VEBM460104 WA380-3 With-Diagrams 09-06 PDF

VEBM460104
Shop Manual
WA380-3
Wheel Loader
Serial Number
WA380H20051 and up
© 2000
All Rights Reserved
Printed in Europe 03/2000
CONTENTS
No. of page
01 GENERAL ......................................................................... 01-1
10 STRUCTURE AND FUNCTION ....................................... 10-1
20 TESTING AND ADJUSTING ............................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ................................... 30-1
40 MAINTENANCE STANDARD........................................... 40-1
00-2
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. Some of the
described service and repair techniques require the use of tools specially designed by
Komatsu for the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this
manual. The cautions accompanying these symbols must always be followed carefully. If any
dangerous situation arises or may possibly arise, first consider safety, and take the neces-
sary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION AND MAINTENANCE MANUAL
carefully BEFORE operating the machine!
Always follow the safety rules valid in your country carefully!
1. Before carrying out any greasing or repairs, Always keep the work area clean and make
read all the precautions given on the decals sure that there is no dirt or oil on the floor.
which are fixed to the machine. Never smoke while working.
Smoke only in the areas provided for smoking.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
PREPARATIONS FOR WORK
• Always wear safety glasses when hitting parts
with a hammer.
7. Before adding oil or making any repairs, park
• Always wear safety glasses when grinding
the machine on hard, level ground, and block
parts with a grinder, etc.
the wheels or tracks to prevent the machine
3. If welding repairs are needed, always have a from moving.
trained, experienced welder carry out the work.
8. Before starting work, lower blade, ripper, bucket
When carrying out welding work, always wear
or any other work equipment to the ground and
welding gloves, apron, glasses, cap and other
install the safety bar on the frame. If this is not
clothes suited for welding work.
possible, insert the safety pin or use blocks to
4. When carrying out any operation with two or prevent the work equipment from falling. In ad-
more workers, always agree on the operating dition, be sure to lock all the control levers and
procedure before starting. Always inform your hang warning signs on them.
fellow workers before starting any step of the
9. When disassembling or assembling, support the
operation. Before starting work, hang UNDER
machine with blocks, jacks or stands before
REPAIR signs on the controls in the operator's
starting work.
compartment.
10. Remove all mud and oil from the steps or other
5. Keep all tools in good condition and learn the
places used to get on and off the machine.
correct way to use them.
Always use the handrails, ladders or steps when
6. Decide a place in the repair workshop to keep getting on or off the machine. Never jump on or
tools and removed parts. Always keep the tools off the machine. If it is impossible to use the
and parts in their correct places. handrails, ladders or steps, use a stand to pro-
vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11. When measuring hydraulic pressure, check that 17. When removing components, be careful not to
the measuring tool is correctly assembled be- break or damage the wiring. Damaged wiring
fore taking any measurements. may cause electrical fires.
12. When removing the oil filler cap, drain plug or 18. When removing piping, stop the fuel or oil from
hydraulic pressure measuring plugs, loosen them spilling out. If any fuel or oil drips onto the floor,
slowly to prevent the oil from spurting out. wipe it up immediately. Fuel or oil on the floor
Before disconnecting or removing components can cause you to slip, or can even start fires.
of the oil, water or air circuits, first remove the
19. As a general rule, do not use gasoline to wash
pressure completely from the circuit.
parts. In particular, use only the minimum of
13. The water and oil in the circuits are hot when gasoline when washing electrical parts. Do not
the engine is stopped, so be careful not to get smoke!
burned.
20. Be sure to assemble all parts again in their
Wait for the oil and water to cool before carry-
original places.
ing out any work on the oil or water circuits.
Replace any damaged parts with new parts.
14. Before starting work, remove the leads from • When installing hoses and wires, be sure
the battery. Always remove the lead from the that they will not be damaged by contact with
negative (–) terminal first. other parts when the machine is being oper-
15. When raising heavy components, use a hoist or ated.
crane. 21. When installing high pressure hoses, make sure
Check that the wire rope, chains and hooks are that they are not twisted. Damaged tubes are
free from damage. dangerous, so be extremely careful when in-
Always use lifting equipment which has ample stalling tubes for high pressure circuits. Also,
capacity. check that connecting parts are correctly in-
Install the lifting equipment at the correct places. stalled.
Use a hoist or crane and operate slowly to
22. When aligning two holes, never insert your fin-
prevent the component from hitting any other
gers or hand. Be careful not to get your fingers
part. Do not work with any part still raised by
caught in a hole.
the hoist or crane.
16. When removing covers which are under internal 23. When assembling or installing parts, always use
pressure or under pressure from a spring, al- the specified tightening torques. When installing
ways leave two bolts in position on opposite protective parts such as guards, or parts which
sides. Slowly release the pressure, then slowly vibrate violently or rotate at high speed, be
loosen the bolts to remove. particularly careful to check that they are in-
stalled correctly.
00-4
F O R EW OR D GENERAL
F O R EW OR D
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel
an accurate understanding of the product and by showing them the correct way to perform repairs and make
judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are
further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

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

This section explains the order to be followed when removing, installing, disassembling or assembling
each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and
without any advance notice. Use the specifications given in the book with the latest
date.
00-5
F O R EW OR D HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES SYMBOLS
Shop manuals are issued as a guide to carrying out So that the shop manual can be of ample practical
repairs. They are divided as follows: use, important safety and quality portions are marked
with the following symbols.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Symbol Item Remarks
Electrical volume:
Attachments volume: } Each issued as one
volume to cover all
models Safety
Special safety precautions are
necessary when performing the
These various volumes are designed to avoid dupli- work.
cating the same information. Therefore, to deal with
Special technical precautions or
all repairs for any model , it is necessary that chas- other precautions for preserv-
sis, engine, electrical and attachment volumes are « Caution ing standards are necessary
available. when performing the work.
DISTRIBUTION AND UPDATING Weight of parts of systems.

Any additions, amendments or other changes will Caution necessary when select-
Weight ing hoisting wire, or when work-
be sent to KOMATSU distributors. Get the most
ing posture is important, etc.
up-to-date information before you start any work.
FILING METHOD Tightening Places that require special at-

tention for the tightening torque
1. See the page number on the bottom of the page. torque during assembly.
File the pages in correct order.
2. Following examples show how to read the page Places to be coated with adhe-
Coat
sives and lubricants, etc.
number.
Example 1 (Chassis volume): Places where oil, water or fuel
Oil, water must be added, and the capac-
10 - 3
ity.
Item number (10. Structure Places where oil or water must

and Function) Drain be drained, and quantity to be
Consecutive page number for drained.
each item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and
Adjusting)
Consecutive page number for
each item.
3. Additional pages: Additional pages are indicated

by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
F O R EW OR D HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause
Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting,
with a hoist, etc. In the DISASSEMBLY and a serious accident can result. Hooks
AND ASSEMBLY section, every part have maximum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing 3) Do not sling a heavy load with one rope alone,
interference with the part to be removed. but sling with two or more ropes symmetri-
cally wound onto the load.
Slinging with one rope may cause turn-
WIRE ROPES ing of the load during hoisting, untwist-
1) Use adequate ropes depending on the weight ing of the rope, or slipping of the rope
from its original winding position on the
of parts to be hoisted, referring to the table
load, which can result in a dangerous
below:
accident.
Wire ropes 4) Do not sling a heavy load with ropes forming

(Standard "Z" or "S" twist ropes a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more ropes,
the force subjected to each rope will increase
Rope diameter (mm) with the hanging angles. The table below
Allowable load (tons)
shows the variation of allowable load (kg)
when hoisting is made with two ropes, each
10 1.0
of which is allowed to sling up to 1000 kg
11.2 1.4 vertically, at various hanging angles.
12.5 1.6 When two ropes sling a load vertically, up to
14 2.2 2000 kg of total weight can be suspended.
This weight becomes 1000 kg when two ropes
16 2.8
make a 120° hanging angle. On the other
18 3.6
hand, two ropes are subjected to an exces-
20 4.4 sive force as large as 4000 kg if they sling a
22.4 5.6 2000 kg load at a lifting angle of 150°.
30 10.0
40 18.0
28.0 α
50
kg
60 40.0
Load capacity (kg)
2000
1900
1700
2000
1400
« The allowable load value is estimated to be
1000
one-sixth or one-seventh of the breaking
1000
strength of the rope used. 500
2) Sling wire ropes from the middle portion of

300 600 900 1200 1500
the hook. Lifting angle (α) SAD00480
00-7
00-8
01 GENERAL
Up to SN WA380H20500:
Dimensions and weights ................................. 01- 3
Dimensions and weights High-Lift .................. 01- 4
Specifications ................................................. 01- 5
Weight table ................................................... 01- 8
List of lubricant and water ............................. 01- 9
SN WA380H20501 and up:
Dimensions and weights ................................. 01-10
Specifications ................................................. 01-11
Weight table ...................................................01-14
List of lubricant and water ............................. 01-15
Outlines of service .......................................... 01-16
General view of controls and gauges ............01-20
Torque list .................................................... 01-22
01-1

Blank for technical reason
01-2
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
DIMENSIONS, WEIGHTS AND OPERATING DATA

Up to SN WA380H20500
Buckets
Bucket capacity as per ISO 7546 m3 3.0 3.3
Specific density t/m3 1.8 1.6

Bucket weight w/o teeth kg 1.580 1.600
Stat. tipping weights, straight kg 14.620 14.600
Stat. tipping weights, articulated 40° kg 13.040 13.015
Breakout force hydraulic kN 166 166
Hydraulic lifting capacity, on ground kN 192 192
Operating weight kg 17.420* 17.450*
a Reach at full lift 45° mm 1.001 1.001

b Dumping height 45° mm 2.970 2.970
c Lift height, hinge pin mm 3.978 3.978
d Bucket to edge height mm 5.462 5.462
e Digging depth mm 30 30
f Carry height, hinge pin mm 445 445
A Overall length mm 7.640 7.640

B Wheelbase mm 3.200 3.200
C Bucket width mm 2.906 3.906
D Width less bucket mm 2.750 2.750
E Track width mm 2.160 2.160
F Ground clearance mm 455 455
H Overall height mm 3.365 3.365
* This dimensions refer Special bucket sizes: The 3,0/3,3 m3 standard buckets
to machines with 23.5R25SPT7LD. 2,8 m3- HD bucket shown in the table can be supplied
4,5 m3 - light material bucket with bold on cutting edge.
* Machines without extra counterweight
01-3
WA380-3H High-Lift
Measurements, operating data

Bucket capacity to ISO 7546 m³ 3.0 3.2
Material density t/m³ 1.7 1.55
Bucket weight without teeth kg 1,545 1,625
Static tipping load, straight kg 11,800 11,700
Static tipping load, 40° angle kg 10,300 10,210
Breakout force, hydraulic kN 157 149
Lifting capacity, hydraulic, on ground kN 156 152
Operating weight kg 18,755 18,835
a Reach at 45° discharge mm 1,180 1,220
b Dumping height at 45° discharge mm 3,610 3,570
c Lift height, hinge pin mm 4,621 4,621
Turning circle to bucket corners mm 6,666 6,690
A Overall length, bucket on ground mm 8,540 8,600
B Wheel base mm 3,200 3,200
C Bucket width mm 2,926 2,926

These figures refer
D Width over tyres mm 2,770 2,770 to machines with
23.5 R25 tyres
E Gauge mm 2,160 2,160

Machines without
additional weights
H Overall height mm 3,385 3,385
U:\DTP\BA380gb\ABMES.TBL
• The actual volumes Material Bucket filling % Density t/m³

are mostly higher
Earth 100 to 115 1.5 to 1.6
than the ISO/SAE
classification. The Clay 100 to 120 1.5 to 1.7
table shows the ideal Sand 100 to 110 1.4 to 1.8

bucket for the type of
Gravel 85 to 100 1.5 to 2.0
material specified.
Rock 75 to 100 1.6 to 2.0
U:\DTP\BA380gb\Schaufel.TBL
01-4
GENERAL SPECIFICATIONS
SPECIFICATIONS Up to SN WA380H20500
Machine model WA380-3
Serial No. H20001- H20500
Operating weight (kg) 17,420

Weight
Distribution (front) (kg)
Distribution (rear) (kg)
Bucket capacity (piled) (m 3) 3.0
Rated load (kg) 5,400
Travel speed FORWARD 1st (km/h) 7.2
FORWARD 2nd (km/h) 11.5
FORWARD 3rd (km/h) 21.6
FORWARD 4th (km/h) 37.0

Performance
REVERSE 1st (km/h) 7.7
REVERSE 2nd (km/h) 12.3
REVERSE 3rd (km/h) 22.1
REVERSE 4th (km/h) 38.0
Gradeability (deg) 25
Center of outside wheel (mm) 6,300

Min. turning
radius Outside portion of (mm) 6,850
chassis (with BOC)
Overall length (mm) 7,640
Overall width (chassis) (mm) 2,750
Bucket width (with BOC) (mm) 2,906
Overall height (top of cab) (mm) 3,380
Wheelbase (mm) 3,200

Dimensions
Min. ground clearance (mm) 455
Height of bucket hinge pin (mm) 3,978
Dumping clearance (tip of BOC) (mm) 2,970
Dumping reach (tip of BOC) (mm) 1,001
Digging depth (10° dump) (with BOC) (mm) 300
01-5
Model Komatsu S6D108

4-cycle, water-cooled, in-line,
Type 6-cylinder, direct injection, with turbocharger
No. of cylinders – bore x stroke (mm) 6 – 108 x 130
Piston displacement (cc) 7,150
Flywheel horsepower (kW (PS)/rpm) 140 (190)

/2,200
Engine
Maximum torque (Nm / rpm) 820

/1,500
Starting motor 24 V 7.5 kW
Alternator 24 V 50 A
Battery 12 V 134 Ah x 2
Torque converter 3-element, 1-stage, single-phase (Komatsu TCA37-2A)
Spur gear, constant-mesh multiple-disc,

Power train
Transmission
hydraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear, torque proportioning
Final drive Planetary gear single stage, splash lubrication

Drive type Front-, rear-wheel drive
Front wheel Fixed-frame semi-floating wheel

Axle, wheel
Rear wheel Center pin support type semi-floating wheel
Tire 23.5-25-16PR
Wheel rim 19.50 x 25T/L
Front tire (MPa (kg/cm2)) 0.304 (3.1)

Inflation pressure
2
Rear tire (MPa (kg/cm )) 0.304 (3.1)
Main brake Front/rear wheel independent braking

Brakes
wet-type sealed disc brakes with hydraulic

power-doubling device
Parking brake Thrust shaft (transmission shaft) braking,
wet-type disc brake
01-6
Type Articulated steering

Steering
system
Structure Hydraulically actuated
Hydraulic pump type

(Hydraulic+Steering+Switch+PPC pump) (SAL(3)100+50+36+(1)25)
(ƒ/min.) 224+112+81+57
Delivery
Control valve
Set pressure for work equipment Spool type

Hydraulic system
(MPa (kg/cm2)) 20.59 (210)
Set pressure for steering Spool type

(MPa (kg/cm2)) 20.59 (210)
Boom cylinder Reciprocating piston

No. – bore x stroke (mm) 2 – 160 x 713
Cylinder
Bucket cylinder Reciprocating piston

Steering cylinder Reciprocating piston

equipment
Link type Single link

Work
Bucket edge type Flat edge with BOC
01-7
GENERAL WEIGHT TABLE
WEIGHT TABLE Up to SN WA380H20500
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WA380-3 Machine model WA380-3
H20001 H20001
Serial No. Serial No.
- H20500 - H20500
Engine 730 Boom cylinder (each) 164
Radiator 165 Bucket cylinder 166
Torque converter 54 Engine hood (with side panel) 191
Transmission 700 Front frame 1,406
Center drive shaft 25 Rear frame 1,199
Front drive shaft 22 Bucket link 56
Rear drive shaft 10 Bellcrank 309
Front axle 1,021 Boom (including bushing) 1,020
Rear axle 971 Bucket (with BOC) 1,583
Axle pivot 111 Counterweight 1,170
Wheel (each), compl. 561 Fuel tank 179
Tire (each) 335 Battery (each) 44
Steering valve 24 Floor, Cab assembly 670
Steering cylinder (each) 25 Cab 295
Hydraulic tank 193 Air conditioner unit 14
Hydraulic, Steering, Switch, PPC pump 46 Operator’s seat 38
Main control valve 71
01-8
GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER Up to SN WA380H20500
LUBRICANTS, FUEL ETC. AND FILLING CAPACITIES

Approx.
WA380-3 Temperature Viscosity filling
Lubricants, fuel etc. BI code ****) Quality grades
ranges ranges capacity in
litres
EO 1540 A CCMC D4 -10° to 50° C SAE 15W-40 *)

EO 1030 A or, if not available, -20° to 40° C SAE 10W-30 31
Engine Engine oil EO
EO 30 API CD , API CE or 0° to 40° C SAE 30 (28 **)
EO 10 API CF -4 -20° to 10° C SAE 10W
CCMC D4
42
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W
(40**)
API CD
Fuchs: RENOGEAR HYDRA ZF 20W-40*)

Komatsu: AXO 75
Universal
Caltex: RPM TRACTOR HYDRAULIC FLUID
transmission and NRS
Axles with standard Chevron: TRACTOR HYDRAULIC FLUID
hydraulic oil
locking differentials Texaco: TDH OIL
type Mobil: MOBILAND SUPER UNIVERSAL
KWA 015 W-1
KWA 015 W-2
2x37
CCMC D4
or engine oil EO EO 30 - SAE 30
or, if not available,
API CD
Axles with multi-disc

locking differentials Universal
type transmission and NRS Fuchs: RENOGEAR HYDRA ZF 20W-40*)
KWA 015 W-3 hydraulic oil
KWA 015 W-4
Hydraulic oil HYD HYD 0530 HVLP, HVLP D -35° to 50° C ISO VG 46 *)
CCMC D4
or engine oil EO EO 10 or, if not available, -35° to 40° C SAE 10W
Hydraulic system, 190
API CD
steering, brakes (138 **)
HEES
or hydraulic oil ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50° C
BIO-E-HYD
technology)
Long-life coolant with

anti-frost and rust Anti-frost and rust
Cooling system SP-C 53
prevention prevention
SP-C
CFPP class B up to 0°C

CFPP class D up to -10°C
Fuel tank Diesel fuel DIN-EN 590 287
CFPP class E up to -15°C
CFPP class F up to -20°C
Grease nipples, Multi-purpose grease -10° to 50° C NLGI 2 *)

MPG-A KP2N-20
central lubrication MPG on a lithium base -35° to -10° C NLGI 0
Coolant NRS R134a (CFC-free) 1500 g

Air conditioning Refrigerating machine
oil NRS PAG (polyalkylglycol oil) 150 cm ³
The specified filling capacities are approximate guidelines; test specifications are binding. The selection of the viscosity class
depends on the predominantly existing outside temperature. The temperature limits are to be regarded as guidelines which can be
exceeded up or down for a brief period.
*) Works filling **) Top-up quantity

****) BI codes are the "standard lubricants" for construction machinery and vehicles of the Hauptverband der Deutschen Bauindustrie e.V.
(BI). The brochure "Regelschmierstoffe für Baumaschinen- und Fahrzeuge" (Standard Lubricants for Construction Machinery and
Vehicles" can be obtained from bookstores or Bauverlag GmbH, Wiesbaden and Berlin, under the ISBN no. 3-7625-3102-1.
U:\DTP\BA380gb\FÜLL-BI.TBL 02.97
01-9
DIMENSIONS, WEIGHTS AND OPERATING DATA

SN WA380H20501 and up
d
a
c
H*
b
f F*
e W A_ACT
*
E
D* B
C* A
Buckets
Bucket capacity as per ISO 7546 m3 3.1 3.4
Specific density t/m3 1.75 1.6

Bucket weight w/o teeth kg 1.560 1.600
Stat. tipping weights, straight kg 14.125 14.110
Stat. tipping weights, articulated 40° kg 12.290 12.270
Breakout force hydraulic kN 155 148
Hydraulic lifting capacity, on ground kN 178,5 176,7
Operating weight kg 17.670** 17.710**
a Reach at full lift 45° mm 1.112 1.148

b Dumping height 45° mm 3.010 2.974
c Lift height, hinge pin mm 4.077 4.077
d Bucket to edge height mm 5.492 5.591
f Carry height, hinge pin mm 425 425
A Overall length mm 7.845 7.900

B Wheelbase mm 3.200 3.200
C Bucket width mm 2.916 3.916
D Width less bucket mm 2.762 2.762
E Track width mm 2.160 2.160
H Overall height mm 3.380 3.380
* This dimensions refer Special bucket sizes: The standard buckets shown in the
to machines with 23.5R25SPT7LD. 3,0 m3- HD bucket table can be supplied with bold on
4,5 m3 - light material bucket cutting edge.
** Machines without extra counterweight
01-10
SPECIFICATIONS SN WA380H20501 and up
H20501 and up
Serial No.
Operating weight (kg) 17,670

Weight
Distribution (front) (kg)
Distribution (rear) (kg)
Bucket capacity (piled) (m 3) 3.1
Rated load (kg) 5,400
Travel speed FORWARD 1st (km/h) 7.2
FORWARD 2nd (km/h) 11.5
FORWARD 3rd (km/h) 21.6
FORWARD 4th (km/h) 37.0

Performance
REVERSE 1st (km/h) 7.7
REVERSE 2nd (km/h) 12.3
REVERSE 3rd (km/h) 22.1
REVERSE 4th (km/h) 38.0
Gradeability (deg) 25
Center of outside wheel (mm) 6,300

Min. turning
radius Outside portion of (mm) 6,850
chassis (with BOC)
Overall length (mm) 7,845
Overall width (chassis) (mm) 2,762
Bucket width (with BOC) (mm) 2,916
Overall height (top of cab) (mm) 3,380
Wheelbase (mm) 3,200

Dimensions
Min. ground clearance (mm) 440
Height of bucket hinge pin (mm) 4,077
Dumping clearance (tip of BOC) (mm) 3,010
Dumping reach (tip of BOC) (mm) 1,112
Digging depth (mm) 44
01-11
Serial No. H20501 and up
Model Komatsu S6D114E1

4-cycle, water-cooled, in-line,
Type 6-cylinder, direct injection, with turbocharger
No. of cylinders – bore x stroke (mm) 6 – 114 x 135
Piston displacement (ccm) 8,300
Flywheel horsepower (kW (PS)/rpm) 141 (192)

/2,200
Engine
Maximum torque (Nm / rpm) 849

/1,400
Starting motor 24 V 7.5 kW
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Torque converter 3-element, 1-stage, single-phase (Komatsu TCA37-2A)
Spur gear, constant-mesh multiple-disc,

Power train
Transmission
hydraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear, torque proportioning
Final drive Planetary gear single stage, splash lubrication

Drive type Front-, rear-wheel drive
Front wheel Fixed-frame semi-floating wheel

Axle, wheel
Rear wheel Center pin support type semi-floating wheel
Tire 23.5-25-16PR
Wheel rim 19.50 x 25T/L
Front tire (MPa (kg/cm2)) 0.304 (3.1)

Inflation pressure
2
Rear tire (MPa (kg/cm )) 0.304 (3.1)
Main brake Front/rear wheel independent braking

Brakes
wet-type sealed disc brakes with hydraulic

power-doubling device
Parking brake Thrust shaft (transmission shaft) braking,
wet-type disc brake
01-12
Serial No. H20501 and up
Type Articulated steering

Steering
system
Structure Hydraulically actuated
Hydraulic pump type

(Hydraulic+Steering+Switch+PPC pump) (SAL(3)100+50+36+(1)25)
(ƒ/min.) 224+112+81+57
Delivery
Control valve
Set pressure for work equipment Spool type

Hydraulic system
(MPa (kg/cm2)) 20.59 (210)
Set pressure for steering Spool type

(MPa (kg/cm2)) 20.59 (210)
Boom cylinder Reciprocating piston

Cylinder
Bucket cylinder Reciprocating piston

Steering cylinder Reciprocating piston

equipment
Link type Single link

Work
Bucket edge type Flat edge with BOC
01-13
GENERAL WEIGHT TABLE
WEIGHT TABLE SN WA380H20501 and up
This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WA380-3 Machine model WA380-3
H20501 and up H20501 and up

Serial No. Serial No.
Engine 670 Boom cylinder (each) 164
Radiator 165 Bucket cylinder 166
Torque converter 54 Engine hood (with side panel) 191
Transmission 700 Front frame 1,406
Center drive shaft 25 Rear frame 1,199
Front drive shaft 22 Bucket link 56
Rear drive shaft 10 Bellcrank 309
Front axle 1,021 Boom (including bushing) 1,020
Rear axle 971 Bucket (with BOC) 1,583
Axle pivot 111 Counterweight 1,170
Wheel (each), compl. 561 Fuel tank 179
Tire (each) 335 Battery (each) 44
Steering valve 24 Floor, Cab assembly 670
Steering cylinder (each) 25 Air conditioner unit 14
Hydraulic tank 193 Operator’s seat 38
Hydraulic, Steering, Switch, PPC pump 46
Main control valve 71
01-14
LIST OF LUBRICANT AND WATER SN WA380H20501 and up
LUBRICANTS, FUEL ETC. AND FILLING CAPACITIES

Approx.
WA380-3 Temperature Viscosity filling
Lubricants, fuel etc. BI code ****) Quality grades
ranges ranges capacity in
litres
CCMC D4
EO 1540 A -10° to 50° C SAE 15W-40 *)
or, if not available, 22,5
Engine Engine oil EO EO 1030 A -25° to 20° C SAE 10W-30
API CE or (19 **)
NRS -40° to 20° C SAE 05W-30
API CF -4 ²)
CCMC D4
42
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W
(40**)
API CD
Fuchs: RENOGEAR HYDRA ZF 20W-40*)

Komatsu: AXO 75
Universal
Caltex: RPM TRACTOR HYDRAULIC FLUID
Axles with standard transmission and NRS
Chevron: TRACTOR HYDRAULIC FLUID
locking differentials hydraulic oil
Texaco: TDH OIL
type Mobil: MOBILAND SUPER UNIVERSAL
KWA 015 W-1
KWA 015 W-2
CCMC D4 2x37
or engine oil EO EO 30 - SAE 30
or, if not available,
API CD
Axles with multi-disc

locking differentials Universal
type transmission and NRS Fuchs: RENOGEAR HYDRA ZF 20W-40*)
KWA 015 W-3 hydraulic oil
KWA 015 W-4
Hydraulic oil HYD HYD 0530 HVLP, HVLP D -35° to 50° C ISO VG 46 *)
CCMC D4
or engine oil EO EO 10 or, if not available, -35° to 40° C SAE 10W
Hydraulic system, 190
API CD
steering, brakes (138 **)
HEES
or hydraulic oil ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50° C
BIO-E-HYD
technology)
Long-life coolant with
anti-frost and rust Anti-frost and rust
Cooling system SP-C 53
prevention prevention
SP-C
CFPP class B up to 0°C
CFPP class D up to -10°C
Fuel tank Diesel fuel DIN-EN 590 287
CFPP class E up to -15°C
CFPP class F up to -20°C
Grease nipples, Multi-purpose grease -10° to 50° C NLGI 2 *)

MPG-A KP2N-20
central lubrication MPG on a lithium base -35° to -10° C NLGI 0
Coolant NRS R134a (CFC-free) 1500 g

Air conditioning Refrigerating machine
oil NRS PAG (polyalkylglycol oil) 150 cm ³
The specified filling capacities are approximate guidelines; test specifications are binding. The selection of the viscosity class
depends on the predominantly existing outside temperature. The temperature limits are to be regarded as guidelines which can be
exceeded up or down for a brief period.
*) Works filling **) Top-up quantity

²) If no engine oil of the API CE or API CF-4 specification is available, API CC or API CD-classified engine oil can be used alternatively. The
oil change intervals must be split in half in this case, however.
³) If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal. With a sulphur content of more than 1.0
%, the oil change interval must be 1/4 normal.
****) BI codes are the "standard lubricants" for construction machinery and vehicles of the Hauptverband der Deutschen Bauindustrie e.V.
(BI). The brochure "Regelschmierstoffe für Baumaschinen- und Fahrzeuge" (Standard Lubricants for Construction Machinery and
Vehicles" can be obtained from bookstores or Bauverlag GmbH, Wiesbaden and Berlin, under the ISBN no. 3-7625-3102-1.
U:\DTP\BA380gb\380gb_mc\FÜLL-BI.TBL 05.97
01-15
• Only use original Komatsu parts for replacement.

