ECMV assembly


1) Install transmission input speed sensor (26).
a Check that the sensor tip is free from iron
dust and flaws. 5) By using guide bolt [1], install L/C ECMV
assembly (15-1), F ECMV assembly (15), 1st
2 Threaded part of sensor:
ECMV assembly (16), and 4th ECMV
Liquid gasket (LG-5) assembly (17) together with plate (18).
3 39.2 to 49 Nm {4 to 5 kgm}

6) Install tube (14).


2) By using guide bolt [2], install R ECMV 7) Install torque converter outlet pressure
assembly (20), 2nd ECMV assembly (21), sensor (13).
3rd ECMV assembly (22), block (23), and 3 Torque converter outlet pressure
filter (24) together with plate (25). sensor:
29.4 to 49 Nm {3.0 to 5.0 kgm}
8) Install torque converter oil temperature
sensor (13-1).
2 Threaded portion of torque
converter oil temperature sensor:
Liquid gasket (LG-5)
3 Torque converter oil temperature
sensor:
29.4 to 49 Nm {3.0 to 5.0 kgm}

3) Install main relief valve (19).


3 Mounting bolt:
44.1 to 53.9 Nm {4.5 to 5.5 kgm}
4) Install torque converter inlet pressure sensor
(19-1).

WA470-7 50-175
50 Disassembly and assembly
Power train

3 Joint bolt
M8: 19.6 to 29.4 Nm {2.0 to 3.0
kgm}
M12: 34.3 to 44.1 Nm {3.5 to 4.5
kgm}

9) Install transmission oil temperature sensor


(12).
2 Threaded part of sensor:
Liquid gasket (LG-5)
3 Sensor:
29.4 to 49 Nm {3 to 5 kgm}

12)Install tube (8) and filter assembly (9).


10)Install transmission output shaft speed
sensor (11).
1] Loosen lock nut (132).
2] Tighten it until the end of sensor (11)
lightly touches tooth tip of gear (133).
a Check that the sensor tip is free from
iron dust and flaws.
2 Threaded part of sensor:
Liquid gasket (LG-5)
3] Return sensor (11) by a half to 1 turn.
a Clearance (a) between the sensor tip
and gear (133) tooth tip is adjusted to 13)Install flange (7) and connect hose (6).
approximately 0.75 to 1.5 mm.
4] Secure sensor (11) with lock nut (132).
3 Lock nut:
49 to 96 Nm {5.0 to 7.0 kgm}
11)Install tubes (10) and (10a).

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50 Disassembly and assembly
Power train

14)Install tube (4) and gauge (5). 18.Install work equipment pump and cooling fan
pump assembly (B).
2 Gauge mounting bolt:
Adhesive (LT-2) 4 Work equipment pump and cooling
3 Gauge mounting bolt: fan pump assembly:
12.7 to 13.7 Nm {1.3 to 1.4 kgm} 160 kg

15)Install tube (3). 19.Install steering pump and power train pump
assembly (A).
3 Tube mounting joint:
9.8 to 12.7 Nm {1.0 to 1.3 kgm} 4 Steering pump and power train pump
assembly:
85 kg

16.Connect the connectors.


a For details of the connectors, see
Troubleshooting, "Connector list and layout".
17.Install emergency steering pump and motor
assembly (1) and bracket (2).

WA470-7 50-177
50 Disassembly and assembly
Power train

Disassembly and assembly of torque converter assembly (WA470-CD00-926-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

790-501-5000 Unit repair stand q 1


33 790-901-2110 Bracket q 1
793T-613-1510 Plate t 1
34 792-213-1110 Wrench t 1
35 790-201-2650 Plate q 1
36 790-201-2740 Spacer q 1
B
37 790-201-2660 Plate q 1
38 792T-415-1410 Spacer q 1
39 790-201-2750 Spacer q 1
40 790-201-2680 Plate q 1
41 790-201-2220 Plate q 1
42 791-830-1770 Push tool q 1
Disassembly (WA470-CD00-530-K-00-A)

a Take care not to damage parts during


disassembly (also during transporting and
storing them). If you damaged a part and the
damage is repairable, repair it before assembly.
If the damage is not repairable (when the repair
can affect part's dimension, precision, surface 3) Remove bolts (6) (12 pieces) to remove
roughness, etc.), replace the part with a new one. pump (7).
1. Place torque converter assembly (1) on blocks.
(Or install it to tool B33.)
2. Stator shaft and pump assembly
1) Install eyebolts to the stator shaft, remove
the bolt (2), and remove stator shaft and
pump assembly (3).

4) By using tool B35, separate stator shaft (5)


and bearing (8).

2) By using tool B34, remove nut (4).


a Install bolts (M12 x 1.75) (2 pieces) to the
bottom of stator shaft (5) diagonally and
fix them by using bar [1].

50-178 WA470-7
50 Disassembly and assembly
Power train

5) Remove seal ring (9) from stator shaft (5).

4. Turbine and case assembly


6) Separate gear (10) and guide (11). 1) Remove pilot (22).
7) Remove bearing (8) from guide (11).

2) Remove snap ring (23) to remove plate (24).


3. Stator assembly
1) Remove stator assembly (13).
2) Remove upper and lower snap rings (14) and
remove race and free wheel assembly (15)
from stator (16).

3) By using tool B36, separate boss (25) and


bearing (26).

3) Remove bushing (18) from the race and free


wheel assembly.
a Take care not to lose ball (21).
4) Remove snap ring (19-1) to remove free
wheel (19) from race (20).

WA470-7 50-179
50 Disassembly and assembly
Power train

4) Remove the mounting bolts to disconnect


turbine (27) and boss (25).

Assembly (WA470-CD00-710-K-00-A)

1. Complete turbine
5. Complete housing assembly Install turbine (27) to boss (25).
1) Remove the mounting bolts to separate
2 Mounting bolt:
complete housing (28) and case (29).
Adhesive (LT-2)
3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}

2) Remove piston (30) from complete housing


(28).
3) Remove seal ring (31) from piston (30).
4) Remove seal ring (32) from complete
2. Turbine and case
housing (28).
Set complete turbine (36) to tool B38 and set
5) By using tool B37, remove bearing (33) from
case (29).
complete housing (28).

3. Disc and plate


6) Remove discs (34) (2 pieces) and plate (35)
Install discs (34) (2 pieces) and plate (35) to
from case (29).
case (29).
2 Disc sliding surface:
Power train oil (TO10)

50-180 WA470-7
50 Disassembly and assembly
Power train

4. Complete housing assembly 4) By using eyebolts [5] (M12 x 1.75), sling


1) Install seal ring (32) to complete housing complete housing assembly (37) and set it to
(28). case (29).
5) Tighten mounting bolts (38).
a Install seal rings (32) as shown in the
figure. 2 Mounting bolt:
Adhesive (LT-2)
2 Periphery of seal ring:
Grease (G0-LI or G2-LI) 3 Mounting bolt:
58.8 to 73.5 Nm {6.0 to 7.5 kgm}

2) Install seal ring (31) to piston (30).


5. Bearing
a Install seal rings (31) as shown in the
By using tool B39, press fit bearing (33).
figure.
a After press fitting the bearing, drip at least 6
2 Periphery of seal ring:
cc of power train oil (TO10) to it and rotate it
Grease (G0-LI or G2-LI) 10 turns.
3) Install piston (30) to complete housing (28).

6. Plate and snap ring


Install spacer (24) and snap ring (23).

WA470-7 50-181
50 Disassembly and assembly
Power train

a Make a mark with paint on the race to


indicate the side to which the free wheel
is installed.
(Make mark (P) at a position where you
can see it after installing the bushing.)

7. Pilot
Install pilot (22).
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}

2) Expansion-fit bushings (18) together with


balls (21) to race (20).
8. Stator assembly
a Apply power train oil (TO10) to the sliding
1) Install snap ring (19-1) and free wheel (19) to surfaces of the bushings.
race (20).
a Apply power train oil (TO10) to the sliding
surface of the free wheel.
a Assemble so that arrow (C) indicated on
the end face of the free wheel cage is as
shown in the figure.
a Arrow (D) indicates the free rotation
direction of the free wheel.
a Take care not to damage sprag (A) of the
free wheel.
a Install the free wheel so that its drag clip
(B) is not hitched in ball groove (E) of the 3) Install snap ring (14-1) to stator (16).
race. 4) Install race and free wheel assembly (15) to
a Insert the free wheel into the race with stator (16) and install snap ring (14).
your hands. a Assemble race and free wheel assembly
(Do not drive the free wheel with a (15) and stator (16) as shown in the
hammer, etc.) figure.

50-182 WA470-7
50 Disassembly and assembly
Power train

2) Install guide (11) to gear (10).

9. Stator shaft and pump assembly


1) By using tool B40, press fit bearing (8) to 3) Install seal ring (9) to stator shaft (5).
guide (11).
2 Periphery of seal ring:
a Check that the manufacturing number (P Grease (G2-LI)
No.) of the inner and outer races and
match mark (A) are identical at the
position shown in the figure.
a After press fitting the bearing, apply at
least 6 cc of power train oil (TO10) to it
and rotate it at least 10 turns to spread
the oil.

4) By using tools B41 and B42, press fit stator


shaft (5) to bearing (8) and gear (10).

WA470-7 50-183
50 Disassembly and assembly
Power train

5) Install pump (7) and tighten bolts (6). 10.Stator assembly and turbine and case assembly
2 Mounting bolt: 1) Set stator assembly (13) to stator shaft (5).
2) Check that the stator rotates as follows when
Adhesive (LT-2)
seen from the boss side (input side: view A).
3 Mounting bolt: • Clockwise: Free rotation
58.8 to 73.5 Nm {6.0 to 7.5 kgm} • Counterclockwise: Locked

6) By using tool B34, tighten nut (4). 3) By using eyebolts [9] (M12 x 1.75), sling and
lower turbine and case assembly (40) and
a Install bolts (M12 x 1.75) (2 pieces) to the tighten bolts (2) lightly.
bottom of stator shaft (5) diagonally and 4) Turn over the torque converter assembly and
fix them by using bar [1]. tighten bolts (2).
2 Nut: 2 Bolt:
Adhesive (LT-2) Adhesive (LT-2)
3 Nut: 3 Bolt:
441 to 490 Nm {45 to 50 kgm} 49.0 to 58.8 Nm {5.0 to 6.0 kgm}

50-184 WA470-7
50 Disassembly and assembly
Power train

Disassembly and assembly of transmission clutch pack assembly (WA470-


CF60-924-K-00-A)

a Special tools By using tool B43, remove bearing (1).

Necessity
Sym-

Q'ty
Part No. Part name
bol

Commercially Puller q 1
available or
Push puller t 1
43 790-101-2501
790-101-3201 Bearing puller t 1
790-201-1310 Plate t 1
Commercially
Puller q 1
44 available
790-201-1410 Plate t 1
790-101-2510 Block t 1 2. Spacer
790-101-2520 Screw t 1 1) Remove snap ring (2).
791-112-1180 Nut t 1
45
790-101-2540 Washer t 1
B 790-101-2450 Adapter t 1
790-201-2860 Spacer t 1
790-101-3501 Puller t 1
46
790-201-1320 Spacer t 1
47 793-415-1170 Seal holder t 1
48 793T-607-1420 Push tool q 1
49 793T-607-1370 Seal holder t 1
50 796T-467-2160 Push tool t 1
51 799-301-1500 Oil leak tester t 1
52 793T-607-1380 Seal holder t 1
53 792T-446-1150 Push tool t 1 2) By using tool B43, remove spacer (3).
54 793T-607-1390 Seal holder t 1
55 795-102-2730 Collar t 1
Disassembly (WA470-CF60-520-K-00-A)

k When placing a clutch pack on blocks, etc.,


degrease its surface sufficiently so that it
does not slip and fall off your hands.

a Take care not to damage parts during


disassembly (also during transporting and
storing them).
If you damaged a part and the damage is
repairable, repair it before assembly.
3. F clutch gear
If the damage is not repairable (when the repair
can affect part's dimension, precision, surface 1) Remove bearing (4).
roughness, etc.), replace the part with a new one.
a Never pry the gear by applying a bar to it
because doing so damages the gear and
housing. Be sure to use bearing pullers for
disassembly.

Assembly of F and 1st clutch pack assembly

[F clutch]
1. Bearing

WA470-7 50-185
50 Disassembly and assembly
Power train

2) Remove F clutch gear (5). 5. Plate, disc, and spring


Remove plate (10), disc (11), and spring (12).

3) Remove plate (6) and bearing (7) from F


clutch gear (5). 6. Plate and bearing
Remove plate (13) and bearing (14).

4. End plate
1) Using vise [3], press end plate (8). 7. Piston
2) Remove snap ring (9). 1) By using bolts [4] (M8 x 1.25), remove piston
3) Remove end plate (8). (15).

50-186 WA470-7
50 Disassembly and assembly
Power train

1) By using tool B44, remove bearing (20).

2) Remove snap ring (16) to remove lubricating


piston (17) from piston (15).
2) Remove spacer (21) and washer (22).

3) Remove 1st clutch gear (23).

3) Remove seal rings (18) and (19) from piston


(15).
4) Remove bearing (24) from 1st clutch gear
(23).

[1st clutch]
8. Bearing and 1st clutch gear
9. Washer

WA470-7 50-187
50 Disassembly and assembly
Power train

Remove washer (25).

2) Remove seal rings (32) and (33) from piston


(31).
10.End plate
1) Using tool B45, press end plate (26).
2) Remove snap ring (27).
3) Remove end plate (26).

Assembly of R and 2nd clutch pack assembly

[R clutch]
11.Plate, disc, and spring 1. Bearing
Remove plate (28), disc (29), and spring (30). By using tool B43, remove bearing (34).

12.Piston 2. Spacer
1) By using bolts [7] (M8 x 1.25), remove piston 1) Remove snap ring (35).
(31).

50-188 WA470-7
50 Disassembly and assembly
Power train

2) Remove bearing (40) from R clutch gear


(39).

2) By using tool B43, remove spacer (36).

5. Plate and bearing


Remove plate (41) and bearing (42).

3. Bearing and plate


Remove bearing (37) and plate (38).

6. End plate
1) By using vise [10] and push tool [11], press
end plate (43).
2) Remove snap ring (44).
3) Remove end plate (43).

4. R clutch gear
1) Remove R clutch gear (39).

7. Plate, disc, and spring


Remove plate (45), disc (46), and spring (47).

WA470-7 50-189
50 Disassembly and assembly
Power train

8. Piston [2nd clutch]


1) By using bolts [12] (M8 x 1.25), remove 9. Transfer shaft 1
piston (48). 1) Remove transfer shaft 1 (53).

2) Remove snap ring (49) to remove lubricating 2) Remove inner race (54) from transfer shaft 1
piston (50) from piston (48). (53).

3) Remove seal rings (51) and (52) from piston


10.Bearing and hub
(48).
1) Remove snap ring (55) and ring (56).

50-190 WA470-7
50 Disassembly and assembly
Power train

2) By using tool B46, remove bearing (57) and 13.Piston


hub (58) as a unit. 1) By using bolts [15] (M8 x 1.25), remove
piston (64).