• When changing or adding oil, do not use a different type of oil.
• Unless otherwise specified, the oil and coolant used at the time of shipment are as shown in the table
below.
Item Lubricating and operating means
Engine Engine oil: API CD, SAE 15W-40
Transmission Engine oil: API CD, SAE 10W
For machines with standard differential TPD:

Axle oil: FUCHS RENOGEAR HYDRA ZF 20W-40 or AXO75
Axles **
For machines with multiple-disk limited-slip differential:
Axle oil: FUCHS RENOGEAR HYDRA ZF 20W-40
Hydraulik tank Hydraulic oil: H-LP, DIN 51 524, part 2, ISO VG 46 or

Engine oil: SAE 10 W, API classification CD
Lubricating nipple EP lubricating grease on lithium basis, NLGI 2
Fuel ASTM D975: No. 2

ASTM D975: No. 1 in winter (from October to March)
Radiator Komatsu super coolant AF-ACL, mixed with 30 % water
Air conditioner cfw free refrigerant R 134a
**)Axle oils (AXO) - The selection of the oils depends on the equipment of the axle:
1a: Standard axles TPD (without multi-disc limited-slip differential)
Characteristics: Type KWA 022 W-1, front

Type KWA 022 W-2, rear
These axles must be filled with the following recommended oil brands:
FUCHS: RENOGEAR HYDRA ZF 20W-40

KOMATSU: AX0 75.
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBILAND SUPER UNIVERSAL
For reasons of harmonization, engine oil in accordance API CD/SAE 30 may be used in the standard
axle instead of axle oil. Any noises from the brakes do not affect the life.
1b: Axles with multi-disc limited-slip differential
Characteristics: Type KWA 022 W-3, front

Type KWA 022 W-4, rear
These must be filled with
FUCHS: RENOGEAR HYDRA ZF 20W-40
The use of not recommended axle oils may cause unnormal noises from the differential.
01-16
GENERAL OUTLINES OF SERVICE
Oil
• Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature given in the Operation and Maintenance Manu-
al. Even if the oil is not dirty, always replace the oil after the specified interval.
• Oil can be compared to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from penetrating.
The majority of problems with machines are caused by the entry of such impurities.
Take particular care not to let any impurities penetrate when storing or adding oil.
• Never mix oils of different grades or brands.
• Always add the specified amount of oil.

Having too much oil or too little oil may both cause problems.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such
cases, please contact your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend to have an analysis of the oil made periodically to check the condition of the machine.
Those who wish to use this service, are requested to their Komatsu distributor.
FUEL
• The fuel pump is a precision instrument; if fuel containing water or dirt is used, it cannot work properly.
• Be extremely careful not to let impurities penetrate when storing or adding fuel.
• Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature (particularly at low temperatures below -15 °C), so
change to a fue matching this temperature.
• To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the
fuel tank after completing the day's work.
• Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and
water from the fuel tank.
• If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from
the circuit.
• If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal.
If the fuel sulphur content is more 1.0 %, the oil change interval must be 1/4 normal.
01-17
COOLANT
• River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to
the engine and radiator causing a defective heat exchange and overheating.
• Do not use water that is not suitable for drinking.
• When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.
• Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is
shipped.
This anti-freeze prevents corrosion in the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is
even in hot areas.
• Anti- freeze is flammable, so be extremely careful not to expose it to open flame or fire.
• The proportion of anti-freeze to water differs according to the ambient temperature.

For details of the mixing ratios, see "24.2.2 CLEANING THE INSIDE OF THE COOLING SYSTEM".
• If the engine overheats, wait for the engine to cool before adding coolant.
• If the coolant level is low, it will cause overheating and corrosion due to the air in the coolant.
GREASE
• Grease is used to prevent twisting and noise at the joints.
• The nipples not included in the maintenance section are nipples for overhaul, so they need not be
lubricated.
If any part becomes stiff after being used for a long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe
off the old grease in places where sand or dirt in the grease would cause the rotating parts to wear.
STORING OIL AND FUEL

• Keep oil and fuel indoors to prevent any water, dirt or other impurities from penetrating.
• When keeping barrels for a long period, lay down the barrel on its side so that the filler port is at the
side (to prevent moisture from being sucked in).
If barrels have to be stored outside, cover them with a waterproof sheet or take other measures to
protect them.
• To prevent any change in quality during long term storage, be sure to use in the order of 'first in - first
out' (use the oldest oil or fuel first).
01-18
BIODEGRADABLE HYDRAULIC OILS AND LUBRICANTS
• The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for Komatsu
machines is permitted. For information on the products cleared for use and best suited for your application
contact our authorized service workshops.
OUTLINE OF ELECTRIC SYSTEM

• If the wiring gets wet or the insulation is damaged, the electric system leaks resulting in hazardous
malfunctions of the machine.
• Maintenance work at the electric system includes: (1) check fan belt tension, (2) check damage or
wear to the fan belt and (3) check battery fluid level.
• Never remove or disassemble any electric components installed in the machine.
• Never install any electric components other than those specified by Komatsu.
• Be careful to keep the electric system free of water when washing the machine or when it is raining.
• When working on the seashore, carefully clean the electric system to prevent corrosion.
• The optional power source must never be connected to the fuse, starter switch, or battery relay.
01-19
GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
GENERAL VIEW OF CONTROLS AND GAUGES

STANDARD TYPE
1 Main monitor
2 Horn switch
3 Hazard lamp switch
4 Directional lever
5 Speed control lever
6 Air conditioner panel
7 Speed control lever stopper
8 Wiper switch
9 Parking brake lever
10 Brake pedal
11 Steering column tilt lever
12 Brake pedal
13 Accelerator pedal
14 Lamp switch
15 Turn signal lever
16 Dimmer switch
17 Starting switch
18 Car radio
19 Kickdown switch
20 Gear hold position
22 Lift arm and bucket control lever GENERAL VIEW

23 Cigarette lighter
24 Safety lock
25 Maintenance monitor
30 31 32
33
30 Turn signal pilot lamp 43
31 High beam pilot lamp
44
32 Centralized checking lamp 34
33 Engine pre-heating pilot lamp 45
WORK MODE
34 Pilot lamp for front working lamp H S Ec
35
35 Pilot lamp for rear working lamp 42
36 Transmission cut-off selector pilot lamp MANUAL 36
37 Parking brake pilot lamp 46
41
38 Central warning lamp
39 Speedometer
40 Transmission shift indicator
41 ALS Electronic 40 39 38 37 470_264j
42 Auto-greasing switch
43 Hold signal
MAIN MONITOR
44 Emergency steering operating monitor
45 Work mode selector switch / SN: WA380H20987 and up
46 Autoshift transmission pilot switch /
SN: WA380H20951 and up
50 Fuel gauge
51 Engine cooling water temperature gauge
52 Torque converter oil temperature gauge
57 Service meter
58 Air cleaner clogging warning pilot lamp
59 Charge monitor
60 Brake oil pressure warning pilot lamp
61 Engine oil pressure warning lamp
62 Engine oil level warning pilot lamp
63 Engine water level warning lamp MAINTENANCE MONITOR
01-20

GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
GENERAL VIEW OF CONTROLS AND GAUGES

WITH MULTI-FUNCTION CONTROL LEVER (if installed)
1. Main monitor
2. Horn switch
3. Hazard lamp switch
5. Speed control lever

6. Air conditioner panel
7. Speed control lever stopper
8. Wiper switch
9. Parking brake lever
10. Brake pedal
11. Steering column tilt lever
12. Brake pedal
13. Accelerator pedal
14. Lamp switch
15. Turn signal lever
16. Dimmer switch
17. Starting switch
18. Car radio
19. Kickdown switch
20. Gear hold position
21. Directional switch
22. Multi-function control lever GENERAL VIEW
23. Cigarette lighter
24. Safety lock
25. Maintenance monitor 32
30 31
33
30. Turn signal pilot lamp 43
31. High beam pilot lamp 44
32. Centralized checking lamp 34
33. Engine pre-heating pilot lamp 45
WORK MODE
34. Pilot lamp for front working lamp 35

H S Ec
35. Pilot lamp for rear working lamp 42

36. Transmission cut-off selector pilot lamp MANUAL 36
37. Parking brake pilot lamp 41 46
38. Central warning lamp
39. Speedometer
40. Transmission shift indicator
41. ALS Electronic 40 39 38 37 470_264j
42. Auto-greasing switch

43. Gear hold signal MAIN MONITOR
44. Emergency steering operating monitor
45. Work mode selector switch / SN: WA380H20987
46. Autoshift transmission pilot switch /
SN: WA380H20951
50. Fuel gauge

51. Engine cooling water temperature gauge
52. Torque converter oil temperature gauge
57. Service meter

58. Air cleaner clogging warning pilot lamp
59. Charge monitor
60. Brake oil pressure warning pilot lamp
61. Engine oil pressure warning lamp
62. Engine oil level warning pilot lamp
63. Engine water level warning lamp
MAINTENANCE MONITOR
01-21

GENERAL TORQUE LIST
TORQUE LIST
Unless otherwise specified, tighten the metric bolts and nuts
to the torque shown in the table. The tightening torque is
determined by the width across flats of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a
Komatsu genuine part of the same size as the part that
was replaced.
Tread diameter Width across

of the bolt (mm) flat (mm)
(a) (b) Nm kgm lbft
6 10 13.2 ± 1.4 1.35 ± 0.15 9.73 ± 1.03

8 13 31,4 ± 2,9 3,2 ± 0,3 23.2 ± 2.1
10 17 65,7 ± 6,8 6,7 ± 0,7 48.5 ± 5.0
12 19 112 ± 9,8 11,5 ± 1,0 82.6 ± 7.2
14 22 177 ± 19 18,0 ± 2,0 131 ± 14
16 24 279 ± 29 28.5 ± 3 206 ± 21

18 27 383 ± 39 39 ± 3 282 ± 29
20 30 549 ± 58 56 ± 6 405 ± 43
22 32 745 ± 78 76 ± 8 549 ± 58
24 36 927 ± 98 94.5 ± 10 684 ± 72
27 41 1320 ± 140 135 ± 15 973 ± 100
30 46 1720 ± 190 175 ± 20 1270 ± 140

33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250
NOTE
When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use
excessive tightening torque: doing so will damage the plastic parts.
01-22
10 STRUCTURE AND FUNCTION
Power train ....................................................... 10-3 Work equipment hydraulic system diagrams . 10-202
Power train system ........................................... 10-4 Work equipment lever linkage ....................... 10-212
Torque converter, transmission piping ...............10-6 Hydraulic tank ............................................... 10-213
Transmission hydraulic circuit diagram ............. 10-7 Oil filter bypass valve ..................................... 10-214
Torque converter ...............................................10-9 PPC valve ..................................................... 10-215
Torque converter oil filter ................................. 10-11 Operation of PPC valve ................................. 10-220
Transmission ................................................... 10-21 PPC relief valve ............................................. 10-223
Transmission control valve ............................... 10-41 Accumulator (for PPC valve) ......................... 10-224
Upper valve ..................................................... 10-42 Main control valve (up to H20383) ................. 10-225
Transmission solenoid valve ............................ 10-44 Relief valve (up to H20383) ........................... 10-229
Pilot reducing valve ......................................... 10-45 Safety valve with suction (up to H20383) ...... 10-230
Main relief valve .............................................. 10-46 Suction valve (up to H20383) ........................ 10-231
Torque converter outlet port valve .................... 10-47 Main control valve (from H20384 up to H20836) . 10-232
Priority valve ................................................... 10-48 Safety valve with suction (H20384 and up) .... 10-234
Directional selector valve ................................. 10-49 Anticavitation valve (H20384 and up) ............ 10-235
H-L selector valve and range selector valve ..... 10-50 Safety valve (H20384 and up) ....................... 10-235
Emergency manual spool ................................ 10-52 Main control valve (H20837 and up) .............. 10-236
Electronic control modulation valve (ECMV) .... 10-53 Operation of cut-off valve (up to H20383) ..... 10-238
Pilot oil filter ....................................................10-56 Work equipment valve operation ................... 10-240
Accumulator valve ........................................... 10-57 Hydraulic safety system (up to H20836) ....... 10-246
Flow control valve ............................................ 10-59 Hydr. safety system location (up to H20836) 10-247
Check valve..................................................... 10-60 Hydraulic safety valve (up to H20836) .......... 10-248
Drive shaft ...................................................... 10-81 Work equipment linkage ............................... 10-261
Axle ................................................................. 10-82 Bucket .......................................................... 10-263
Differential ...................................................... 10-84 Bucket positioner and boom kick-out ............ 10-264
Final drive ....................................................... 10-91 Wiring diagrams (up to H20500) .................. 10-273
Axle mount, center hinge pin ........................... 10-92 Wiring diagrams (from H20501 up to 20836) 10-281
Steering piping .............................................. 10-111 Wiring diagrams (from H20837 up to 20986) 10-282
Steering control, orbit roll .............................. 10-112 Wiring diagrams (H20987 and up) ................ 10-283
Orbit roll valve ................................................ 10-113 Machine monitor system ............................... 10-291
Steering valve................................................ 10-114 Transmission auto-shift control system .......... 10-298
Overload relief vavle ...................................... 10-115 Transmission controller ................................. 10-303
Steering relief valve ....................................... 10-117 ALS ............................................................... 10-321
Operation of demand valve ............................ 10-118 Sensors ........................................................ 10-341
Brake piping ................................................. 10-151 Engine starting circuit ................................... 10-346
Park brake and foot brake circuits ................ 10-152 Engine stop circuit ........................................ 10-347
Brake valve ................................................... 10-153 Preheating circuit .......................................... 10-348
Accumulator charge valve ............................. 10-158 Electric transmission ..................................... 10-361
Accumulator for brake system ...................... 10-162 Combination switch ....................................... 10-362
Brake circuit diagram.................................... 10-164 Kick-down, hold switch .................................. 10-364
Brake ............................................................ 10-176 Kick-down electric circuit diagram ................ 10-365
Parking brake control .................................... 10-178 Transmission cut-off function ........................ 10-370
Parking brake ............................................... 10-179 Parking brake: Transmission neutralizer ....... 10-371
Parking brake valve ....................................... 10-180 Air conditioner .............................................. 10-451
Hydraulic piping ............................................ 10-201
10-1
2
10-2
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1. Transmission 4. Front axle 7. Rear drive shaft

2. Torque converter 5. Front drive shaft 8. Rear axle
3. Engine 6. Center drive shaft
Outline
• The motive force from engine (3) passes through • The motive force from the output shaft of the
the engine flywheel and is transmitted to torque transmission passes through center drive shaft
converter (2), which is connected to the input (6), front drive shaft (5) and rear drive shaft (7),
shaft of transmission (1). and is then transmitted to front axle (4) and rear
• The transmission has six hydraulically actuated axle (8) to drive the wheels.
clutches, and these provide four speed ranges
for both FORWARD and REVERSE. The trans-
mission speed ranges can be selected manu-
ally.
10-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
POWER TRAIN SYSTEM
10-4
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
1. Front tire Outline

2. Final drive • The motive force from engine (17) passes
3. Wet type multiple disc brake through the flywheel and is transmitted to torque
4. Differential converter (18).
5. Front axle The torque converter uses oil as a medium. It
6. Front drive shaft converts the transmitted torque in accordance
7. Flange bearing with the change in the load, and transmits the
8. Center drive shaft motive force to the input shaft of the transmis-
9. Parking brake sion.
10. Transmission In addition, the motive force of the engine passes
11. Rear drive shaft through the pump drive gear of the torque con-
12. Final drive verter, and is transmitted to hydraulic, steering
13. Wet type multiple disc brake switch, PPC Pump (19) and torque converter
14. Differential charging pump (20) to drive each pump.
15. Rear axle • Transmission (10) operates the directional spool
16. Rear tire and speed spool of the transmission valve
17. Engine through the solenoid valves, and actuates the
18. Torque converter six hydraulically actuated clutches to select one
19. Hydraulic, steering switch, PPC Pump of the four FORWARD or REVERSE speeds.
20. Torque converter charging pump The transmission speed range is selected manu-
ally.
• The output shaft of transmission (10) transmits
the power to the front and rear axles.
At the front, the power is transmitted to front
axle (5) through center drive shaft (8), flange
bearing (7), and front drive shaft (6).
At the rear, the power is transmitted to rear axle
(15) through rear drive shaft (11).
• The motive force transmitted to front axle (5)
and rear axle (15) has its speed reduced by the
bevel gear and pinion gear of differentials (4)
and (14), and is then transmitted to the sun
gear shaft through the differential mechanism.
• The motive force of the sun gear is rduced
further by the planetary mechanism and is trans-
mitted to the wheels through the axle shaft.
10-5
STRUCTURE AND FUNCTION TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER, TRANSMISSION PIPING
1. Transmission 5. Torque converter charging pump

2. Torque converter 6. Transmission control valve
3. Radiator 7. Pilot oil filter
4. Oil cooler 8. Oil filter
10-6
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
10-7
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case 14. Solenoid valve (FORWARD, 24. 3rd clutch

2. Strainer 2nd) 25. 4th clutch
3. Hydraulic pump (SAL45+20) 15. Solenoid valve (REVERSE, 26. REVERSE clutch
4. Flow control valve 2nd) 27. FORWARD clutch
5. Oil filter 16. Hand brake valve 28. Parking brake
6. Pilot reducing valve 17. Range selector valve 29. Torque converter
7. Electronic modulation valve 18. H-L selector valve 30. Oil cooler
8. Main relief valve 19. Directional selector valve 31. Transmission lubrication
9. Emergency manual spool 20. Valve (no function) 32. Torque converter outlet valve
10. Pilot oil filter 21. Accumulator 33. Check valve
11. Priority valve 22. 1st clutch 34. Accumulator
12. Solenoid valve (1st, 4th) 23. 2nd clutch
13. Solenoid valve (3rd, 4th)
10-8
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
1. Turbine 6. Housing Specifications

2. Drive case 7. PTO gear (drive) Model: TCA37-2A
3. Stator 8. Pump Type: 3 element,1 stage,1 phase
4. Pilot 9. Output shaft (Transmission Stall torque ratio: 3.37
5. Stator shaft input shaft)
10-9
STRUCTURE AND FUNCTION TORQUE CONVERTER
Path of motive force

• The torque converter is installed between the
engine and the transmission.
The motive force from the engine enters drive
case (4) from flywheel.
Drive case (4), pump (5), and PTO gear (drive)
(6) are each secured by bolts and are rotated
directly by the rotation of the engine.
The motive force of pump (5) uses oil as a
medium to rotate turbine (2) and transmit the
motive force to transmission input shaft (11).
• The motive force of drive case (4) is used as

the motive force to drive the gear pump through
PTO gear (drive) (6).
Flow of oil
• The oil supplied from the torque converter charg-
ing pump enters inlet port A, passes through
the oil passage of stator shaft (8), and flows to
pump (5).
The oil is given centrifugal force by pump (5),
enters turbine (2), and transmits the energy of
the oil to the turbine. Turbine (2) is fixed to
transmission input shaft (11), so the motive force
is transmitted to the transmission input shaft.
The oil from turbine (2) is sent to stator (3), and
enters the pump again. However, part of the oil
is sent from the stator through outlet port B to
the cooler.
10-10
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER

1. Relief valve
2. Element
3. Center bolt
4. Drain plug
Specifications
Filter mesh size: 10 microns
Filtering area: 8900 cm2
Relief pressure: 0.34 MPa (3.5 bar)
Operation
• The oil from the torque converter charging pump
enters filter inlet port A. It is filtered from the
outside of element (2) to the inside, and flows
to outlet port B.
• If element (2) becomes clogged with dirt, or the

oil temperature is low and the pressure rises at
inlet port A, the oil from inlet port A opens relief
valve (1) and flows directly to outlet port B in
order to prevent damage to the pump or ele-
ment (2).
10-11
10-12
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
10-21
1. Transmission case 11. 3rd clutch

2. Transmission control valve 12. 4th clutch
3. Accumulator valve 13. Rear coupling
4. Oil filter 14. Output shaft
5. Torque converter charging pump 15. Parking brake
(SAL (2) 45 + 20) 16. Front coupling
6. Transmission oil filler 17. 2nd, 4th shaft
7. REVERSE clutch 18. 2nd clutch
8. FORWARD clutch 19. 1st, 3rd shaft
9. Input shaft 20. 1st clutch
10. Torque converter 21. REVERSE idler gear
22. Strainer
Outline
• The transmission is installed behind the torque • The transmission uses the combination of the
converter. The motive force from the torque con- forward or reverse clutches and the four speed
verter passes through the transmission input clutches to shift to F1 – 4 or R1 – 4, and trans-
shaft and enters the transmission. mits the motive force from the input shaft to the
output shaft.
10-22
FORWARD, REVERSE CLUTCH
1. Spacer 5. FORWARD, REVERSE cylin- a. FORWARD clutch oil port

2. Thrust washer der b. REVERSE clutch oil port
3. REVERSE gear 6. FORWARD clutch c. Lubrication oil port
4. REVERSE clutch 7. FORWARD gear
8. Input shaft
1ST, 3RD CLUTCH
1. 1st, 3rd shaft 6. 3rd clutch a. 1st clutch oil port

2. Idler gear 7. 3rd gear b. 3rd clutch oil port
3. 1st gear 8. Thrust washer c. Lubrication oil port
4. 1st clutch 9. Spacer
5. 1st, 3rd cylinder
10-23
2ND, 4TH CLUTCH
1. Idler gear 6. 2nd, 4th shaft a. 2nd clutch oil port

2. 2nd gear 7. 4th gear b. 4th clutch oil port
3. 2nd clutch 8. Thrust washer c. Lubrication oil port
4. 2nd, 4th cylinder 9. Idler gear
5. 4th clutch
10-24
Operation of clutch
When operated
• The oil sent from the transmission valve passes
through the oil passage inside shaft (1), and
goes to the rear face of piston (6) to actuate the
piston.
• When piston (6) is actuated, separator plate (2)
is pressed against clutch disc (3) and forms
shaft (1) and clutch gear (4) into one unit to
transmit the motive force.
• Oil is drained from oil drain hole (5) at this time,
but this does not affect clutch operation since
less oil is drained than supplied.
When not actuated

• If the oil from the transmission valve is shut off,
the pressure of the oil acting on the rear face of
piston (6) drops.
• The piston is returned to its original position by
wave spring (7), so shaft (1) and clutch gear (4)
are separated.
• When the clutch is disengaged, the oil at the
rear face of the piston is drained by centrifugal
force through oil drain hole (5), preventing the
clutch from remaining partially engaged.
10-25
FORWARD 1ST
Operation
• In forward 1st, forward clutch (8) and 1st clutch • Since the 1st clutch is engaged, the motive
(20) are engaged. The motive force from the force transmitted to 1st and 3rd cylinder gear
torque converter transmitted to input shaft (9) is (32) is transmitted from 1st gear (25) via the 1st
transmitted to output shaft (14). clutch to 2nd and 4th cylinder gear (33), then
• The clutch discs of forward clutch (8) and 1st transmitted to output shaft (14) via 2nd and 4th
clutch (20) are held by the hydraulic pressure shaft (17), idler gear (31) and output gear (34).
applied to the piston.
• The motive force from the torque converter is
transmitted from input shaft (9) via forward clutch
(8) to forward gear (23), then transmitted to 1st
and 3rd cylinder gear (32).
10-26
STRUCTURE AND FUNKTION TRANSMISSION
FORWARD 2ND
Operation
• In forward 2nd, forward clutch (8) and 2nd clutch transmitted to the 2nd gear is transmitted
(18) are engaged. The motive force from the from 2nd and 4th cylinder gear (33) via the
torque converter transmitted to input shaft (9) is 2nd clutch to output shaft (14) via 4th shaft
transmitted to output shaft (14). (17), idler gear (31) and output gear (34).
• The clutch discs of forward clutch (8) and 2nd
clutch (18) are held by the hydraulic pressure
applied to the clutch piston.
(8) to forward gear (23), then transmitted via
1st and 3rd cylinder gear (32), 1st and 3rd shaft
(19), and idler gear (29) to 2nd gear (26). Since
the 2nd clutch (18) is engaged, the motive force
10-27
FORWARD 3RD
Operation
• In forward 3rd, forward clutch (8) and 3rd clutch • Since 3rd clutch (11) is engaged, the motive
(11) are engaged. The motive force from the force transmitted to 1st and 3rd cylinder gear
torque converter transmitted to input shaft (9) is (32) is transmitted from 3rd gear (27) via the
transmitted to output shaft (14). 3rd clutch, then to output shaft (14) via 2nd and
• The clutch discs of forward clutch (8) and 3rd 4th shaft (17), idler gear (31) and output gear
clutch (11) are held by the hydraulic pressure (34).
(8) to forward gear (23), then to 1st and 3rd
cylinder gear (32).
10-28
FORWARD 4TH
Operation
• In forward 4th, forward clutch (8) and 4th clutch • Since the 4th clutch is engaged, the motive
(12) are engaged. The motive force from the force transmitted to the 4th gear is transmitted
torque converter transmitted to input shaft (9) is from 2nd and 4th cylinder gear (33) via the 4th
transmitted to output shaft (14). clutch, then to output shaft (14) via 2nd and 4th
• The clutch discs of forward clutch (8) and 4th shaft (17), idler gear (31) and output gear (34).
clutch (12) are held by the hydraulic pressure
(8) to forward gear (23), then transmitted via
1st and 3rd cylinder gear (32) to 4th gear (28).
10-29
TRANSMISSION
REVERSE 1ST
Operation
• In reverse 1st, reverse clutch (7) and 1st clutch cylinder gear (32) via idler gear (29) and 1st
(20) are engaged. The motive force from the and 3rd shaft (19). Since the 1st clutch is en-
torque converter transmitted to input shaft (9) is gaged, the motive force transmitted to 1st and
transmitted to output shaft (14). 3rd cylinder gear (32) is transmitted from 1st
• The clutch discs of reverse clutch (7) and 1st gear (25) via the 1st clutch to 2nd and 4th
clutch (20) are held by the hydraulic pressure cylinder gear (33), then transmitted to output
applied to the piston. shaft (14) via the 2nd and 4th shaft, idler gear
• The motive force from the torque converter is (31) and output gear (34).
transmitted from input shaft (9) via reverse clutch
(7) to reverse gear (24). The direction of rota-
tion is reversed by idler gear (21), and the mo-
tive force is then transmitted to 1st and 3rd
10-30
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL VALVE

(Turned 180° when installed in machine)
1. Upper valve b. Clutch oil pressure measure- f. Measurement port for torque
2. Lower valve ment port converter outlet port oil pres-
3. Solenoid valve c. Measurement port for torque sure
4. Electronic modulation valve converter inlet port oil pressure g. To oil cooler
5. Emergency manual spool d. Priority pressure measurement h. Parking brake oil pressure
a. Main oil pressure measure- port measurement port
ment port e. Pilot pressure measurement i. From pump
port
Outline
• The oil from the pump passes through the flow • The transmission controller senses the travel
valve and torque converter oil filter, enters the speed and the engine speed when the machine
transmission, and is divided into the pilot circuit is traveling. It actuates the proportional solenoid
and clutch actuation circuit. The priority valve valve according to the command current from
adjusts the delivery pressure of the pump and the transmission controller to control the oil flow
ensures the pilot pressure and oil pressure used and oil pressure. This allows the clutch to en-
to release the parking brake. gage smoothly and reduces the shock when
• The pressure of the oil flowing to the clutch cir- shifting gear.
cuit is regulated by the electronic modulation In addition, when the machine is traveling, the
valve. The transmission is automatically shifted clutch pressure is kept constant.
to the optimum speed range, and the appropri- The pressure of the oil flowing to the pilot valve
ate clutch is actuated. is regulated by the pilot reducing valve, and ac-
In addition, the oil relieved by the main relief tuates the directional and range spools as the
valve is supplied to the torque converter. solenoid valves are switched ON or OFF.
• When the directional and range spools are
switched, the oil, whose pressure regulated by
the modulation valve, is supplied to the selected
clutch to provide the necessary speed range.
10-41
UPPER VALVE
1. Upper valve body

2. Emergency manual spool
3. Pilot reducing valve
4. Torque converter outlet port valve
5. Main relief valve
6. Modulation valve
6. Electronic modulation valve (ECMV)
10-42
LOWER VALVE
1. Solenoid valve (FORWARD) 8. Priority valve a. 3rd, 4th orifice

2. Directional selector valve 9. Solenoid valve (Parking brake) b. 2nd orifice
3. Lower valve body 10. Solenoid valve (Range se-lec-
4. H-L selector valve tor)
5. Solenoid valve (REVERSE) 11. Solenoid valve (H-L selector)
6. Range selector valve
7. Parking brake valve
10-43
TRANSMISSION SOLENOID VALVE
Function
• When the gear shift lever is operated to move
in forward or reverse, electric signals are sent
to four solenoid valves mounted on the trans-
mission valve, activating the FORWARD/RE-
VERSE, H-L or range spool, according to the
combination of solenoid valves which are opened
and closed.
Operation
1. Solenoid valve OFF
The oil from pilot reducing valve (1) flows to
ports a and b of H-L selector spool (2) and
range selector spool (3). The oil at a and b is
blocked by solenoid valves (4) and (5), so se-
lector spools (2) and (3) are moved to the right
in the direction of arrow.
As a result, the oil from the pump flows to the
2nd clutch.
2. Solenoid valve ON
When the speed lever is operated, the drain
ports of solenoid valves (4) and (5) open. The
oil at ports a and b of selector spools (2) and
(3) flows from ports c and d to the drain circuit.
Therefore, the pressure in the circuits at ports a
and b drops, and the spools are moved to the
left in the direction of the arrow by return springs
(6) and (7).
As a result, the oil at port e flows to the 4th
clutch and switches from 2nd to 4th.
Actuation table for solenoid valve and clutch