11.End plate
1) Using tool B45, press end plate (59). 2) Remove seal rings (65) and (66) from piston
2) Remove snap ring (60). (64).
3) Remove end plate (59).

12.Plate, disc, and spring Assembly of 3rd and 4th clutch pack assembly
Remove plate (61), disc (62), and spring (63). [4th clutch]
1. Bearing
1) By using tool B43, remove bearing (67) and
plate (68).
2) Remove bearing (69).

WA470-7 50-191
50 Disassembly and assembly
Power train

4. End plate
1) Using vise [16], press end plate (75).
2) Remove snap ring (76).
3) Remove end plate (75).

2. Ring, cover, and collar


1) Remove ring (70) and cover (71).

5. Plate, disc, and spring


Remove plate (77), disc (78), and spring (79).

2) Remove collar (72) and seal ring (73).

6. Plate, bearing, and washer


Remove plate (80), bearing (81), and washer
(82).

3. Cylinder assembly
By using bolts (M8 x 1.25) remove cylinder
assembly (74).

7. Piston
1) By using bolts [17] (M8 x 1.25), remove
piston (83).

50-192 WA470-7
50 Disassembly and assembly
Power train

[3rd clutch]
9. Bearing, spacer, and plate
1) Remove bearing (89).
a Stick tapes, etc. to bearing sliding surface
(a) of the shaft for protection.
2) Remove spacer (90).

2) Remove seal rings (84) and (85) from piston


(83).

3) Remove spacers (91) and (92).

8. 4th gear
1) Remove 4th gear (86).

4) Remove bearing (93) and plate (94).

2) Remove plate (87) and bearing (88) from 4th


gear (86).

10.3rd gear
1) Remove 3rd gear (95).

WA470-7 50-193
50 Disassembly and assembly
Power train

2) Remove bearing (96) from 3rd gear (95). 13.Piston


1) Remove piston (102).

11.End plate
1) Using vise [18], press end plate (97). 2) Remove seal rings (103) and (104) from
2) Remove snap ring (98). piston (102).
3) Remove end plate (97).

14.Plate, bearing, and washer


12.Plate, disc, and spring Remove plate (105), bearing (106), and washer
Remove plate (99), disc (100), and spring (101). (107).

50-194 WA470-7
50 Disassembly and assembly
Power train

2) Using tool B47, fit seal rings (103) and (104)


to piston (102).
a Leave it for 2 to 3 minutes as it is.

Assembly (WA470-CF60-720-K-00-A)

a Clean all parts and check them for dirt or


damage before assembling.
a Press-fit the inner race of each bearing until it 3) Install piston (102).
reaches to the end face of the shaft.
2 Seal ring contact surface:
a After installing each bearing, drip at least 6 cc of Power train oil (TO10)
power train oil (TO10) to it and rotate it at least
10 turns.
a Check that snap ring is fitted to the groove
securely.
a Immerse the disc in clean power train oil for 2
minutes or longer before assembling it.
a Press fit each bearing so that no clearance is
made between it and its mating parts in the axial
direction.
Assembly of 3rd and 4th clutch pack assembly

[3rd clutch] 3. Plate, disc, and spring


1. Plate, bearing, and washer Install plate (99), disc (100), and spring (101) in
Install plate (105), bearing (106), and washer this order.
(107).
a Be careful not to install plate (105) and
washer (107) in the reverse order (The
washer is thinner than the plate).

4. End plate
1) Using vise [18], press end plate (97).
2) Install snap ring (98).
a Check that the snap ring is fitted in the
2. Piston groove securely.
1) Install seal rings (103) and (104) to piston
(102) as shown in the figure. a Check that the end plate is returned to the
snap ring position.

WA470-7 50-195
50 Disassembly and assembly
Power train

a Check that the match marks (numbers)


stamped on the right and left spacers are
the same, and fit them together without
leaving a gap.
2 Spacer (91):
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LM-
G)

5. 3rd gear
1) Install bearing (96) to 3rd gear (95).

3) By using tool B48, press fit spacer (90).


a When press fitting it, direct the concave
side down.

2) Install 3rd gear (95).

4) Install bearing (89) and plate (87).

6. Bearing, spacer, and plate


1) Install plate (94) and bearing (93).

7. Check of clearance
Move 3rd gear (95) up and down and check that
dimension (a) is in the standard value by using a
dial gauge.
• Dimension (a): 0.14 to 1.03 mm
2) Install spacers (92) and (91).

50-196 WA470-7
50 Disassembly and assembly
Power train

10.Plate, disc, and spring


[4th clutch]
Install plate (77), disc (78), and spring (79) in this
8. Piston
order.
1) Install seal rings (84) and (85) to piston (83)
as shown in the figure.
2) By using tool B49, fit seal rings (84) and (85)
to piston (83).
a Leave it for 2 to 3 minutes as it is.

11.End plate
1) Using vise [16], press end plate (75).
2) Install snap ring (76).
a Check that the snap ring is fitted in the
groove securely.
3) By using eyebolts [17] (M8 x 1.25), install
piston (83). a Check that the end plate is returned to the
snap ring position.
2 Seal ring contact surface:
Power train oil (TO10)

12.4th gear
Install 4th gear (86) to cylinder assembly (74).
9. Plate, bearing, and washer
Install washer (82), bearing (81), and plate (80).
a When installing plate (80), direct the
protruded side up.

WA470-7 50-197
50 Disassembly and assembly
Power train

2) Install cover (71).


13.4th gear and cylinder assembly
1) Install bearing (88) to the shaft. 3 Mounting bolt:
27 to 34 Nm {2.8 to 3.5 kgm}
3) Install ring (70).
2 Both end faces of ring:
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LM-
G)

2) Install 4th gear and cylinder assembly (108).

15.Bearing
1) By using tool B50, press fit bearing (69).
2 Both end faces of bearing:
Molybdenum disulfide lubricant or
molybdenum disulfide grease (LM-
G)
14.Ring, cover, and collar
1) Install seal rings (73) and collars (72).
2 Periphery of seal ring:
Grease (G2-LI)

2) Install plate (68) and bearing (67).

50-198 WA470-7
50 Disassembly and assembly
Power train

2) By using tool B52, fit seal rings (65) and (66)


to piston (64).
a Leave it for 2 to 3 minutes as it is.

16.Check of clearance
Move 4th gear (86) up and down and check that
dimension (b) is in the standard value by using a
dial gauge.
• Dimension (b): 1.75 to 3.25 mm 3) By using bolts [15] (M8 x 1.25), install piston
(64).
2 Seal ring contact surface:
Power train oil (TO10)

17.Operation check of clutch


By using tool B51, supply compressed air to the
oil hole of the shaft to check that the 3rd and 4th
clutches operate.
2. Plate, disc, and spring
a If the gear on the side to which air is supplied Install plate (61), disc (62), and spring (63) in this
is locked, the operation of the clutch is order.
normal.

3. End plate
Assembly of R and 2nd clutch pack assembly 1) Using tool B45, press end plate (59).
2) Install snap ring (60).
[2nd clutch]
a Check that the snap ring is fitted in the
1. Piston
groove securely.
1) Install seal rings (65) and (66) to piston (64)
as shown in the figure.

WA470-7 50-199
50 Disassembly and assembly
Power train

a Check that the end plate is returned to the


snap ring position.

6. Transfer shaft 1
1) By using tool B53, press fit inner race (54) to
4. Hub transfer shaft 1 (53).
Install hub (58).

2) Install transfer shaft 1 (53).


5. Bearing
2 Mounting bolt:
1) By using tool B50, press fit bearing (57).
Adhesive (LT-2)
3 Mounting bolt:
59 to 74 Nm {6 to 7.5 kgm}

2) Install ring (56) and snap ring (55).

[R clutch]
7. Piston
1) Install seal rings (51) and (52) to piston (48)
as shown in the figure.
2) By using tool B54, fit seal rings (51) and (52)
to piston (48).
a Leave it for 2 to 3 minutes as it is.

50-200 WA470-7
50 Disassembly and assembly
Power train

8. Plate, disc, and spring


3) Install dowel pin (50a) and lubricating piston
Install plate (45), disc (46), and spring (47) in this
(50) to piston (48).
order.
4) Install snap ring (49).
a Check that it is fitted in the groove
securely.

9. End plate
1) By using vise [10] and push tool [11], press
end plate (43).
2) Install snap ring (44).
a Check that the snap ring is fitted in the
groove securely.
a Check that the end plate is returned to the
snap ring position.

5) By using eyebolts [12] (M8 x 1.25), install


piston (48).
2 Seal ring contact surface:
Power train oil (TO10)

10.Plate and bearing


Install plate (41) and bearing (42).

WA470-7 50-201
50 Disassembly and assembly
Power train

1) By using tool B50, press fit spacer (36).

11.R clutch gear


1) Install bearing (40) to R clutch gear (39).
2) Install snap ring (35).

2) Install R clutch gear (39).


14.Bearing
By using tool B50, press fit bearing (34).

12.Bearing and plate


Install plate (38) and bearing (37).
15.Check of clearance
Move R clutch gear (39) up and down and check
that dimension (c) is in the standard value by
using a dial gauge.
• Dimension (c): 0.28 to 0.95 mm

13.Spacer

50-202 WA470-7
50 Disassembly and assembly
Power train

3) By using bolts [7] (M8 x 1.25), install piston


(31).
2 Seal ring contact surface:
Power train oil (TO10)

16.Operation check of clutch


By using tool B51, supply compressed air to the
oil hole of the shaft to check that the R and 2nd
clutches operate.
a If the gear on the side to which air is supplied 2. Plate, disc, and spring
is locked, the operation of the clutch is Install plate (28), disc (29), and spring (30) in this
normal. order.

Assembly of F and 1st clutch pack assembly 3. End plate


1) Using tool B45, press end plate (26).
[1st clutch] 2) Install snap ring (27).
1. Piston
a Check that the snap ring is fitted in the
1) Install seal rings (32) and (33) to piston (31)
groove securely.
as shown in the figure.
2) By using tool B52, fit seal rings (32) and (33) a Check that the end plate is returned to the
to piston (31). snap ring position.
a Leave it for 2 to 3 minutes as it is.

4. Washer
Install washer (25).

WA470-7 50-203
50 Disassembly and assembly
Power train

5. 1st clutch gear 7. Bearing


1) Install bearing (24) to 1st clutch gear (23). By using tool B55, press fit bearing (20).

2) Install 1st clutch gear (23). 8. Check of clearance


Move 1st clutch gear (23) up and down and
check that dimension (d) is in the standard value
by using a dial gauge.
• Dimension (d): 0.1 to 1.1 mm

6. Washer and spacer


Install washer (22) and spacer (21).
a When installing spacer (21), direct the
chamfered side up.
[F clutch]
9. Piston
1) Install seal rings (18) and (19) to piston (15)
as shown in the figure.
2) By using tool B54, fit seal rings (18) and (19)
to piston (15).

50-204 WA470-7
50 Disassembly and assembly
Power train

a Leave it for 2 to 3 minutes as it is.

10.Plate and bearing


Install plate (13) and bearing (14).
3) Install dowel pin (17a) and lubricating piston
(17) to piston (15).
4) Install snap ring (16).
a Check that it is fitted in the groove
securely.

11.Plate, disc, and spring


Install plate (10), disc (11), and spring (12) in this
order.

12.End plate
1) Using vise [3], press end plate (8).
2) Install snap ring (9).
5) By using bolts [4] (M8 x 1.25), install piston
(15). a Check that the snap ring is fitted in the
groove securely.
2 Seal ring contact surface:
Power train oil (TO10) a Check that the end plate is returned to the
snap ring position.

WA470-7 50-205
50 Disassembly and assembly
Power train

15.Spacer
1) By using tool B50, press fit spacer (3).

13.F clutch gear


1) Install bearing (7) and plate (6) to F clutch
gear (5) in this order.
2) Install snap ring (2).

2) Install F clutch gear (5).


16.Bearing
By using tool B50, press fit bearing (1).

14.Bearing
Install bearing (4).
17.Check of clearance
Move F clutch gear (5) up and down and check
that dimension (e) is in the standard value by
using a dial gauge.
• Dimension (e): 0.28 to 0.95 mm

50-206 WA470-7
50 Disassembly and assembly
Power train

18.Operation check of clutch


By using tool B51, supply compressed air to the
oil hole of the shaft to check that the F and 1st
clutches operate.
a If the gear on the side to which air is supplied
is locked, the operation of the clutch is
normal.

WA470-7 50-207
50 Disassembly and assembly
Power train

Removal and installation of front axle assembly (WA470-DA20-924-K-00-A)

k Place the machine on a level ground, and 4 Front tire and rim assembly:
turn the parking brake switch to ON position.
700 kg
k Set the frame lock bar to LOCK position, and
chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".) 6. Disconnect brake hose (4).

Removal (WA470-DA20-520-K-00-A)

1. Start the engine, set the bucket in the dumping


position, raise the machine gradually so that the
front tires are lifted off the ground by
approximately 5 cm.
2. Set stand [1] under the front frame.

7. Remove the mounting bolts to remove front


drive shaft (5). [*2]
a Make matchmarks on the coupling and drive
shaft, and then remove them.

3. Remove front cover (2) of the front frame.

8. Sling front axle assembly, and set jack [2] under


the the assembly.

4. Sling the front tire and rim assembly (3) by using


the belt sling.
5. Remove the mounting bolts to remove the front
tire and rim assembly. [*1]

50-208 WA470-7
50 Disassembly and assembly
Power train

9. Remove mounting bolt (6) of the front axle


assembly, and remove front axle assembly (7)
while slowly lowering the jack and hoist. [*3]

4 Front axle assembly (7):


1,300 kg

Installation (WA470-DA20-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
3 Mounting bolt of front tire and rim
assembly:
823 to 1,029 Nm {84 to 105 kgm}
[*2]
3 Drive shaft mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*3]
3 Mounting bolts of front axle assembly:
1,617 ± 167 Nm {165 ± 17 kgm}
• Air bleeding
Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from wheel
brake circuit".

WA470-7 50-209
50 Disassembly and assembly
Power train

Removal and installation of rear axle assembly (WA470-DAC0-924-K-00-A)

k Place the machine on a level ground, and 6. Set jack [3] under the counterweight to support
turn the parking brake switch to ON position. the rear frame end.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of 7. Wind the rear tire and rim assembly (3) with the
battery disconnect switch".) belt sling, and sling them.
8. Remove the mounting bolts, and remove the
Removal (WA470-DAC0-520-K-00-A)
rear tire and rim assembly (3). [*1]
1. Remove full-length fenders on the right and left
sides. For details, see "Removal and installation 4 Rear tire and rim assembly:
of full-length fender assembly". 700 kg
2. Place block [1] between the right and left rear
axles and rear frame.

9. Remove the fuel tank assembly. For details, see


"Removal and installation of fuel tank assembly".
3. Start the engine, set the bucket in the dumping 10.Remove cover (4) on left side.
position, raise the machine gradually so that
front tires are lifted off the ground.
4. Place stand [2] under the rear frame.

11.Disconnect connector R60 (5) and clamp (5a).

5. Tilt the bucket slowly to lower the front tires to


the ground thoroughly, and raise the rear tires
above the ground.

50-210 WA470-7
50 Disassembly and assembly
Power train

12.Disconnect clamps (6) (2 places). 16.Disconnect rear drive shaft (12). [*2]
a Another is in the upper part of the figure. a Make matchmarks on the coupling and drive
shaft, and then remove them.

13.Disconnect grease tubes (7) and (8).


17.Remove cover (13a).

14.Remove step (9) on the right side.


18.Remove emergency steering relay (13).
a Otherwise the mounting bolt on the rear left
side of the rear axle is not removed.

15.Disconnect brake hoses (10) and (11).

WA470-7 50-211
50 Disassembly and assembly
Power train

4 Rear axle and support assembly:


1,500 kg

19.Sling the rear axle assembly, and set jack [4]


under rear support (14).
20.Remove mounting nuts (15) on the right and left
sides of the rear support. [*3] 24.Sling one side of the rear axle assembly with a
crane and support the opposite side by using
pallet jack [6], forklift, etc.
25.Pull out the rear axle and rear support assembly
(16) in a lateral direction of the machine. Sling
the rear axle and rear support assembly (16)
again to install them stably.

21.Fix rear supports (14) on the right and left sides


of rear axle assembly (15) by using lever block
[5].
a This prevents the rear support from rotating
during removal.

22.Pull out the rear axle assembly and rear support


26.Remove retainer (18) of front support (17) on the
together as a unit toward the rear of the machine
machine body side. [*4]
by using the jack and crane.
a Pull them out until the supporting portion at
the front of the rear axle is removed from the
front support.
23.Remove the rear axle and rear support
assembly (16) while slowly lowering the jack and
crane.

50-212 WA470-7
50 Disassembly and assembly
Power train

30.Remove thrust washer (23) from the rear


support.
31.Remove the mounting bolt to remove thrust
plate (24) and thrust washer (23). [*8]
32.Remove rear support (14).

4 Rear support: 150 kg


33.Remove packing (25) and bushing (26) from the
rear support. [*9]

27.Remove packing (19) from retainer (18). [*5]

Installation (WA470-DAC0-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
28.Remove packing (20) and bushing (21) from the
front support. [*6] 3 Mounting bolt of rear tire and rim
assembly:
823 to 1,029 Nm {84 to 105 kgm}
[*2]
3 Rear drive shaft mounting bolts:
98 to 123 Nm {10 to 12.5 km}
[*3]
2 Rear axle mounting bolt:
Engine oil
3 Rear axle assembly mounting bolt:
1,180 to 1,470 Nm {120 to 150 kgm}
29.Sling rear support (14), and remove thrust cap [*4]
(22). [*7]
2 Front support retainer mounting bolt:
Adhesive (LT-2)
3 Front support retainer mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
[*5]
a Securely install packing (19) to the groove with
its lip facing to the machine front.
[*6]
a Securely install packing (20) to the groove with
its lip facing to the axle housing side.

WA470-7 50-213
50 Disassembly and assembly
Power train

a Install bush (21) with chamfer (c) facing to the


axle housing side so that clearance (d) is in the
dimension as follows.
• Clearance (d): 0.5 mm
2 Contacting surface of front support
bushing:
Grease (G2-LI)

• Air bleeding
Bleed air from the brake circuit. For details, see
Testing and adjusting "Bleeding air from wheel
brake circuit".

[*7]
2 Thrust cap mounting bolt:
Adhesive (LT-2)
3 Thrust cap mounting bolt:
245 to 308 Nm {25 to 31.5 kgm}
[*8]
2 Thrust plate mounting bolt:
Adhesive (LT-2)
3 Thrust plate mounting bolt:
245 to 308 Nm {25 to 31.5 kgm}
[*9]
a Securely install packing (25) to the groove with
its lip facing to the axle housing side.
a Install bush (26) with chamfer (a) facing to the
axle housing side so that clearance (b) is in the
dimension as follows.
• Clearance (d): 0.5 mm
2 Contacting surface of support bushing:
Grease (G2-LI)

50-214 WA470-7
50 Disassembly and assembly
Power train

Disassembly and assembly of axle housing assembly (WA470-DA04-924-K-00-A)

a Special tools

Necessity
Q'ty
Symbol Part No. Part name

Commercially
1 Puller q 1
D16 available
2 790-201-1410 Plate t 1
1 793T-622-2520 Block t
2 790-101-2520 Screw t 1
3 791-112-1180 Nut t 1
4 790-101-2540 Washer t 1
Leg 2. Axle assembly
5 790-101-2620 t 2
Place the axle assembly on blocks [1].
D17 6 790-101-2570 Plate t 4
7 790-101-2560 Nut t 2 a Set blocks [1] so that the assembly does not
8 790-101-2740 Adapter t 2 lean when one axle housing assembly is
9 790-201-1410 Plate t 1 removed.
10 790-101-2102 Puller assembly t 1
11 790-101-1102 Hydraulic pump t 1
1 790-101-2800 Bearing puller t 1
D18 2 793T-622-2530 Bolt t 2
3 01643-32060 Washer t 2
D19 793T-622-2540 Spacer q 1
D20 793T-622-2550 Spacer q 1
1 793T-622-1330 Push tool t 1
D21
2 793T-622-1340 Spacer t 1
1 793T-622-1370 Support t 2
D22
2 01010-50830 Bolt t 6
D23 793T-622-2510 Spacer t 1 3. Axle housing assembly
D24 793T-622-1510 Holder t 1
1) Sling axle housing assembly (8), and remove
D25 79A-264-0021 Push-pull scale q 1
the housing mounting bolts.
a The following photos and illustrations show the a When removing both right and left axle
front axle housing as an example. housing assemblies, put a match mark on
a The front and rear axle housings have different each housing and the differential case to
appearance but have the same internal prevent confusion.
structure. 2) Remove axle housing assembly (8).

Disassembly (WA470-DA04-520-K-00-A)
4 Axle housing assembly:
1. Draining oil 280 kg
Remove oil plug (1) to drain oil.

6 Axle oil
Front axle: 57l
l
Rear axle: 56l
l

WA470-7 50-215
50 Disassembly and assembly
Power train

3) Change the sling application position and set


axle housing assembly (8) straight up.

5. Ring gear
By using tool D16, pull up ring gear (12) evenly
to remove it from axle housing assembly (13).
4. Planetary carrier assembly:
1) Remove axle shaft mounting bolt (9), and a Install a plate to the bolt end at the center of
sling and remove planetary carrier assembly tool D16 to adjust the height of the bolt.
(10). a Be careful that the hooks of tool D16 do not
a Be careful not to damage washer (9a). come off the ring gear.

4 Planetary carrier assembly:


65 kg

6. Axle shaft
1) Set axle housing (14) so that it does not fall
down.
2) By using tool D17, push down axle shaft (15),
and separate it from bearing (26).
3) Sling axle housing (14).

2) Remove shims (11).


a Note the thickness of shims for assembly
purpose.

50-216 WA470-7
50 Disassembly and assembly
Power train

8. Axle housing
Remove outer races (18) and (19) from axle
housing (14).

7. Axle shaft bearing

k Do not heat or flame-cut the bearing to


9. Planetary carrier
remove it.
1) Drive spring pin (21) of the planetary carrier
1) Install bolts (b) to bolt holes (a) of tool D18. into shaft (20) so that the pin does not
protrude from in shaft (22).
a Be careful not to drive in spring pin (21)
insufficiently.
a After driving in, rotate the gear and check
that shaft (22) rotates.

2) Install tool D18 to the bottom of bearing (16)


and fix it securely.
3) Insert washers (c) between bolts (c) and
flange face.
4) Loosen bolts (b), and remove bearing (16).
5) Remove oil seal (17).
2) Pull out shaft (22) by using a press.
3) Pull out spring pin (21) from removed shaft
(22).

WA470-7 50-217
50 Disassembly and assembly
Power train

Assembly (WA470-DA04-720-K-00-A)

1. Axle housing
1) By using tool D19, press fit outer race (18) to
axle housing (14).

4) Remove planetary gear (23), holder (24), and


washer (9a) from planetary carrier (20).

2) By using tool D20, press fit outer race (19) to


axle housing (14).

5) Remove bearing (25) from planetary gear


(23).

50-218 WA470-7
50 Disassembly and assembly
Power train

3. Axle housing and shaft


2. Axle shaft
1) Install tool D22-1 under oil seal (17).
1) By using tool D21, press fit oil seal (17) and
bearing (16) simultaneously to axle shaft a Adjust tool D22-2 so that the top face of
(15). tool 22-1 touches oil seal (17) lightly and
an even clearance is made between
a Press fit until oil seal sleeve (17a) is flush
them.
with face "d" of the axle shaft and check
that there is no gap to bearing (16).
2 Press-fit portion of oil seal and
bearing:
Axle oil
2 Oil seal lip:
Grease (G2-LI)
a Apply a grease evenly without surge to
opposite side (P part) of oil seal rip.
a Apply to 40 to 60 % of the total volume of
the lip space uniformly.
2) Sling axle housing (14) horizontally and
lower it slowly while positioning it to oil seal
(17) described above.
a Insert the axle housing by utilizing its
weight.
a After installing the axle housing, leave
tool D22 installed until step 3).
3) By using tool D23, press fit bearing (26) to
axle shaft (15).

WA470-7 50-219
50 Disassembly and assembly
Power train

2 Bearing roller part: Rear axle:


Axle oil 28.4 to 54.9 N {2.9 to 5.6 kg}
• Press-fitting force of bearing (26): 32.36 ±
3.24 kN (3,300 ± 330 kg)

4) Remove tool D22-2 described above and pull


out tool D22-1 horizontally.
a Pull out tool D22-1 while pressing it
against the end face of axle housing (14).
• Clearance (a): Max. 0.2 mm
a Check that oil seal (17) is not tilted.

6) If the starting torque is out of the standard


value, perform the following work.
a When starting torque is below standard
value
1] Remove planetary carrier (20).
2] Press-fit bearing (26) further according to
step 3.-3).
3] Perform steps 1) through 5) and check
that the starting torque is in the standard
4. Selection of shims value.
1) Install planetary carrier (20) to the spline of
axle shaft (15). a When starting torque is over standard
2) Install tool D24 and finger-tighten mounting value
bolt (9). 1] Loosen bolt (9) 1 to 2 turns.
2] Sling axle shaft and housing assembly (8)
a Install planetary carrier (20) without the approximately 20 to 30 mm by 2-point
gear. sling method.
a Remove all adhesive sticking to mounting 3] While rotating axle shaft (15), hit its
bolt (9) and its hole. flange several times with a copper
3) Tighten mounting bolt (9) while rotating axle hammer, etc. in the arrow direction to
housing (14). relieve excessive preload on bearings
4) Rotate axle housing (14) to fit bearings (16) (16) and (26).
and (26) thoroughly. a TBe careful not to hit axle shaft (15)
5) Install tool D25 to hole (h) of axle housing too much to avoid damage to oil seal
(14) to measure the starting torque. (17).
• Starting torque • Lowering distance of axle shaft
Front axle: (Reference value): 0.3 mm
30.4 to 57.8 N {3.1 to 5.9 kg}

50-220 WA470-7
50 Disassembly and assembly
Power train

4] Perform steps 3) through 5) and check


that the starting torque is in the standard
value.

2) Install holder (24) and washer (9a) into


planetary carrier (20).
a Thinly apply grease to the mounting face
on the holder side of washer (9a).
2 Planetary carrier side contact
surface of holder (24):
Molybdenum disulfide lubricant
(LM-S or LM-P)
3) Install planetary gear (23).

7) By using a depth micrometer, measure


distance H between the end faces of tool
D24 and axle shaft.
8) Subtract thickness (t) of tool D24 from
dimension H and set the result as (H - t) and
determine the shim thickness from it.
• Shim thickness (mm) = (H - t) -0.05/0 4) Press fit shaft (22) while aligning spring pin
9) Remove planetary carrier (20). holes (22a) of the shaft and planetary carrier.
2 Shaft:
Axle oil
5) Drive in spring pin (21) until it is flush with
planetary carrier (20) (part j).

5. Planetary carrier
1) Install bearing (25) to planetary gear (23).

WA470-7 50-221
50 Disassembly and assembly
Power train

1) Install shims (11) selected in Steps 4 to 8) to


the end face of axle shaft.

6) Tap the end face of shaft (22) and the


differential side of planetary gear (23) to push
back bearing (25). Then, check that 2) Install planetary carrier assembly (10).
planetary gear (23) rotates smoothly. 3) Tighten mounting bolts (9).
a Before starting the above work, be sure to
degrease and clean axle shaft bolt
mounting holes and mounting bolts.
a Before installation, clean the shaft end
face and the spline of planetary carrier.

k When installing planetary carrier


assembly (10), take extreme care not
to get your fingers caught in the gear,
etc.
2 End face of planetary carrier
assembly (10) (bearing contact
6. Ring gear surface):
1) Press fit ring gear (12) to axle housing (14). Molybdenum disulfide lubricant
a When installing ring gear (12), direct its (LM-S or LM-P)
chamfered side down and align its pin 2 Mounting bolt:
holes with those of axle housing (14). Adhesive (LT-2)
a Press fit ring gear (12) horizontally, while 3 Mounting bolt:
taking care not to slant it.
2) Insert pins (12a) (6 pieces). Front axle:
824 to 1,030 Nm {84 to 105 kgm}
a When inserting them, take care not to hit
ring gear (12). Rear axle:
662 to 829 Nm {67.5 to 84.5 kgm}

7. Planetary carrier assembly:

50-222 WA470-7
50 Disassembly and assembly
Power train

4) Rotate axle housing (14) to fit the bearings 3) Install guide bolt [5].
thoroughly. 4) Sling axle assembly (8) horizontally and
5) Install tool D25 to hole (h) of axle housing install it slowly, while aligning it with the
(14) to measure the starting torque. spline groove and guide bolts [5].
• Starting torque a Be careful not to damage the brake piston
Front axle: surface and plate surface when installing
30.4 to 115.6 N {3.1 to 11.8 kg} the assembly.
Rear axle: 5) Tighten the mounting bolts in diagonal order.
28.4 to 129.3 N {2.9 to 13.2 kg}
3 Housing mounting bolt:
a If the starting torque is out of the standard
490 to 608 Nm {50 to 62 kgm}
value, perform adjustment again from
Step 4.-6).
6) Install dial gauge [4] to axle housing (14) and
check that the planetary carrier has no end
play in its end face.

8. Axle housing assembly


1) Degrease and clean the mounting faces of
axle housing (14) and differential housing.
2) Apply liquid gasket (A) without a break.
a Apply liquid gasket at the center of mating
surface in the drawing.
2 Housing mating surface:
9. Refilling of oil
Liquid gasket (Locktite 515)
1) Tighten drain plug (1) and add oil to the
specified level through the oil filler port.