¡ : Current flows
FORWARD REVERSE H-L Range
Solenoid valve Solenoid valve Solenoid valve Solenoid valve
F-1 ¡ ¡
F-2 ¡
F-3 ¡ ¡
F-4 ¡ ¡ ¡
N
R-1 ¡ ¡
R-2 ¡
R-3 ¡ ¡
R-4 ¡ ¡ ¡
10-44
PILOT REDUCING VALVE
Function
• The pilot reducing valve controls the pressure
used to actuate the directional selector spool,
H-L selector spool, range selector spool, and
parking brake spool.
Operation
• The oil from the pump enters port a, passes
through port b of pilot reducing spool (1), enters
spools (2) and (3) in the lower valve, and fills
the pilot circuit.
The oil at port b passes through the orifice and
flows to port c.
• When the pressure in the pilot circuit rises, the

pressure at port c also rises. This overcomes
the tension of spring (4) and moves pilot reduc-
ing spool (1) to the right in the direction of the
arrow.
For this reason, port a at port b are shut off, so
the pressure at port c is maintained.
10-45
MAIN RELIEF VALVE
Function
• The main relief valve regulates the pressure of
the oil flowing to the clutch circuit and distrib-
utes the oil flow between the clutch circuit and
the torque converter.
Operation
1. The oil from the pump passes through the pri-
ority valve, then through ports A and B of until
the main relief valve (1) specified pressure is
reached, and flows to the modulation valve.
2. If the pressure is above the specified value, the

oil which has passed through main relief valve
(1) orifices c and d presses poppet (2), moving
main relief valve (1) to the right, and is released
to port E, maintaining the pressure at the speci-
fied value. The oil released from port E flows to
the torque converter.
10-46
TORQUE CONVERTER OUTLET PORT VALVE
Function
• The torque converter outlet port valve is installed
in the outlet line of the torque converter and
adjusts the maximum pressure of the torque
converter.
Operation
• The oil at port a passes through the orifice in
spool (1) and flows to port c.
• When the pressure at port a rises, the pressure

at port c also rises. This overcomes the tension
of spring (2) and moves spool (1) to the left in
the direction of the arrow to allow oil to flow
from port a to port b.
• If the pressure at port a becomes even higher,

spool (1) is moved further to the left in the
direction of the arrow, and the oil flows from
port a to port b and drain port d. (Cold relief)
10-47
PRIORITY VALVE
Function
• The priority valve regulates the pump's discharge
pressure and provides the pilot oil pressure and
parking brake release oil pressure.
• If the pressure in the circuit reaches a level
above the measured oil pressure, the priority
valve acts as a relief valve, releasing the pres-
sure to protect the hydraulic circuitry.
Operation
1. The oil from the pump enters port a and sepa-
rates into the oil flowing to parking brake valve
(1), priority valve (2) and the pilot circuit.
2. The oil at port a passes through priority valve

(2) orifice b and flows to port c.
When the oil pressure at port c overcomes the
force of return spring (3), priority valve (2) moves
to the left and the oil flows to port d.
3. If the oil pressure at port c reaches a level

above the measured value, priority valve (2)
moves further to the left and is connected to the
drain circuit from port e, protecting the hydraulic
circuitry.
10-48
DIRECTIONAL SELECTOR VALVE
Operation
1. When at neutral
• Solenoid valves (4) and (5) are OFF and the
drain port is closed. The oil from the pilot circuit
passes through the oil hole in the emergency
manual spool and fills ports a and b of the
directional spool.
• In this condition, P1 + spring force (1) = P2 +
spring force (2), so the balance is maintained.
Therefore, the oil at port c does not go to the
FORWARD or REVERSE clutch.
2. When at FORWARD
• When the directional lever is placed at the FOR-
WARD position, solenoid valve (4) is switched
ON and drain port d opens. The oil which is
filling port a is drained, so P1 + spring force (1)
< P2 + spring force (2). When this happens, the
directional spool moves to the left, and the oil at
port c flows to port e and is supplied to the
FORWARD clutch.
10-49
H-L SELECTOR VALVE AND RANGE SELECTOR VALVE

• The H-L and range selector valves are oper-
Function ated according to the combination of the sole-
• When the gear shift lever is operated, electric noid valves, making it possible to select the
signals are sent to the solenoid valves paired speed (1st to 4th).
with the H-L selector valve and range selector
valve.
Operation
1. 2nd speed
• When solenoid valves (1) and (2) are OFF, the
drain port is closed. The oil P1 from the pilot
circuit overcomes the force of the H-L selector
spool (4) and range selector spool (5) springs
(3) and moves spools (4) and (5) to the left.
The oil in the clutch circuit passes from H-L
selector spool (4) port a through range selector
spool (5) port b and is supplied to the 2nd clutch.
10-50
2. 4th speed 3. 1st and 3rd speeds

• When solenoid valves (1) and (2) are ON, the • For the 1st speed, solenoid valve (1) is OFF,
drain port is open. The oil from the pilot circuit solenoid valve (2) is ON, and the oil in the
passes through solenoid valves (1) and (2) and clutch circuit passes from H-L selector spool
is drained, so H-L selector spool (4) and range (4) port a through range selector spool (5)
selector spool (5) are moved to the right by the port e and is supplied to the 1st clutch.
force of springs (3). The oil in the clutch circuit • For the 3rd speed, solenoid valve (1) is ON,
passes from H-L selector spool (4) port c through solenoid valve (2) is OFF, and the oil in the
range selector spool (5) port d and is supplied clutch circuit passes from H-L selector spool
to the 4th clutch. (4) port c through range selector spool (5)
port f and is supplied to the 3rd clutch.
10-51
EMERGENCY MANUAL SPOOL
Function
• Should the electric system malfunction and the
forward/reverse solenoid valves cannot be ac-
tuated, the emergency manual spool actuates
the forward and reverse clutches manually.
Operation
1. When the emergency manual spool is at neu-
tral (during normal operation)
• The oil from the pilot valve passes through
emergency manual spool (1), enters the lower
valve directional spool (2) ports "a" and "b" and
is sealed by forward solenoid valve (4) and re-
verse solenoid valve (3).
2. When the emergency manual spool is actuated

(to the forward side)
• When emergency manual spool (1) is pulled
out, the oil from the pilot valve passes through
emergency manual spool (1) and flows only into
directional spool (2) port "a", not into port "b".
This generates a pressure difference between
ports "a" and "b", directional spool (2) moves to
the left, oil flows into the forward clutch and the
clutch is engaged.
10-52
ELECTRONIC CONTROL MODULATION VALVE (ECMV)
Structure of ECMV
• The ECMV (Electronic Control Modulation Valve)
consists of a proportional solenoid valve and the
ECMV spool.
Proportional solenoid valve and ECMV

A propulsion force as shown in the diagram on the
right is generated by the command current from the
transmission controller.
The propulsion force generated by the proportional

solenoid acts on the pressure control spool and
generates the oil pressure shown in the diagram on
the right.
Therefore, by controlling the command current, it is
possible to change the propulsion force, actuate the
pressure control valve, and control the oil flow and
oil pressure
Operation of ECMV
The ECMV is controlled by the command current
sent from the transmission controller to the propor-
tional solenoid. The relationship between the clutch
pressure and the command current for the propor-
tional solenoid in the ECMV is as shown in the
diagram on the right.
10-53
1. Before shifting gear

Regardless of whether the machine is traveling
or the transmission is in neutral, at least one of
the clutches is engaged, and a command cur-
rent flows to proportional solenoid (1) from the
transmission controller. The oil from the priority
valve enters chamber A, passes through throttle
a and flows to chamber B. Some of the oil in
chamber B passes through port C and enter
chamber D.
The oil in chamber D pushes out piston (4), and
the reaction to this moves spool (3) to the right
to try to close throttle a. In this way, the hydrau-
lic pressure is maintained when the propulsion
force of shaft (2) of proportional solenoid (1)
and the reaction (hydraulic pressure) of spool
(3) are in balance.
(Clutch retention pressure is maintained)
2. When shifting gear (immediately after shifting

gear)
When the gear is shifted, the selector spool is
switched. The oil pressure at the clutch which
was previously engaged is drained, and the port
opens to the clutch which is to be newly en-
gaged. The command current to proportional
solenoid (1) becomes the trigger current imme-
diately after shifting gear. Spool (3) continues to
be pushed to the left, and oil starts to fill the
clutch chamber.
3. When shifting gear (setting initial pressure)

Immediately after oil fills the clutch chamber, the
command current to the solenoid is dropped to
the set value for the initial pressure. Therefore,
the propulsion force of shaft (2) of the propor-
tional solenoid valve becomes smaller, and the
clutch pressure becomes the set value for the
initial pressure.
10-54
4. Adjusting pressure
When the electric current flows to proportional
solenoid (1), a propulsion force proportional to
the current is generated. This propulsion force
of shaft (2) of solenoid (1) is adjusted by the oil
pressure at the clutch port applied to spool (3)
so that it is in balance with the reaction force.
In other words, the clutch pressure is controlled
by controlling the command current sent to so-
lenoid (1).
Manual operation of ECMV

If the machine must be moved in an emergency,
such as when there is any failure in the electrical
system of the transmission control, it is possible to
use manual operation to engage the transmission.
(For details, see the operation and maintenance
manual.)
Method of engaging
(i) Disconnect all connectors to the transmission
control valve.
(ii) Remove the manual selector lock plate, then
push in or pull out the spool.
FORWARD: Pull out
REVERSE: Push in
(iii) Push in the adjustment screw of the proportional
solenoid valve to the end.
Speed range when engaged: 2nd
10-55
PILOT OIL FILTER
1. Oil filter seat Specifications

2. Element Filtering area: 170 cm2
3. Case Filter mesh size: 105 µ
A. Inlet port
B. Outlet port
Outline
• The pilot oil filter is mounted on the transmission
lower valve, and filters dirt from the oil flowing to
the pilot circuit.
10-56
ACCUMULATOR VALVE
1. Piston (1st clutch) Outline

2. Piston (FORWARD clutch) • The accumulator valve is installed in the FOR-
3. Piston (2nd clutch) WARD, 1st, 2nd clutch circuit. When the trans-
4. Body mission shifts gear, the accumulator valve slowly
5. Spring (2nd clutch) reduces the oil pressure to the clutch that was
6. Stopper (2nd clutch) first engaged in order to prevent loss of torque
7. Spacer (2nd clutch) and to reduce the transmission shock when
8. Spring (FORWARD clutch) shifting gear. It temporarily stores the clutch oil
9. Spacer (FORWARD clutch) pressure in order to allow gear shifting to be
10. Stopper (FORWARD clutch) carried out smoothly without any time lag.
11. Spacer (1st clutch) (To make it possible to reduce the oil pressure
12. Spring (1st clutch) to the clutch slowly, there are throttles installed
13. Cover in the directional spool, H-L spool and range
14. Stopper (1st clutch) spool of the transmission control valve.)
10-57
Operation
1. Shifting down when digging (kick-down F2 à
F1)
When the transmission is in F2, oil pressure is
stored in the 2nd clutch accumulator.
When the kick-down is operated, the F1 clutch
is engaged, but the oil pressure in the accumu-
lator is maintained for the 2nd clutch until the
torque is transmitted to the 1st clutch. In this
way, it is possible to shift gear smoothly without
losing the torque.
Moving out after digging (F1 à R2)

When the transmission is in F1, oil pressure is
stored in the accumulator for the FORWARD
clutch and 1st clutch.
When shifting to R2 after completing digging
operations, the R2 clutch is engaged, but the oil
pressure for the FORWARD clutch and 1st clutch
is maintained in the accumulator. This makes it
possible to reduce the loss of torque due to the
reaction force to the product being handled,
and to move back smoothly without shock.
10-58
FLOW CONTROL VALVE
1. Spool a. To transmission valve

2. Body b. From pump
3. Spring c. To clutch lubricating circuit
d. Orifice
Outline
• The oil from the pump is distributed to the clutch
lubricating circuit with the transmission valve
circuit.
• When the engine speed is low and the pump's
oil discharge is low, the oil is sent with priority to
the transmission valve circuit, increasing the
clutch oil pressure response.
Operation
• The oil from the pump passes from port b
through orifice d and enters the transmission
valve from port a.
• When the oil from the pump reaches a level
above the specified oil pressure, spool (1) moves
to the right, and the oil flows from port c to the
clutch lubricating circuit.
10-59
CHECK VALVE
Outline
• The check valve is mounted on the fitting sur-
face of the transmission valve (lower valve) and
transmission case.
• A check valve is provided in the forward/reverse
valve's drain circuit, stabilizing shifting perform-
ance when shifting between forward and re-
verse.
1. Directional spool
2. Check valve
10-60
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft

2. Flange bearing
3. Center drive shaft
4. Rear drive shaft
Outline
• The motive force from the engine passes • The drive shaft has the following purpose in
through the torque converter and the transmis- addition to simply transmitting the power.
sion. Some of it is transmitted from rear drive The drive shaft has a universal joint and sliding
shaft (4) to the rear axle, while the rest goes joint to enable it to respond to changes in the
from center drive shaft (3) through flange bear- angle and length. This enables the drive shaft
ing (2) and front drive shaft (1) to the front axle. to transmit the motive force when the machine
is articulated and to protect the components
from damage from shock when the machine is
being operated or shock from the road surface
when the machine is traveling.
10-81
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT AXLE
1. Oil supply port and level plug

2. Coupling
3. Differential
4. Wet-type multi-disc brake
5. Final drive
6. Axle housing
7. Axle shaft
8. Drain plug
10-82
STRUCTURE AND FUNCTION AXLE
REAR AXLE
1. Oil supply port and level plug

2. Coupling
3. Differential
4. Wet-type multi-disc brake
5. Final drive
6. Axle housing
7. Axle shaft
8. Drain plug
10-83
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL (TPD)
FRONT DIFFERENTIAL
1. Side gear (Teeth 12)

2. Pinion (Teeth 9)
3. Shaft
4. Bevel gear (Teeth 41)
5. Sun gear shaft
6. Bevel pinion (Teeth 9)
10-84
REAR DIFFERENTIAL
1. Side gear (Teeth 12)

2. Pinion (Teeth 9)
3. Shaft
4. Bevel gear (Teeth 41)
5. Sun gear shaft
6. Bevel pinion (Teeth 9)
10-85
Outline
• The motive force from the engine is transmitted
to the front and rear axles via the torque con-
verter, the transmission and the propeller shaft.
• In the axle, the motive force is transmitted from
pinion gear (1) to bevel gear (5), shifted 90°
and reduced, and transmitted to sun gear shaft
(2) via differential (4).
• The motive force of the sun gear is further re-
duced by planetary gear-type final drive, and
transmitted to the axle shaft and wheel.
When moving straight forward

• When moving straight forward, the speed of
rotation of the left and right wheels is equal, so
pinion gear (4) in the differential assembly does
not rotate, and the motive force of carrier (6) is
transmitted equally to the left and right sun gear
shafts (2) via the pinion gear (4) and side gear
(3).
When turning
• When turning, the rotating speed of the left and
right wheels is different, so pinion gear (4) and
side gear (3) in the differential assembly rotate
according to the difference between the rotating
speed of the left and right wheels. The motive
force of carrier (6) is then transmitted to the sun
gear shafts (2).
10-86
TORQUE PROPORTIONING DIFFERENTIAL Ordinary differential
Function
• Because of the nature of their work, 4-wheel-
drive loaders have to work in places where the
road surface is bad. In such places, if the tires
slip, the ability to work as a loader is reduced,
and also the life of the tire is reduced. The
torque proportioning differential is installed to
overcome this problem.
• In structure it resembles the differential of an
automobile, but differential pinion gear (3) has
an odd number of teeth. Because of the differ-
ence in the resistance from the road surface,
the position of meshing of pinion gear (3) and
side gear (4) changes, and this changes the
Torque proportioning differential
traction of the left and right tires.
Operation
When traveling straight (equal resistance from road
surface to left and right tires)
• If the resistance from the road surface to the
left and right wheels is the same, the distance
between pinion gear (2) and meshing point “a”
of left side gear (1) is the same as the distance
between pinion gear (2) and meshing point “b”
of right side gear (3).
• Therefore the left side traction TL and the right
side traction TR are balanced.
When traveling on soft ground (resistance from road

surface to left and right tires is different)
• On soft ground, if the tire on one side slips, the
side gear of the tire on the side which has least
resistance from the road surface tries to rotate
forward. Because of this rotation, the meshing
of pinion gear (2) and side gear changes.
• If left side gear (1) rotates slightly forward, the
distance between the pinion gear and the mesh-
ing point “a” of the left side gear becomes
longer than the distance between the pinion
gear and the meshing port “b” of the right side
gear. The position is balanced as follows.
a x TL = b x TR
The ratio between the distances to “a” and “b”
can change to 1 : 1.38.
• Therefore when the ratio of the distances to “a”
and “b” is less than 1 : 1.38 (that is, the differ-
ence between the resistance from the road sur-
face to the left and right tires is less than 38%),
the pinion gear will not rotate freely, so drive
force will be given to both side gears, and the
tires will not slip.
Because of this effect, the tire life can be in-
creased by 20 – 30%, and at the same the
operating efficiency is also increased.
10-87
LIMITED SLIP DIFFERENTIAL
Function
• Because of the nature of their work, 4-wheel drive

loaders have to work in places where the road
surface is bad. In such places, if the tires slip, the
ability to work is reduced. The torque proportioning
selflocking differential is installed to overcome this
problem.
Operation
• The locking effect depends on the internal friction of
the differential. It is produced by two multi-disc
brakes, which are arranged symmetrically in the
differential cage. With a conventional differential
one wheel can be stopped or slowed down without
any difficulty when the vehicle is jacked up, the
engine running and a gear engaged. The other
wheel will then revolve correspondingly faster. With
the selflocking differential this process is rendered
more difficult due to the multi-disc brakes, in fact it
will become increasingly more difficult with increas-
ing torque.
• This characteristic is due to the fact that the torque

acting on the differential cage (1 is transmitted to
the cross pins (3) via the two thrust rings (2),
which are unable to revolve radially, but are ar-
ranged in the differential cage in such a manner
that they can move in an axial direction. The reac- 1) Crownwheel
tion forces which occur, when torque is transmitted, 2) Differential cage
exert outward axial forces on the wedge shaped 3) Cover
surfaces (4) of the thrust rings (2), thereby produc- 4) Axle shaft sun wheel
ing a pressure on the discs. As the outer discs (5) 5) Differential planet pinion (bevel pinion)
are locked in the differential cage (1) and the inner 6) Cross pins
discs (6) are splined to the sun wheels (7), a 7) Thrust rings
relative rotation of the axle shafts to the differential 9) Outer disc
cage is rendered more difficult. 10) Inner disc
11) Thrust washer
• The outward forces produce in the multidisc brakes 13) Wedged shaped surface on thrust rings
a load dependant locking torque, which is always
directly proportional to the input torque. The locking
effect adapts itself to the changing engine torque
and also to the torque increase produced by the
different gear speeds. This is a special advantage
for heavy duty off-road applications, where large
torques must be transmitted.
10-88
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Planetary gear (Teeth 27)

2. Planetary carrier
3. Axle shaft
4. Ring gear (Teeth 72)
5. Sun gear shaft (Teeth 18)
Outline
• As the final function the final drive operates to
reduce the rotative speed of the motive force
from the engine and increases the driving force.
• Ring gear (4) is press-fitted in the axle housing
and fixed in place by a pin.
• The motive force transmitted from the differen-
tial to the sun gear shaft (5) is reduced using a
planetary gear mechanism, increasing the driv-
ing force.
The increased driving force is transmitted to the
tires via planetary gear (2) and axle shaft (3).
10-89
STRUCTURE AND FUNCTION AXLE MOUNT, CENTER HINGE PIN
AXLE MOUNT, CENTER HINGE PIN
1. Front axle
2. Rear axle
3. Front frame
4. Rear frame
5. Upper hinge pin
6. Lower hinge pin
10-90
STRUCTURE AND FUNCTION AXLE MOUNT, CENTER HINGE PIN
FRONT AXLE CENTER HINGE PIN

• Front axle (1) is fixed directly to front frame (3) • Front frame (3) and rear frame (4) are joined by
by tension bolts so that it receives the force hinge pins (5) and (6) through the bearings. In
during operations directly. addition, the steering cylinders are connected
to the left and right front and rear frames, and
REAR AXLE the angle of articulation of the frame (the turn-
• Rear axle (2) has a structure which allows the ing angle) is adjusted according to the move-
center of rear frame (4) to float so that all the ment of the cylinders.
tires are in contact with the ground surface,
even when traveling on soft ground.
10-91
10-92
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
1. Steering cylinder
2. Steering valve
3. Hydraulic tank
4. Hydraulic pump
5. Oil cooler
10-111
STRUCTURE AND FUNCTION STEERING COLUMN, ORBIT ROLL
STEERING CONTROL, ORBIT ROLL
1 Steering wheel 3 Tilt lever
2 Steering column 4 Orbit-roll
Outline
• The orbit-roll steering is fully hydraulically operated. • When the steering wheel is turned, the orbit-
There is no mechanical steering connection be- roll passes oil to the steering demand valve.
tween the front and rear machine frame. The steer- The amount of oil is proportional to the turning
ing action is achieved through pipes, hoses and the of the steering wheel. The steering demand
steering cylinders. valve is moved to the left or right depending
on the turned direction of the steering wheel.
10-112
STRUCTURE AND FUNCTION STEERING COLUMN, ORBIT ROLL
ORBIT ROLL VALVE
1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Cover 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve 12. Check valve
10-113
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
1. Safety valve (with suction) A. To steering cylinder

2. Check valve B. To steering cylinder
3. Steering spool Pa. From orbit-roll
4. Relief valve Pb. From orbit-roll
5. Flow control spool P1. From steering pump
P2. From switch pump
PB. To work equipment circuit
T. To tank (oil cooler)
10-114
OVERLOAD RELIEF VAVLE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
• The overload relief valve is installed to the steer-
ing valve. It has the following two functions:
When the steering valve is at neutral, if any
shock is applied to the cylinder, and an abnor-
mal pressure is generated, the oil is relieved
from this valve. In this way, it functions as a
safety valve to prevent damage to the cylinder
or hydraulic piping. On the other hand, if nega-
tive pressure is generated at cylinder end, it
functions as a suction valve to prevent a vacuum
from forming.
Operation
Acting as relief valve
• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. Oil
passes through the hole in poppet (1) and acts
on the different areas of diameters d1 and d2,
so check valve poppet (3) and relief valve pop-
pet (2) are firmly seated in position.
• When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens. The oil flows around pilot poppet (4),
passes through the drill hole, and flows to port
B.
10-115
• When pilot poppet (4) opens, the pressure at

the back of poppet (1) drops, so poppet (1)
moves and is seated with pilot poppet (4).
• Compared with the pressure at port A, the inter-

nal pressure is low, so relief valve poppet (2)
opens. When this happens, the oil flows from
port A to port B, and prevents any abnormal
pressure from forming.
Acting as suction valve

• When negative pressure is formed at port A,
the difference in area of diameters d3 and d4
causes check valve poppet (3) to open. When
this happens, the oil from port B flows to port A,
and prevents any vacuum from forming.
10-116
STEERING RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The steering relief valve is inside the steering
valve, and sets the maximum circuit pressure
of the steering circuit when the steering valve is
actuated. When the steering valve is being ac-
tuated, if the steering circuit goes above the set
pressure of this valve, oil is relieved from this
valve. When the oil is relieved, the flow control
spool of the demand valve is actuated, and the
oil is drained to the steering circuit.
10-117
OPERATION OF DEMAND VALVE
Operation of relief valve
• When the pressure in the circuit rises and • When flow control spool (6) moves, the oil from
reaches the pressure set by adjustment screw the steering pump is drained, and the oil from
(1) and spring (2), pilot poppet (4) opens and the the switch pump id released to the main control
oil is drained. valve, so the pressure in the steering circuit is
• When this happens, the balance between the prevented from going above the set value.
pressure in pressure-receiving chamber (I) and
pressure-receiving chamber (II) is lost, so de-
mand spool (6) moves to the left in the direction
of the arrow.
10-118
Operation of demand valve
Steering spool at neutral
• The oil from the steering pump enters port A and • When the pressure at pressure-receiving cham-
the oil from the switch pump enters port B. ber (I) reaches a certain level (set by spring (5)),
• When steering spool (2) is at neutral, pressure- notch (f) opens and the oil from the steering
receiving chamber (II) is connected to the drain pump flows to the drain circuit. At the same
circuit through orifice (b), and notch (c) is closed. time, notch (g) closes, and all the oil from the
• Notch (c) is closed, so the pressure of the oil at switch pump all flows to the main control valve.
port A and port B rises. This pressure passes
through orifice (a), goes to pressure-receiving
chamber (I), and moves demand spool (1) to the
left in the direction of the arrow.
10-119
Steering spool operated

• Engine at low speed
• When steering spool (2) is pushed (operated), • The merged oil passes through notches (c) and
pressure-receiving chamber (II) and the drain cir- (d), pushes up load check valve (4), and flows to
cuit are shut off, and at the same time, notch (c) the cylinder. The return oil from the cylinder
opens. passes through notch (e) and enters the drain
• Because of this, the pressure in pressure-receiv- circuit.
ing chamber (II) rises, and demand spool (1) • In this condition, the pressure before passing
moves to the right in the direction of the arrow through notch (c) is sent to pressure-receiving
until notch (h) closes. chamber (I) and the pressure after passing
• The passage from port B to the main control through notch (c) is sent to pressure- receiving
valve is shut off, the oil from the switch pump chamber (II).
pushes up merge check valve (3), and the oil is Demand spool (1) acts to keep the differential
merged with the oil at port A from the steering pressure on both sides of notch (c) at a con-
pump. stant value. Therefore, an oil flow which matches
the opening of notch (c) is discharged from the
cylinder port. These pressure differences (con-
trol pressures) are set by spring (5).
10-120
Engine at high speed
• No support oil is needed from the switch pump, • The oil from the steering pump passes through
so the steering pump pressure rises until notch notches (c) and (d), pushes up load check valve
(g) closes and the merge passage at port B is (4), and flows to the cylinder. The return oil from
shut off. the cylinder passes through notch (e) and flows
• The pressure difference on both sides of notch to the drain circuit.
(c) is controlled only by notch (f), and the ex- • Notch (g) is closed, so the oil from the switch
cess oil from the steering pump is drained from pump is sent from port B to the main control
notch (f) to the drain circuit. (At this point, notch valve.
(g) is fully closed.)
10-121
Operartion of steering valve
Neutral
• The steering valve is not being operated, so • When the pressure at ports A and B rises, flow
steering spool (1) does not move. control spool (4) moves to the left in the direc-
• The oil from the steering pump enters port A. tion of the arrow, and the oil from the steering
The oil from the switch pump enters port B. pump passes through port C of the spool and is
drained.
The oil from the switch pump passes through
port D, and all flows to the main control valve.
10-122
Turning right
• When the steering wheel is turned to the right, The oil from the left and right cylinders passes
the pressure oil from the Orbit-roll valve acts on through load check valve (3) of the steering spool,
steering spool (1), and steering spool moves to and is drained.
the left in the direction of the arrow. The oil from the switch pump enters port B,
The oil from the steering pump enters port A, pushes flow control spool (2) to push open check
passes through demand spool (2) to steering valve (5), and is merged with the oil from the
spool (1). It then pushes open load check valve steering pump.
(4) of the spool, and flows to the bottom end of
the left cylinder and the rod end of the right
cylinder to turn the machine to the right.
10-123
Turning left
• When the steering wheel is turned to the left, The oil from the left and right cylinders passes
the pressure oil from the Orbit-roll valve acts on through load check valve (4) of the steering spool,
steering spool (1), and steering spool moves to and is drained.
the right in the direction of the arrow. The oil from the switch pump enters port B,
The oil from the steering pump enters port A, pushes flow control spool (2) to push open check
flows through flow control spool (2) to steering valve (5), and is merged with the oil from the
spool (1). It then pushes open load check valve steering pump.
(3) of the spool, and flows to the rod end of the
left cylinder and the rod end of the right cylinder
to turn the machine to the left.
10-124
STRUCTURE AND FUNCTION EMERGENCY STEERING
EMERGENCY STEERING
Outline:
• The following two pages provide a summary of the
emergency steering installed in the WA-3H ma-
chines. These show the location of components and
flow of hydraulic oil for the WA470-3H during vari-
ous operating conditions; the summary applies ac-
cordingly for all other WA-3H machines.
Operating modes
1. Switch ignition on
• The red control lamp on the main monitor
flashes.
2. Motor started
goes out.
3. The machine is driven in any gear

• Steering pressure builds up.
• At the same time, the steering pump generates
a control pressure with which the change-over valve
is activated.
• The emergency steering pump is driven by the
transmission via the wheels, axles and cardan shafts.
• This sucks hydraulic oil from the tank and pumps it
through the flow indicator to the change-over valve.
• The green control lamp on the main monitor lights
up if hydraulic oil is flowing from the emergency
steering pump to the change-over valve.
• The change-over valve is now switched so that the
hydraulic oil flows back into the tank.
4. The motor is switched off or the steering pump does

not pump any hydraulic oil and the machine coasts.
• There is no steering pressure present.
• The control pressure generated by the steering pump
is not present either.
• The change-over valve is switched over by spring
force.
• The emergency steering pump is driven by the
transmission via the wheels, axles and cardan shafts,
and sucks hydraulic oil from the tank and pumps it
through the flow indicator to the change-over valve.
• The red control lamp on the main monitor flashes
because the generated control pressure has col-
lapsed.
• The change-over valve is now switched so that the
hydraulic oil being pumped by the emergency steer-
ing pump is fed into the steering circuit. A non-
return valve in the line section prevents hydraulic oil
from flowing back to the steering pump.
10-125
1
EMERGENCY STEERING Up to SN WA380H20836

Schematic sketch only!
Ports can be in different places!
1. Oil tank 7. Steering pressure port