5 Axle oil
Front axle: 57 l
Rear axle: 56 l

WA470-7 50-223
50 Disassembly and assembly
Power train

2) Check the oil level by using oil filler port/ oil


level gauge (1-1).

50-224 WA470-7
50 Disassembly and assembly
Power train

Disassembly and assembly of differential assembly (WA470-DC10-924-K-00-A)

a Special tools 2. Oil temperature sensor (rear differential)


1) Remove cover (3).

Necessity
2) Disconnect connector (4) and remove oil

Q'ty
Symbol Part No. Part name temperature sensor (5).
3. Rear support (rear differential)
Unit repair stand Remove rear support (6). For details, see
1 790-501-5000 q 1
"Removal and installation of rear axle assembly".
D1 2 790-901-2110 Bracket q 1
3 790T-901-3440 Plate q 1
D2 793T-622-2570 Eyebolt t 2
D3 790-201-2730 Spacer q 1
1 793T-615-1730 Spacer (F) q 1
D4
2 790-201-2770 Spacer (R) q 1
1 790-201-2780 Spacer (F) q 1
D5
2 793T-623-1210 Spacer (R) q 1
1 796-765-1110 Push tool t 1
D6
2 790-201-2750 Spacer t 1
1 796-765-1110 Push tool (F) t 1
D7
2 792T-413-1120 Push tool (R) t 1
D8 79A-264-0021 Push-pull scale q 1
1 793T-622-1310 Push tool t 1
D9 2 790-101-5421 Grip t 1
3 01010-51240 Bolt t 1
1 793T-622-1310 Push tool t 1
2 793T-622-1320 Spacer t 1
D10
3 790-101-5421 Grip t 1
4 01010-51240 Bolt t 1
D11 793T-622-1360 Push tool t 1
1 793T-622-2560 Wrench t 1
D12
2 01316-10616 Bolt t 2
D13 793T-615-1730 Spacer q 1
799-101-5230 Adapter t 1 4. Axle housing assembly
1
07002-11423 O-ring t 1 Remove the right and left axle housing
D14 assemblies. For details, see "Disassembly and
2 793-605-1001 Brake tester t 1
3 790-101-1102 Hydraulic pump t 1 assembly of axle housing assembly".
D15 799-301-1500 Oil leak tester kit t 1 5. Differential assembly
D25 79A-264-0021 Push - pull scale q 1 Place differential assembly (7) on blocks [1] and
stabilize it. (Or install it to tool D1.)
• (F): For front differential
• (R): For rear differential a When using tool D1, remove the cage
assembly referring to Step 8.
Disassembly (WA470-DC10-520-K-00-A) 6. Cover
a Photos and illustrations, except those which Remove cover (8).
indicate the component name, show the front
differential.
a The front and rear differentials have different
external appearance and shape but have the
same internal structure.
1. Brake piping
1) Remove tube (1).
2) Remove slack adjuster (2). (Front differential)
a The slack adjuster of the rear differential
is installed to the rear frame.

WA470-7 50-225
50 Disassembly and assembly
Power train

7. Brake
8. Cage assembly
1) Remove sun gear shaft (9).
1) Sling the differential case, and set it with
2) Remove bolts (10) and remove outer plate
cage assembly (20) up.
(11).
2) Remove mounting bolts (21).
3) Remove plates (12), wave springs (13) and
discs (14). a Put a match mark on the cage and
differential case for assembly purpose.
a Put a mark on them to avoid confusion
3) Tighten the forcing screws to raise cage
between the right and left side parts.
assembly (20) until you can see the O-ring.

4) By using tool D2, remove cage assembly


(20).

4 Cage assembly:
60 kg

4) Supply air into brake oil port (15), and


remove piston (16).

50-226 WA470-7
50 Disassembly and assembly
Power train

3) Remove all the mounting bolts of bearing


carrier (24) and install guide bolts [3].
4) Tighten forcing screws [4] to remove bearing
carrier (24).
a Make bearing carriers on the right and left
sides identifiable to prevent confusion.
a Note the thickness and number of shims
used for assembly purpose.

5) Remove shims (22).


a Note the number of shims used for
assembly purpose.

5) Remove outer race (24a) and seals (24b)


and (24c) from bearing carrier (24).

9. Bearing carrier
1) Set the differential case so that the mounting
face of the cover removed in step 6 is up.
2) Sling differential carrier assembly (23).
a The figure shows the limited slip
differential specification.)
10.Differential carrier assembly
1) Remove differential carrier assembly (23)
from differential case (25).
a Be careful that the sling does not come
off.

WA470-7 50-227
50 Disassembly and assembly
Power train

a The figure shows the limited slip


differential specification.

4 Differential carrier assembly:


110 kg

3) Remove washer (64) and side gear (65).


4) Remove spider shaft (66) and pinion gear
(67) together as a unit.

2) Remove gear cover (26) from the differential


case.

5) Remove spherical washer (68), pinion gear


(67), and bushing (69) from spider shaft (66).

11.Disassembly of differential carrier assembly


(Conventional differential specification)
1) Remove case (62).

6) Remove side gear (70) and washer (71) from


case (72).

2) Remove bearing (63) from case (62).

50-228 WA470-7
50 Disassembly and assembly
Power train

7) Remove bevel gear (73) and bearing (74) 2) Remove bearing (27) from cover (28).
from case (72).

3) Remove plates (31) (2 pieces) and discs (32)


12.Disassembly of differential carrier assembly (2 pieces).
(Limited slip differential specification)
a Identify parts on the right and left sides to
prevent confusion.
1) Remove cover (28) and bearing (27) together
as a unit.
a Put a match mark on cover (28) and case
(29) for assembly purpose.

4) Remove pressure ring (33) and side gear


(34).

a Washer (30) is attached to back side


groove of removed cover (28).

WA470-7 50-229
50 Disassembly and assembly
Power train

5) Remove pinion (35) and spider shaft (36).

13.Pinion and cage


6) Remove side gear (37) and pressure ring 1) Remove mounting bolts (17) to remove
(38). holder (17a).
2) Remove coupling (19) and protector (18)
together.
a Do not remove protector (18) from
coupling (19) except when necessary.
3) Remove O-ring (19a).

7) Remove discs (39) (2 pieces) and plates (40)


(2 pieces).
8) Remove washer (41).

4) By using tool D3 and a press, pull pinion


gear (45) out of cage (44).
5) Remove dust seal (49), oil seal (50), bearing
(46), and outer races (47) and (48) from cage
(44).

9) Turn over case (29), and remove bolts (42) to


remove bevel gear (43) and bearing (29a).

6) Remove bearing inner race (52) from pinion


gear (45).

50-230 WA470-7
50 Disassembly and assembly
Power train

a After press-fitting the bearing, check that


there is no clearance between it and
pinion.

Assembly (WA470-DC10-720-K-00-A)

1. Pinion and cage


1) By using tool D4, press-fit outer race (47) to
4) Set pinion gear (45) upright and install cage
cage (44).
(44).
a After press-fitting the outer race, check 5) By using tool D7, press-fit bearing (46) to
that there is no clearance between it and pinion (45) while rotating cage (44).
cage. • Press-fitting force of bearing (26): 24.5 to
29.4 kN {2,500 to 3,000 kg}
3 Bearings (46) and (52):
Axle oil

2) By using tool D5, press-fit outer race (48) to


cage (44).
a After press-fitting the outer race, check
that there is no clearance between it and 6) Install protector (18) to coupling (19).
cage. 7) Install coupling (19) to pinion gear (45).
8) Measure thickness (h) of holder (17a).
9) Install holder (17a), and tighten bolt (17)
lightly.
3 Bolt (17):
117.6 Nm {12 kgm}
10)Insert the depth gauge to hole (A) for shim
adjustment, and measure dimension (j) from
the end face of holder (17a) to the end face
of pinion gear (45).
11)Calculate clearance (k) between holder (17a)
and pinion gear (45), and record it.
• Clearance (k) = dimension (j) - thickness
3) By using tool D6, press-fit bearing (52) to (h)
pinion (45). 12)Remove bolt (17), holder (17a) and coupling
(19), and then release the pre-load of
bearing.

WA470-7 50-231
50 Disassembly and assembly
Power train

a Select thickness of shims (45a) based on


clearance (k) calculated in Step 11).
• Shim thickness (t) = clearance (k) +
0.07
• Set shim thickness (mm): 0.15, 0.18,
0.2, 0.5mm
17)Install coupling (19) and holder (17a), then
tighten bolt (17).
3 Bolt (17):
824 to 1030 Nm {84 to 105 kgm}
18)Rotate cage (44) clockwise and
counterclockwise 10 turns or more each.
13)Install tool D25 to hole (B) of cage (44) to 19)Install tool D25 to hole (B) of cage (44) to
measure the starting torque. measure the starting torque.
• Starting torque (at release): Max. 13.6 N • Starting torque (front differential):
{1.4 kg} 13.6 to 45.4 N {1.4 to 4.7 kg}
• Starting torque (rear differential):
13.6 to 59.7 N {1.4 to 6.1 kg}
20)If the starting torque is out of the standard
value, adjust shim (45a) thickness and
repeat Steps 17) to 19).
a Check that the starting torque is in the
standard value.
a Variation of the starting torque per 0.01
mm of shim thickness is as follows.
• Front differential: 8.8 N {0.88 kg}
• Rear differential: 12.2 N {1.22 kg}
21)After checking that the starting torque is in
14)If the starting torque exceeds the standard the standard value, remove bolt (17), holder
value, hit the end face of pinion gear (45) (17a), shim (45a) and coupling (19).
with a copper hammer, etc. in the arrow
direction to relieve excessive pre-load of
bearing.

22)By using tool D9, press fit oil seal (50) to


cage (44).
a Press so that dimension C is 14 ± 0.5
15)Perform Step 13) again and check that the
mm.
starting torque is in the standard value.
16)Install shim (45a). 2 Oil seal lip:
Grease (G2-LI)
a Apply a grease evenly without surge to
opposite side (P part) of oil seal rip.

50-232 WA470-7
50 Disassembly and assembly
Power train

2 Bolt (17):
Adhesive (LT-2)
3 Bolt (17):
824 to 1,030 Nm {84 to 105 kgm}
2) Install plug (17b).

3. Assembly of differential carrier assembly


(Limited slip differential specification)
a Assemble parts of right and left cases
referring to identification marks made in
disassembly.
1) By using tool D11, press fit bearing (29a) to
23)By using tool D10, press fit dust seal (49) to case (29).
cage (44). 2) By using tool D11, press fit bearing (27) to
cover (28).
2 Dust seal lip:
Grease (G2-LI)

3) Place bevel gear (43) on blocks [6] with its


gear side down.
2. Coupling 4) Install guide bolts [7] to bevel gear (43).
1) Install coupling (19), O-ring (19a), shim (45a), 5) Sling case (29) down and install it to bevel
and holder (17a) to pinion gear (45), and gear (43), then tighten bevel gear mounting
tighten bolt (17). bolts (42).
a Be careful not to damage the seal when 2 Mounting bolt:
installing coupling (19). Adhesive (LT-2)
2 Bearing side end face of coupling 3 Mounting bolt:
(19):
245 to 309 Nm {25 to 31.5 kgm}
Molybdenum disulfide lubricant
(LM-S or LM-P)

WA470-7 50-233
50 Disassembly and assembly
Power train

7) Install pressure ring (38) and side gear (37).

6) Turn over case (29), and install washer (41),


plate (40), and disc (39) in this order. 8) Install pinion gear (35) and spider shaft (36).

a When installing the disc, positions of


notches (a) and (b) must be aligned.
a Since the disc has different thickness
depending on the differential, see the
following when installing it.
• Front differential
Outside diameter: 198 mm, thickness: 3.6
mm
• Rear differential
Outside diameter: 185 mm, thickness 3.2
mm
2 Plate and disc: 9) Install side gear (34) and pressure ring (33).
Axle oil

10)Install disc (32) and plate (31) in this order.


a For the installation procedure, see step
6).

50-234 WA470-7
50 Disassembly and assembly
Power train

11)Adjust clearance (g) between cover (28) and


plate (31).
1] By using depth gauge [11], measure
dimension (d) between end faces of case
(29) and plate (31) while applying a load
of 686 N {70 kg}.
2] Measure dimension (f) from the end face
of cover (28) to the flange.
3] Calculate clearance (g) by the following
expression and check that it is in the
standard value.
• Clearance (g) = d – f = 0.2 to 0.75 mm
4] When clearance (g) is out of the standard 12)Install washer (30) to cover (28).
value, select the thickness of plate (31) to
set the clearance in the standard value. a Apply a thin film of grease to the washer
and attach it to the cover.
a In order to keep the same plate
thickness (sum of 2 plates) on the
right and left sides, replace them at
the same time. Then, install them
according to the preceding procedure
from step 7).
• Types of shim thickness: 3.1 mm and
3.2 mm

13)Install bearing (27) and cover (28) together


to case (29).
a When installing, align the match marks
made during disassembly.
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}

WA470-7 50-235
50 Disassembly and assembly
Power train

1] Install sun gear shafts (9) to the right and


left sides of the differential carrier
assembly.
2] Fix the sun gear shaft on one side.
3] Install tool D12 and torque wrench [12] to
the other sun gear shaft to measure the
rotating torque.
a When measuring, keep the differential
case rotating freely.
• Rotating torque
Front differential:
Max. 15 Nm {1.5 kgm}
14)Adjusting clearance in axial direction of the Rear differential:
side gear. Max. 10 Nm {1.0 kgm}
1] By using a feeler gauge, measure 4] If the rotating torque exceeds the
clearances (e1) and (e2) between the standard value, disassemble the
side gears (34) and (37) and washers differential carrier assembly again and
(30) and (41) respectively through the repeat the preceding steps 12) and 15).
right and left shaft hole of the limited slip
differential.
• Clearances (e1) and (e2)
Front differential:
0.2 to 0.4 mm
Rear differential:
0.15 to 0.35 mm
2] If the differential assembly is placed
vertically as shown in the figure,
clearance (e1) becomes zero.
Accordingly, measure clearance (e2).
• Clearance (e2): 0.4 to 0.8 mm
3] When clearances (e1) and (e2) are out of
the standard value, select the washer 4. Assembly of differential carrier assembly
thickness to set the clearances within the (Conventional differential specification)
standard value. 1) By using tool D11, press fit bearing (74) to
case (72).
a When replacing the washer, install it
2) Install bevel gear (73) to case (72).
according to the same procedure as
the preceding steps 6) and after. 2 Bevel gear mounting bolt:
• Types of shim thickness: 4.0 mm and Adhesive (LT-2)
4.1 mm
3 Bevel gear mounting bolt:
245 to 309 Nm {25 to 31.5 kgm}

15)Measure the differential torque under no


load.
3) Install washer (71) and side gear (70) to case
(72).

50-236 WA470-7
50 Disassembly and assembly
Power train

4) Install bushing (69), pinion gear (67), and 8) Install case (62).
spherical washer (68) to spider shaft (66).
3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}

5) Install pinion gear (67) and spider shaft (66)


as a unit.
6) Install side gear (65) and washer (64). 5. Gear cover
Install gear cover (26) to the differential case.
2 Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
98 to 123 Nm {10.0 to 12.5 kgm}

7) By using tool D11, press fit bearing (63) to


case (62).

6. Shim adjustment of bearing carrier


1) Sling differential carrier assembly (23) and
set it to its installed position in differential
case (25).

WA470-7 50-237
50 Disassembly and assembly
Power train

3 Mounting bolt:
157 to 196 Nm {16 to 20 kgm}

2) By using tool D13, press fit outer races (24a)


to the right and left bearing carriers (24).
3) Install seals (24b) and (24c) to the bearing
carrier. 6) Rotate the bevel gear at least 10 turns each
clockwise and counterclockwise to fit it.
7) By using tool D8 or a spring scale, measure
the starting torque of the bevel gear.
a Measure at the maximum diameter
position of the bevel gear.
• Starting torque:
Front differential:
19.6 to 27.4 N {2.0 to 2.8 kg}
Rear differential:
21.6 to 30.4 N {2.2 to 3.1 kg}
a If the starting torque is out of the standard
value, adjust it by increasing or
4) Install guide bolts [3] to the right and left decreasing the shim thickness.
bearing carrier mounting holes of the a Thickness of shims on each side must be
differential case. 0.3 to 1.25 mm.
• Set shim thickness:
0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm

5) Install the right and left bearing carriers (24)


together with a shim (80).
a Select a proper shim, referring to the
7. Cage assembly
thickness and quantity of the shims on
the right and left sides checked during 1) Fit O-ring (20a) in the groove of cage
disassembly. assembly (20).

a Rotate the bevel gear when tightening 2 O-ring:


them. Axle oil or grease (G2–LI)
2 Bearing: Axle oil a Thinly apply oil.

50-238 WA470-7
50 Disassembly and assembly
Power train

2) Install guide bolts [6] to differential case (25). 2) If the backlash is out of the standard value,
3) Install standard shims (22) (of the quantity adjust the shims according to the following
and thickness checked during disassembly). procedure.
a Set the thinner shims on the cage side. a Moving of shims must not vary the sum of
thicknesses of the right and left shims.
a Determine the final quantity and
thickness of the shims after adjusting the a If the backlash is over the standard value,
backlash in step 8 and checking the move a part of shims (a) to shims (b).
contacts in step 9.
a If the backlash is below the standard
4) By using tool D2, install cage assembly (20).
value, move a part of shims (b) to shims
3 Mounting bolt: (a).
245 to 309 Nm {25 to 31.5 kgm}

9. Checking tooth contact


8. Adjusting backlash 1) Thinly apply red lead to the tooth surface of
1) Using dial gauge [7], measure the backlash the pinion gear, then rotate the bevel gear
of bevel gear. back and forth to check the tooth contact
patterns left on the bevel gear.
a Measure the backlash at 3 points on the 2) Center of tooth contact must be at the
periphery of the bevel gear and check midportion of tooth height and must also be
that the dispersion of the measured at approximately 33% (x) position of tooth
values is 0.1 mm or less. length measured from the small end (C). The
• Standard backlash: 0.30 to 0.41 mm width of the tooth contact must be 30 to 60%
(y) of the tooth length. And check that tooth
tip (A), dedendum (B), small end (C) and
large end (D) are all not exposed to strong
contact.
a If the differential is adjusted in this way,
correct tooth contact is ensured when the
load is applied.

WA470-7 50-239
50 Disassembly and assembly
Power train

10.Adjusting tooth contact When the pinion gear is too close to the bevel
If no correct tooth contact pattern is found in the gear
testing, adjust it according to the following
a Tooth contact pattern is as shown in the
procedure.
figure.
a Adjustment is done by increasing or 1) Increase shims (d) to move the pinion gear in
decreasing shims (a) and (b) (to move the direction (E).
bevel gear) and increasing or decreasing 2) Adjust shims (a) and (b) to move the bevel
shims (d) (to move the pinion gear). gear in direction (F).
a In order not to change the preload of the
bearing, do not change the total thickness of
shims (a) and (b).
a After adjusting tooth contact, check the
backlash again.

When the bevel gear is too close to the pinion


gear
a Tooth contact pattern is as shown in the
figure.
1) Decrease shims (d) to move the pinion gear
When the pinion is too far from the bevel gear in direction (C).
2) Adjust shims (a) and (b) to move the bevel
a Tooth contact pattern is as shown in the
gear in direction (D).
figure.
1) Decrease shims (d) to move the pinion gear
in direction (C).
2) Adjust shims (a) and (b) to move the bevel
gear in direction (D).

50-240 WA470-7
50 Disassembly and assembly
Power train

When the bevel gear is too far from the pinion a Leave the pressure at 4.9 MPa {50 kg/
gear cm2} for 5 minutes and check that
pressure drop is 0.1 MPa {1.0 kg/cm2} or
a Tooth contact pattern is as shown in the
less.
figure.
1) Increase shims (d) to move the pinion gear in a If oil leakage is detected, remove the
direction (E). brake piston and check the O-ring and
2) Adjust shims (a) and (b) to move the bevel seal for any damage. Then install them
gear in direction (F). again.

11.Brake
1) Install the seal to piston (16), and install the
piston to the differential and carrier
assembly.
a (15) is the brake oil port.
2 Seal:
Grease (G2-LI)

5) Install disc (12), wave spring (13), and plate


(14) in this order.
a When installing disc (12), positions of
holes (H) (6 places) must be aligned.
a When installing wave spring (13), set cuts
(a) at intervals of 120 degrees.
a If the wave spring is installed in the same
direction, their returning force is uneven.
2) Install tool D14 to brake oil port (15) of
Take care.
differential case (25) and bleed air from the
cylinder.
3) Operate tool D14 to increase the pressure to
1.4 MPa {14 kg/cm2}}.
a Leave the pressure at 1.4 MPa {14 kg/
cm2} for 5 minutes and check that
pressure drop is 0.3 MPa {3.5 kg/cm2} or
less.
4) If oil leakage is not found in the preceding
check, increase the pressure further to 4.9
MPa {50 kg/cm2}.

WA470-7 50-241
50 Disassembly and assembly
Power train

• Front differential

6) Install outer plate (11) and sun gear shaft (9),


and tighten mounting bolt (10). • Rear differential
3 Bolt (10):
27 to 34 Nm {2.8 to 3.5 kgm}

7) By using tool D15, supply air to brake oil port


(15) to allow the piston to move smoothly.

13.Axle housing
Install the right and left axle housing assemblies.
For details, see "Disassembly and assembly of
axle housing assembly".
14.Rear support (rear differential)
12.Cover Install rear support (6). For details, see
Install cover (7) to differential case (8). "Removal and installation of rear axle assembly".
a Apply liquid gasket (A) without a break. 15.Oil temperature sensor (rear differential)
1) Install oil temperature sensor (5) and connect
a Apply liquid gasket (A) at the center of
connector (4).
mating surface in the drawing.
2 Threaded portion of oil
2 Cover mounting surface:
temperature sensor:
Liquid gasket (Locktite 515)
Liquid gasket (LG-5)
3 Mounting bolt:
3 Oil temperature sensor:
157 to 196 Nm {16 to 20 kgm}
29.4 to 49.0 Nm {3 to 5 kgm}

50-242 WA470-7
50 Disassembly and assembly
Power train

2) Install cover (3).


3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}
16.Brake piping
1) Install slack adjuster (2). (Front differential)
2) Install tube (1).

17.Refilling of oil
1) Tighten drain plug (1-2) and add oil to the
specified level through the oil filler port.

5 Axle oil
Front axle: 57 l
Rear axle: 56 l

2) Check the oil level by using oil filler port/ oil


level gauge (1-1).

WA470-7 50-243
50 Disassembly and assembly
Steering system

Steering system (ALL-F000-001-K-00-A)

Removal and installation of steering valve assembly (WA470-F570-924-K-00-A)

Removal (WA470-F570-520-K-00-A) 5. Remove covers (2) and (3).


1. Turn the steering wheel fully to the left.
2. Raise the boom and support it by jack [1].

k Support the boom securely.

6. Disconnect hoses (4) and (5).

k Place the machine on a level ground, and


turn the parking brake switch to ON
position.

k Chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK. 7. Disconnect hoses (6) to (8) from the steering
valve.
k Turn the starting switch to OFF position, 8. Disconnect hose (9) from tube (11).
and stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)
3. Drain the hydraulic oil.

6 Hydraulic tank: 173l l


4. Remove cover (1) of the front frame.

9. Remove U-bolts (10) (6 places). [*1]


10.Disconnect tubes (11) to (14).

50-244 WA470-7
50 Disassembly and assembly
Steering system

hydraulic oil through the system. Then check the


oil level again.

5 Hydraulic tank: 173l l


• Air bleeding
Bleed air from each part. For details, see Testing
and adjusting.

11.Sling steering valve assembly (15).


a Pass lifting tool [2] between the front frame
and operator's cab.
12.Remove the mounting bolt, and remove steering
valve assembly (15) toward the right side of the
machine body.

4 Steering valve assembly (15): 30 kg

Installation (WA470-F570-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
3 U-bolt (10):
10.8 to 26.5 Nm {1.1 to 2.7 kgm}
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the

WA470-7 50-245
50 Disassembly and assembly
Brake system

Brake system (ALL-G000-001-K-00-A)

Removal and installation of brake charge valve assembly (WA470-G2H0-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-G2H0-520-K-00-A)

1. Drain the hydraulic oil.

6 Hydraulic tank: 173l l


2. Remove fender cover (1).
3. Remove covers (2) and (3).

Installation (WA470-G2H0-720-K-00-A)

• Perform installation in the reverse order of


removal.
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Hydraulic tank: 173l l


• Air bleeding
4. Disconnect hose (4). Bleed air from the brake circuit. For details, see
5. Remove tubes (5) and (6). Testing and adjusting "Bleeding air from wheel
6. Disconnect hoses (7) to (10). brake circuit".
7. Remove mounting bolts (3 pieces) from inside of
the machine, and remove brake charge valve
assembly (11).

50-246 WA470-7
50 Disassembly and assembly
Brake system

Removal and installation of parking brake disc and plate (WA470-GJ72-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

793T-607-1550 Bracket t 1
B 1 01051-62240 Bolt t 1
01643-32260 Washer t 1

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and 6. Remove mounting bolts (6) (2 pieces), and
chock the wheels. tighten them alternately into plug mounting part
(a). [*4]
k Lower the work equipment to the ground,
and set the work equipment lock switch to a Remove bolts (6) (2 pieces) on the diagonal
LOCK. positions.
a Piston (7) is pulled back by tightening bolts
k Turn the starting switch to OFF position, and (6), then the parking brake is released.
stop the engine.
a Tighten the bolts (2 pieces) gradually and
k Turn the battery disconnect switch to OFF evenly.
position, and remove the key. (For details, (Tighten the bolts approximately three turns
see Testing and adjusting, "Handling of after it contacts the seat surface.)
battery disconnect switch".) 7. Remove remaining bolts (6) (2 pieces). [*4]
8. Among 12 bolts (8), remove all the bolts other
Removal (WA470-GJ72-520-K-00-A) than 2 bolts diagonally installed. [*5]
1. Drain oil from the transmission case.

6 Transmission case: 65 l
2. Remove oil filler pipe (1).
3. Remove guard (2) and disconnect center drive
shaft (3) from the transmission.
a Retract the center drive shaft. [*1]
4. Remove coupling (4). [*2]
5. Remove plug (5). [*3]

9. Set jack [1] under cover (9).

WA470-7 50-247
50 Disassembly and assembly
Brake system

10.Install guide bolt [2], and remove the bolts


remained in step 8. [*5]
11.By using forcing screw [3] (M12 x 1.75),
separate cover (9) and piston together as a unit
from housing (10). [*6]

k Remove cover (9) from guide bolt [2]


while supporting the cover by 2 persons
and slowly lower jack [1].

4 Cover and piston assembly: 35 kg

15.Remove plates (13) (7 pieces), springs (14) (6


pieces), and discs (15) (6 pieces). [*8]

12.To prevent housing (10) from removing,


diagonally install 2 bolts (8) removed in step 8.
13.By using tool B1, push spacer (11) to remove
ring (12).
Installation (WA470-GJ72-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
a Tighten drive shaft mounting bolts according to
the following procedure.
1. Check that the mating yoke and the seat of the
drive shaft spider are free from rust, foreign
material (masking material), bruise, etc.
2. Set the yoke key slot in the vertical position,
place the drive shaft on the lower part of the
faucet joint portion, and insert the key into the
key slot.
3. Lightly tighten the four upper and lower bolts
until the spider contacts the seat of the yoke.
a Use a plastic (or copper) hammer to tap them
for contacting if fit of keyway portion and
faucet joint is harder. (Do not use a hard
metal hammer since it can damage the cross
bearing)
3 Mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}
[*2]
2 Mounting bolt of coupling (4):
14.Install bolts [4] (M8 x 1.25) to the tapped holes
and remove spacer (11). [*7] Adhesive (LT-2)

50-248 WA470-7
50 Disassembly and assembly
Brake system

3 Mounting bolt of coupling (4):


662 to 829 Nm {67.5 to 84.5 kgm}
[*3]
3 Plug (5):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
[*4]
3 Housing mounting bolt:
98.1 to 122.6 Nm {10 to 12.5 kgm}
[*5]
3 Cover mounting bolts:
98.1 to 122.6 Nm {10 to 12.5 kgm}
[*6]
2 O-ring of piston:
Grease (G2-LI)
[*7]
2 O-ring of spacer:
Grease (G2-LI)
[*8]
a Install plate (13), spring (14) and disc (15) in the
order indicated in the figure.
a Be careful that spring (14) does not get caught.

Refilling of oil
• Refill with oil to the specified level through the oil
filler port. Run the engine to circulate the oil
through the system. Then check the oil level
again.

5 Transmission case: 65 l

WA470-7 50-249
50 Disassembly and assembly
Undercarriage and frame

Undercarriage and frame (ALL-DT00-001-K-00-A)

Removal and installation of center hinge pin (WA470-H1L2-924-K-00-A)

a Special tools

Necessity
Sym-

Q'ty
Part No. Part name
bol

1 790-101-2300 Push puller t 1


2 793-520-2370 Push tool t 1
3 793-520-2350 Push tool t 1
4 793-520-2540 Guide t 1
E
5 793-520-2360 Bar t 2
6 791-112-1180 Nut t 2
7 790-101-1120 Hydraulic pump t 1 5. Set jack [3] under the counterweight.
8 790-101-2102 Puller (30 ton) t 1

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.
6. Remove the mounting bolts, and remove front
k Turn the battery disconnect switch to OFF drive shaft (1). [*1]
position, and remove the key. (For details, a Make matchmarks on the coupling and drive
see Testing and adjusting, "Handling of shaft, and then remove them.
battery disconnect switch".)