2. Steering pump 8. Check valve
3. Emergency steering pump 9. Input port emergency steering pump
4. Change-over valve 10. Suction piping emergency steering pump
5. Flow indicator 11. Drain
6. Pressure switch
10-126
1
Function
• 8 pistons (17) are located in the pump housing
(16) in star formation. The stroke movement is
achieved with the cam shaft (14) which runs on
roller bearings. The heads of the pistons (17)
run on a slide ring (12) which itself is mounted
on a slide bearing (13) mounted on the cam.
The pistons (17) are kept in constant contact
with the slide ring (12) by springs (18). The
springs (18) are located in the hollow-drilled
pistons (17) and rest against the sealing screws.
The pump sucks in via the cam space of the
pump housing. The pistons, which have several
inlet holes around their circumference, immerse
downwards into the cam space so that oil can
flow into the inside of the piston through the inlet
holes. The inlet holes are closed again during
the upward movement by the cylinder wall after
a specific stroke distance. The oil pumped by
the further upward movement of the pistons is
fed through axial holes from the cylinder spaces
into a ring space which is sealed by a common
plate valve (10). The plate valve is held in place
by a waveform spring washer. The oil is dis-
charged via the plate valve (10) in the ring
collecting area in the cover which is connected
to the discharge connection hole. The plate valve
(10) carries out a waveform motion during this
action corresponding to the consecutive piston
strokes. A fairly even delivery of approx. 25 l/
min. sets in during acceleration at rotational 1 Circlip
speeds representing a travel speed of approx. 2 Deep-groove ball bearing
19 km/h. This characteristic results from the 3 Spacer ring
constantly decreasing time for the oil to flow 4 Double-lipped waveform sealing ring
from the cam space into the piston interior. The 5 O-ring
pump’s delivery characteristics are the same for 6 Pump cover, drive side
forward and reverse drive. 7 O-ring
8 Needle bearing
9 Waveform spring washer
10 Plate valve
11 Thrust ring
12 Slide ring
13 Slide bearing between cam shaft 14
and slide ring 12
14 Cam shaft
15 O-ring
16 Pump housing
17 Piston
18 Spring
19 Sealing ring
20 Sealing screw
21 Pump cover
10-127
CHANGE-OVER VALVE EMERGENCY STEERING

P. Input pressure emergency pump

PP. PPC pressure
D. To steering circuit
T. To tank
L. Connector pressure switch
10-128
1
EMERGENCY STEERING
Outline:
• The following two pages provide a summary of the
emergency steering installed in the WA-3H ma-
chines. These show the location of components and
flow of hydraulic oil for the WA320-3H during vari-
ous operating conditions; the summary applies ac-
cordingly for all other WA-3H machines.
Operating mode with time relay

1. Switch ignition on (for min. 6 seconds)
• The red control lamp on the main monitor flashes.
• The emergency steering pump is switched on
automatically by a time relay.
• Steering pressure builds up and the green con-
trol lamp on the main monitor flashes.
• After 6 seconds the time relay switches off the
emergency steering pump and the green con-
trol lamp on the main monitor goes out.
2. Engine started
is off.
The green control lamp on the main monitor is
still off.
3. The engine is switched off or there is no oil flow

from the steering pump and the machine is coast-
ing.
• There is no steering pressure present.
• The emergency steering pump is switched on
by a pressure switch (3 bar). When the emer-
gency steering pump is in operation, hydraulic
oil is sent to the steering line and the green
control lamp on the main monitor is on.
• The red control lamp on the main monitor is on
because the steering pressure has collapsed.
• A check valve prevents hydraulic oil from flow-
ing back to the steering pump.
10-129
2
EMERGENCY STEERING SN WA380H20837 and up

1 2 3 4 5 6
7 8 9
1. Emergency steering pump 7. Pressure line

2. Pressure switch (3 bar) 8. Suction line
3. PPC pump 9. Priority valve for steering pump
4. Steering pump
5. Switch pump
6. Hydraulic pump
10-130
1
Function
• The gear pump employed is a self-priming pres-
sure/volume type. It produces an rpm dependent oil
volume flow. The housing (1) contains two axial free
floating bearing plates (2) that support the drive
shaft (4) and the layshaft (5).
The housing is fitted with a mounting plate (6) and
endcover (7).
The drive shaft gear and layshaft gear are meshed
together. Rotation of the shafts cause a displace-
ment of the pressure fluid form the suction side (S)
to the pressure outlet (P). The two bearing plates
are axially loaded with working pressure. This is
restricted through the use of an asymmetric pres-
sure area applied to a special sealring combination
(8). The pressure area is connected to the pres-
sure chamber of the gear housing through a chan-
nel (10). Because of this construction the bearing
surface of the bearing plates is pressed onto the
bearing surfaces of the drivegear and laygear. Lu-
brication of the support bearings is achieved with
the pressure fluid. On the suction side and the
pressure side the bearing plates have groves to
improve filling and displacement characteristics.
1. Housing S Suction port

2. Bearing plates P Pressure port
4. Drive shaft
5. Layshaft
6. Mounting plate
7. Endcover
8. Seal combination
9. Pressure area
10. Channel
10-131
1
EMERGENCY STEERING PUMP

1
2 2
3 3
1. Electric motor (24V, 2kW)

2. Check port (M10x1)
3. Pressure relief valve (120 ±7 bar)
4. Starter relay (24V, 80A)
10-132
1
WIRING DIAGRAM EMERGENCY STEERING

Operating mode with time relay
S109
Ground
Description Description
H111 Lamp steering oil pressure B305 Sender emergency steering pump pressure (7 bar)
H306 Lamp emergency steering pump B307 Sender air pressure (3 bar)
S109 Plug for taster test emergency steering pump K159 Time relay (6 sec.) for test emergency steering pump
V118 Diode K161 Relay emergency steering pump
XFS Connector fuses K414 Rpm sensor emergency steering pump
XL Connector platform P426 Main Monitor
XR Connector rear frame M160 Emergency steering pump
10-133
1
HYDRAULIC DIAGRAM EMERGENCY STEERING

1 1A
3
CF
H PSP
1. Pump and motor (emergency steering pump)
1A. Pressure relief valve (120 ±7 bar)
2. Pressure switch (7 bar)
H Port from hydraulic tank

P SP Port from steering pump
CF Outlet port to steering
10-134
1
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
1. Front axle (with multi-disc brake) Outline

2. Right brake valve • When the brake valve is activated, the oil sent
3. Left brake valve from the pump passes through the accumulator
4. Accumulator charge valve charge valve, shuts off the drain circuit in the
5. Hydraulic oil tank valve, actuates the piston, and activates the
6. Accumulator front and rear brakes.
7. Hydraulic pump (series of four pumps)
8. Accumulator
9. Rear axle (with multi-disc brake)
10. Transmission valve
10-151
STRUCTURE AND FUNCTION BRAKE CONTROL CIRCUITS
PARK BRAKE AND FOOT BRAKE CIRCUITS

Up to Serial Number: WA380H20338
Park brake circuit Foot brake circuit

1 Transmission 9 Pump
2 Pump 10 Filter
3 Priority valve 11 Accumulator charge valve
4 Park brake cylinder 12 Check valve
5 Pressure switch 13 Low pressure switch
6 Park brake valve 14 Accumulators: One front axle, one rear axle
7 Accumulator 15 L.H. brake valve
8 Check valve 16 R.H. brake valve
17 Wheel cylinders
18 Transmission cut-off switch
19 Brake lamp switch
20 Accumulator (45 cc)
10-152
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE Up to Serial Number: WA380H20338
BRAKE VALVE (RIGHT)
1. Brake pedal (left, right brake) 9. Spool (left brake)

2. Rod (right brake) 10. Cylinder (left brake)
3. Pilot piston (right brake)
4. Spool (right brake) A. Pilot port (right brake)
5. Upper cylinder (right brake) B. To rear brake (right brake)
6. Spool (right brake) C. To front brake (right brake)
7. Lower cylinder (right brake) D. Drain (left, right brake)
8. Rod (left brake) E. To pilot port (left brake)
F. From accumulator charge valve
10-153
BRAKE VALVE (LEFT) Up to Serial Number: WA380H20338
Outline
• There are two brake valves installed in parallel In addition, the left brake pedal operates the
under the front of the operator’s cab, and these transmission cut-off switch to actuate the trans-
are actuated by depressing the pedal. mission solenoid valve electrically and set the
• When the right pedal is depressed, oil is sent to transmission to neutral.
the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
10-154
Operation
Brake applied (right brake valve)
Upper portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C
and actuates the rear brake cylinders.
Lower portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the front
brake cylinders.
Brake applied (left brake pedal)

• When pedal (7) is depressed, spool (10) is
pushed up by rod (8) and spring (9), and drain
port c is closed. The oil from the pump and the
accumulator flows from port E to port F.
• Port F of the left brake valve and port PP of the
right brake valve are connected by a hose, so
the oil flowing to port F flows to pilot port PP of
the right brake valve.
• The oil entering pilot port PP enters port G from
orifice d, and pushes piston (11). The spring
pushes spool (3) down, so the operation is the
same as when the right brake valve is de-
pressed.
10-155
Applying brake when upper valve fails (right brake

valve)
• Even if there is leakage of oil in the upper pip-
ing, spool (5) is moved down mechanically when
pedal (1) is depressed, and the lower portion is
actuated normally.
The upper brake is not actuated.
Applying brake when lower valve fails (right brake
valve)
• Even if there is leakage of oil in the lower pip-
ing, the upper portion is actuated normally.
When actuation is balanced

Upper portion
• When oil fills the rear brake cylinder and the
pressure between port A and port C becomes
high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes
up spool (3) and shuts off the circuit between
port A and port C. When this happens, drain
port a stays closed, so the oil entering the brake
cylinder is held and the brake remains applied.
Lower portion
• When spool (3) in the upper portion moves up
and the circuit between port A and port C is
shut off, oil also fills the front brake cylinder at
the same time, so the pressure in the circuit
between port B and port D rises. The oil enter-
ing port J from orifice f of spool (5) pushes up
spool (5) by the same amount that spool (3)
moves, and shuts off port B and port D. Drain
port b is closed, so the oil entering the brake
cylinder is held, and the brake is applied.
• The pressure in the space in the upper portion
is balanced with the operating force of the pedal,
and the pressure in the space in the lower por-
tion is balanced with the pressure in the space
in the upper portion. When spools (3) and (5)
move to the end of their stroke, the circuits
between ports A and C and between ports B
and D are fully opened, so the pressure in the
space in the upper and lower portions and the
pressure in the left and right brake cylinders is
the same as the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
10-156
Brake released (right brake valve)

Upper portion
• When pedal (1) is released and the operating
force is removed from the top of the spool, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port a is opened and the oil from the
brake cylinder flows to the hydraulic tank return
circuit to release the rear brake.
Lower portion
• When the pedal is released, spool (3) in the
upper portion moves up. At the same time, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port b is opened and the oil from the
brake cylinder flows to the hydraulic tank return
circuit to release the front brake.
10-157
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
ACCUMULATOR CHARGE VALVE
A. To PPC valve Function

ACC. To brake valve • The accumulator charge valve is actuated to
PP. To brake valve maintain the oil pressure from the pump at the
P. From pump specified pressure and to store it in the accu-
T. Drain mulator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load on the pump.
10-158
1. Valve body
2. Safety relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
10-159
Operation
1. When no oil is being supplied to accumulator
(cut-out condition)
• The pressure at port B is higher than the set

pressure of the relief valve (R1), so piston (8) is
forcibly pushed up by the oil pressure at port B.
Poppet (6) is opened, so port C and port T are
short circuited.
• The spring chamber at the right end of spool
(15) is connected to port C of the relief valve
(R1), so the pressure becomes the accumulator
pressure. The oil from the pump enters port P,
pushes spool (15) to the right at a low pressure
equivalent to the load on spring (14), and flows
from port A to the PPC valve.
At the same time, it also passes through ori-
fices (17), (18), and (16), and flows to the tank.
2. When oil is supplied to accumulator
1) Cut-in condition
• When the pressure at port B is lower than the
set pressure of the relief valve (R1), piston (8)
is pushed back down by spring (5). Valve seat
(7) and poppet (6) are brought into tight con-
tact, and port C and port T are shut off.
(15) is also shut off from port T, so the pres-
sure rises, and the pressure at port P also rises
in the same way.
• When the pressure at port P goes above the
pressure at port B (accumulator pressure), the
supply of oil to the accumulator starts immedi-
ately. In this case, it is decided by the size
(area) of orifice (17) and the pressure differ-
ence (equivalent to the load on spring (14))
generated on both sides of the orifice. A fixed
amount is supplied regardless of the engine
speed, and the remaining oil flows to port A.
10-160
2) When cut-out pressure is reached

• When the pressure at port B (accumulator pres-
sure) reaches the set pressure of the relief valve
(R1), poppet (6) separates from valve seat (7),
so an oil flow is generated and the circuit is
relieved.
• When the circuit is relieved, a pressure differ-
ence is generated above and below piston (8),
so piston (8) moves up, poppet (6) is forcibly
opened, and port C and port T are short
circuited.
(15) is connected to port C of the relief valve
(R1), so the pressure becomes the tank pres-
sure.
• The pressure at port P drops in the same way
to a pressure equivalent to the load on spring
(14), so the supply of oil to port B is stopped.
3. Safety relief valve (R3)

• If the pressure at port P (pump pressure) goes
above the set pressure of the relief valve (R3),
the oil from the pump pushes spring (3). Ball
(11) is pushed up and the oil flows to the tank
circuit, so this sets the maximum pressure in
the brake circuit and protects the circuit.
10-161
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
ACCUMULATOR FOR BRAKE SYSTEM
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function Specifications
• The accumulator is installed between the charge Gas used: Nitrogen gas
valve and the brake valve. It is charged with Charge amount: 3000 cc
nitrogen gas between cylinder (3) and free pis- Charging pressure
ton (4), and uses the compressibility of the gas For service brakes: 3.4 ± 0.15 MPa
to absorb the pulse of the hydraulic pump or to (35 ± 1.5 bar) (at 50°C)
maintain the braking force and to make it possi- For parking brakes: 15 bar (at 50°)
ble to operate the machine if the engine should
stop.
10-162
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
1. Top cover
2. Piston
3. Cylinder
4. End cover
5. Plug
Function Specifications
• The accumulator is installed between the brake Gas used: Nitrogen gas
valve and brake piston. Nitrogen gas is injected Charge amount: 45 cc
between cylinder (1) and free piston (2), and its Charging pressure: 0.3 ± 0.05 MPa
compression is used to act as a damper when (3 ± 0.5 bar) (at 50°C)
the brake pressure between brake valve and
brake piston is rising.
10-163
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM

Serial Number: WA380H20339 - 20470

1 Transmission 9 Pump
2 Pump 10 Filter
3 Priority valve 11 Accumulator charge valve
4 Park brake cylinder 12 Check valve
5 Pressure switch 13 Low pressure switch
6 Park brake valve 14 Accumulators: One front axle, one rear axle
7 Accumulator 15 L.H. brake valve
8 Check valve 16 R.H. brake valve
17 Brake cylinder
18 T/M cut-off
19 Brake light switch
20 Accumulator
21 Switch valve
10-164
BRAKE VALVE (DUAL CIRCUIT)

Function:
• The purpose of the brake valve is to allow a controled

increase or decrease of brake pressure when the
brake pedal is operated.
Operation:
Brakes released:
• Accumulator pressure is available at inlet ports 1.1

/ 1.2 of the brake valve. Ports 2.1 / 2.2 are con-
nected to the return ports 5.1 / 5.2 and the wheel
brake pressure is released.
1.1 / 1.2 From the brake accumulators

2.1 / 2.2 To the wheel brakes
2.4 / 2.5 Pressure check points
5.1 / 5.2 Return ports to the tank
A Spring assembly
C1, C2 Spool valve
R1, R2 Springs
10-165

Partial braking:
• When the brake valve is operated hydraulic pres- • When the braking process is ended a con-
sure, proportional to the actual foot force, is applied nection is again established between brake
to the brakes. The spring assembly (A) beneath the cylinder 2.1 / 2.2 and the drain 5.1 / 5.2,
base plate (E) is designed so that braking pressure pressure ports 1.1 and 1.2 are closed.
changes according to the foot plate (B) angle. In
the lower braking range the vehicle can be braked • The arrangement of pistons in the valve en-
proportionally. sures that even if one braking circuit fails the
other remains fully operational. This is
• If the vehicle is braked more, piston (C1) is moved achieved by means of the mechanical actua-
down with the increased spring pressure (A). The tion of both pistons and requires slightly more
piston (C1) applies spring pressure (R1) to the pedal pressure.
lower piston (C2). The pistons cut off the outlet
ports 5.1 and 5.2. Further movement opens the Limiting braking pressure:
ports 1.1 and 1.2 allowing oil pressure to pass to
the wheel brake cylinders. The applied foot force • The movement restriction screw (D) on the
now determines the braking force. The pistons (C1) base plate (E) below the pedal (B) is used to
and (C2) are held in a stable position between the limit the brake pedal movement. This in turn
applied foot force and the spring pressure plus the limits the applied braking pressure.
applied brake hydraulic pressure.When this point is
reached ports 1.1 / 1.2 and 5.1 / 5.2 are closed Failure of a circuit:
and the applied pressure at 2.1 and 2.2 is held.
• In the event of the lower brake circuit failing,
Full braking: the upper circuit will remain operational. Pis-
ton (C1) is operated mechanically by spring
• When the brake pedal (B) is fully actuated piston (A). In the event of the upper circuit failing,
(C1) moves into mechanical contact with piston piston (C1) and spring (A) will mechanically
(C2). Ports 5.1 and 5.2 close. Ports 1.1 and 1.2
open and full brake pressure is allowed to flow to
the brakes.
10-166
BRAKE VALVE (SINGLE CIRCUIT)

• When the braking process is commenced,
slide (C) is mechanically actuated via spring
Function: assembly (A). As slide (C) moves downward,
• The purpose of the brake valve is to sensitively it will first close return 5 via the control edge,
increase and decrease the braking pressure when thus establishing a connection between ac-
the brake pedal is actuated. cumulator port 1 and port 2 for the wheel
brake cylinders. The foot force applied now
Operation: determines the output braking pressure. Con-
trol slide (C) is held in the control position by
Ready Position the force applied (spring assembly) and the
• When the braking system is ready for operation, its hydraulic pressure below slide (C) (balance
accumulator pressure acts directly on port 1 of the of forces). After output of the braking pres-
brake valve. A connection is established between sure, slide (C) is in a partial braking position,
ports 2 and 5 so that the wheel brake (port 2) is causing ports 1 and 5 to close and holding
pressureless via the return (port 5). the pressure in port 2.
Full Braking Position
Partial Braking • When pedal (B) is fully actuated, an end
• When the brake valve is actuated, an amount of position of the brakes is reached and a con-
hydraulic pressure is output as a ratio of the foot nection established between accumulator port
force applied. 1 and brake cylinder port 2. Return 5 is
• The spring assembly (A) beneath base plate (E) is closed at this point.
designed in such a way that the braking pressure • When the braking process is ended, a con-
changes depending on the angle. In the lower brak- nection is once again established between
ing pressure range, the vehicle can be slowed sen- brake cylinder port 2 and return port 5, clos-
sitively. ing accumulator port 1.
Limiting the Braking Pressure

• Pedal restriction screw (D) on base plate (E)
below pedal (B) is used to limit the braking
pressure. This will cause the accumulator
pressure building up in the braking system to
be limited.
10-167
STRUCTURE AND FUNCTION BRAKE SYSTEM
BRAKE HYDRAULIC CIRCUIT DIAGRAM

Serial Number: WA380H20471 and up

1. Transmission 9. Pump
2. Pump 10. Filter
3. Priority valve 11. Low pressure switch
4. Park brake cylinder 12. Accumulators: One front axle, one rear axle
5. Pressure switch 13. Switch valve
6. Park brake valve 14. L.H. brake valve
7. Accumulator 15. R.H. brake valve
8. Check valve 16. T/M cut-off
17. Brake light switch
18. Accumulator
19. Brake cylinder
10-168

Function:
• The purpose of the brake valve is to allow a control-

led increase or decrease of brake pressure when
the brake pedal is operated.
Operation:
Brakes released:
• Accumulator pressure is available at inlet ports 1.1

/ 1.2 of the brake valve. Ports 2.1 / 2.2 are con-
nected to the return ports 5.1 / 5.2 and the wheel
brake pressure is released.
1.1 / 1.2 From the brake accumulators

2.1 / 2.2 To the wheel brakes
2.4 / 2.5 Pressure check points
5.1 / 5.2 Return ports to the tank
A Pilot pressure from left
brake pedal
10-169

Partial braking: Full braking:
• When the brake valve is operated hydraulic pres- • When the brake pedal is fully actuated, a
sure, proportional to the actual foot force, is applied final position is reached and ports 1.1 and
to the brakes. The spring assembly beneath the 1.2 are connected to port 2.1 / 2.2 at the
base plate is designed so that braking pressure brakes while drain ports 5.1 / 5.2 are closed.
changes according to the foot plate angle. In the • When the braking process is ended a con-
lower braking range the vehicle can be braked nection is again established between brake
proportionally. cylinder 2.1 / 2.2 and the drain 5.1 / 5.2,
pressure ports 1.1 and 1.2 are closed.
• If the vehicle is braked more, the upper piston is • The arrangement of pistons in the valve en-
moved down with the increased spring pressure. sures that even if one braking circuit fails the
The upper piston applies spring pressure to the other remains fully operational. This is
lower piston. The pistons cut off the outlet ports 5.1 achieved by means of the mechanical actua-
and 5.2. Further movement opens the ports 1.1 and tion of both pistons and requires slightly more
1.2 allowing oil pressure to pass to the wheel brake pedal pressure.
cylinders. The applied foot force now determines
the braking force. The pistons are held in a stable
position between the applied foot force and the Failure of a circuit:
spring pressure plus the applied brake hydraulic
pressure. When this point is reached ports 1.1 / • In the event of the lower brake circuit failing,
1.2 and 5.1 / 5.2 are closed and the applied pres- the upper circuit will remain operational. The
sure at 2.1 and 2.2 is held. piston is operated mechanically by the springs.
In the event of the upper circuit failing, the
lower circuit will remain operational. The lower
piston and is operated mechanically by the
springs and the piston.
• If the left brake valve is operated, a pressure
establishes at port 2.1 and passes to port 3
of the right brake valve. This pressure oper-
ates a piston in the right brake pedal that
operates the brake slide. Oil flows from ports
1.1 / 1.2 to the cylinder ports 2.1 / 2.2
(brake).
10-170
BRAKE VALVE (SINGLE CIRCUIT)

Function: The foot force applied now determines the

• The purpose of the brake valve is to sensitively output braking pressure. The control slide is
increase and decrease the braking pressure when held in the control position by the force ap-
the brake pedal is actuated. plied (spring assembly) and the hydraulic
pressure below the slide (balance of forces).
Operation: After output of the braking pressure, the slide
is in a partial braking position, causing ports
Ready Position 1.1 and 5.1 to close and holding the pressure
• When the braking system is ready for operation, its in port 2.1.
accumulator pressure acts directly on port 1.1 of
the brake valve. A connection is established be- Full Braking Position
tween ports 2.1 and 5.1 so that the wheel brake • When the pedal is fully actuated, an end
(port 2) is pressureless via the return (port 5). position of the brakes is reached and a con-
nection established between accumulator port
Partial Braking 1.1 and brake cylinder port 2.1. Return 5.1 is
• When the brake valve is actuated, an amount of closed at this point.
hydraulic pressure is output as a ratio of the foot • When the braking process is ended, a con-
force applied. nection is once again established between
• The spring assembly beneath base plate is designed brake cylinder port 2.1 and return port 5.1,
in such a way that the braking pressure changes closing accumulator port 1.1.
depending on the angle. In the lower braking pres-
sure range, the vehicle can be slowed sensitively. Limiting the Braking Pressure
• When the braking process is commenced, the slide • The pedal restriction screw on the base plate
is mechanically actuated via a spring assembly. As below the pedal is used to limit the braking
the slide moves downward, it will first close return 5 pressure. This will cause the accumulator
via the control edge, thus establishing a connection pressure building up in the braking system to
between accumulator port 1.1 and port 2.1 for the be limited.
wheel brake cylinders.
1.1 From accumulator
2.1 Control pressure to port 3
5.1 Return port
10-171
BRAKE PRESSURE REGULATING VALVE

Ready position:
• When the accumulators are fully charged, oil enter-

ing the regulating valve at inlet port 1 causes a
pressure rise. This, in turn, opens a connection
between inlet port 1 and the return port 5 so that the
oil from the pump returns directly to the tank. The
rear spring chamber of valve A is not pressurized.
• The charged accumulator pressure holds slide B in
the discharge detent position E1 so that the rear
spring chamber of valve A is connected directly to
return port 5 through orifice G. Check valve D
installed at port 21 and 23 keeps pressure stable.
The shuttle valve H causes the accumulator with the
lowest pressure to be shut off so that the remaining
accumulator can be used to operate the brakes. 1. Inlet port
The shuttle valve also allows brake operation if pres- 21/23. To brake
sure is lost in one line due to a burst pipe. 27. Accumulator
28. Pressure switch
5. Return port
J. Safety valve
Switch on pressure: 70 +8 bar

Switch off pressure: 100 -8 bar
max. operating pressure: 110 bar
Charging process:
• When the accumulator pressure drops to a preset between port 1 and port 5 is reestablished.
value, spring pressure C will force the control valve The pump oil flow returns to the tank. Check
B to move to the charge detent position E2. Oil valve D ensures that accumulator pressure
flows via orifice F to the spring chamber of valve A. is maintained. The safety valve J check max.
This causes valve A to float. A minimum oil flow pressure of 100 bar. The pressure switch 28
goes to the return port 5 and back to the tank, the operates at 52 bar.
maximum oil flow goes to ports 21 / 23 via check
valve D. Pressure in the accumulators rises to
approx. 150 bar. The control valve B returns to the
discharge detent position E1 and the connection
10-172
ACCUMULATOR (FOR BRAKE)

Gas pressure: 35 bar

Capacity: 2.8 l
Function:
• Because fluids are not compressable they can not

store energy. In hydropneumatic accumulators a
gas is used, which can be compressed. The gas
used is nitrogen.
• Accumulators are used in braking systems to store
the energy supplied by the hydraulic pump. The
stored energy can be used in an emergency, for
example when the pump is not working. It is also
used to absorb shocks and oscillations in the sys-
tem.
Operation:
• The accumulator consists of two chambers divided

by a diaphragm (C). The one chamber contains
nitrogen (B). The other chamber (A) is connected
to the hydraulic system. When the hydraulic pres-
sure rises oil enters the accumulator and com-
presses the nitrogen. The gas volume decreases
and the pressure rises. When the hydraulic pres-
sure falls the gas volume increases and forces the
hydraulic oil out of the accumulator into the hydrau-
lic circuit.
• The diaphragm is fitted with a disc seal (D). This

will close the acccumulator when there is no hy-
draulic pressure.
10-173
ACCUMULATOR FOR PPC VALVE

Gas pressure: 17 bar

Capacity: 0,48 l
Function
• The accumulator is installed between the hy-
draulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under
their own weight by using the pressure of the
nitrogen gas compressed inside the accumula-
tor to send the pilot oil pressure to the main
control valve to actuate it.
Operation
• After the engine stops , if the PPC valve is at
"Hold", chamber A inside the bladder is com-
pressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa (30
bar). When this happens, the bladder is ex-
panded by the pressure of the nitrogen gas in
chamber A, and the oil inside chamber B is
used as the pilot pressure to actuate the main
control valve.
10-174
BRAKE ACCUMULATOR UNIT

Ports:
T M22 x 1,5
P, VA, HA, PPC, Orbitrol M16 x 1,5
Me1, Me2 M14 x 1,5
Me3 G 1/4
max. flow 62 l/min
max. pressure 110 bar
Pressure regulating valve:

Switch on press. 70 +8 bar
Switch off press. 100 -8 bar
Outline
• The brake accumulator unit consists of the pressure
regulating valve, a hydraulic block, accumulators for
service brake and PPC circuit (emergency boom
lowering); a check valve for PPC pressure and a
hydraulic oil filter.
1. Decompression spindel
2. Decal
3. Strainer
J. Pressure regulating valve
10-175
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Differential housing 6. Axle housing

2. Piston 7. Sun gear shaft
3. Inner ring 8. Spring
4. Disc 9. Brake housing
5. Outer ring 10. Bearing carrier
Outline
• The brakes have a wet-type multi-disc struc- • Linings are provided on both sides of disc
ture, and consist of piston (2), inner ring (3), (4). The disc is incorporated between inner
disc (4), outer ring (5) and spring (8). ring (3) and outer ring (5), and is coupled by
• The brake cylinder consists of differential hous- the sun gear shaft's spline.
ing (1) and bearing carrier (10), and incorpo-
rates piston (2).
Inner ring (3) and outer ring (5) are coupled by
the brake housing (9) spline.
10-176
STRUCTURE AND FUNCTION BRAKE
Operation
When the brakes are activated
• When the brake pedal is pressed, the oil which
has passed from the hydraulic oil tank via the
pump through the accumulator charge valve acts
on the piston in the brake cylinder and piston
(2) slides.
• Therefore, disc (4), which is between inner ring
(3) and outer ring (5), stops rotating and the
machine is braked.
When the brakes are released

• When the oil pressure is released, piston (2)
returns to its original position by the return force
of spring (8), a gap is produced between inner
ring (3) and outer ring (5), and disc (4) is freed.
The linings attached to disc (4) are provided
with latticed grooves.
When the disc is turning, oil flows in these
grooves, cooling the linings.
10-177
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake lever and valve 3. Transmission (built in parking brake)