Removal (WA470-H1L2-520-K-00-A)

1. Remove the work equipment assembly. For


details, see "Removal and installation of work
equipment assembly".
2. Remove the operator's cab and floor frame
assembly. For details, see "Removal and
installation of operator's cab and floor frame
assembly".
3. After removing the work equipment assembly,
sling the boom foot pin installation part (hole on
the front frame side) by using the belt sling.
4. Support the rear frame (34) by using jack [1] and 7. Remove lock bolt (2a), and remove right and left
put blocks [2] under its right and left to adjust its pins (2) on the rod side of the steering cylinder.
height. [*2]
a After removing the pins, retract the piston
rods of the cylinders.
a Record the number and thickness of the
shims on the frame.

50-250 WA470-7
50 Disassembly and assembly
Undercarriage and frame

8. Disconnect connectors FR1 (3), FR2 (4), FR3 15.Disconnect hoses (17) to (20) on the front frame
(5), and FR4 (6). side.
9. Disconnect hose (7). 16.Disconnect hose (21) on the front frame side.

10.Disconnect hoses (8) and (9). 17.Disconnect hoses (22) and (23) from steering
11.Remove clamp (8a). valve (24).

12.Disconnect hoses (10) to (13). 18.Remove lock bolt (25a) and pull out lower hinge
13.Remove clamps (14a) and (15a). pin (25). [*3]
14.Disconnect hoses (14) to (16).

WA470-7 50-251
50 Disassembly and assembly
Undercarriage and frame

19.Remove bolts (26) (4 pieces) and spacer (27). a Check that all pipings and harnesses are
[*4] disconnected.
20.Remove bolts (28) (6 pieces) and remove
a Be careful that the lower spacer of the upper
retainer (29). [*5]
hinge is not caught in the rear frame.
a Record the number and thickness of the
a Slide the crane forward while slinging the
shims between the retainer and frame.
front frame.

21.Remove plate (30), and pull out upper hinge pin


(31). [*6] 24.Remove the mounting bolt from the upper hinge
pin of front frame (33), and remove retainer (36).
a Adjust the heights of the front and rear
[*8]
frames by using the jacks so that pins can be
removed by hand. a Record the number and thickness of the
shims between the retainer and frame.

22.Remove spacer (32).


25.Remove dust seal (37) from retainer (36). [*9]

23.Pull out front frame (33) forward slowly to


disconnect it from rear frame (34). [*7] 26.Remove spacer (38) and dust seal (39) from the
a Remove the frame lock bar in advance. lower side of the upper hinge pin of front frame
(33). [*10]
a When disconnecting, be careful of the 27.Remove bearing (40) from the upper hinge pin
balance. of front frame (33). [*11]

50-252 WA470-7
50 Disassembly and assembly
Undercarriage and frame

28.Remove bushings (41) on the top and bottom 31.Remove dust seal (44) from the lower hinge of
from the lower hinge of rear frame (34). [*12] front frame (33), and remove bearing (45). [*15]

29.Remove the mounting bolt from the lower hinge Installation (WA470-H1L2-720-K-00-A)
of front frame (33), and remove retainer (42).
[*13] • Perform installation in the reverse order of
removal.
a Record the number and thickness of the [*1]
shims between the retainer and frame.
3 Drive shaft mounting bolts:
98 to 123 Nm {10 to 12.5 kgm}
[*2]
a Adjust clearance (a) and (b) of the mounting
surfaces of the cylinder and frame to the
specified value by using shims.
• Clearance (a) and (b): Max. 0.5 mm
a Be sure to provide clearance.

30.Remove dust seal (43) from retainer (42). [*14]

[*8], [*9], [*10], [*11]

WA470-7 50-253
50 Disassembly and assembly
Undercarriage and frame

a Assemble the upper hinge pin according to the between retainer and hinge to the specified
following procedure. value.
1. Install tools E1 to E8 to top of the upper hinge • Clearance (d): Max. 0.1 mm (average)
pin of front frame (33), set bearing (40) on tool
3 Mounting bolt:
E1, and install it from upper side to press-fit
portion to press-fit. 20 ± 2 Nm {2 ± 0.2 kgm}
4. After adjustment using shims, tighten every
a When press-fitting it, use tool E4 as a guide. retainer mounting bolt to the specified torque.
a Be careful that the bearing does not tilt. 2 Mounting bolt:
a When replacing bearing (40), replace it as a Liquid adhesive (Loctite LT-2)
set with spacers (32) and (38).
3 Mounting bolt:
a For spacers (32) and (38), see steps 22 and 98 to 123 Nm {10 to 12.5 kgm}
26.
2 Inner portion of bearing: Grease (G2-
LI)

2. Press fit dust seal (37) to retainer (36).


a When press-fitting it, direct dust seal lip
surface outward.
a Insert it to the position 3.2 mm lower than the
top edge surface.
2 Dust seal lip:
Grease (G2-LI)
2 Outer periphery of metal outer ring of
dust seal: 5. Install dust seal (39) and spacer (38) from the
bottom of front frame (33).
Adhesive (Loctite No. 601)
a When press-fitting it, direct dust seal lip
surface outward.
a When installing spacer (38) from the bottom,
direct its larger chamfered-side to bearing.
a Insert dust seal (39) to 1.5 mm below the end
face of boss.

3. Tighten retainer (36) evenly using 3 mounting


bolts. Select shims to adjust clearance (b)

50-254 WA470-7
50 Disassembly and assembly
Undercarriage and frame

[*12], [*13], [*14], [*15] 3. Lightly tighten retainer (42) evenly using 3
mounting bolts. Select shims to adjust clearance
a Install the lower hinge according to the following
(e) between retainer and hinge to the specified
procedure.
value.
1. Press fit bearing (45) to front frame (33) with
• Clearance (e): Max. 0.1 mm (average)
tools E1 to E8.
3 Mounting bolt:
a When press-fitting it, use tool E1 as a guide.
20 ± 2 Nm {2.0 ± 0.2 kgm}
a Be careful that the bearing does not tilt. 4. After adjustment using shims, tighten every
2 Inner portion of bearing: retainer mounting bolt to the specified torque.
Grease (G2-L1) 2 Mounting bolt:
Liquid adhesive (Loctite LT-2)
3 Mounting bolt:
98 to 123 Nm {10 to 12.5 kgm}

2. Press fit dust seal (43) to retainer (42).


a When press-fitting it, direct dust seal lip
surface outward.
2 Dust seal lip surface:
Grease (G2-L1)
2 Outer periphery of metal outer ring of
dust seal:
Liquid adhesive (Loctite 601)

5. Press-fit dust seal (44) from top of front frame.


a When press-fitting it, direct dust seal lip
surface outward.

WA470-7 50-255
50 Disassembly and assembly
Undercarriage and frame

2 Dust seal lip:


Grease (G2-L1)
2 Outer periphery of metal outer ring of
dust seal
Adhesive (Loctite No. 601)
6. Using press, etc., press-fit bushing (41) to lower
hinge of rear frame (34).

3. Install retainer (29) to upper hinge pin (31) using


spacer (27) and mounting bolt (26).
3 Pin mounting bolt (26):
20 ± 2 Nm {2.0 ± 0.2 kgm}
4. Tighten retainer (29) evenly using three
mounting bolts (28). Measure clearance (c)
between hinge and retainer in two places and
calculate the average value to select shims.
[*3], [*4], [*5], [*6], [*7] • Clearance (c): Max. 0.2 mm
a Install the front frame and rear frame according 3 Retainer mounting bolt (28):
to the following procedure. 20 ± 2 Nm {2.0 ± 0.2 kgm}
k When aligning mounting holes for the pin, 5. Tighten pin (31), retainer (29), and mounting bolt
use a bar and the like. Never insert your (28) to the specified torque.
finger into the holes. 2 Pin and retainer mounting bolts (26)
and (28):
a Be sure to align pin holes accurately.
Liquid adhesive (Loctite LT-2)
1. Insert upper hinge pin (31) and install spacer
(32). 3 Pin mounting bolt (26):
206 ± 19.6 Nm {21 ± 2 kgm}
3 Retainer mounting bolt (28):
98 to 123 Nm {10 to 12.5 kgm}

2. Install plate (30) by tightening it lightly to prevent


upper hinge pin (31) from removing.

6. Tighten the mounting bolts of plate (30) to the


specified torque.

50-256 WA470-7
50 Disassembly and assembly
Undercarriage and frame

7. Insert lower hinge pin (25) and tighten lock bolt


(25a).

WA470-7 50-257
50 Disassembly and assembly
Undercarriage and frame

Removal and installation of counterweight assembly (WA470-H700-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 4. Disconnect connector R20 (10) on the left inside
position, and remove the key. (For details, the rear frame.
see Testing and adjusting, "Handling of a Remove the harness clamp and pull out the
battery disconnect switch".) harness toward outside the machine body.
Removal (WA470-H700-520-K-00-A)

1. Open full - fender (1) and side cover (2).


a Open them on the other side in the same
way.

5. Disconnect connector R21 (11) on right inside


the rear frame.
a Remove the harness clamp and pull out the
harness toward the outside the machine
body.
2. Remove cover (3) and plate (4).
a Remove them on the other side in the same
way.

6. Remove battery (12).


a Remove it on the other side in the same way.

3. Disconnect terminals (5) and (6), and remove 4 Battery (12): 50 kg


plates (7) to (9).
a Perform the same work on the opposite side.

50-258 WA470-7
50 Disassembly and assembly
Undercarriage and frame

10.Remove mounting bolts (2 pieces) and remove


counterweight assembly (16). [*2]

4 Counterweight assembly (16):


1,700 kg

7. Remove mounting bolts (4 pieces) and remove


additional counterweight (13). [*1]

4 Additional counterweight (13): 390 kg

Installation (WA470-H700-720-K-00-A)

• Perform installation in the reverse order of


removal.
[*1]
3 Additional counterweight (13) mounting
bolt:
1,520 to 1,912 Nm {155 to 195 kgm}
[*2]
3 Counterweight assembly (16) mounting
8. Open the grille at the rear of the machine body bolts:
and remove pin (14). 1,520 to 1,912 Nm {155 to 195 kgm}

9. Remove cover (15) at the rear of the fuel tank.

WA470-7 50-259
50 Disassembly and assembly
Undercarriage and frame

Removal and installation of full-length fender assembly (WA470-H560-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-H560-520-K-00-A)

1. Open and sling full-length fender assembly (1).


2. Remove mounting bolts (2) (4 pieces) from the
bottom and sling and remove full-length fender
assembly (1).

4 Full-length fender assembly (1): 75 kg

Installation (WA380-H560-720-K-00-A)

Perform installation in the reverse order to removal.

50-260 WA470-7
50 Disassembly and assembly
Hydraulic system

Hydraulic system (ALL-C000-001-K-00-A)

Removal and installation of hydraulic tank assembly (WA470-PM30-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 6. Disconnect hoses (3) to (6).
position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-PM30-520-K-00-A)

1. Drain the hydraulic oil.

6 Hydraulic tank: 173l l


2. Remove full-length fender assembly. For details,
see ""Removal and installation of full-length
fender assembly"".
3. Remove the engine hood assembly. For details,
see "Removal and installation of engine hood
7. Disconnect hoses (7) to (9) on the left side of the
assembly".
hydraulic tank.
4. Remove cover (1) under the hydraulic tank.
a Remove it on the other side as well.

8. Disconnect connector E33 (10).


9. Remove clamps of harness (11) (2 pieces).
5. Disconnect hose (2) on the right side of the
hydraulic tank.

WA470-7 50-261
50 Disassembly and assembly
Hydraulic system

13.Remove mounting bolt of breather (17), remove


all the clamps of hose (18), and move it.

10.Disconnect tubes (12) to (14) from the hydraulic


tank.
14.Remove cover (19) at the top of the hydraulic
tank.

11.Disconnect hose (15).

15.Sling the hydraulic tank assembly.


16.Remove mounting bolts (20) (3 pieces) each on
the right and left sides.

12.Sling and remove bracket (16).

4 Bracket (16): 30 kg

17.Sling hydraulic tank assembly (21), and remove


it.

4 Hydraulic tank assembly (21): 280 kg

50-262 WA470-7
50 Disassembly and assembly
Hydraulic system

Installation (WA470-PM30-720-K-00-A)

• Perform installation in the reverse order of


removal.
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Hydraulic tank: 173l l


• Air bleeding
Bleed air from the circuit. For details, see Testing
and adjusting, "Bleeding air from work
equipment circuit".

WA470-7 50-263
50 Disassembly and assembly
Hydraulic system

Removal and installation of control valve assembly (WA470-R404-924-K-00-A)

Removal (WA470-R404-520-K-00-A)

1. Turn the steering wheel fully to the left.


2. Raise the boom and support it by jack [1].

k Support the boom securely.

5. Disconnect connectors F25 (2), F24 (3), and


F22 (4). Move the harnesses.
6. Remove bracket (4-1).

k Place the machine on a level ground, and


turn the parking brake switch to ON
position.

k Chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.
7. Disconnect connectors F26 (5), F20 (6), F23 (7),
k Turn the starting switch to OFF position, and F21 (8). Move the harnesses.
and stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling
battery disconnect switch".)

k Release remaining pressure from the area


between the hydraulic cylinders and
control valves and from the ECSS
(Electronically Controlled Suspension
System) circuit. For details, see Testing
and adjusting, "Releasing remaining
pressure from work equipment circuit". 8. Disconnect hoses (9) and (10).

3. Drain the hydraulic oil.

6 Hydraulic tank: 173l l


4. Remove cover (1) of the front frame.

50-264 WA470-7
50 Disassembly and assembly
Hydraulic system

15.Disconnect tubes (22) and (23). Fix them to the


machine body side by using a rope, etc.

9. Disconnect connector F10 (11).

10.Disconnect hoses (12) to (14).


16.Remove mounting bolts (24) (4 pieces) on the
bottom of the control valve.

11.Disconnect hoses (15) and (16).

17.Sling control valve assembly (25), and remove


it.

4 Control valve assembly (25): 140 kg

12.Remove U-bolts (17) and (18).


13.Remove bracket (19).
14.Remove tubes (20) and (21).

WA470-7 50-265
50 Disassembly and assembly
Hydraulic system

Installation (WA470-R404-720-K-00-A)

• Perform installation in the reverse order of


removal.
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Hydraulic tank: 173l l


• Air bleeding
Bleed air from the circuit. For details, see Testing
and adjusting, "Bleeding air from work
equipment circuit".

50-266 WA470-7
50 Disassembly and assembly
Hydraulic system

Removal and installation of steering pump and power train pump


assembly (WA470-C200-924-K-01-A)
k Place the machine on a level ground, and
turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 10.Remove clamp (9).


position, and remove the key. (For details, 11.Disconnect tube (10).
see Testing and adjusting, "Handling of
battery disconnect switch".)

Removal (WA470-C200-520-K-01-A)

1. Drain the hydraulic oil.

6 Hydraulic tank: 173l l


2. Remove engine hood assembly. For details, see
"Removal and installation of engine hood
assembly".
3. Remove hydraulic tank assembly. For details,
see "Removal and installation of hydraulic tank
assembly".
12.Disconnect connector R90 (11).
4. Remove the operator's cab and floor frame
assembly. For details, see "Removal and
installation of operator's cab and floor frame
assembly".
5. Remove tube (1).
6. Disconnect hoses (2) to (5).