2. Transmission control valve 4. Parking brake emergency release
Outline
• The parking brake is a wet type multiple-disc brake • When the parking brake is applied, the neu-
built into the transmission. It is installed to the out- tralizer relay is switched on and the transmis-
put shaft bearing, and uses the pushing force of a sion control unit keeps the transmission in
spring to apply the brake mechaniclly and hydraulic neutral, but the last selected gear is still shown
power to release the brake. on the monitor display.
• When the parking brake lever (1) installed in the • Emergency release of the parking brake is
operator's compartment is switched ON, the parking possible. It can used when moving the ma-
brake valve shuts off the oil pressure to the parking chine if the machine has stopped because of
brake and the parking is applied. When the parking trouble in the engine or transmission unit. If
brake lever is switched OFF, the oil pressure flows the engine is OFF and the parking brake
to the parking brake cylinder and the parking brake accumulators are empty, the parking brake is
is released. locked by spring force.
10-178
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
1. Parking brake manual release bolt Outline

2. Piston • The parking brake is activated mechanically by
3. Spring spring (3). It is a wet-type multi-disc brake which
4. Transmission output shaft brakes the transmission's output shaft (4).
5. Disc • The pushing force of spring (3) pushes piston
6. Plate (2) against disc (5) and plate (6), braking output
7. Spring shaft (4).
10-179
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE VALVE

Function
• The parking brake valve is installed inside the
operators compartment, and controls the park-
ing brake cylinder.
Operation
1. Parking brake applied
• When the parking brake lever is put in the ON
position, the drain circuit is open. The oil from
the park brake cylinder then flows to the drain
circuit. Therefore, the parking brake is applied
by the force of the spring in the parking brake
cylinder.
2. Parking brake released

• When the parking brake lever is put in the OFF
position, the drain circuit is closed. The oil from
the pump flows to the brake cylinder, the spring
is compressed and the parking brake is re-
leased.
Park brake circuit
1 Transmission
2 Pump
3 Pressure control valve 27 bar
4 Park brake cylinder
5 Pressure switch
6 Park brake valve
7 Accumulator
8 Check valve
10-180
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
1. Bucket cylinder
2. Steering valve
3. Hydraulic tank
4. PPC valve
5. Hydraulic pump
6. Oil cooler
7. Accumulator
8. Accumulator
charge valve
9. Cut-off valve
10. Boom cylinder
11. Main control valve
Outline
• The hydraulic system consists of the work equip- • Control of the maximum pressure in the hydrau-
ment circuit and the steering circuit. The work lic circuit is carried out by the relief valve inside
equipment circuit controls the actuation of the the main control valve. A safety valve (with suc-
bucket and attachments. tion) is installed in the bucket cylinder circuit to
• The oil in hydraulic tank (3) is sent to main protect the circuit.
control valve (11) by hydraulic pump (5). If the • Accumulator (7) is installed in the PPC pilot
spools for the bucket and boom in the main circuit, and makes it possible to lower the boom
control valve are at the HOLD position, the oil to the ground even when the engine has stopped.
flows to the drain circuit of the main control • Hydraulic tank (3) is a pressurized sealed type
valve, is filtered by the filter inside the hydraulic and has a breather equipped with a relief valve.
tank (3), and then returns to the tank. This makes it possible to pressurize the inside
• When the work equipment control levers are of the tank and also to prevent any negative
operated, the PPC valve bucket spool or boom pressure, thereby preventing any cavitation of
spool is actuated, and the spools of the main the pump.
control valve are actuated by hydraulic pressure
to send the oil from the main control valve to
boom cylinder (10) or bucket cylinder (1) to
operate the boom or bucket.
10-201
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM

Up to Serial Number:
WA380H20383
10-202
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Filter
9. Accumulator charge valve
10. Accumulator
11. PPC valve
12. Steering valve (Orbit-roll)
13. Safety valve
14. Steering demand valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
14D. Safety and Suction valve
16. Cut-off valve
17A. Main relief valve
17B. Bucket spool
17C. Safety and suction valve
17D. Boom spool
17E. Suction valve
18. Boom cylinder
19. Bucket cylinder
20. Oil cooler
21. Safety valve
22. Float valve
23. Emergency steering pump
24. Divider valve
10-203
Serial Number:
WA380H20384 to
WA380H20500
10-204
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Safety valve
9. Brake circuit
11. Att. cylinder
13. Safety valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
15A. Safety relief valve
15B. PPC relief valve
16. Accumulator
17A. PPC valve
17B. PPC valve att. spool
18. Boom cylinder
19. Bucket cylinder
20B. Bucket spool
20D. Boom spool
20E. Suction valve
20F. Att. spool (option)
20G. Cut-off valve
21. Filter
23. Flow valve
24. Divider valve
25. Float valve
26. Oil cooler
10-205
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
WORK EQUIPMENT HYDRAULIC DIAGRAM WA380-3

From Serial Number: WA380H20501
up to Serial Number: WA380H20836
10-206

WORK EQUIPMENT HYDRAULIC DIAGRAM From Serial Number: WA380H20501

1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Safety valve
9. Brake circuit
11. Att. cylinder
13. Steering stop valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
16A. Accumulator brake
16B. Accumulator PPC
17A. PPC valve
18. Boom cylinder
19. Bucket cylinder
20B. Bucket spool
20D. Boom spool
20E. Suction valve
20G. Cut-off valve
21. Filter
23. Flow valve
24. Divider valve
25. Float valve
26. Oil cooler
10-207


19
11
18
ALS(Option)
20E
20C
20G
20A
20D
20B
20F
10
20
14
14D
17B
14B
14C
14A
13
9
17A
12
15
16A
16B
2
15B
15A
24
21
1
22A
4 5 6 7
22
23
10-208
WORK EQUIPMENT HYDRAULIC DIAGRAM

1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Oil cooler
9. Brake circuit
11. Att. cylinder (option)
14A. Demand spool
14B. Steering spool
14C. Relief valve
16A. Accumulator brake
16B. Accumulator PPC
17A. PPC valve
18. Boom cylinder
19. Bucket cylinder
20B. Bucket spool
20C. Safety and suction valve (option)
20D. Boom spool
20E. Suction valve
20G. Cut-off valve
21. Filter
10-209

11
19
18
ALS (Option)
20E
20C
20G
20A
20H
20 I
20D
20B
20F
10
14
9
14D
17B
14B
14C
14A
13
17A
12
15
16A
16B
2
15B
15A
21
24
1
22A
4 5 6 7
23
22
10-210

WORK EQUIPMENT DIAGRAM SN WA380H20987 and up
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC / Brake pump
8. Oil cooler
9. Brake circuit
11. Attachment cylinder (option)
14A. Demand spool
14B. Steering spool
14C. Relief valve
14D. Safety and suction valve
15B. Pressure relief valve
16A. Accumulator for brake
16B. Accumulator for PPC
17A. PPC valve
17B. PPC valve attachment spool
18. Boom cylinder
19. Bucket cylinder
20B. Bucket spool
20C. Safety and suction valve (option)
20D. Boom spool
20E. Suction valve
20F. Attachment spool (option)
20G. Cut-off valve
20H. Staudruckventil (10 bar)
20 I. 2-Stufen-Abschaltventil
21. Filter
10-211

STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. Boom lever 6. Solenoid valve for bucket lever

2. Kick-down switch 7. Solenoid valve for boom lever
3. Hold switch 8. Safety lever
4. Bucket lever 9. PPC valve
5. Attachment lever
10-212
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Breather
2. Filter bypass valve
3. Oil filler
4. Oil filter
5. Sight gauge
6. Hydraulic tank
Outline
• The oil sent to the cylinders from the hydraulic tank circuit. If the oil filter is clogged, the filter
via the pump and through the work equipment con- bypass valve is activated, preventing the oil
trol valve merges with the oil of the various parts in from returning directly to the tank and caus-
the return circuit. Some of this oil is cooled by the ing damage to the oil filter. In addition, the
oil cooler, flows into the tank, is filtered by oil filter filter bypass valve is also activated when a
(4), and returns to hydraulic tank (6). vacuum is generated in the circuit.
• Oil filter (4) is of a type which filters all the oil in the
10-213
STRUCTURE AND FUNCTION HYDRAULIC TANK
OIL FILTER BYPASS VALVE

When the filter is clogged
Bypass valve (1) opens and the oil returns directry
to the tank without passing through the filter.
Bypass valve set pressure: 0.125 MPa (1.27 bar)
When negative pressure is formed in the return

circuit.
Valve (2) moves up and acts check valve.
Check valve set pressure: 0.025 MPa (0.26 bar)
BREATHER
• Preventing negative pressure inside tank

The tank is a pressurized sealed type, so if the
oil level inside the hydraulic tank goes down,
there will be negative pressure in the tank. If
this happens, a poppet is opened by the differ-
ence between the pressure inside the tank and
the atmospheric pressure, and air is let in to
prevent negative pressure from forming inside
the tank.
• Preventing rise in pressure inside tank

If the pressure in the circuit rises above the set
pressure during operations because of the
change in the oil level in the hydraulic cylinders 1. Body
or the rise in the temperature, the sleeve is 2. Filter element
actuated to release the pressure inside the hy- 3. Poppet
draulic tank. 4. Sleeve
10-214
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
P. From PPC pump

P1. To bucket cylinder bottom end
P2. To boom cylinder head end
P3. To boom cylinder bottom end
P4. To bucket cylinder head end
T. Drain
10-215
1. Bolt
2. Piston
3. Plate
4. Collar
5. Retainer
6. Centering spring
7. Metering spring
8. Valve
9. Body
10-216
PPC VALVE
P. From PPC pump

P1. To bucket cylinder bottom end
P2. To boom cylinder head end
P3. To boom cylinder bottom end
P4. To bucket cylinder head end
T. Drain
For details, see PPC valce up to

SN WA380H20383
10-217
JOYSTICK, SERVO CONTROL VALVE

• Oil, from the brake/servo pump flows to the servo • All functions with detent holding magnets,
control valve connection P. The PPC-pressure re- (lift, tilt in and float) have detent balls (19)
lief valve, fitted into the brake unit, controls the as shown in the section drawing.
amount of PPC pressure.
Oil pressure is now available at all four servo oper-
ating pistons (16) to operate the main control
pistons through the connections 1 to 4.
• When the joystick (6) is in the neutral position the

connections 1 to 4 are connected through the drillings
in the servo pistons (16) to the return channel T.
This ensures that the control valves in the main
control valve block are also in the neutral position.
7
1. Lower
2. Tilt in
3. Lift
4. Tip out 8
5. Kick down switch
17
6. Joystick
9
7. Rubber cover
8. Universal joint 18
9. Rod with magnet 10
holding plate
10. Detent magnet for 19 11
connections 1 to 3
11. Rod pressure point 12
12. Pressure rod
13. Spring plate 13
14. Return spring
14
15. Control spring
16. Control piston 15
17. Rod
18. Rod guide
16
19. Detent ball 320_m c03
P. Servo oil pressure from the brake/servo pump
T. Oil return channel to the hydraulic tank
10-218

PPC VALVE (MULTIFUNCTION LEVER) / OPTION
1. Switch Forward-Neutral-Reverse
2
2. Switch Kickdown-Hold
Z
Z-Z
XMFS (Section 12 /Page 1 wiring diagram)

1. Forward
2. (+)
3. Neutral
4. Reverse
XL 204 (Section 25 /Page 1 wiring diagram)

5. Kickdown
6. (-)
7. Hold
10-219
OPERATION OF PPC VALVE

Function
• The oil from the pump enters port P. The circuit
is closed by spool (8), so the oil is drained from
relief valve (1).
At the same time, the oil at port PA1 of the main
control valve is drained from port f of spool (8).
In addition, the oil at port PB1 is drained from
port f of spool (8).
10-220

FUNCTION OF PPC VALVE Schematic sketch only!
The PPC valve supplies pressure oil from the charg-

ing pump to the side face of the spool of each
control valve according to the amount of travel of
the control lever.
This pressure oil actuates the spool.
Operation
1. Control lever at “hold” (Fig. 1)
Ports PA1, P4, PB1 and P1 are connected to
drain chamber D through fine control hole (f) in
valve (8).
2. Control lever operated slightly (fine control) (Fig.

2):
When piston (2) starts to be pushed by plate
(10), retainer (5) is pushed. Valve (8) is also
pushed by spring (7) and moves down.
When this happens, fine control hole (f) is shut
off from drain chamber D. At almost the same
time it is connected to pump pressure chamber
PP, and the pilot pressure of the control valve is
sent through fine control hole (f) to port P4.
When the pressure at port P4 rises, valve (8) is
pushed back. Fine control hole (f) is shut off
from pump pressure chamber PP. At almost the
same time it is connected to drain chamber D,
so the pressure at port P4 escapes to drain
chamber D.
Valve (8) moves up and down until the force of
spring (7) is balanced with the pressure of port
P4.
The position of valve (8) and body (9) (when
fine control hold (f) is midway between drain
chamber D and pump pressure chamber PP)
does not change until the head of valve (8)
contacts the bottom of piston (2).
Therefore, spring (7) is compressed in propor-
tion to the travel of the control lever, so the
pressure at port P4 also rises in proportion to
the travel of the control lever. The spool of the
control valve moves to a position where the
pressure of port PA1 (same as pressure at port
P4) and the force of the return spring of the
control valve are balanced.
10-221

3. Control lever moved back from slightly operated Schematic sketch only!
position to hold (Fine control) (Fig. 3):
When plate (10) starts to be pushed back, pis-
ton (2) is pushed up by a force corresponding
to the force of centering spring (6) and the pres-
sure at port P4.
At the same time, fine control hole (f) of valve
(8) is connected to drain chamber D, so the oil
at port P4 escapes.
If the pressure at port P4 drops too far, valve (8)
is pushed down by spring (7). Fine control hole
(f) is shut off from drain chamber D, and at
almost the same time it is connected to pump
pressure chamber PP. The pump pressure is
supplied until the pressure at port PA1 returns
to a pressure equivalent to the position of the
lever.
When the spool of the control valve returns, the
oil in drain chamber D flows in from fine control
hole (f’) of the valve which has not moved. The
extra oil then flows through port P1 to chamber
PB1.
4. Control lever operated to end of travel (Fig. 4):

Plate (10) pushes piston (2) down, and piston
(2) forcibly pushes in valve (8).
Fine control hole (f) is shut off from drain cham-
ber D, and is connected to pump pressure cham-
ber PP.
Therefore, pressure oil from the charging pump
passes through fine control hole (f), and flows
from port P4 to chamber PA1 to push the spool
of the control valve.
The oil returning from chamber PB1 flows from
port P1 through fine control hole (f’) to drain
chamber D.
10-222

STRUCTURE AND FUNCTION PPC RELIEF VALVE
PPC RELIEF VALVE

1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Function
• The PPC relief valve is between the PPC, brake
pump and the PPC valve. When the PPC pump
is not being actuated, or when any abnormal
pressure is generated, the oil sent from the
pump is relieved from this valve to prevent any
damage to the pump or circuit.
Operation
• The relief valve is installed to the charge valve.
Port A is connected to the pump circuit and port
C is connected to the drain circuit.
The oil passes through the orifice in main valve
(1) and fills port B.
In addition, pilot poppet (4) is seated in valve
seat (3).
• When the pressure at port A and port B reaches
the set pressure, pilot poppet (4) opens and the
oil pressure at port B escapes from port D to
port C to lower the pressure at port B.
• When the pressure at port B goes down, a
difference in pressure is generated at ports A
and B by the orifice of main valve (1). Main
valve (1) is opened by the pressure at port A
and the oil at port A is drained to port C to
relieve the circuit.
10-223
STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC VALVE)
ACCUMULATOR (FOR PPC VALVE)

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen gas
Gas amount: 500 cc
Max. actuation pressure: 3.4 MPa (35 bar)
Min. actuation pressure: 1.2 MPa (12 bar)
Function
• The accumulator is installed between the hy-
draulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under
their own weight by using the pressure of the
nitrogen gas compressed inside the accumula-
tor to send the pilot oil pressure to the main
control valve to actuate it.
Operation
• After the engine stops, if the PPC valve is at
hold, chamber A inside the bladder is com-
pressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa (30
bar). When this happens, the bladder is ex-
panded by the pressure of the nitrogen gas in
chamber A, and the oil inside chamber B is
used as the pilot pressure to actuate the main
control valve.
10-224
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE Up to Serial Number: WA380H20383

2-SPOOL
A. From work equipment pump G. To bucket cylinder bottom side

B. From switch pump (via steering valve) H. From PPC valve port P1
C. To bucket cylinder rod side I. From PPC valve port P3
D. To boom cylinder rod side J. From PPC valve port P4
E. Drain port (to tank) K. From PPC valve port P2
F. To boom cylinder bottom side
10-225
1. Cut-off valve assembly

2. Unload valve
3. Bucket spool
4. Boom spool
5. Check valve
6. Suction valve
7. Cut-off relief valve
8. Screen
9. Safety valve (with suction)
10. Check valve
10-226
3-SPOOL Up to Serial Number: WA380H20383
A. From switch pump (via steering valve) I. From work equipment pump
B. To attachment cylinder J. From attachment PPC valve
C. To bucket cylinder rod side K. From PPC valve port P1
D. To boom cylinder rod side L. From PPC valve port P3
E. Drain port (to tank) M. From attachment PPC valve
F. To boom cylinder bottom side N. From PPC valve port P4
G. To bucket cylinder bottom side O. From PPC valve port P2
H. To attachment cylinder
10-227
1. Cut-off valve assembly 5. Boom spool 9. Screen

2. Unload valve 6. Check valve 10. Safety valve (with suction)
3. Attachment spool 7. Suction valve 11. Check valve
4. Bucket spool 8. Cut-off relief valve 12. Main relief valve
10-228
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Function
The relief valve is installed to the inlet portion of
the main control valve. If the oil goes above the
set pressure, the relief valve drains the oil to
the tank to set the maximum pressure for the
work equipment circuit, and to protect the cir-
cuit.
Operation
• Port A is connected to the pump circuit and port
C is connected to the drain circuit. The oil passes
through the orifice in main valve (1), and fills port
B. Pilot poppet (3) is seated in valve seat (2).
• If the pressure inside ports A and B reaches the
set pressure of pilot poppet spring (4), pilot pop-
pet (3) opens and the oil pressure at port B es-
capes from port D to port C, so the pressure at
port B drops.
• When the pressure at port B drops, a difference
in pressure between ports A and B is created by
the orifice of main valve (1). The main valve is
pushed open and the oil at port A passes through
port C, and the abnormal pressure is released to
the drain circuit.
• The set pressure can be changed by adjusting
the tension of pilot poppet spring (4). To change
the set pressure, remove the cap nut, loosen the
locknut, then turn adjustment screw (5) to adjust
the set pressure as follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
10-229
SAFETY VALVE (WITH SUCTION)

1. Suction valve
2. Main valve
3. Pilot piston
4. Main valve spring
5. Suction valve spring
6. Valve body
Function
• The safety valve is in the bucket cylinder circuit
inside the main control valve. If any abnormal
pressure is generated by any shock to the cylin-
der when the main control valve is at the neu-
tral position, this valve relieves the abnormal
pressure to prevent damage to the cylinder.
Operation
Operation as safety valve
• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The oil
pressure at port A is sent to port D from the
hole in pilot piston (3). It is also sent to port C
by the orifice formed from main valve (2) and
pilot piston (3).
Pilot piston (3) is secured to the safety valve,
and the size of the cross-sectional surface
(cross-sectional area) has the following rela-
tionship: d2 > d1 > d3 > d4.
• If abnormal pressure is created at port A, suc-
tion valve (1) is not actuated because of rela-
tionship d2 > d1 >, but relationship between port
A and port C is d3 > d4, so main valve (2)
receives oil pressure equivalent to the differ-
ence between the areas of d3 and d4. If the
oil pressure reaches the force (set pressure) of
main valve spring (4), main valve (2) is actu-
ated, and the oil from port A flows to port B.
10-230
Operation as suction valve

• If any negative pressure is generated at port A,
port D is connected with port A, so there is also
negative pressure at port D. The tank pressure
of port B is applied to port E, so the suction
valve (1) receives oil pressure a, which is equal
to the difference in the area of d2 and d1 be-
cause of the tank pressure at port E. Therefore,
oil pressure e moves the valve in the direction
of opening, and oil pressure a acts to move
suction valve (1) in the direction of closing.
When the pressure at port A drops (and comes
close to negative pressure), it becomes lower
than hydraulic pressure e. The relationship be-
comes oil pressure e > oil pressure a + force of
valve spring (5), and suction valve (1) opens to
let the oil from port B flow into port A and pre-
vent any negative pressure from forming at port
A.
SUCTION VALVE
1. Main poppet
Up to Serial Number: WA380H20383 2. Sleeve
3. Spring
Function
• This valve acts to prevent any negative pres-
sure from forming in the circuit.
Operation
• If any negative pressure is generated at port A
(boom cylinder rod end) (when a pressure lower
than tank circuit port B is generated), main pop-
pet (1) is opened because of the difference in
area between d1 and d2, and oil flows from port
B at the tank end to port A at the cylinder port
end.
10-231
MAIN CONTROL VALVE From Serial Number: WA380H20384

2-SPOOL
A. From work equipment pump 1. Checkpoint cut-off pressure (M10x1)

B. From switch pump (via steering valve) 2. Cut-off pressure valve
C. To bucket cylinder rod side 3. Main relief valve
D. To boom cylinder rod side 4. To safety valve
E. Drain port (to tank)
G. To bucket cylinder bottom side
H. From PPC valve port P1
I. From PPC valve port P3
J. From PPC valve port P4
K. From PPC valve port P2
10-232

MAIN CONTROL VALVE

2-SPOOL
1. Boom spool
2. Bucket spool
4. Safety valve (with suction)
5. Check valve
10-233
SAFETY VALVE WITH SUCTION
Mounted in the lift, tip-in, tip-out circuits
Operation:
• The safety valve (with suction) is mounted in the
main hydraulic-control-valve between port (A), con-
nected with the cylinder and port (B) connected to
the oil return line. If the control-spool is in the
neutral position and shook action on the cylinder
causes the pressure to rise above the normal work-
ing pressure, the valve (5) will open and protect the
cylinder and pipes.
• If there is cavitation at port (A), channel connected

to lift-cylinder, piston-rod side, the valve (2) will
open and oil flows from port (B), connection to the
oil return line, to (A). this prevents cavitation taking
place in the cylinders. When there is cavitation at
(A) then the pressure at port (A) is lower than at
port (B).
1. Adjusting screw
2. Pilot valve housing, torque 85 Nm
3. Valve housing, torque 95 Nm
4. Pilot valve
5. Shock valve
6. Pilot spool
7. Lock nut, torque 30 Nm
8. Pilot valve spring
9. Shock and anticavitation valve spring
10. O-ring
11. Seal ring
12. Seal ring
13. Seal ring
14. Anticavitation valve
A. Connection to the cylinder
B. Connection to the oil return piping
10-234
ANTICAVITATION VALVE
• Mounted in the boom lowering circuit
Operation:
• If there is cavitation at (A), channel connected to

lift cylinder, piston-rod side, the valve (2) will open
and oil flows from (B), connection to the oil return
line, to (A).
When there is cavitation at (A) then the pressure at
(A) is lower than at (B).
1. Valve housing, torque 95 Nm

2. Anticavitation valve
3. Valve spring
4. Seal ring
5. O-ring
6. End cap, torque 85 Nm
7. O-ring
A. Lift cylinder connection, piston rod side
B. Oil return line to the hydraulic tank
SAFETY VALVE
(PILOT REDUCING VALVE)
1. Lock nut
2. Adjusting screw
3. Threaded hole
4. Spring
5. Pilot reducing valve
6. Valve seat
7. Spring
8. Valve piston
10-235
MAIN CONTROL VALVE

2-SPOOL
K
I
J H
C
A
B
3 1 4

10-236

MAIN CONTROL VALVE

3-SPOOL
K
I
J H
C
A
B
3 1 4

10-237

OPERATION OF CUT-OFF VALVE

Function
• The cut-off valve is mounted between the switch
pump and work equipment valve. It switches the
oil flow from the switch pump between the work-
ing equipment valve and the drain, according to
operating conditions, and controls the speed of
the work equipment.
• Cut-off operation conditions

0: Cut-off (drain)
x: Not actuated (to main control valve)
More Less
– than than
160 bar 160 bar
Standard
Specification – 0 x
Machine
Operation
1. When the work equipment valve is held
The oil at the switch pump (the oil from the
steering valve) presses up check valve (1),
merges with the oil from the work equipment
pump and flows to the work equipment valve.
2. When the work equipment valve is activated

1) When the work equipment pump pres-
sure is lower than the cut-off pressure
As when the work equipment valve is
held, the oil at the switch pump (the oil
from the steering valve) presses up check
valve (1), merges with the oil from the
work equipment pump and flows to the
work equipment valve.
10-238
2) When the work equipment pump pres-

sure is higher than the cut-off pressure
When the cut-off pressure is reached, the
pressure of the oil in chamber a opens cut-
off valve (2), and the oil in unload valve (3)
chamber b passes through cut-off valve (2)
chamber c and is drained. The oil in unload
valve (3) chamber d passes through ori-
fices e and f, and into chamber b causing
the oil pressure in chamber d decrease,
and unload valve (3) to open. Thus, the oil
from the switch pump is drained.
10-239
WORK EQUIPMENT VALVE OPERATION

BOOM AND BUCKET SPOOL HOLD POSITION
Schematic sketch:
Operation
• The oil from the switch pump which has passed port B passes around the spool and returns to
through the cut-off valve and the work equip- the tank from the drain circuit.
ment pump's oil enter port A and the maximum • The oil from the PPC pump enters PPC valve
pressure is regulated by relief valve (1). port L, but since the boom and bucket levers
• Since the bucket spool (2) is at the neutral po- are at the neutral position, the oil returns to the
sition, the bypass circuit is open, and the oil at tank from the PPC relief valve.
port A passes around the spool and flows to
port B. The boom (3) spool is also at the neutral
position, so the bypass circuit is open, the oil at
10-240

BOOM SPOOL AT RAISE POSITION

Schematic sketch:
Operation
• When boom lever (4) is pulled, oil flows from boom spool (3) bypass circuit. The bypass cir-
PPC valve port L to port N and port S. The oil at cuit is closed by boom spool (3), so the oil
port T passes through port M and flows to the pushes open check valve (5). The oil from check
drain circuit. The oil pressure at port S presses valve (5) flows to port D and to the cylinder
boom spool (3) and sets it to the RAISE posi- bottom side.
tion. • The oil on the cylinder rod side enters drain port
• The oil from the pump passes through the F from port E and returns to the tank, causing
bucket spool (2) bypass circuit and flows to the the boom to raise.
10-241

BOOM SPOOL AT LOWER POSITION

Schematic sketch:
Operation
• When boom lever (4) is pushed, oil flows from cuit is closed by boom spool (3), so the oil
PPC valve port L to port M and port T, and the pushes open check valve (5). The oil from
oil at port S flows to the drain circuit. The oil check valve (5) flows to port E and to the
pressure at port T pushes boom spool (3) and cylinder rod side.
sets it to the LOWER position. • The oil on the cylinder bottom side enters
• The oil from the pump passes through the drain port F from port D and returns to the
bucket spool (2) bypass circuit and flows to the tank, causing the boom to lower.
boom spool (3) bypass circuit. The bypass cir-
10-242

BOOM SPOOL AT FLOAT POSITION

Schematic sketch:
Operation
• When boom lever (4) is pressed in further from pushed open. In addition, boom cylinder raise
the LOWER position (to the FLOAT position), circuit D and lower circuit E are both connected
boom spool (3) moves further from the LOWER to the drain circuit, so the boom lowers under
position and is set to the FLOAT position. its own weight.
• The oil from the pump passes through the • When the bucket is touching the ground, it can
bucket spool (2) bypass circuit and flows to the move up and down in accordance with the
boom spool (3) bypass circuit. Boom spool (3) ground surface contour.
causes the oil in the bypass circuit to flow to the
drain circuit, so the check valve (5) cannot be
10-243

BUCKET SPOOL AT TILT POSITION

Schematic sketch:
Operation
• When bucket lever (6) is pulled, the oil pres- • The oil from port A passes from check valve (7)
sure at PPC valve port L is released from port through port G and to the bottom side of the
P to port R, and the oil at port V flows to the bucket cylinder.
drain circuit. The oil pressure at port R sets • The oil on the bucket cylinder's rod side flows
bucket spool (2) to the TILT position. from port H to drain port F and returns to the
• Since the bypass circuit is closed by bucket tank, causing the bucket to tilt.
spool (2), the oil at port A pushes open check
valve (7).
10-244

BUCKET SPOOL AT DUMP POSITION

Schematic sketch:
Operation
• When bucket lever (6) is pushed, the oil pres- the bucket cylinder.
sure at PPC valve port L is released from port • The oil on the bucket cylinder's bottom side
Q to port V, and the oil at port R flows to the flows from port G to drain port F and returns to
drain circuit. The oil pressure at port V sets the tank, causing the bucket to dump.
bucket spool (2) to the DUMP position.
• Since the bypass circuit is closed by bucket
spool (2), the oil at port A pushes open check
valve (7). The oil from port A passes from check
valve (7) through port H and to the rod side of
10-245