13.Sling steering pump and power train pump


assembly (12) and remove them. [*1]

4 Steering pump and power train pump


assembly (12):
7. Disconnect hose (6). 80 kg
8. Disconnect connector R86 (7).
9. Remove tube (8).

WA470-7 50-267
50 Disassembly and assembly
Hydraulic system

Installation (WA470-C200-720-K-01-A)

• Perform installation in the reverse order of


removal.
[*1]
2 Hose insertion portion of tube (1):
Liquid gasket (LG-9)
3 Hose clamp of tube (1):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Mounting bolt of steering pump and
power train pump assembly (12):
235 to 285 Nm {23.5 to 29.5 kgm}
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
hydraulic oil through the system. Then check the
oil level again.

5 Hydraulic tank: 173l l


• Air bleeding
Bleed air. For details, see Testing and adjusting,
"Bleeding air from steering cylinder circuit".

50-268 WA470-7
50 Disassembly and assembly
Hydraulic system

Removal and installation of work equipment pump and cooling fan pump
assembly (WA470-C200-924-K-00-A)
k Place the machine on a level ground, and 10.Remove clamp (9).
turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details, 11.Sling the work equipment pump and cooling fan
see Testing and adjusting, "Handling of pump assembly (10), and remove them. [*2]
battery disconnect switch".)
4 Work equipment pump and cooling
Removal (WA470-C200-520-K-00-A)
fan pump assembly (10):
1. Drain the hydraulic oil. 160 kg

6 Hydraulic tank: 173l l


2. Remove engine hood assembly. For details, see
"Removal and installation of engine hood
assembly".
3. Remove hydraulic tank assembly. For details,
see "Removal and installation of hydraulic tank
assembly".
4. Remove the operator's cab and floor frame
assembly. For details, see "Removal and
installation of operator's cab and floor frame
assembly".
5. Remove steering pump and power train pump
assembly. For details, see "Removal and
installation of steering lubrication pump and Installation (WA470-C200-720-K-00-A)
power train pump assembly". • Perform installation in the reverse order of
6. Remove hose (1). [*1] removal.
7. Disconnect tube (2). [*1]
8. Disconnect hoses (3) to (6).
2 Hose (1) insertion portion:
Liquid gasket (LG-9)
3 Clamp of hose (1):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
3 Mounting bolt of work equipment pump
and cooling fan pump assembly (10):
235 to 285 Nm {23.5 to 29.5 kgm}
• Refilling of oil
Refill with oil to the specified level through the oil
filler port. Start the engine to circulate the
9. Disconnect connectors R29 (7) and R71 (8), and hydraulic oil through the system. Then check the
remove the connectors from the brackets. oil level again.
a Remove the harness clamp as well.

WA470-7 50-269
50 Disassembly and assembly
Hydraulic system

5 Hydraulic tank: 173l l


• Air bleeding
Bleed air. For details, see Testing and adjusting,
"Bleeding air from work equipment circuit" and
"Bleeding air from hydraulic fan circuit".

50-270 WA470-7
50 Disassembly and assembly
Hydraulic system

Disassembly and assembly of hydraulic cylinder assembly (WA470-PPZ0-924-K-00-A)

a Special tools 3) Pull out cylinder head and piston rod


assembly (3) from cylinder (4), sling them,

Necessity
and remove them.
Sym-

Q'ty
Part No. Part name
bol a When the piston rod assembly is pulled
out of the cylinder, oil flows out. So
1 790-502-1003 Cylinder repair stand t 1 prepare a container to receive the oil.
F1
2 790-101-1102 Hydraulic pump t 1
Socket (width across
F2 90-302-1280 flats: 55 mm) t 1
1 790-330-1100 Wrench assembly t 1
F3
2 790-102-2304 Wrench assembly t 1
1 790-102-4300 Wrench assembly t 1
F4
2 790-102-4310 Pin t 1
1 790-720-1000 Expander t 1
2 796-720-1650 Ring (*1) t 1
F5 3 07281-01029 Clamp (*1) t 1
4 796-720-1680 Ring (*2) t 1
5 07281-01589 Clamp (*2) t 1
1 790-201-1500 Push tool kit t 1 4) Set cylinder head and piston rod assembly
2 790-101-5021 • Grip 1 (3) on tool F1.
3 01010-50816 • Bolt 1 5) By using tool F2, remove nut (5).
F6
4 790-201-1570 • Plate 1 a Width across flats of nut: 55 mm
5 790-201-1990 Plate t 1 6) Remove piston (6) and remove cylinder head
6 790-201-1660 • Plate 1 (2).
1 790-201-1702 Push tool kit t 1
2 790-101-5021 • Grip 1
3 01010-50816 • Bolt 1
F7
4 790-201-1761 • Push tool 1
5 790-201-1930 • Push tool 1
6 790-201-1851 • Push tool 1
*1: For steering cylinder
*2: For lift cylinder and bucket cylinder
Disassembly (WA470-PPZ0-520-K-00-A)

1. Disassembling cylinder head for steering


cylinder and piston assembly
1) Set cylinder assembly (1) on tool F1. 2. Disassembling lift cylinder, cylinder head for
2) By using tool F3-1 or F3-2, remove cylinder bucket cylinder, and piston rod assembly
head (2) from the cylinder. 1) Set cylinder assembly (1) on tool F1.
2) Remove mounting bolt of cylinder head (2).
Width across flats of bolt
Cylinder
(mm)
Lift cylinder 27
Bucket cylinder 30

WA470-7 50-271
50 Disassembly and assembly
Hydraulic system

3) Pull out cylinder head and piston rod


a If screw (7) is punched securely and hard
assembly (3) from cylinder (4) while slinging
to remove, tighten it further once. Then
them, and remove them.
tap its threaded portion with tap [1] and
a When the piston rod assembly is pulled remove the screw.
out of the cylinder, oil flows out. So
prepare a container to receive the oil.

6) By using tool F4, remove piston assembly


(6).
4) Set cylinder head and piston rod assembly a When tool F4 is not used, use drilled
(3) on tool F1. holes (p) (10 mm in diameter: 2 places) to
5) Remove lock screw (7) of the piston loosen the piston assembly.
assembly from piston (6). 7) Remove head assembly (2).
a This screw is for both lift cylinders and
bucket cylinders.
• Size: M12 x 1.75

50-272 WA470-7
50 Disassembly and assembly
Hydraulic system

3. Disassembly of piston assembly [Lift cylinder and bucket cylinder]


[Steering cylinder] 1) Remove the O-ring and backup ring (11).
Remove wear ring (8) and piston ring (9) from 2) Remove snap ring (12) and remove dust seal
piston (6). (13).
3) Remove rod packing (14).
4) Remove buffer ring (15).
5) Remove snap ring (16a) and remove
bushing (16).

[Lift cylinder and bucket cylinder]


Remove wear ring (8), piston ring (9), the O-ring,
backup ring (10) and ring (10a) from piston (6).

Assembly (WA470-PPZ0-720-K-00-A)

a Take care not to damage packings, dust seals,


O-rings, etc.
a When installing the backup ring, do not install it
forcibly. Warm it in hot water (temperature is
approximately 50 to 60°C), and then install it.
1. Assembly of cylinder head assembly
a When using tool F6 (plate) and F7 (push tool),
refer following.
• F6-4, F7-4: Steering cylinder
4. Disassembly of cylinder head assembly • F6-5, F7-5: Lift cylinder
[Steering cylinder] • F6-6, F7-6: Bucket cylinder
1) Remove the O-ring and backup ring (11). [Steering cylinder]
2) Remove snap ring (12) and remove dust seal 1) By using tool F7, press-fit bushing (16) and
(13). install snap ring (16a).
3) Remove rod packing (14). 2) Install buffer ring (15).
4) Remove buffer ring (15). 3) Install rod packing (14).
5) Remove snap ring (16a) and remove 4) By using tool F6, install dust seal (13) and
bushing (16). secure it with snap ring (12).
6) Remove O-ring (17). 5) Install the backup ring and O-ring (11).
6) Install O-ring (17).

WA470-7 50-273
50 Disassembly and assembly
Hydraulic system

2. Assembly of piston assembly


1) By using tool F5-1, expand piston ring (9).
a Set the piston ring to the tool and rotate
the handle 8 to 10 turns to expand the
piston ring.
2) Remove piston ring (9) from tool F5-1 and
install it to piston (6).
3) Compress piston ring (9) by using tool F5.
a When using tool F5 (ring and clamp),
refer following combination.
• F5-2, 3: Steering cylinder
• F5-4, 5: Bucket cylinder and lift
[Lift cylinder and bucket cylinder] cylinder
1) By using tool F7, press-fit bushing (16) and 4) Install wear ring (8).
install snap ring (16a). 5) Install the backup ring, O-ring (10) and ring
2) Install buffer ring (15). (10a). (Lift cylinder and bucket cylinder)
3) Install rod packing (14).
4) By using tool F6, install dust seal (13) and a When installing the backup ring, do not
secure it with snap ring (12). install it forcibly but warm it in hot water at
5) Install the backup ring and O-ring (11). approximately 50 to 60°C, and then install
it.

a Steering cylinder is shown below.

50-274 WA470-7
50 Disassembly and assembly
Hydraulic system

5) Sling and install cylinder head and piston rod


assembly (3) to cylinder (4).
6) By using tool F3-1 or F3-2, install cylinder
head (2) to cylinder(4).
3 Cylinder head:
677 ± 67.5 Nm {69 ± 6.9 kgm}
7) Bend the lock of cylinder head (2) toward the
cut-out portion of the cylinder side.
8) Remove cylinder assembly (1) from tool F1.

a Lift cylinder and bucket cylinder are shown


below.

3. Assembly of cylinder head and piston rod for


steering cylinder
1) Set piston rod assembly (3) on tool F1.
2) Install cylinder head (2) and piston (6) to the
piston rod.
3) Install nut (5) and tighten it by using tool F2.
2 Threaded part of piston rod:
Adhesive (Loctite No. 262 and 4. Assembly of cylinder head and piston rod for lift
equivalent) cylinder and bucket cylinder
1) Set piston rod assembly (3) on tool F1.
3 Nut:
2) Install head assembly (2).
1.67 ± 0.17 kNm {170 ± 17 kgm}
(width across flats: 55 mm)

3) Assemble piston assembly (6) according to


the following procedure.
4) Set cylinder (4) to tool F1.
• When reusing the rod and piston
assembly (6)

WA470-7 50-275
50 Disassembly and assembly
Hydraulic system

1] Screw in piston assembly (6), and tighten


it until the screw holes are matched by
using tool F4.
a Clean them thoroughly and remove all
chips and dirt.
a Remove burrs and sharp edges from
threaded part by using a file.

2] Make 1 threaded hole for installing screw


(7).
a Drill a hole in horizontal into the V-
groove where piston (6) and the
threads of rod (3) mesh with each
other.
• Drilling dimensions (mm)

2] Tighten screw (7). a Make the hole in following


dimensions.
2 Threaded part of screw:
• Tap to be used: M12 x 1.75
Adhesive (Loctite No. 262 and • Tap drill hole diameter: 10.3 mm
equivalent) • Tap drill hole depth: 27 mm
3 Screw (7): • Tapping depth: 20 mm
58.9 to 73.6 Nm {6 to 7.5 kgm}
3] Punch 4 places on the circumference of
the threaded part [2] with a punch.
4] Apply torque of 41.2 to 88.2 Nm {4.2 to 9
kgm} to screw (7) in the direction of
loosening. Check the screw does not
loose.

3] After making the hole, remove all chips


and dirt, and clean the hole thoroughly.
4] Tighten screw (7).
2 Threaded part of screw:
Adhesive (Loctite No. 262 and
equivalent)
• When either or both of the rod and piston 3 Screw (7):
assembly (5) are new 58.9 to 73.6 Nm {6 to 7.5 kgm}
1] Screw in piston assembly (6) until it 5] Punch 4 places on the circumference of
reaches rode end (r), and then tighten it the threaded part with a punch.
to the specified torque by using tool F4. 6] Apply torque of 41.2 to 88.2 Nm {4.2 to 9
3 Piston assembly (6): kgm} to screw (7) in the direction of
loosening. Check the screw does not
294 ± 29.4 Nm {30 ± 3.0 kgm} loose.

50-276 WA470-7
50 Disassembly and assembly
Hydraulic system

4) Set cylinder (4) to tool F1.


5) Sling and install cylinder head and piston rod
assembly (3) to cylinder (4).
6) Install cylinder head (2) to cylinder (4).
3 Mounting bolt:
373 ± 54 Nm {38.0 ± 5.5 kgm}
(lift cylinder)
530 ± 78.5 Nm {54 ± 8 kgm}
(bucket cylinder)

WA470-7 50-277
50 Disassembly and assembly
Work equipment

Work equipment (ALL-L000-001-K-00-A)

Removal and installation of work equipment assembly (WA470-L100-924-K-00-A)

k Place the machine on a level ground, and


turn the parking brake switch to ON position.

k Set the frame lock bar to LOCK position, and


chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF 5. Sling bucket cylinder (3).
position, and remove the key. (For details, 6. Remove pin (4) to separate the cylinder rod from
see Testing and adjusting, "Handling of the bell crank. [*3]
battery disconnect switch".)
4 Bucket cylinder (3): 210 kg
Removal (WA470-L100-520-K-00-A)

1. Sling the bucket link, and remove pin (1). [*1]


a By using the lever block, fix the bucket link.
a If shims are inserted, check and record the
number and thickness.
2. Remove pins (2) on the right and left sides. [*2]
a If shims are inserted, check and record the
number and thickness.
3. Start the engine and travel the machine in
reverse direction to separate the bucket from the
boom.
7. Remove cover (5a).
8. Disconnect connector F30 (5b).

4. Set supporting stand [1] at the boom end and


release remaining pressure in the piping.
9. Sling lift cylinder (6) and remove pin (6a). [*4]
a If shims are inserted, check and record the
number and thickness.
a Lower the lift cylinder after placing a block [2]
on the top of axle.

4 Lift cylinder: 200 kg

50-278 WA470-7
50 Disassembly and assembly
Work equipment

a When slinging, insert block [3].


14.Pull out pin (9) to remove boom, bell crank and
bucket link assembly (8). [*6]
a If shims are inserted, check and record the
number and thickness.

4 Boom, bell crank and bucket link


assembly:
1,950 kg

10.Remove cover (7a).

15.Sling bucket link (11) and pull out pin (12) and
remove it.

4 Bucket link: 90 kg
11.Disconnect connector F11 (7b).
12.Remove bolts (2 pieces) and remove boom
angle sensor assembly (7). [*5]

16.Remove covers (12a) and (12b).

13.Sling the boom, bell crank and bucket link


assembly (8).

WA470-7 50-279
50 Disassembly and assembly
Work equipment

17.Disconnect connector (12c).


21.Remove dust seal (18) and bushing (19) from
18.Remove bucket angle sensor unit (12). [*7]
bell crank (13). [*9]

19.Sling bell crank (13) and pull out pin (14) and
remove it. [*8] 22.Remove dust seal (20) and bushing (21) from
bucket linkage (11). [*9]
4 Bell crank angle: 390 kg

20.Remove dust seal (16) and bushing (17) from Installation (WA470-L100-720-K-00-A)

boom (15). [*9] • Perform installation in the reverse order of


removal.
k When aligning the mounting holes for the pin,
never insert your fingers in the holes.

k Before starting the engine, check that the


directional lever is in the neutral position and
the parking brake is applied.

[*1]
a Install the bucket link according to the following
procedure.

50-280 WA470-7
50 Disassembly and assembly
Work equipment

1. Sling bucket link (11) and install O-ring (22). k When aligning mounting holes for the pin,
2. Align the pin hole positions of bucket (23) and never insert your fingers in the holes.
bucket link (11).
[*5]
k Do not insert your finger to the pin hole. For checking operation after adjustment of
installation position, see Testing and Adjusting,
a Be careful that the O-ring does not get
"Testing and adjusting boom position detection
caught.
lever".
3. Insert the shim so that clearance (a) is even on
right and left sides. Install pin (1) and lock it with [*6]
the bolt. a Install the boom, bell crank and bucket linkage
• Clearance (a): Max. 1.5 mm assembly according to the following procedure.
• Set shim thickness: 1.5 mm, 3.0 mm 1. Sling boom, bell crank and bucket linkage
assembly to align the pin hole positions of front
frame (25) and lift arm (15).

k Do not insert your finger to the pin hole.


2. Insert the shim so that clearance (d) is even on
right and left sides. Install pin (10) and lock it
with the bolt.
• Clearance (d): Max. 1.5 mm
• Set shim thickness: 1.0 mm, 1.5 mm, 3.0 mm

k After installing the pin, install the support


stand at the end of the boom.
[*2]
a Install the pin according to the following
procedure.
1. Install O-ring (24) to bucket (23).
2. Use the lift arm control lever to align the pin hole
positions of bucket (23) and lift arm (15).

k Do not insert your finger to the pin hole.


a Take care so that the O-ring does not get
caught.
3. Insert the shim so that clearance (b) is even on
right and left sides. Install pin (1) and lock it with
the bolt. [*7]
• Clearance (b): Max. 1.5 mm a For checking operation after adjustment of
• Set shim thickness: 1.5 mm, 3.0 mm installation position, see Testing and Adjusting,
"Testing and adjusting bucket position detection
lever".
[*8]
a Fix the bucket link to the bell crank by using the
lever block.
[*9]
a Press-fit the bushings by using puller [4], etc.
2 Inner surface of bushing:
Molybdenum disulfide lubricant (LM-P)
a The following figure shows the boom as an
example.
[*3] [*4]

WA470-7 50-281
50 Disassembly and assembly
Work equipment

a Install the dust seal with its lip (a) facing outside.
a The following figure shows the boom (bucket
side).

• Greasing
Grease each pin after installation is completed.
2 Pins:
Molybdenum disulfide grease (LM-G)

50-282 WA470-7
50 Disassembly and assembly
Cab and its attachments

Cab and its attachments (ALL-K000-001-K-00-A)

Removal and installation of operator's cab and floor frame


assembly (WA470-K000-924-K-00-A)
k Place the machine on a level ground, and 4. Remove the hydraulic tank assembly. For details,
turn the parking brake switch to ON position. see "Removal and installation of hydraulic tank
assembly".
k Set the frame lock bar to LOCK position, and 5. Remove covers (1) on right and left sides.
chock the wheels.

k Lower the work equipment to the ground,


and set the work equipment lock switch to
LOCK.

k Turn the starting switch to OFF position, and


stop the engine.

k Turn the battery disconnect switch to OFF


position, and remove the key. (For details,
see Testing and adjusting, "Handling of
battery disconnect switch".)
6. Remove right fender rubber cover (2).
k Loosen the cap of the hydraulic tank slowly
to release the pressure in the hydraulic tank.

k If you disconnect the heater hose when the


coolant in the radiator is still hot, you may be
scalded. Wait until the coolant temperature
drops before starting the work.

k Collect the refrigerant (air conditioner gas:


R134a) from the air conditioner circuit.

a Never release the refrigerant (air conditioner


gas: R134a) to the atmosphere.
a Ask a qualified person for collecting, adding, and 7. Remove cover (3).
filling operations of the refrigerant (air
conditioner gas: R134a).
k If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Accordingly, put on the
protective eyeglasses, gloves and working
suits with long sleeves for collecting and
filling operations.

Removal (WA470-K000-520-K-00-A)

1. Collect refrigerant (air conditioner gas: R134a).


[*1] 8. Disconnect connectors R43 (5) and R45 (6) of
• Refrigerant to be collected: 1,100 ± 50 g washer tank (4).
2. Remove the full-length fender assembly. For • R43 (front: black), R45 (rear: white)
details, see "Removal and installation of full- 9. Disconnect washer hoses (7).
length fender assembly".
3. Remove the engine hood assembly. For details, a Remove clamp (7a) as well.
see "Removal and installation of engine hood
assembly".

WA470-7 50-283
50 Disassembly and assembly
Cab and its attachments

13.Remove mounting bolts (14a) (4 pieces), and


remove brake valve (14) from bracket (14b).
a Lower brake valve (14) and hose together as
a unit.

10.Remove toolbox (8).

14.Disconnect connectors (9 pieces) from harness


(15).
• Front side, from top: L36A, RVC, LR5, LR7,
LR8, LR9, LR12, LR6, and LR2
• Back side, from top: LR3, LR4, and LR11

11.Disconnect connector L09 (9).


a Remove clamp (9a) as well.

15.Disconnect ground cable (16) to (18).

12.Disconnect hoses (10) to (13), from the Orbitrol


valve.

16.Remove clamp (19) and disconnect connectors


LR1 (20) and LT1 (21).
a Since the connector LR1 is secured with
screws, loosen them before disconnecting
the connector. And be sure to prevent the
rubber seal at the edge from coming off. [*2]

50-284 WA470-7
50 Disassembly and assembly
Cab and its attachments

17.Remove air conditioner hoses (22) and (23), and 20.Remove the monitor controller assembly. For
remove heater hoses (24) and (25). [*3] details, see "Removal and installation of monitor
controller assembly."
21.Remove mounting bolts (27) of operator's cab
and floor frame assembly.

18.Remove the floor mat, and mounting bolts (23)


of the operator's cab and floor frame assembly.
a Remove only bolts (2 pieces) in front.
22.Remove mounting bolts (28) (4 pieces) of
viscous mount lock plates under the floor frame.
23.Remove lock bolts (29) (4 pieces) and stopper
mounting bolts (30) (4 pieces). [*4]

19.Remove grommet (25) inside shoes box (24),


and remove mounting bolts (26) of operator's
cab and floor frame assembly.
24.Sling operator's cab and floor frame assembly
(31), and remove them.
a Before removing the assembly, check that all
wiring and piping are disconnected.

4 Operator's cab and floor frame


assembly (31):
1,000 kg

WA470-7 50-285
50 Disassembly and assembly
Cab and its attachments

Installation (WA470-K000-720-K-00-A) [*4]


• Perform installation in the reverse order of 3 Stopper mounting bolt (30):
removal. 1,180 to 1,470 Nm {120 to 150 kgm}
[*1]
a Refill the air conditioner circuit with refrigerant
(air conditioner gas: R134a).
a Filling quantity: 1,100 ± 50 g
[*2]
• When connecting connector LR1 (20), take care
that the protect rubber seal at the end does not
get caught.
3 Screw:
2.2 to 2.8 Nm {0.23 to 0.29 kgm}
[*3]
a When connecting the air conditioner hose, be
careful of the followings.
1. Do not remove stoppers plugging piping until
installation of piping is started.
2. Be careful that dirt, dusts, or water do not enter
into air conditioner tubes when installing them.
3. Check that the O-ring is installed to the air
conditioner tube connection before installation.
4. Check that the O-ring is not damaged or
deteriorated.
5. Apply compressor oil for refrigerant (R134a) to
the O-ring when connecting the refrigerant
piping.
2 O-ring and threaded portion:
Compressor oil for R134a
(DENSO: ND-OIL8, VALEO THERMAL
SYSTEMS: ZXL100PG, SANDEN: SP-
10 (equivalent to PAG46))
a Tighten sleeve nuts (22a) and (23a) at hose
connections to the following torque.
3 Sleeve nut (22a):
30 to 35 Nm {3.1 to 3.6 kgm}
3 Sleeve nut (23a):
12 to 15 Nm {1.2 to 1.5 kgm}

50-286 WA470-7
50 Disassembly and assembly
Cab and its attachments

Removal and installation of operator's cab glass (stuck window


glass) (WA380-K183-924-K-00-A)
a Special tools a When the glass surface is narrow, you can
use an ultrafine wire (piano wire, etc.) [2] and

New/Redesign
pliers [3]. In this case, clip both ends of wire

Necessity
Quantity
with pliers (or wind wire around pliers) and

Sketch
Symbol Part No. Part name insert wire to the position where adhesive
stays to cut it off.

1 793-498-1120 Clear plate t 2


2 2 793-498-1130 Plate t 2
X 3 793-498-1110 Magnet t 2
Lifter (suction
3 793-498-1210 cup) t 2

k Stop the machine on a level ground and


apply the parking brake.

k Set the lock bar to the front and rear frames


to lock them and chock wheels.

k Lower the work equipment to the ground. a When you use a seal cutter or ultrafine wire,
take care not to damage parts in the
k Stop the engine, turn the battery disconnect operator's cab (such as resin covers).
switch to the OFF position, and remove the
key. a When removing shattered window glass, it is
allowed to use cutter knife [4] and a
a Place the machine at the place where it is not screwdriver. (Applying a screwdriver directly
wet or windy. Open the door either on right or left. to an unbroken window glass most possibly
Do not close the door until cure of the glass ends up breaking the glass.)
replacement is finished. a When using a cutter knife [4], insert a flat
(Because the glass may be dropped by head screwdriver to the cutting edge to cut
increasing of internal pressure inside the cab if through while widening the cutting edge.
the door is opened or closed.)
Removal (WA380-K183-520-K-00-A)

a All-stuck window glass is employed for the


operator's cab installed on this machine.
a Remove the window glass to be replaced
according to the following procedure.
1. By using seal cutter [1], cut off the adhesive
between damaged window glass (1) and
operator' cab (2).

2. Remove the window glass.


Installation (WA380-K183-720-K-00-A)

1. By using scraper [5], eliminate adhesives left on


the bonding surface.
a Since adhesive left on a part of the bonding
surface of the operator's cab can detach and
drop the window glass, adhesive must be
completely removed.

WA470-7 50-287
50 Disassembly and assembly
Cab and its attachments

a Take care not to damage the painted surface


when cleaning adhesive.

4. Attach dam rubber (double-coated adhesion


tape) (4) along the inner edge of window glass
mounting surface.
2. Using white gasoline, remove oil, dusts and
stains from bonding surfaces on operator's cab • Size of dam rubber: 7 x 4.8 mm
(2) and window glass (3) a When attaching dam rubber, try as much as
a Clean them thoroughly since insufficient possible not touch cleaned surfaces.
cleaning induces defective adhesion. a Do not remove the release tape on glass-
a Black-colored portions on the rear side of bonding side of dam rubber until installation
window glasses must be entirely cleaned. of window glass is started.

a After cleaning, leave them as is five minutes


for natural drying.

a Take care not to allow dam rubber (4) to peel


off from the cab surface at corner portion (b).
3. If you have peeled off painting unintentionally
while removing adhesives using a scraper, coat
such portions with paint.
a Installing a window glass on unpainted
surfaces can gather rust there.
a Do not paint the portions that are coated with
primer.

50-288 WA470-7
50 Disassembly and assembly
Cab and its attachments

a For the right and left windows and rear and fit the window glass to the operator's
window, dam rubber is attached all around cab.
them. Start bonding of dam rubber from the
upper center position of the window and,
after bonding it almost around the window,
stop at a point about 5 mm away from
starting point "c" to leave the clearance.

4) Check clearance between window glass (3)


and operator's cab (2) on both sides. Adjust
the window glass so that uniform clearance
is obtained on both sides.
5) Attach tape [6] between window glass (3)
and operator' cab (2), and draw a line (a) on
5. Perform position alignment of replacing window the tape for position alignment.
glasses. 6) Using a knife, cut the tape at a position
1) Using an adhesive, stick X2-2 (thin steel between window glass (3) and operator's cab
plate) to tool X2-1 (spacer). (2), and remove the window glass.
• Thickness (t) of spacer: 5 mm a Do not remove tapes left on the window
2) Attach tool X2-3 (magnet) to tools X2-1 and glass and operator's cab until installation
X2-2, and set them in two lower window
of window glass is started.
glass installed positions of operator's cab (2).

6. Apply primer.
a Since useful life of primer (5) is four months
from the date of production, be sure not to
use an overdue primer.
a Make sure to use primer within two hours
from opening its cap.
a Even when it is plugged again immediately
after opening, be sure to use it within 24
hours from opening.
(A primer must be disposed when 24 hours have
elapsed from opening.)
1) Agitate both primers for paint surface and
3) By using tool X3 (suction cup), place window glass sufficiently before use.
glass (3) on tool X2-1 (5 mm thick spacer)

WA470-7 50-289
50 Disassembly and assembly
Cab and its attachments

a When a primer was chilled-stored in a


depository, leave it half a day in room
temperature before agitating it.
(Bedewing of a primer results if you
immediately open the lid of a primer that has
been chilled-stored in a depository until then.
So it must be exposed to room temperature
for a sufficient period of time.)
2) When reusing a brush (6) for applying a
primer, clean it using white gasoline before
use.
a After cleaning, check again that the brush
is free from stains or fouling.
a A separate brush must be prepared for
the primer for paint surface and that for
glass.

4) Apply primer (8) for glass uniformly to the


black portions on bonding surface of window
glass (3).
2 Primer for glass:
3) Apply primer (7) for paint surface uniformly to
SUNSTAR Glass Primer 580
the portion outside the dam rubber (4) of
SUPER
operator's cab (2) to which adhesive is
applied. a Two times are the upper limit of primer
application.
2 Primer for paint surface:
(Application beyond two times cause
SUNSTAR paint surface primer
degradation.)
580 SUPER
a Coating position: Apply the primer to the
a Two times are the upper limit of primer
entire area of dimension "d" where
application.
window glass (3) bonds to the operator's
(Application beyond two times cause cab. Dimension "d" is relative to dam
degradation.) rubber (4) and operator's cab (2).
a Coating position: Entire area of dimension • Primer coating dimension "d": 23 mm
"d" located outside the dam rubber.
a Do not apply the primer to about 5 mm of
• Primer coating dimension "d": 23 mm the border area between the black and
a After coating, leave the coated surface for transparent portions on the window glass.
more than five minutes (but no longer a After coating, leave the coated surface for
than 8 hours) for natural drying. more than five minutes (but no lon

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