AUFBAU UND FUNKTION HYDRAULIC SAFETY SYSTEM
HYDRAULIC SAFETY SYSTEM

1. Description:
• All the WA - 3 type machines have a hydraulic system

fitted. It consists of:
A float valve (2) in the hydraulic tank (1), a restricted
pressure connection (3) in the steering or switch pump
hydraulic system and a safety valve (5).
The system ensures that a minimum amount of hydrau-
lic oil is always available for emergency steering if
there is a sudden loss of hydraulic oil, respectivly that
the oil from the work equipment can return to the
hydraulic tank.
2. Operation:
2.1 Normal condition with the engine running and correct

hydraulic oil level.
• A restricted amount of oil, under pressure, is taken

from the connection (3) in the steering or switch pump
system and is directed through a pilot pipe (4) to the
float valve (2) in the hydraulic tank (1).
This oil , which is under pressure is also available at
the safety valve (5). The safety valve is now held open
against spring pressure. Hydraulic oil can flow in the
pressure pipe (6) from the main pumps to the main
control valve in the working hydraulic system.
2.2 Emergency situation:
• This occurs when a steering pump / switch pump or

the engine breaks down, or there is a hydraulic oil leak
and the oil level in the hydraulic tank drops to a
minimum.
Pressure in the pipe (4) drops, because the float valve
opens when the oil level in the hydraulic tank drops or
the pumps or the engine are not running. Because of
the drop in pressure in the pilot pipe (4) the safety
valve (5) switches over and the hydraulic oil is directed
through the safety valve, through the return pipe (7)
back to the hydraulic tank.
10-246

HYDRAULIC SAFETY SYSTEM LOCATION


Ports can be in different places!
1. Hydraulic oil tank 5. Safety valve

2. Float valve 6. Main working hydraulic pipe
3. Restricted connection 7. Oil return pipe
4. Pilot pipe 8. Switch pump pressure pipe
10-247

HYDRAULIC SAFETY VALVE

1. Housing
2. Valve piston
3. Spring
Function:
• If a leak occurs between the safety valve and one
of the working cylinders in one of the pipes or the
main hydraulic valve, the safety valve directs the
main oil flow back to the hydraulic tank.
If the oil level in the hydraulic tank drops to a
minimum, so that the float valve opens, the safety
valve directs the oil flow from the main working
circuit back to the hydraulic tank.
Float valve
10-248

STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
1. Bellcrank 4. Boom
2. Bucket cylinder 5. Bucket link
3. Boom cylinder 6. Bucket
10-261
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
10-262
STRUCTURE AND FUNCTION BUCKET
BUCKET
1. Bucket (3.1m3)
2. Bolt-on cutting edge
3. Plate
10-263
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
1. Proximity switch
2. Plate
3. Bucket cylinder rod
4. Lever
5. Proximity switch
10-264
BUCKET POSITIONER
• The bucket positioner is an electrically actuated
system which is used to set the bucket to the
desired angle when the bucket is moved from
the DUMP position to the TILT position. When
the bucket reaches the desired position, the
bucket lever is returned from the TILT position
to the HOLD position, and the bucket is auto-
matically set to the suitable digging angle.
• Lever (4) is secured to bucket cylinder rod (3)
by bolts. In addition, proximity switch (5) fixed
to the cylinder by bolts.
• When the bucket is moved from the DUMP
position to the TILT position, the bucket cylinder
rod moves to the left, and at the same time,
lever (4) also moves to the left. Proximity switch
(5) separates from lever (4) at the desired posi-
tion, and the bucket lever is returned to neutral.
BOOM KICK-OUT
• The boom kick-out is an electrically actuated
system. It acts to move the boom lever to the
HOLD position and stop the boom at the de-
sired position before the boom reaches the maxi-
mum height.
• Plate (2) is fixed to the boom. In addition, prox-
imity switch (1) is fixed to the frame.
When the boom is moved from the LOWER
position to the RAISE position, the boom rises,
and when it reaches the desired position, the
proximity switch and lever come together and
the system is actuated to return the boom lever
to the HOLD position.
10-265
Operation of proximity switch
Boom RAISE
• When the boom is lower than the set position
for the kick-out, the detector (steel plate) is not
above the detection surface of the proximity
switch, so the proximity switch load circuit is
shut off.
The relay switch is turned OFF and the current
for the solenoid is shut off.
• When the boom lever is moved to the RAISE

position, the boom spool is held at the RAISE
position by the cam follower and cam on the
lever, and the boom rises.
10-266
• When the boom rises and reaches the set posi-

tion for the kick-out, in other words, the detector
(steel plate) is in position on the detection sur-
face of the proximity switch, an electric current
is sent to the solenoid by the action of the prox-
imity switch and relay circuit. As a result, the
solenoid is actuated, and the cam is pulled away
from the cam detent, so the boom spool is re-
turned to the HOLD position by the return spring.
Action of proximity switch
When detector is in position When detector is separated

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

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

(solenoid circuit)
10-267
Operation of proximity switch

Bucket TILT
• When the bucket is lower than the set position
for the auto-leveler, the detector (steel plate) is
not above the detection surface of the bucket
proximity switch, so electric current flows in the
proximity switch load circuit. The relay switch is
turned OFF and the current for the solenoid is
shut off.
• When the bucket lever is moved to the TILT

position, the bucket spool is held at the TILT
position by the cam follower and cam on the
lever, and the bucket tilts.
10-268
• When the bucket tilts and reaches the set posi-

tion for the bucket leveler, in other words, the
detector (steel plate) separates from the detec-
tion surface of the proximity switch, electric cur-
rent is sent to the solenoid by the action of the
proximity switch and relay circuit.
As a result, the solenoid is actuated, and the
cam is pulled away from the cam detent, so the
bucket spool is returned to the HOLD position
by the return spring.
Action of proximity switch
When detector is in position When detector is separated

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

(relay switch circuit)
Relay switch load circuit

Current is shut off Current flows
(solenoid circuit)
10-269
STRUCTURE AND FUNCTION CAB
10-270
STRUCTURE AND FUNCTION WIRING DIAGRAMS
Throw this page out and

insert foldout from appendix.
(compare page number)
10-273

10-275

10-277

10-279
Wiring Diagrams
From SN WA380H20501
up to SN WA380H20836
10-281/1

WA380-3 Wiring diagram

active Fig. 1
Sect. Sect.
20 STDSW Switch emergency contr. transm. 109 K 385 Relay back-up alarm
6 S 43 Starting switch 21 KTDR 1 Relay emergen. contr. transm. 1
10 S 58 Battery main switch 16 KTDR 2 Relay emergen. contr. transm. 2
14 S 127 Switch parking brake 25 XOP 6 Option 20 km/h
23 S 260.1 Switch transmission cut-off 27 XOP 7 Option automatic "OFF"
24 S 260.2 Footswitch transmission cut-off 26 XRPM Option engine rpm
12 S 261 Switch gear selection 6 G 10 Generator
25 S 417.1 Kick-down switch 10 G 57 Battery
25 S 417.2 Hold switch 8 M9 Starting motor
22 A1 Transmission controller 4 H 76 Lamp pre-heating
28 P 384 Speed display 14 H 126 Lamp parking brake
18 P 425 Gear display 23 H 260 Lamp transmission cut-off
3 P 426 Main monitor 24 YH Solenoid High
3 R 12 Flame plug 23 YS Solenoid Speed
V Diode 20 YM Solenoid Modulation
V 118 Diode 5 x 16 Y 236 Solenoid Forward
7 K 106 Relay battery 18 Y 237 Solenoid Reverse
9 K158 Relay starting motor 3 Y 320 Solenoid engine stop
1 K 167 Time relay for Y 320 28 B2 Sender speed
6 K 208 Relay neutral position 26 B 228 Engine rpm sender
2 K 282 Relay pre-heating 4 B 14 Temp. sender pre-heating
2 K 283 Relay pre-heating 66 B 398 Sender engine oil
14 K 200 Relay parking brake 11 S 439 Switch drive direction
Connectors
XL Connector platform XT Connector transmission
XC Connector cab XR Connector rear frame
XF Connector front frame X FS Connector fuses
XM Connector engine
Fuses
F... Fuse
380EL1.tbl
10-281/2

10-281/3


10-281/4


active Fig. 2
Sect. Sect.
44 S8 Horn switch 55 H 100.2 Lamp lamp working light
48 S 51.1 Switch working light front 34 H 318 Lamp ALS
52 S 51.2 Switch working light rear 38 M7 Front wiper motor
31 S 117.1 Proximity switch lift cut-off 41 M 182.1 Front washer motor
30 S 117.2 Proximity switch return to dig 43 M 182.2 Rear washer motor
34 S 316 Switch ALS 40 M 248 Rear wiper motor
38 S 331.3 Switch front wiper / washer 49 E3 Working lamp front left
40 S 331.4 Switch rear wiper / washer 50 E4 Working lamp front tright
29 Y 214 Detent magnet Float 53 E 60 Working lamp rear left
32 Y 217 Detent magnet Lift 54 E 61 Working lamp rear right
34,36 Y 315... Solenoid ALS
45 B 8.1 Horn left
46 B 8.2 Horn right
46 K8 Relay Horn
32 K 139 Relay lift cut-off
30 K 209 Relay return to dig
42 K 337 Relay wiper interval
49 K 432 Relay front working light
53 K 433 Relay rear working light
V 118... Diode 5 x
X ALS Option ALS
51 H 100.1 Lamp front working light
Connectors
XL Connector platform XR Connector transmission
XC Connector cab XK Connector air-conditioner
XM Connector engine XH Connector engine hood
Fuses
F... Main fuse electric
380EL2.tbl
10-281/5

active Fig. 3
Sect. Sect.
60 B 13 Sender engine water temp. 65 H 30 Lamp engine oil press.
65 B 19 Sender engine oil pressure 58 H 98 Lamp fuel level
63 B 255 Sender engine water level 61 H 109 Lamp T/C temp.
68 B 262 Sender air filter control 78 H 111 Lamp steering oil press.
62 B 304 Sender brake pressure 60 H 170 Lamp engine water temp.
79 B 305 Flow indicator emergen. steering 63 H 259 Lamp engine water level
78 B 307 Sender air pressure 69 H 263 Lamp air filter
61 B 323 Sender T/C temp. 62 H 288 Lamp brake press.
72 B 335 Warner Sub-, Main Monitor 79 H 306 Lamp emergency steering
66 B 398 Sender engine oil level 80 H 334.1 Central warning lamp
58 R 97 Sender fuel level 81 H 334.2 Central check lamp
70 G 10 Generator 66 H 399 Lampe engine oil level
64 K 19.1 Relay engine oil level
66 K 262.1 Relay air filter control
76 E 35.1 Lumination Main Monitor
75 E 35.2 Lumination Sub Monitor
74 P 21 Working hour gauge
59 P 25 Engine water temp. gauge
61 P 26 T/C oil temp. gauge
58 P 96 Fuel level gauge
76 P 426 Main Monitor
75 P 427 Sub Monitor
70 H 28 Lamp Generator
Connectors
XL Connector platform X TL Connector transmission
XM Connector engine
Fuses
F... Fuse
380EL3.tbl
10-281/6

10-281/7


10-281/8


active Fig. 4
Sect. Sect.
105 S 70 Switch brake light 85 E 243 Turning signal left
87 S 101 Switch waring lamp 91 E 244 Turning signal right
99 S 331.1 Switch headlights 96 K 67.1 Indicator relay 2+1
87 S 331.2 Switch turning signal 94 K 67.2 Indicator relay 3+1
110 B 279 Horn back off alarm 93 K 101 Relay waring lamp
V 118.. Diode 91,93 K 163... Relay turning signal
100 H 29 Lamp main head light 109 K 385 Relay back off alarm
89 H 31.1 Lamp turning signal right
86 H 31.2 Lamp turning signal left
94 E1 Headlight left
97 E2 Headlight right
85 E5 Turning signal front left
91 E6 Turning signal front right
101 E 68.1 Rear light left
100 E 69.1 Rear light right
86 E 68.2 Turning signal rear left
89 E 69.2 Turning signal rear right
105 E 68.3 Brake light left
106 E 69.3 Brake light right
108 E 68.4 Reversing light left
109 E 69.4 Reversing light right
103 E 71 Number plate light left
104 E 72 Number plate light right
Connectors
XC Connector cab
Fuses
F... Fuse
380EL4.tbl
10-281/9

active Fig. 5
Sect. Sect.
116 S 195 Switch rotating warning light
121 M 405 Motor pump centr. grasing
121 A 407 Controller centr. grasing
115 R 246 Cigarette lighter
113 E 123 Cab light
116 E 130 Rotating warning light
119 T 250 Transformer 24V-12V
119 A 249 Casette radio
118 W 309 Ariel with booster
118 B 245.1 Speaker, left
119 B 245.2 Speaker, right
Connectors
XC Connector cab XR Connector raer frame
X GR Connector back off alarm X RA Connector radio
XM Connector engine X LGRE Connector centr. grasing
X LOP Connector options
Fuses
F... Fuse
380EL5.tbl
Wiring colour
Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour
W ws white G gn green Gr gr gray Ch an anthrazit
B sw black L bl blue P rs pink O or orange
R rt red Br br brown Sb hbl light blue V vi violett
Y ge yellow Lg hgn light green Dg dgn dark green
270EL6.tbl
10-281/10

10-281/11


10-281/12

Wiring Diagrams
From SN WA380H20837
10-282/1

active Fig. 1
Sect. Sect.
20 STDSW Switch emergency contr. transm. 14 K 200 Relay parking brake
6 S 43 Starting switch 109 K 385 Relay back-up alarm
10 S 58 Battery main switch 21 KTDR 1 Relay emergen. contr. transm. 1
14 S 127 Switch parking brake 16 KTDR 2 Relay emergen. contr. transm. 2
22 S 260.1 Switch transmission cut-off 25 XOP 6 Option 20 km/h
23 S 260.2 Footswitch transmission cut-off 27 XOP 7 Option automatic "OFF"
12 S 261 Switch gear selection 26 XRPM Option engine rpm
25 S 417.1 Kick-down switch 6 G 10 Generator
25 S 417.2 Hold switch 10 G 57 Battery
11 S 439 Switch drive direction 8 M9 Starting motor
22 A1 Transmission controller 4 H 76 Lamp pre-heating
28 P 384 Speed display 14 H 126 Lamp parking brake
18 P 425 Gear display 23 H 260 Lamp transmission cut-off
3 P 426 Main monitor 24 YH Solenoid High
3 R 12 Flame plug 23 YS Solenoid Speed
V Diode 20 YM Solenoid Modulation
V 118 Diode 5 x 16 Y 236 Solenoid Forward
7 K 106 Relay battery 17 Y 237 Solenoid Reverse
9 K 158 Relay starting motor 3 Y 320 Solenoid engine stop
1 K 167 Time relay for Y 320 26 B2 Sender speed
6 K 208 Relay neutral position 28 B 228 Engine rpm sender
2 K 282 Relay pre-heating 4 B 14 Temp. sender pre-heating
2 K 283 Relay pre-heating 65 B 398 Sender engine oil
Connectors
XM Connector engine
Fuses
F... Fuse
380EL1a.tbl
10-282/2


10-282/3

10-282/4

active Fig. 2
Sect. Sect.
44 S8 Horn switch 55 H 100.2 Lamp lamp working light
48 S 51.1 Switch working light front 34 H 318 Lamp ALS
52 S 51.2 Switch working light rear 38 M7 Front wiper motor
31 S 117.1 Proximity switch lift cut-off 41 M 182.1 Front washer motor
30 S 117.2 Proximity switch return to dig 43 M 182.2 Rear washer motor
34 S 316 Switch ALS 40 M 248 Rear wiper motor
38 S 331.3 Switch front wiper / washer 49 E3 Working lamp front left
40 S 331.4 Switch rear wiper / washer 50 E4 Working lamp front tright
29 Y 214 Detent magnet Float 53 E 60 Working lamp rear left
32 Y 217 Detent magnet Lift 54 E 61 Working lamp rear right
34,36 Y 315... Solenoid ALS
45 B 8.1 Horn left
46 B 8.2 Horn right
46 K8 Relay Horn
32 K 139 Relay lift cut-off
42 K 337 Relay wiper interval
49 K 432 Relay front working light
53 K 433 Relay rear working light
V 118... Diode 5 x
X ALS Option ALS
51 H 100.1 Lamp front working light
Connectors
Fuses
380EL2.tbl
10-282/5


active Fig. 3
Sect. Sect.
60 B 13 Sender engine water temp. 59 P 25 Engine water temp. gauge
65 B 19 Sender engine oil pressure 61 P 26 T/C oil temp. gauge
63 B 255 Sender engine water level 58 P 96 Fuel level gauge
68 B 262 Sender air filter control 77 P 426 Main Monitor
62 B 304 Sender brake pressure 73 P 427 Sub Monitor
Sender emergen. steering pump
79 B 305 70 H 28 Lamp Generator
pressure
78 B 307 Sender air pressure 65 H 30 Lamp engine oil press.
61 B 323 Sender T/C temp. 58 H 98 Lamp fuel level
72 B 335 Warner Sub-, Main Monitor 61 H 109 Lamp T/C temp.
66 B 398 Sender engine oil level 78 H 111 Lamp steering oil press.
58 R 97 Sender fuel level 60 H 170 Lamp engine water temp.
74 M160 Emergency steering pump 63 H 259 Lamp engine water level
70 G 10 Generator 69 H 263 Lamp air filter
64 K 19 Relay engine oil level 62 H 288 Lamp brake press.
Time relay for test emergency
75 K 159 79 H 306 Lamp emergency steering
steering pump
74,75 K 161... Relay emergency steering pump 80 H 334.1 Central warning lamp
66 K 262 Relay air filter control 81 H 334.2 Central check lamp
73 K 414 Rpm sensor emerg. steerg. pump 66 H 399 Lampe engine oil level
Plug for taster test emergency
76 E 35.1 Lumination Main Monitor 76 S 109
steering pump
75 E 35.2 Lumination Sub Monitor
74 P 21 Working hour gauge
Connectors
XM Connector engine
Fuses
F... Fuse
380EL3a.tbl
10-282/6


10-282/7

10-282/8

active Fig. 4
Sect. Sect.
99 S 331.1 Switch headlights 91 K 67 Indicator relay
87 S 331.2 Switch turning signal 93 K 101 Relay waring lamp
110 B 279 Horn back off alarm 104 K 165 Relay brake light
V 118.. Diode 109 K 385 Relay back off alarm
100 H 29 Lamp main head light 15 KTDR2 Relay gear box emerg. control
Connectors
XC Connector cab
Fuses
F... Fuse
380EL4a.tbl
10-282/9


active Fig. 5
Sect. Sect.
113 E 123 Cab light
Connectors
Fuses
F... Fuse
380EL5.tbl
Wiring colour
270EL6.tbl
10-282/10

10-282/11

10-282/12
Wiring Diagrams
10-283/1


active plus Fig. 1
Sect. Sect.
20 STDSW Switch emergency contr. transm. 2 K 283 Relay pre-heating
6 S 43 Starting switch 14 K 200 Relay parking brake
10 S 58 Battery main switch 109 K 385 Relay back-up alarm
14 S 127 Switch parking brake 21 KTDR 1 Relay emergen. contr. transm. 1
22 S 260.1 Switch transmission cut-off 16 KTDR 2 Relay emergen. contr. transm. 2
23 S 260.2 Footswitch transmission cut-off 25 XOP 6 Option 20 km/h
12 S 261 Switch gear selection 26 XRPM Option engine rpm
25 S 417.1 Kick-down switch 6 G 10 Generator
25 S 417.2 Hold switch 10 G 57 Battery
11 S 439 Switch drive direction 8 M9 Starting motor
26 SOP 7 Auto shift transm. pilot switch 4 H 76 Lamp pre-heating
22 A1 Transmission controller 14 H 126 Lamp parking brake
28 P 384 Speed display 23 H 260 Lamp transmission cut-off
18 P 425 Gear display 24 YH Solenoid High
3 P 426 Main monitor 23 YS Solenoid Speed
3 R 12 Flame plug 20 YM Solenoid Modulation
27 RES 1 Resistor manual shift 16 Y 236 Solenoid Forward
V Diode 17 Y 237 Solenoid Reverse
V 118 Diode 5 x 3 Y 320 Solenoid engine stop
7 K 106 Relay battery 26 B2 Sender speed
9 K 158 Relay starting motor 28 B 228 Engine rpm sender
1 K 167 Time relay for Y 320 4 B 14 Temp. sender pre-heating
6 K 208 Relay neutral position 65 B 398 Sender engine oil
2 K 282 Relay pre-heating
Connectors
XM Connector engine
Fuses
F... Fuse
380EL1b.tbl
10-283/2


10-283/3


10-283/4


active plus Fig. 2
Sect. Sect.
45 S8 Horn switch 43 K 337 Relay wiper interval
48 S 51.1 Switch working light front 49 K 432 Relay front working light
52 S 51.2 Switch working light rear 53 K 433 Relay rear working light
31 S 117.1 Proximity switch lift cut-off V 118... Diode 5 x
30 S 117.2 Proximity switch return to dig X ALS Option ALS
34 S 316 Switch ALS 51 H 100.1 Lamp front working light
38 S 331.3 Switch front wiper / washer 55 H 100.2 Lamp lamp working light
40 S 331.4 Switch rear wiper / washer 34 H 318 Lamp ALS
33 Y 213 Detent magnet Float 39 M 7 Front wiper motor
29 Y 214 Detent magnet Tilt 42 M 182.1 Front washer motor
32 Y 217 Detent magnet Lift 43 M 182.2 Rear washer motor
34,36 Y 315... Solenoid ALS 40 M 248 Rear wiper motor
46 B 8.1 Horn left 49 E 3 Working lamp front left
47 B 8.2 Horn right 50 E 4 Working lamp front tright
46 K8 Relay Horn 53 E 60 Working lamp rear left
32 K 139 Relay lift cut-off 54 E 61 Working lamp rear right
Connectors
Fuses
380EL2b.tbl
10-283/5


active plus Fig. 3
Sect. Sect.
59 B 13 Sender engine water temp. 77 P 426 Main Monitor
64 B 19 Sender engine oil pressure 73 P 427 Sub Monitor
63 B 255 Sender engine water level 74 M 160 Emergency steering pump
66 B 262 Sender air filter control 68 G 10 Generator
62 B 304 Sender brake pressure 68 H 28 Lamp Generator
Sender emergen. steering pump
78 B 305 64 H 30 Lamp engine oil press.
pressure
77 B 307 Sender air pressure 58 H 98 Lamp fuel level
60 B 323 Sender T/C temp. 60 H 109 Lamp T/C temp.
70 B 335 Warner Sub-, Main Monitor 77 H 111 Lamp steering oil press.
65 B 398 Sender engine oil level 59 H 170 Lamp engine water temp.
58 R 97 Sender fuel level 63 H 259 Lamp engine water level
64 K 19 Relay engine oil level 67 H 263 Lamp air filter
Time relay for test emergency
74 K 159 62 H 288 Lamp brake press.
steering pump
74,75 K 161... Relay emergency steering pump 78 H 306 Lamp emergency steering
73 K 208 Relay neutral position 81 H 334.1 Central warning lamp
66 K 262 Relay air filter control 82 H 334.2 Central check lamp
73 K 414 Rpm sensor emerg. steerg. pump 65 H 399 Lamp engine oil level
72 P 21 Working hour gauge 79 E 35.1 Lumination Main Monitor
59 P 25 Engine water temp. gauge 73 E 35.2 Lumination Sub Monitor
Plug for taster test emergency
60 P 26 T/C oil temp. gauge 76 S 109
steering pump
58 P 96 Fuel level gauge V 118... Diode
Connectors
XM Connector engine
Fuses
F... Fuse
380EL3b.tbl
10-283/6


10-283/7


10-283/8


active plus Fig. 4
Sect. Sect.
99 S 331.1 Switch headlights 91 K 67 Indicator relay
87 S 331.2 Switch turning signal 93 K 101 Relay waring lamp
110 B 279 Horn back off alarm 104 K 165 Relay brake light
V ... Diode 109 K 385 Relay back off alarm
101 H 29 Lamp main head light 15 KTDR2 Relay gear box emerg. control
Connectors
XC Connector cab
Fuses
F... Fuse
380EL4b.tbl
10-283/9


active plus Fig. 5
Sect. Sect.
116 K 442 Relay accelerator pedal
117 K 443 Relay work mode
115 Y 218 Way valve
119 Y 442 Solenoid accelerator
115 A1 Transmission controller
116 HS Lamp Standard mode
117 HH Lamp High mode
118 HE Lamp Economy mode
122 H 195 Lamp rotating warning light
113 E 123 Cab light
Connectors
Fuses
F... Fuse
380EL5b.tbl
Wiring colour
270EL6.tbl
10-283/10


10-283/11


10-283/12

STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Sensors:
1. Fuel level
2. Engine water level
3. Torque converter oil temperature
4. Engine water temperature
5. Engine oil level
6. Brake oil pressure
7. Engine oil pressure
8. Air cleaner clogging
Outline
• The machine monitor system uses the sensors • The displays can be broadly divided into the
and other devices installed to various parts of following: Cautions displayed on the monitors
the machine to observe the condition of the ma- (abnormalities in the machine where an alarm is
chine. It processes this information swiftly and given) and normal conditions which are always
displays it on the monitor panel to inform the displayed on the instrument panel (pilot lamps
operator of the condition of the machine. and readings for the gauges, speedometer, and
• The machine monitor system consists of the service meter).
main monitor, maintenance monitor, sensors, • There are also various switches built into the
switches, relays, alarm buzzer, and power monitor panel which function to operate the ma-
source. chine.
10-291
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
4H 4D 4E 4A 4C 4B 1 2
3A 4I
5A WORK MODE
5D
H S Ec
5E
MANUAL 5F
5C 5G
4J 4G
SDW0b228
1. CHECK lamp 5. Switches
2. CAUTION lamp 5A.**Work mode selection switch
3. Caution item 5C. ALS (if equipped)
3A. Emergency steering actuated 5D. Working lamp (front) switch
4. Pilot item 5E. Working lamp (rear) switch
4A. Turn signal (left) 5F. Transmission cut-off switch
4B. Turn signal (right) 5G.* Auto shift transmission pilot switch
4C. Hi beam
4D. Shift indicator ** Pos. 5A (added), Serial number: WA380H20987 and up
4E. Speedometer * Pos. 5G (added), Serial number: WA380H20951 and up
4F. Hold position
4G. Parking brake
4H. Emergency steering normal
4I. Preheating
4J. Failure action code
Outline
• The main motor has a display function for the • A liquid crystal display and LEDs are used for
speedometer and other gauges and a switching the display. The switches are embossed sheet
function to control the electric components and switches.
controllers.
• There is one CPU (Central Processing Unit) in-
stalled internally, and this processes the signals
from the sensors and outputs the display.
10-292

MAIN MONITOR DISPLAY FUNCTION
Display
Symbol Display item Display range Display method
category
When there is Display flashes (for details, see

Check Check abnormality display on MAINTENANCE MONITOR
maintenance monitor DISPLAY FUNCTION)
Emergency steering
When actuated Display flashes
actuated
Parking brake actuated,

Display flashes and buzzer
transmission not at
Caution sounds
neutral
Caution
Display flashes (buzzer may
When there is
also sound) (for details, see
abnormality display on
MAINTENANCE MONITOR
maintenance monitor
DISPLAY FUNCTION)
Hi beam When operated Display lights up
Turn signal
When operated Display lights up
(left, right)
Display lights up
Buzzer sounds when parking
Parking brake When operated
brake is applied and shift lever
is not at N
Pilot When normal (oil is

Emergency steering
flowing in hydraulic Display lights up
normal
circuit)
Lights up
Lighting up time changes
according to engine water
Preheating When preheating temperature when starting
switch is turned ON (for details,
see PREHEATING OUTPUT
FUNCTION)
Shift hold When shift is held Display lights up
Digital display (display switches

Speedo-
Travel speed 0 – 99 km/h between tachometer and
meter
speedometer)
Shift
Shift indicator 1–4N Digital display
indicator
When controller detects

failure and action by Digital display
Failure operator is needed, Buzzer sounds
action Failure action code CALL is displayed, (For details of the travel data
code or CALL and E M M display mode, see TROUBLE
(action code) are DATA DISPLAY MODE)
displayed in turn
10-293
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
E.C.S.S. function is actuated or Lights up E.C.S.S. function actuated

E.C.S.S. Electronic stopped each time switch is
pressed Goes out E.C.S.S. function stopped
Front working lamp lights up

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

Lights up Rear working lamp lights up
Working lamp goes out each time switch is
(rear) pressed when side lamps are
lighted up Goes out Rear working lamp goes out
Transmission cut-off function is Lights up Cut-off function actuated

Transmission
actuated or stopped each time
cut-off
switch is pressed Goes out Cut-off function stopped
Manual shift function of

Lights up transmission actuated
Auto shift transmission is actuated
* Transmission shift Manual shift function of
or stopped each time switch is
"Manual / Automatic" Goes out transmission stopped;
pressed
Automatic actuated
The relevant work mode is selected
if switch is pressed:
Work mode: recommended for:
H (igh) high loading performance (H) lights up High mode actuated,
short loading cycles (S, Ec) off Standard and economy mode
max. breakout / lifting forces stopped
**3-stage S (standard) load and carry (S) lights up Standard mode actuated,
operating mode road driving (H, Ec) off High and economy mode
stopped
Ec (onomy) load and carry (Ec) lights up Economy mode actuated,

road driving (H, S) off High and standard mode
low fuel consumption stopped
** (added) Serial number: WA380H20987 and up

* (added) Serial number: WA380H20951 and up
10-294

TROUBLE DATA DISPLAY MODE
Item Switch operation Actuation
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and
trouble data display switch turned ON, press 2nd switch failure code is displayed on speedometer
mode from top on left side of main display and time elapsed since failure is
monitor (switch below emergency displayed on failure action code display.
steering display) and working lamp (1) Failure code is a two-digit display
(front) switch simultaneously given in numbers or letters.
for at least 5 seconds. The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item.
Clearing failure code Press working lamp (rear) switch Failure code and time elapsed since
for at least 2 seconds failure being displayed are cleared.
Failure code for problem now occurring
(flashing display) cannot be cleared.
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch
simultaneously for at least
5 seconds, or start the engine.
10-295
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
1. Check items (Checks before 3. Gauge items 6. Monitor module

starting) 3A. Fuel level 7. Switch module
1A. Engine water level 3B. Engine water tempera-
1B. Engine oil level ture
2. Caution items (warning 3C. Torque converter oil
items) temperature
2A. Engine oil pressure 5. Service meter
2B. Battery charge 5A. Service meter numeric
2C. Brake oil pressure display
2D. Air cleaner 5B. Service meter RUN pilot
(1A. Engine water level) lamp
Outline
• The maintenance monitor has a display function for • The monitor module has a built-in CPU (Cen-
the caution items and gauges, and switch functions tral Processing Unit). It processes the signal
to control the work equipment controller (if equipped). from the sensors, and carries out the display
• The maintenance monitor consists of the monitor and output.
module, switch module, service meter, case, and • A liquid crystal display and LEDs are used for
other mechanisms. the display portions. The switches are em-
bossed sheet switches.
10-296
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION
Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Check Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
CHECK lamp flashes
Engine water level Below low level Displays when engine is running
Display when normal: OFF
Display when abnormal: Flashes
Engine oil pressure Below specified CAUTION lamp flashes
pressure Buzzer sounds
Brake oil pressure Below specified

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

Display when normal: OFF
CAUTION lamp flashes
Battery charge When charge is Displays when engine is running

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

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

level
Flashes when level is 1
Engine water temperature One place lights up to show

Gauges applicable level
Flashes when level is 6 or 7
Torque converter oil One place lights up to show

temperature applicable level
Flashes when level is 6 or 7
10-297
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM

SYSTEM STRUCTURE DIAGRAM
No. Input No. Output

(D) (D)
1 Directional switch signal (1) F SOL
à à
(D) (D)
2 Range switch signal (2) R SOL
à à
(D) (D)
3 Transmission cut-off signal (3) HL SOL
à à
(D) (D)
4 Kick-down switch signal (4) SP SOL
à à
(D) Transmission (A)
5 Hold switch signal (5) Modulation valve solenoid
à controller
à
(D) (P)
6 Neutralizer relay signal
à à (6) Engine speed signal
(P) (D)
7 Travel speed signal
à à (7) Kick-down signal
(P) (D)
8 Engine speed signal
à à (8) Alarm buzzer signal
(D) (N)
9 Model selection signal (Engine) (9) Hold signal
à à
(N)
à (10) Buzzer signal
(N)
(11) Failure code
à
A: Analog signal
D: Digital signal
P: Pulse signal
N: Network signal
CONTROL FUNCTION
Auto shift
Hold function
Kick-down function
Safety function
Troubleshooting
Model selection function (Engine)
Outline
• The auto-shift control system receives the posi-
tion signals from the directional lever and range
lever, the engine speed signal, travel speed sig-
nal, and signals from other switches. The trans-
mission controller drives the speed solenoid valve
and automatically carries out shift control to
select the optimum speed range for the trans-
mission.
10-298
SHIFT CONTROL SYSTEM FUNCTION

OUTPUT SIGNALS
INPUT SIGNALS 1. Transmission solenoid output
1. Directional lever The F and R solenoids correspond to the F and
This selects F (FORWARD), R (REVERSE), R positions of the directional lever.
and N (Neutral). Positions 1 to 4 of the speed lever actuate the
2. Speed lever H-L solenoid and speed solenoid to select the
This selects the optimum speed range when clutches to give the 1st to 4th transmission
using auto-shift FORWARD or REVERSE. Nor- speeds. This combination is then output to the
mally, if the speed lever is at position 2 or above, transmission. (See Table 1)
the transmission will be set to 2nd when the
machine starts. Table 1 Transmission solenoid output
When the auto shift used, and the gear shift
lever is moved 4 à 3 à 2 à 1 when the Speed
Solenoid Clutch
machine is traveling with the transmission in range
force, the transmission will also shift down im- F R HL SP F R 1 2 3 4
mediately 4 à 3 à 2 à 1. (Priority given to N ¡
speed lever!)
F1 ¡ ¡ ¡¡
3. Engine speed sensor
When the engine is running at low speed (less F2 ¡ ¡ ¡
than 1450 rpm), the auto shift is stopped. When F3 ¡ ¡ ¡ ¡
shifting between forward and reverse or when F4 ¡ ¡ ¡ ¡ ¡
coasting, the present speed range is maintained R1 ¡ ¡ ¡ ¡
and the shift shock is reduced.
R2 ¡ ¡ ¡
When the machine is traveling in 2nd, and the
engine speed changes from low speed (less R3 ¡ ¡ ¡ ¡
than 1450 rpm) to high speed (more than 1450 R4 ¡ ¡ ¡ ¡ ¡
rpm), the speed range is kept at 2nd to allow
the machine to accelerate more easily.
4. Travel speed sensor 2. Modulation output
The speed range is determined according to There is a data map for each shift pattern, and
the travel speed. In addition, the change in speed the solenoid command current is controlled ac-
is determined from the pulse count to decide cording to the data to reduce the shift shock
whether to shift up or down. when engaging the clutches. (See Table 2)
5. Neutralizer 3. Hold function (maintaining present speed range)
The parking brake actuation signal is input to When the hold switch is turned ON, the existing
the controller and the transmission is shifted to speed range is held, and even if the travel speed
neutral. goes down, the transmission does not shift
6. Transmission cut-off signal down. However, if the direction of travel is shifted
When the controller receives the transmission between forward and reverse, the transmission
cut-off signal, it shifts the transmission to neu- shifts down, and then it shifts up to the speed
tral. After the signal is canceled, it selects a range according to the change in the condi-
speed range that matches the travel speed at tions. (This prevents any unnecessary shift down
that point. on level ground or unnecessary shift up when
traveling downhill.) (See Table 2, Item 4)
10-299
4. Kick-down function Normally, the transmission shifts to 1st only if

If the operator wishes, he can override all the the speed lever is placed at 1 or if the kick-
automatic conditions and shift down forcibly to down switch is pressed.
1st (when traveling at below 11.6 km/h in 4th or b) REVERSE (See Table 2. Item 2)
3rd, or when traveling at any speed in 2nd). Directional lever at R, speed lever at 4
(See Table 2. Item 7) The transmission range is shifted according to
When the transmission has been shifted to 1st the travel speed in the same way as for a).
by the kick- down, the switch pump cut-off sig- 2. Changing direction (switching between forward
nal to the electronic governor controller is and reverse)
switched ON. (When the directional lever is shifted to the op-
When the travel speed increases, the transmis- posite direction from the direction of travel)
sion is shifted up in accordance with the auto If the travel speed and engine speed are in
shift up conditions, or it is shifted to 2nd when area I in Fig. 2, the transmission output shifts to
the direction is shifted between forward and re- 2nd speed in the same direction as the direc-
verse. tional lever regardless of the speed range. Fol-
This function is also available when holding the lowing this, the transmission shifts up to match
speed range (hold, engine at low speed). the travel speed. (See Table 2. Item 8)
SHIFT CHARACTERISTICS Example:
1. Auto shift (See Table 2. Item 1,2) Directional lever: F à N à R
When the engine speed is above 1450 rpm, the Transmission output:
transmission is shifted as follows according to F4 à N à R2 à R3 à R4
the travel speed. In area II in Fig. 2, the transmission output re-
a) FORWARD (See Table 2. Item 1) verses, but the speed range shifts down to 2nd
Directional lever at F, speed lever at 4 in accordance with the travel speed. Then, after
Shift up the actual direction of travel of the machine
(i) When starting, the transmission is set to changes to the same direction as the direc-
the F2 torque converter range. tional lever, the transmission shifts up in ac-
(ii) When the accelerator pedal is depressed, cordance with the travel speed. (To prevent dam-
the engine speed rises and the machine age to the clutch) (See Table 2. Item 9,10)
travels faster. If the engine speed contin- However, when the hold function is ON, the
ues to rise and the travel speed reaches transmission does not shift down.
10.0 km/h (10.5 km/h), the transmission is Example:
shifted up to F3. Directional lever: F à N à R
If there is insufficient acceleration, the trans- Transmission output:
mission shifts up when the travel speed F4 à N à R4 à R3 à R2
reaches the figure shown in ( ). (The transmission shifts down while the ma-
(iii) Immediately after the transmission shifts up, chine is coasting in forward)
the engine speed will drop momentarily, but R2 à R3 à R4
if the machine continues to travel faster and (The machine shifts up when traveling in
the travel speed reaches 17.5 km/h, the reverse)
transmission is shifted up to F4. However, if the speed lever is at 1, the trans-
mission remains in 1st.
Shift down 3. Switching F – N – F (R – N – R) (lever re-
(i) If the machine is traveling in F4 and the turned)
load increases, the transmission will shift A speed range that matches the speed is se-
down F3 if the travel speed drops below lected. (See Table 2. Item 11,12)
15.5 km/h. 4. Skip shift
(ii) If the travel speed drops further to 10.5 km/ When the machine is coasting in 3rd or 4th
h (10.0 km/h), the transmission is shifted (engine speed below 1450 rpm), and the accel-
down to F2. erator pedal is depressed (engine speed above
If there is insufficient deceleration, the trans- 1450 rpm), the speed range is held if the travel
mission shifts down when the travel speed speed is more than 8 km/h. If the travel speed
reaches the figure shown in ( ). is less than 8 km/h, the transmission is shifted
With the auto shift, the transmission does down to 2nd to make it easier to accelerate.
not shift down to 1st even if the travel speed (See following page, table 2, Item 3)
drops.
10-300

5. No-shift time Fig. 1 Automatic gear shift graph (High mode)

This is the time that the speed range is held after
shifting. The speed cannot be shifted until this
time has elapsed. (To prevent shift hunting) No-
shift time differs according to the shift condi-
tions. (See Table 2)
6. Priority of Kickdown function

Kickdown has priority over gear hold. If shift
down from 4th, 3rd or 2nd is operated to 1st
gear by use of Kickdown then 1st gear is fixed
by using the gear hold switch. The machine will
select 1st or 2nd gear according to directional Fig. 3 Bidirectional change lever / gear position
change of lever`s position. Bidirectional change Gear Position:
lever position:
FàNàF F1àNàF1
RàNàR R1àNàR1
FàNàRàNàF F1àNàR2àNàF2
RàNàFàNàR R1àNàF2àNàR2
Table 2: Gear shift characteristics
Item Clutch Speed (km/h) No-shift time (sec)
1.Normal gear shift 1 → 2 Min. 5,3 (5,5) 2
2 → 3 Min. 10,2 (10,7) 2
3 → 4 Min. 18,0 1
4 → 3 Less than 16,0 1
3 → 2 Less than 10,7(10,2) 2
*(Economy / Standard mode) 2 → 3 Min. 7,0 2
2.Engine speed 4→2 Less than 1,0 0
(less than 1450 rpm) 3→2 Less than 1,0 0
3.Engine speed (less than 1450 rpm 4→2 Less than 8,0 2
→ more than 1450 rpm) 3→2 Less than 8,0 2
4.Shifting up when hold is ON 1→2 Min. 5,3 0
2→3 Min. 10, 0
3→4 Min. 18,0 0
5.Kick-down 2→1 Whole range 5
OFF → ON 3→1 Less than 12,1 5
4→1 Less than 12,1 5
6.Directional lever 4→2 Note 1) 2
(Area I) (F →) N → R 3→2 ––– 2
(R →) N → F 1→2 2
7.Directional lever →4 Min. 18,0 0
(Area II) (F →) N → R →3 Less than 16,0 - 18,0 0
(R →) N → F Note 2) 0
8.Directional lever →4 Min. 18,0 0

F→N→F →3 Less than 10,2 - 18,0 0
R→N→ R →2 Less than 10,2 0
Note 1: Engine speed less than 2000 rpm and travel speed less than 16 km/h, or travel speed less
than13 km/h.
Note 2: When engine speed is more than 2000 rpm → 3 if travel speed is 13 km/h to 18.0 km/h
See Fig. 2, for details of Area I and Area II. * Serial number: WA380H20987 and up
10-301

SAFETY FUNCTION TROUBLESHOOTING

1. Alarm buzzer The controller always observes if the electronic
If the direction of travel is switched between devices (the solenoids which receive the con-
forward and reverse in area III in Fig. 3 (travel troller output signals, and the engine speed sen-
speed above 13 km/h and engine speed above sor and travel speed sensor which take in the
1800 rpm, or travel speed above 14 km/h), the input signals) are functioning normally.
alarm buzzer will sound to prevent damage to If there is any abnormality in any of these
the clutch. devices, the controller judges the condition and
functions to inform the operator of the decision
2. N priority for directional lever with the alarm buzzer, and at the same time, to
The controller is equipped with an interlock func- display the abnormality as a failure code on the
tion which always gives the neutral output when main monitor.
the lever is at N.
3. Neutral safety
When the directional lever is at any position
other than N, the transmission is set in neutral
and the machine does not start even if the
starting switch is turned ON. This condition is
canceled if the directional lever is returned to
the N position. (To prevent unexpected move-
ment of the machine when the engine is started)
4. Speed lever priority

If the speed lever is shifted down when traveling
downhill, the transmission is shifted down imme-
diately to make use of the braking force of the
engine.
5. Manual shift
If there should be any disconnection in the MODEL SELECTION FUNCTION
travel speed sensor or any other failure, and the
input of the travel speed stops, the lever opera- Model selection
tion becomes manual.
• The model is selected using the CN ENG
Example: plug. This informs the transmission controller
Directional lever F, speed lever 4 à F4 of the type of engine. A dummy plug is lo-
Directional lever R, speed lever 2 à R2 cated on this connection on the Komatsu
engine. This ensures that the correct data
records for switching control are activated in
the transmission controller.
10-302
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
CN1 CN2 CN3

1 NETWORK signal 1 Directional switch F 1 –
2 – 2 Range switch 2 2 –
3 Modulation valve, Sol (+) 3 Range switch 4 3 –
4 – 4 Neutralizer relay signal 4 Travel speed signal (+)
5 – 5 – 5 Engine speed signal
6 – 6 – 6
7 – 7 Engine selection CN ENG 7 –
8 Power source input (+24V) 8 Engine selection CN ENG 8 –
9 GND 9 Signal GND output 9 –
10 HL, Sol 10 – 10 –
11 SP, Sol 11 Directional switch N 11 –
12 NETWORK signal 12 Directional switch R 12 Travel speed signal (–)
13 Sensor power source (+24V) 13 Range switch 1 13 –
14 Modulation valve, Sol (–) 14 Range switch 3 14 Engine speed signal output
15 – 15 – 15 Buzzer signal output
16 – 16 Transmission cut-off switch 16 Brake signal output
17 Solenoid power source input (+24V) 17 Kick-down switch
18 Power source input (+24V) 18 Hold switch
19 GND 19 –
20 R, Sol 20 –
21 F, Sol
10-303
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
COMBINED T/M AND ALS-CONTROLLER
CN1 Connector
CN2 Connector
CN3 Connector
CONNECTOR SIGNALS
CN1 (CNL29) CN2 (CNL30) CN3 (CNL31)

1 NETWORK signal 1 Directional switch F 1
2 2 Range switch 2 2
3 Modulation valve, Sol (+) 3 Range switch 4 3 ALS selected
4 4 Neutralizer relay signal 4 Travel speed signal (+)
5 5 Automatic OFF 5 Engine speed signal
6 6 ECSS-Switch 6
7 Sol. 3 (+) (Lo) 7 Engine select 7 Sol. 1 (+)
8 Power source input (+24V) 8 Engine select 8
9 GND 9 Signal GND output 9* Work mode input
10 HL, Sol 10* Work mode output 10
11 SP, Sol 11 Directional switch N 11
12 NETWORK signal 12 Directional switch R 12 Travel speed signal (–)
13 Sensor power source (+24V) 13 Range switch 1 13
14 Modulation valve, Sol (–) 14 Range switch 3 14 Engine speed signal output
15 15 Pressure switch (ALS off) 15 Buzzer signal output
16 Sol. 3 (-) (Lo) 16 Transmission cut-off switch 16 Sol. 2 (+) (Hi)
17 Solenoid power source input (+24V) 17 Kick-down switch * Serial number: WA380H20987
18 Power source input (+24V) (BR) 18 Hold switch
19 GND 19 ECSS select
20 R, Sol 20 20 km/h select
21 F, Sol * Serial number: WA380H20987
10-304

STRUCTURE AND FUNCTION E.C.S.S.
E.C.S.S.
(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
1. E.C.S.S. (Electronic Controlled Suspension

System)
• This system uses a combination of relieving the
hydraulic oil from the work equipment and
switching ON/OFF an accumulator which is
charged with high pressure gas. The controller
carries out automatic control of these in accord-
ance with the travel condition of the machine to
give resilience to the up and down movement
of the work equipment and to suppress the vi-
bration of the chassis when traveling at high
speed. In this way, it improves the ride for the
operator, prevents spillage of the load, and im-
proves the operating efficiency.
• Special solenoid valves (ON-OFF valves) are
used to control the ON-OFF switching of the
accumulator (high pressure, low pressure) and
the opening and closing of the relief valves.
• With this system, it is possible to handle four
models (WA320, WA380, WA420, and WA470)
with the same system simply by changing the
connections of the model selection wiring har-
ness.
2. Structure of system
• The E.C.S.S. consists of the following electronic
devices.
1) E.C.S.S controller (M type controller)
2) Input devices: E.C.S.S switch (system
switch), pressure switch (boom cylinder bot-
tom pressure), travel speed sensor, model
selection wiring harness, speed range se- Serial communication
lection wiring harness Main-
3) Output devices: solenoid valves (relief valve, monitor + 24V
→
high pressure accumulator, low pressure ac-

cumulator) Solenoid
Travel speed sensor (relief)
+
Solenoid
- E.C.S.S.
(High pressure accumulator)
Pressure switch
Solenoid
controller (Low pressure
accumulator)
Speed range
selection
Serial communication
→ to main monitor
Model selection
wiring harness
10-321
3. Content of control
• In response to the input on the left side of the
table below, the controller carries out the output
on the right side to control the system.
œ: ON
x: OFF
Input Output
E.C.S.S switch Speed range [Note 2] Travel Solenoid Solenoid Solenoid
Pressure
(system ON-OFF) speed (1) (2) (high (3) (low
switch
[Note 1] H-L Speed [Note 3] (relief) pressure) pressure)
1 OFF – – – – x x x
OFF OFF
2 OFF ON Min. 5 km/h ON ¡ ¡ x

ON ON
OFF OFF
3 ON OFF ON Min. 5 km/h OFF ¡ ¡ ¡

ON ON
4 ON OFF – – x x x
Min. 5 km/h
5 – –
[Note 4]
– x x x
Note 1: The E.C.S.S system is switched ON-OFF Note 3: Input pulse frequency when travel speed
by operating the E.C.S.S switch on the is 1 km/h
main monitor. Model Pulse frequency (Hz)
When the system is ON, the E.C.S.S LED
WA320-3 54.41
display on the main monitor lights up.
The ON-OFF condition of the system is WA380-3 47.70
retained even after the engine stops or WA420-3 40.96
the starting switch is turned OFF. The next WA470-3 44.46
time that the starting switch is turned ON,
the system is set to the same condition as Note 4: If the travel speed exceeds 5 km/h when
before it was turned OFF. the output is OFF, the output is turned
(Main monitor function) ON.
Starting switch OFF à Machine stops à When the output is ON, the output stays ON
Starting switch ON until the travel speed reaches 3 km/h, and
When system is ON à System ON
[
When system is OFF à System OFF
] when the travel speed goes below 3 km/h,
the output is turned OFF.
Note 2: Relationship between speed range signal
and shift position
Speed range
Shift position
H-L Speed
1st OFF ON
2nd OFF OFF
3rd ON OFF
4th ON ON
ON: +24V, OPEN
OFF: 0V, CLOSED
10-322
4. Self-diagnostic function
• This system always observes the condition of
the system, and displays the condition of the
system (LED code, see table below) in the con-
troller self-diagnostic display portion.
• If there is any abnormality in the controller itself
or in the input or output devices, the controller
carries out troubleshooting of the abnormality. It
turns all the output OFF and displays the error
code (failure code) in the self- diagnostic dis-
play portion and the main monitor.
LED codes
LED Condition
Content
display of system
01 Selects model as WA320-3
Normal
Pressure switch ON
55
(displays only when ON)
Error in solenoid (relief)
d0
system
Error in solenoid
d1
(high pressure) system
Error Error in solenoid
d2 Abnormal
code (low pressure) system
Abnormality in travel speed
d3
sensor system
Abnormality in model
d4 selection (non-available
combination is selected)
1) Displays on controller
• Error code displays [E] à [dx] (where x is a
numeral from 0 to 4 in the table above)
repeatedly in turn.
• If more than one abnormality occurs at the
same time, all the appropriate error codes
are displayed in turn.
• When the starting switch is turned OFF
(controller power OFF, the error codes are
reset and not written to memory.
• When checking the LED display, read the
code with the connector facing down.
2) Displays on main monitor
• For details, see MAIN MONITOR TROU-
BLE DATA DISPLAY.
10-323
5. Controller
1. Controller
2. Self-diagnostic display
Input/output signals
CN1 CN2 CN3
Input/ Input/ Input/
No. Name of signal No. Name of signal No. Name of signal
output output output
1 Serial signal – 1 Model selection Input 1 – –
2 – – 2 Model selection Input 2 – –
3 – – 3 Model selection Input 3 – –
4 – – 4 Model selection (Parity) Input 4 Travel speed sensor (+) Input
5 – – 5 – – 5 – –
6 – – 6 – – 6 – –
7 – – 7 – 7 – –
8 Power source input (+24V) – 8 Pressure switch Input 8 – –
9 GND – 9 – – 9 – –
10 – – 10 – – 10 – –
11 Solenoid (low pressure) Output 11 – – 11 – –
12 Serial signal – 12 – – 12 Travel speed sensor (–) Input
13 – – 13 Travel speed H-L Input 13 – –
14 – – 14 Travel speed SPEED Input 14 – –
15 – – 15 SAS SW Input 15 – –
16 – – 16 – – 16 – –
Solenoid power source 17 – –
17 –
input (+24V) 18 – –
18 Power source input (+24V) – 19 – –
19 GND – 20 – –
20 Solenoid (high pressure) Output
21 Solenoid (relief) Output
Model selection table

CN2-1 CN2-2 CN2-3 CN2-4
WA320-3 x x x ¡
WA380-3 x x ¡ x
WA420-3 x ¡ x x ¡: GND
WA470-3 x ¡ ¡ ¡ x : OPEN
10-324
E.C.S.S.-SYSTEM STRUCTURE DIAGRAM
10-325
E.C.S.S.-SYSTEM STRUCTURE DIAGRAM (E.C.S.S. PLUS)
Serial Number: WA380H20357

to WA380H20383
10-326
E.C.S.S.-ELECTRIC-CIRCUIT DIAGRAM
10-327
ALS-CONTROL UNIT
1. Two - way valve

1.1 Cover mounting screws
Connections: Torque 50+5 Nm, size 8mm
A. Lift cylinder - piston end side 2. Electrically controlled 3/2 valve
B. Lift cylinder - piston rod side Torque 22+5 Nm, size 22mm
P. Pump pressure 2.1. Solenoid mounting screw
T. Return to the tank Torque 4+1 Nm, size 20mm
M. Pressure test point for accumulator pressure 3. Electrically controlled 2/2 valve
SP. Connection possibility for further accumulators Torque 130+10 Nm, size 47.6mm
3.1. Solenoid mounting screw
Torque 5+3 Nm, size 19mm
4. Pressure reducing valve
Adjusting value 98+5 Nm,
Torque 47+7 Nm, size 25.4mm
5. Pressure cap, oil side size 5mm
6. Check valve
7. Accumulator unit
* 7.1 Accumulator mounting screws with pres-
sure washer
Torque 30+5 Nm, size 13mm
8. Pressure test point
* Use only original parts for

accumulator assembly
10-328

ALS-SYSTEM STRUCTURE DIAGRAM
1. Main hydraulic control valve 1. Two - way valve

2. Lift cylinde 2. Electrically controlled 3/2 valve
3. ALS-control unit with connections: 3. Electrically controlled 2/2 valve
A Lift cylinder piston side 4. Pressure reducing valve
B Lift cylinder piston rod side 5. Pressure cap, oil side
P Working hydraulic pressure 6. Check valve
T Return oil to the tank 7. Accumulator unit
M Pressure check point
Sp Connections for further accumulators
(1 accumulator for WA380-3H)
(2 accumulators for WA420-3/WA470-3)
10-329
10-330
STRUCTURE AND FUNCTION SENSORS
SENSORS
Function
• The sensors are a contact type sensor with one
end grounded to the chassis. The signal from
the sensor is input directly to the monitor panel,
and when the contacts are closed, the panel
judges the signal to be normal.
However, the engine oil pressure uses a relay
to reverse the sensor signal.
Sensor detection Sensor When When

item method normal abnormal
Engine oil level Contact ON OFF
Radiator water
level Contact ON OFF
Engine water
temperature Resistance – –
Torque converter
oil temperature Resistance – –
Fuel level Resistance – –
Electro-
Engine speed magnetic – –
Engine oil
pressure Contact OFF ON
ENGINE OIL LEVEL SENSOR
1. Connector
2. Bracket
3. Float
4. Switch Function
• This sensor is installed to the side face of the
oil pan. When the oil goes below the specified
level, the float goes down and the switch is
turned OFF. This makes the maintenance moni-
tor flash to warn of the abnormality. The check
lamp also lights up at the same time to warn of
the abnormality.
10-341
RADIATOR WATER LEVEL SENSOR
1. Float Function
2. Sensor • This sensor is installed to the top of the radia-
3. Connector tor. If the coolant goes below the specified level,
the float goes down and the switch is turned
OFF. The caution lamp and alarm buzzer are
also actuated at the same time to warn of the
abnormality.
ENGINE WATER TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR
1. Connector Function
2. Plug • These sensors are installed to the engine cylin-
3. Thermistor der block and transmission case. The change
in the temperature changes the resistance of
the thermistor, and a signal is sent to the main-
tenance monitor to display the temperature. If
the display on the maintenance monitor reaches
the specified position, the lamp flashes and the
buzzer sounds to warn of the abnormality.
10-342
FUEL LEVEL SENSOR
1. Connector Function
2. Float • The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down as the level of the fuel changes. As the
5. Spring float moves up and down, the arm actuates a
6. Contact variable resistance, and this sends a signal to
7. Spacer the maintenance monitor to display the fuel level.
When the display on the maintenance monitor
reaches the specified level, the warning lamp
flashes.
10-343
ENGINE SPEED SENSOR
1. Magnet Function
2. Terminal • The engine speed sensor is installed to the ring
3. Case gear portion of the flywheel housing. A pulse
4. Boot voltage is generated by the rotation of the gear
5. Connector teeth, and a signal is sent to the controller and
monitor panel.
ENGINE OIL PRESSURE SENSOR
1. Plug Function
2. Contact ring • This sensor is installed to the engine block and
3. Contact the diaphragm detects the oil pressure. If the
4. Diaphragm pressure goes below the specified pressure, the
5. Spring switch is turned ON, and a relay is actuated to
6. Terminal turn the output OFF. This makes the mainte-
nance monitor flash to warn of the abnormality.
The caution lamp and alarm buzzer are also
actuated at the same time to warn of the abnor-
mality.
10-344
TRANSMISSION CUT-OFF SWITCH
1. Case 5. Tube
2. Seal film 6. Connector
3. Disc 7. Cover
4. Vinyl tape 8. Spring
Outline Specifications
• When the left brake pedal is operated, the switch WA380-3
detects the oil pressure in the brake circuit, Min. 18 V
Voltage
shuts off the electric power to the solenoid valve value Max. 32 V
circuit for the directional clutch, and shifts the Min. 5 mA
Current
transmission to neutral. value Max. 0.1 A
10-345
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT

Up to SN: WA380H20500
Function
• A neutral safety circuit which inhibits engine start- status is set.
ing when the directional lever is at any position • The current also flows in the following circuit:
other than N (neutral) is used to assure safety. Starting switch terminal BR à battery relay
coil à ground connection.
Operation • This closes the battery relay switch.
• When the starting switch is set to the START When the directional lever is set to the N
position, voltage flows in the following circuit: (neutral) position, the directional lever switch's
Starting switch terminal BR à stopping motor neutral contact is closed. At this time, current
relay terminals 1 and 2 à ground connection. flows to neutral relay terminals 1 and 2 and
This excites the relay coil. the coil is excited.
• The current from the battery flows in the follow- • This causes current to flow in the following
ing circuit: Engine stopping motor terminals A circuit 1: Starting switch terminal C à neu-
and B à relay terminals 5 to 3 à motor. This tral relay terminals 5 to 3 à starter terminal
turns the motor. (The cable stretches.) C.
• When the motor turns, terminal D also turns. • The following circuit is formed: à battery re-
When the non-continuous section of terminal D lay à`starter terminal B. The engine then
reaches terminal B, the circuit from terminal A starts. When the directional lever is at a po-
to terminal B opens and the current from the sition other than N (neutral), circuit 1 is not
battery to the motor is interrupted. The motor formed, so the engine does not start.
tends to keep turning due to inertia, but when
the non-continuous section of terminal D comes
in contact with terminal B, both motor poles are
grounded, so the motor stops turning.
• In this status, the stopping motor cable is fully
extended, the fuel injection pump's stopping le-
ver is at the FULL position, and the operating
10-346
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Up to SN: WA380H20500
Function
• The system is equipped with an electrical fuel • When the motor rotates, terminal D also rotates
cut device (engine stop motor) which makes it at the same time. When the non-continuous
possible to start or stop the engine by turning portion of terminal D reaches terminal C, the
the starting switch ON or OFF. This improves circuit from terminal A to C opens, and the
the ease of operation. current from the battery to the motor is shut off.
The motor attempts to continue rotating under
Operation inertia, but when the continuous portion of ter-
• When the starting switch is turned OFF, start- minal D contacts terminal C, both poles of the
ing switch terminals B, BR and C are opened. motor are connected to the ground, and the
• The current in the stop motor relay is shut off motor stops rotating.
by the starting switch, so the coil is not excited. • In this condition, the stop motor cable is com-
Therefore, terminals 3 and 6 are closed. pletely pulled in, and the fuel injection pump
• The current from the battery flows from engine lever is set to the STOP position to stop the
stop motor terminals A – C à relay terminals 6 engine.
– 3 à motor to rotate the motor. (The cable is
pulled in)
10-347
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
PREHEATING CIRCUIT Up to SN: WA380H20500

QUICK GLOW SYSTEM (QGS)
Outline Operation
• The quick glow system (QGS) is provided to • When the starting switch is set to the ON (ACC)
improve engine starting performance in cold re- position, a signal flows from starting switch ter-
gions. The QGS acts to reduce preheating time, minal BR to the controller in the main monitor,
and also sets the preheating time automatically and the preheat output is connected to the
according to the water temperature when the ground. The preheat relay coil is excited, the
starting switch is operated. preheat relay is activated, and this activates the
• When the starting switch is turned from OFF to glow relay.
ON (ACC), the preheat pilot lamp on the main A current flows in the following circuit: Battery
monitor panel lights up and the engine is à battery relay à glow relay à glow plug. This
preheated with the glow plug. The preheating sets the preheating mode.
time is set by the QGS controller in the main • When the signal indicated that preheating is
monitor, which detects the water temperature completed is sent from the controller, the preheat
using the QGS water temperature sensor in the relay turns OFF, the glow relay also turns OFF,
engine. and preheating is completed.
• When the pilot lamp is lighted, the engine is
being preheated. Set the starting switch to the
ON position. If the starting switch is turned to
the START position, preheating is canceled.
10-348
QUICK GLOW SYSTEM Up to SN: WA380H20500

• The output of main monitor is different for quick
glow system and ribbon heater. The output is se-
lected by DIP SW1 (Selection of machine).
• The WA380-3H is equipped with a quick glow sys-

tem. The working time of pilot light (T1) is not equal
to working time of relay (T2). At a coolant tempera-
ture of 0°C at sensor (Connector CNE05), the pilot
light is active for 3sec., whereas the relay is active
for 30sec. After engine start, pre-heating continoues
for time T2.
10-349
STRUCTURE AND FUNCTION START / STOP / PREHEATING CIRCUIT
ENGINE START / STOP / PREHEATING CIRCUIT

Ground
10-350
STRUCTURE AND FUNCTION START / STOP / PREHEATING CIRCUIT
Sect. Sect.
6 S 43 Starting switch 6 G 10 Generator
10 S 58 Battery main switch 10 G 57 Battery
12 S 261 Switch gear selection 8 M9 Starting motor
3 P 426 Main monitor 4 H 76 Lamp pre-heating
3 R 12 Flame plug 3 Y 320 Solenoid engine stop
V Diode 4 B 14 Temp. sender pre-heating
V 118 Diode 5 x 6 K 208 Relay neutral position
7 K 106 Relay battery 2 K 282 Relay pre-heating
9 K158 Relay starting motor 2 K 283 Relay pre-heating
1 K 167 Time relay for Y 320
Connectors
XM Connector engine
Fuses
F... Fuse
motor.tbl
Engine start Preheating
• Voltage flows in the following circuit: Starting motor • Voltage flows in the following circuit: Starting
terminal 30, alternator terminal B+, battery relay (K motor terminal 30, alternator terminal B+,
106) terminal 30 and starting switch terminal 30. battery relay (K 106) terminal 30 and starting
When the starting switch is turned (terminal 15), switch terminal 30.
relay K106 is activated. Engine stop solenoid Y 320 When the starting switch is turned (terminal
moves for 0,5 sec with high current in B-A position, 15), relay K106 is activated. Engine stop
then moves in hold-position A-C. Current flows in solenoid Y 320 moves for 0,5 sec with high
the preheating control circuit. current in B-A position, then moves in hold-
• When the starting switch is turned further (terminal position A-C. Current flows in the preheating
50a), relay neutral position (K 208) is activated, and control circuit.
current flows via terminal 30-87 if the gear lever is in • Temperature switch B 14 is closed, ground is
neutral position. Current flows to the starting motor connected to the main monitor and terminal
relay K 158 and the starting motor starts turning. 85 of the preheating relay K 282. Relay K282
and relay K 283 are activated. Current flows
to the preheating system. The lamp on the
Engine stop main monitor is activated via pin 15 of con-
nector XL 06. Preheating time depends on
• If the starting switch is moved in the stop position, the temperature and is controlled by the main
current is interrupted on terminal 15, relay K 106 monitor.
opens and the engine stop solenoid Y 320 moves in
stop position.
10-351
RIBBON HEATER
• The output of main monitor is different for quick

glow system and ribbon heater. The output is se-
lected by DIP SW1 (Selection of machine).
Pre-heating
time
T1: Time pilot light is ON
T2: Time glow plug is working
Pilot light
Temperature (°C)
Function
If starting switch is turned to START position

during pre-heating
Controller
reset
10-352
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION
CONTROL
1. Transmission cut-off selector switch 8. Fuse boxes

2. Transmission controller 9. Engine RPM
3. Directional lever 10. Emergency switch
4. Speed lever 11. Transmission control valve
5. Kick-down switch 12. Speed sensor
6. Maintenance monitor 13. Transmission cut-off switch
7. Relays 14. Brake valve (left)
15. Brake valve (right)
Function
1 Selection of F, R, and N positions Using directional lever
2 Selection of speed range Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch
3 Kick-down switch without using the speed lever. If directional lever is operated to R or N,
speed range automatically returned to 2nd.
4 Transmission cut-off function Transmission is shifted to neutral when left brake is operated
It is possible to select whether to actuate or not actuate the
transmission cut-off function. In this way, it is possible to obtain the
5 Transmission cut-off selector function same or greater ease of operation as on conventional loaders with the
left brake when carrying out scooping work or when loading or unloading
the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking
6 Neutralizer brake applied, the transmission is shifted to neutral when the parking
brake is applied.
If the directional lever is not at the N position, the engine will not start
7 Neutral safety function when the starting switch is turned. This prevents the machine from
starting suddenly. (For details, see STARTING CIRCUIT.)
When traveling in reverse, the backup lamp lights up and the backup
8 Warning function
horn sounds to warn people in the area.
10-361
COMBINATION SWITCH
Outline
• The directional lever has three positions and the body by three screws. When each lever is op-
speed lever switch has four positions. As an erated to the desired position, the switch, which
individual part, the switch does not have a detent is interconnected by a shaft, acts to allow elec-
mechanism; the detent mechanism is in the com- tric current to flow to that circuit only.
bination switch. Each switch is positioned by two
pins, and is secured to the
General locations, function

1 Directional lever switch Switches between F, R, and N
2 Speed lever switch Selects speed range
Stopper used to prevent speed lever from entering 3rd or 4th during
3 Speed lever stopper
operations
4 Turn signal indicators Direction indicator lamps used when turning left or right
Turn signal indicator lever automatically returns to central position
5 Self cancel
after machines turns left or right
6 Lamp switch Switches on clearance lamp, head lamp, parking lamp, etc.
7 Dimmer switch Selects high beam for travel and low beam for passing
Makes both left and right turn signal indicator lamps flash at the
8 Hazard switch
same time
9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes
10-362
Operation
• Directional lever (1) and shaft (2) of the speed
lever of the combination switch form one unit
with magnet (3), and magnet (3) also moves
together with lever (1).
• Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (3), and hole
IC (4) is positioned on the board to match each
position.
• When directional lever (1) is operated to the F
position, magnet (3) is immediately above hole
IC (4) for the F position of the control switch.
The magnetism from magnet (3) passes
through the gap and case (6), and magnetism
is applied to hole IC (4).
• When this happens, hole IC (4) is inside a mag-
netism detection circuit, so it detects the mag-
netism of magnet (3) and sends the F position
signal to the electric current amplification cir-
cuit. In the electric current amplification circuit,
a signal is output to actuate the transmission.
10-363
STRUCTURE AND FUNCTION KICK-DOWN, HOLD SWITCH
KICK-DOWN, HOLD SWITCH
1. Kick-down switch
2. Spring
3. Wiring harness
4. Spring
5. Hold switch
KICK-DOWN SWITCH HOLD SWITCH

Operation
• The hold switch is installed to the boom lever,
• The kick-down (shifting down from 2nd à 1st) is and when the hold switch is pressed, the speed
actuated only when traveling in F2. range displayed on the main monitor transmis-
• When traveling in F2, if it is desired to shift down sion indicator is held.
to 1st without operating the speed lever, operate • Press the hold switch again to cancel.
the kick-down switch on the boom lever to ON to
shift down to F1.
• After this, even if the kick-down switch is pressed,
the transmission is kept at F1.
Cancellation (or not actuated)

• When directional lever is at N
• When directional lever is at R
• When speed lever is not at 2nd
• When starting switch is OFF
10-364
STRUCTURE AND FUNCTION KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
2
2
2
2
10-365
Normal operation
(directional lever at F, speed lever at 2)
Directional lever set to F

• When the directional lever is set to the F posi-
tion, electric current flows from the battery ⊕,
à directional lever switch terminal 1 – 2 à
transmission controller FORWARD terminal 1,
and flows as the FORWARD output signal from
terminal 21 à FORWARD solenoid (1) à
ground, and the solenoid valve is actuated.
• When the parking brake is moved to the RE-
LEASE position, the electric current flows from
the battery ⊕, à parking brake safety relay ter-
minal 5 – 3 à parking brake switch terminal 3 –
2 à neutralizer relay terminal 1 – 2 à ground,
and terminals 3 – 5 of the neutralizer relay are
connected.
Speed lever set to 2

• When the speed lever is at position 2, no elec-
tric current flows to H-L solenoid (3), speed
solenoid (4) and R solenoid (2). In this condi-
tion, the transmission control valve is set to F2
by the action of F solenoid (1).
• No current flows if the kick-down switch is not
pressed. Therefore, the kick-down is not actu-
ated, and the transmission is held in F2.
Solenoid actuation table

Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD (1) ¡ l ¡ ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
Speed select (4) ¡ ¡ ¡ ¡
10-366
Kick-down switch operated

(When operating in F2)
(When kick-down switch is pressed ON)
• When the kick-down switch is pressed, electric
current flows from the transmission controller
kick-down terminal (17) and enters the con-
troller. The kick-down circuit is formed inside
the controller, so the solenoid output signal flows
from terminals 21 and 11 to FORWARD sole-
noid (1) and speed solenoid (4). The solenoid
valves are actuated and the transmission is set
to F1.
• This kick-down circuit continues to be actuated
from this point even if the kick-down switch is
returned. (Self-hold circuit)
• In this way, when the speed lever is at F2, the

transmission is automatically shifted to F1 when
the kick- down switch is pressed. At the same
time, it will be held in F1 by the self-hold func-
tion of the kick-down relay even when the kick-
down switch is released. However many times
the kick-down switch is pressed, the transmis-
sion will stay in F1.

FORWARD (1) l ¡ ¡ ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
Speed select (4) l ¡ ¡ ¡
10-367
Canceling actuation of kick-down switch (Case I)

(Directional lever moved to N or R)
• When the directional lever is moved to the R

position, the F terminal contacts of the lever
are turned off, so the electric current stops flow-
ing from the battery ⊕ à speed lever switch
terminal 1 – 2 à transmission controller.
• The FORWARD circuit inside the transmission
controller is opened, so no electric current flows
to the kick-down circuit. In this way, the self-
hold circuit of the kick- down is canceled and
solenoid (4) is no longer actuated.
(When the directional lever is moved to N posi-
tion, the actuation is the same as above and
the kick-down circuit is canceled.)
In addition, the FORWARD circuit is also
opened, so solenoid (1) is no longer actuated.
• When the directional lever is moved the R posi-

tion, the REVERSE circuit is formed from the
battery ⊕ à speed lever terminal 1 – 4
àtransmission controller REVERSE terminal 12
à inside of controller. Current flows from the
output signal terminal (20) à REVERSE sole-
noid 2 à ground, and the REVERSE solenoid
valve is actuated. Therefore, only REVERSE
solenoid (2) is actuated, and the transmission is
set to R2.

FORWARD (1) ¡ ¡ ¡ ¡
REVERSE (2) ¡ l ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
10-368
Canceling actuation of kick-down switch (Case II)

(speed lever moved to position other than 2)
• If the speed lever is operated to any position

other than 2, terminal contact 2 of the lever is
switched OFF, so the current stops flowing from
the battery ⊕ à speed lever switch terminal 1 –
6 à transmission controller.
• Therefore, the kick-down circuit connected to
the 2nd circuit is also shut off inside the trans-
mission controller, and solenoid (4) is no longer
actuated.
• When the speed lever is moved to position 3,
solenoid (3) is actuated. In addition, the direc-
tional lever is at the F position, so solenoid (1)
is actuated. Therefore, solenoids (1) and (3)
are actuated and the transmission is set to F3.

FORWARD (1) ¡ ¡ l ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) l ¡ ¡ ¡
10-369
STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF FUNCTION
TRANSMISSION CUT-OFF FUNCTION

(See page 10-365 for wiring diagram)
Outline
• If the transmission cut-off selector switch on the
main monitor is turned ON (pilot lamp lights
up), the transmission cut-off switch installed to
the left brake pedal is actuated. When the left
brake pedal is operated, the brakes are ap-
plied, and the transmission is shifted to neutral
at the same time. If the transmission cut-off
selector switch is set to the OFF position (pilot
lamp goes out), the transmission is not shifted
to neutral even when the brake is operated, so
the left brake functions only as a brake in the
same way as the right brake.
• When the output flow of transmission controller
terminal 16 to the ground is interrupted, it is
judged that the transmission has been cut off.
Operation
1. When transmission cut-off selector switch is
turned ON
• When the main monitor's transmission cut-off
selector switch is turned ON, the transmission
cut-off selector switch is opened, the output from
transmission controller terminal 16 passes only
through the transmission cut-off switch to the
ground, and voltage is applied to transmission
solenoid F (FORWARD) or R (REVERSE).
• When the left brake pedal is pressed, the trans-
mission cut-off switch is opened and the output
flow of transmission controller terminal 16 to
the ground is interrupted. At the same time, the
voltage of transmission controller terminals 20
(R) and 21 (F) is interrupted, the transmission
is set to neutral (N), and the brakes work nor-
mally.
2. When transmission cut-off selector switch is

turned OFF
• When the transmission cut-off selector switch
is turned OFF, the transmission cut-off selector
switch closes, and the output from transmission
controller terminal 16 flows from the transmis-
sion cut-off selector switch and the transmis-
sion cut-off switch to the ground. Because of
this, voltage is applied to transmission solenoid
F (FORWARD) or R (REVERSE) regardless of
the position of the transmission cut-off switch,
and the transmission is not set to neutral even
when the left brake pedal is pressed.
10-370
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
PARKING BRAKE: TRANSMISSION NEUTRALIZER
Outline
• When the starting switch is turned ON and the • At the same time the parking brake warning
parking brake is applied, current flows from the light, in the main monitor, is connected to
main battery relay through the neutralizer relay, chassis through the parking brake switch and
contacts 1. to 2. and over the parking brake switch is switched ON.
to chassis.
• The neutralizer relay is now operated, contacts

3. to 5. open and the transmission control unit
puts the transmission in neutral.
10-371
10-372
STRUCTURE AND FUNCTION AIR-CONDITIONER
AIR-CONDITIONER
Contents
Page
General
Introduction ............................................................................................................................................. 10-453
Summary ................................................................................................................................................ 10-453
Physical principle .................................................................................................................................... 10-453
Properties - R134a ................................................................................................................................. 10-453
Physical datas R134a and R12 .............................................................................................................. 10-454
New components in R134a circuit .......................................................................................................... 10-454
Function
Refrigeration circuit ................................................................................................................................. 10-456
Condenser .............................................................................................................................................. 10-458
Vaporiser ................................................................................................................................................ 10-459
Filter with dryer ....................................................................................................................................... 10-460
Description
Design of the air conditioning .................................................................................................................. 10-462
Installation: WA 270-3, WA320-3 H20561 and up ................................................................................... 10-462
Installation: WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 ................................................. 10-463
Security
Handling coolants ................................................................................................................................... 10-466
First aid ................................................................................................................................................... 10-467
Operation
Operating controls .................................................................................................................................. 10-470
Operation: WA 270-3, WA320-3 H20561 and up .................................................................................... 10-471
Operation: WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 .................................................. 10-472
Settings ................................................................................................................................................... 10-474
Maintenance
Maintenance timetable ............................................................................................................................ 10-475
Maintenance instructions ........................................................................................................................ 10-476
Regular maintenance.............................................................................................................................. 10-476
Instructions for filling ............................................................................................................................... 10-477
Evacuation .............................................................................................................................................. 10-478
Vacuum test ........................................................................................................................................... 10-478
Siphoning off coolant .............................................................................................................................. 10-478
Filling ...................................................................................................................................................... 10-478
Filling quantities (R134a) ........................................................................................................................ 10-478
Checking the coolant level ...................................................................................................................... 10-479
Checking the compressor oil level .......................................................................................................... 10-479
Changing compressor oil ........................................................................................................................ 10-480
Exchanging magnetic clutch ................................................................................................................... 10-480
Exchanging compressor ......................................................................................................................... 10-481
Installing O-ring couplings ...................................................................................................................... 10-482
Installing conical nipple connections ....................................................................................................... 10-482
10-451
Page
Electrical system
Plug assignment: Controller for WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 .................. 10-484
Circuit diagram: Controoler for WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 ................... 10-485
Circuit diagram air conditioner unit: WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 ........... 10-486
Plug assignment: circuit diagram air conditioner unit for WA 270-3, WA320-3 H20561 and up .............. 10-488
Circuit diagram air conditioner unit: WA 270-3, WA320-3 H20561 and up ............................................. 10-489
Technical details
Heater ..................................................................................................................................................... 10-490
Air conditioner ......................................................................................................................................... 10-490
Circulating air filter .................................................................................................................................. 10-490
Fresh air filter ......................................................................................................................................... 10-490
Condenser .............................................................................................................................................. 10-490
Compressor ............................................................................................................................................ 10-491
Filter dryer .............................................................................................................................................. 10-491
Filling quantities ...................................................................................................................................... 10-491
Pressure and safety switch ..................................................................................................................... 10-491
Magnetic clutch....................................................................................................................................... 10-491
Fault diagnosis
Preconditions .......................................................................................................................................... 10-494
Fan ......................................................................................................................................................... 10-495
Operating mode selector switch ............................................................................................................. 10-496
Circulating air mode ................................................................................................................................ 10-497
Temperature settings .............................................................................................................................. 10-498
Air conditioning mode ............................................................................................................................. 10-499
Troubleshooting
Checks prior to troubleshooting .............................................................................................................. 10-501
Troubleshooting ...................................................................................................................................... 10-502
10-452
IN GENERAL
Introduction
The air conditioning systems of our wheel loaders are now filled with the environmentally
friendly coolant R134a (tetrafluorethane) following the withdrawal of official approval of the
coolant R12 (dichlorfluormethane) on January 1, 1995.
General
• Liquid cooling gas absorbs heat when it turns into gas.

This takes place in the vaporiser.
When the gas turns into liquid gas the heat is dissipated.
This takes place in the condenser.
The air conditioner does not produce cold air, it takes the temperature from the
surrounding warm air and dissipates it.
Physical principal
• Physically, heat moves from a warm element towards a cold element. When this
occurs, the fast moving molecules in the warm element transfer a part of their energy
to the slow moving molecules in the cold element. This causes the fluid used in the air
conditioner to change form. Individual atoms, which make up the molecules, change
their position. When this happens the fluid changes from gas to liquid.
e.g.: This reaction can be seen with water. Water is normally liquid between 0°C and
100°C. If the water is heated, it becomes steam. The water changes from a liquid form
into a gas form. If the water is cooled it becomes ice. The water changes from a liquid
form into a solid form.
Characteristics - R134a
- Colourless, odorless, tasteless

- Incombustible, so there is no danger of ignition or explosion
- Chemically stable
- Does not decompose structural materials
- Ozone depletion potential (ODP) of 0
- Global warming potential (GWP) substantially lower than that of R12.
10-453
Physical datas R134a and R12

Unit R134a R12
Molecular formula - CH2FCF3 CCl2F2
Molecular name - 1,1,1,2-Tetraflouro- Chloroflurocarbon

ethan
Agent class - HFKW FCKW
Molecular weight - 102.03 120.91
Boiling point (at 1.013bar) °C -26.5 -29.79
Critical temperature °C 101.15 111.8
Critical pressure bar 40.64 41.5
Critical density kg/l 0.508 0.558
ODP(Ozone Depletion - 0 1.0

Potential)
GWP (Global Warming - 0.24 - 0.29 2.8 -3.4

Potential)
New components in the R134a circuit
Part name Change Identification label
Compressor Compressor oil, seals R134a
Drier Molecular sieve R134a
Expansion valve Valve control characteristic R134a
Piping hose R134a - magnetic clutch
Seals new material
Refrigerant oil old: mineral oil / new: synthetic oil
10-454
FUNCTION
10-455
The coolant circuit
• The coolant R134a circulates throughout the system in an enclosed circuit.
• Gaseous coolant under low pressure is sucked from the vaporiser (8) by the compres-
sor (2). This places the gaseous coolant under high pressure (approx. 20 - 30 bar) and
forwards it to the condenser (3).
The gaseous coolant transcends into a liquid state in the condenser (3) because of the
applied pressure and removal of heat. Fans blow outside air through the condenser to
cool the warming coolant. The heat removed from the air fed into the operator's cab is
passed on to the outside air. The coolant is still under high pressure at this point.
The coolant passes through the filter dryer (4) and the pressure switch (5) at the
entrance to the vaporiser (8) in this state. The coolant is filtered and dried in the filter
dryer (4). It is also a compensation tank at the same time.
The throttle effect of the expansion valve (7) reduces the pressure and the temperature
of the coolant. It makes sure that only as much coolant flows into the vaporiser (8) as
can actually be vaporised. The liquid coolant then reverts to its gaseous state in the
vaporiser.
Outside air is fed through the vaporiser (8) by the fresh air fan. While passing through
the vaporiser (8) , the warmth it contains is extracted from the outside air before it flows
through the air vents into the operator's cab.
That completes the circuit.
10-456
1. Magnetic clutch 8. Vaporiser

2. Compressor 9. Icing protection switch
3. Condenser 10. High-pressure, gaseous
4. Filter dryer 11. High pressure, liquid
5. High-pressure switch 12. Low-pressure, liquid
6. Low-pressure switch 13. Low-pressure, gaseous
7. Expansion valve
10-457
The condenser
With a cooling system, warmth at a place where it is not required is transported to another
place where the warmth absorbed by the vaporiser is fed on to the condenser. In the
condenser, the gaseous coolant is cooled and liquefied. The warmth removed during
liquefying is dissipated into the air by the condenser.
The coolant flows through three zones during this:
1st zone: The gaseous coolant is cooled to condensation temperature by dissipation of

warmth (pre-cooling zone).
2nd zone: The coolant transcends into liquid state by dissipation of the condensation
heat at a constant temperature (condensation zone).
3rd zone: The liquid coolant is cooled to below the condensation temperature, i.e. it is
overcooled (overcooling zone).
The pressure (condensation pressure) is approximately constant in all three zones. The
coolant leaves the condenser in a liquid state and, consequently, can be used again in the
coolant circuit.
End of pre-cooling zone
End of condensation zone
End of overcooling zone
10-458
The vaporiser
Liquid coolant is sprayed into the vaporiser and converted to a gaseous state. During this
process, the coolant boils in the vaporiser. The temperature of the coolant can fall well
below the freezing point during boiling. The coolant adopts a very similar behaviour to
boiling water in the vaporiser. The warmth which the coolant requires to evaporate is
withdrawn from its environment. At the end of the vaporising process, the coolant emerges
as steam. The actual vaporiser has been lengthened in order to allow any liquid bubbles
which may possibly have been carried along as a result of the turbulence time to
evaporate as well. This extension is called the after-vaporiser.
End of vaporising zone

End of vaporiser Begin of overheating zone
Vaporised
overheated
coolant
Injector nozzle
Liquid
coolant
Begin of vaporising zone
There are two fundamental methods of operation for vaporisers:

- Inundated vaporisers (disc vaporisers)
- Dry expansion vaporisers (round pipe and serpentine vaporisers)
While inundated vaporisers are generally bound to upright installation and coolant flow
and require special measures for ensuring oil return and avoiding cavitation, dry expansion
vaporisers where overheated steam is fundamentally present at the outlet can be installed
in virtually any position without any special measures having to be taken.
10-459
Inspection
glass
The filter/dryer to expansion
valve
The volume of circulating coolant varies

with changing thermal load. The filter dryer
contains the required quantity of coolant for
this. It removes bubbles from the from
condenser
condensing coolant so that only liquid
coolant is forwarded to the expansion valve Cleaning
(bubbles in the coolant reduce the sieve
performance of the air conditioning unit).
Drying
Remove moisture from the coolant. agent
Inspection glass allows a visual check of

level of coolant in system.
Design
The filter dryer contains a cleaning sieve, a drying agent for removing the moisture from
the coolant, an inspection glass for checking the level of coolant and a pressure switch
(high and low pressure) which switches the compressor off when the pressure on the high
pressure side of the system is too low or too high.
Important instructions for operation
Because the drying agent in the filter dryer is very hygroscopic it immediately absorbs
moisture on coming into contact with the air and loses its demoisturising property. The
drying agent cannot absorb more than approx. 6-12 g moisture. For this reason, the inlet
and outlet have to be sealed tight with plugs whenever the filter dryer is removed.
When installing the air conditioning unit in
the vehicle, install all other parts and
pipelines first before removing the plugs
and mounting the filter dryer. Attention must
be paid that the inlet and outlet are not
confused. If the inlet and the outlet have the
same form, the connection marked "IN" or
with an arrow pointing in the direction of the Outlet
housing has to be connected to the
condenser side. If connected the other way Inlet
round, gaseous coolant flows into the
expansion valve which results in a
considerable drop in the coolant
performance of the system.
10-460
DESCRIPTION
10-461
Design of air conditioner
1 Compressor
2 Suck pipe
3 Pressure pipe
4 Filling valves
5 Condenser 1
6 Connection hose condenser of 1+2
7 Condenser 2
8 Filter-drier with inspection glass
9 Air intake
10 Vaporizer
11 Thermistor
12 Heat exchanger radiator
13 Fan
14 Air filter outside air
15 Air filter inside air
16 Expansion valve
17 Switch for high and low pressure
18 Air outlet
Installation: WA 270-3 /
WA 320-3 SN H20561 and up
1 2
1. Controller
2. Fan
3. Thermistor
3
4. Vaporizer
7
5. Pressure switch
4
5 6. Filter dryer
6
7. Condenser
8. Pipe from Compressor

8 9
9. Pipe to compressor
10-462
Installation: WA 320-3 up to SN H20561 /

WA 380-3
1. Vent
2. Vent (Window)
3. Air conditioner condenser
4. Dry receiver
5. Compressor
6. Hot water inlet port
7. Hot water outlet port
8. Air conditioner unit
Installation: WA 420-3 / WA 470-3
1. Vent
2. Vent (Window)
3. Vent
4. Dry reciever
6. Compressor
8. Air conditioner unit
10-463
10-464
SAFETY
10-465
Handling coolants
When coolant circuits are opened, the contents may escape in liquid or vapour form. The
higher the pressure in the circuit, the more violently this will happen.
Wear safety goggles

Wear safety goggles. These prevent coolant from getting into your eyes, which may cause
severe frostbite damage.
Wear protective gloves

Coolants are good solvents of greases and oils. They therefore remove the protective film
of grease on contact with the skin. Degreased skin however, is sensitive to cold and
disease-causing bacteria.
Suitable protective gloves are an effective way of avoiding degreasing skin.
Do not get liquid coolant onto the skin

A coolant is designed for cooling. For this purpose, it needs to evaporate. The coolant
extracts the heat for evaporation from its environment, even if this is the skin, and very low
temperatures are reached in the process. This leads to local freezing (frostbite).
Do not breathe in coolant vapours in high concentrations

All coolants - even those which are liquid at room temperature - evaporate when the circuit
is opened. The vapours mingle with the ambient air.
In the case of all types of coolant except for RI 1 and R113, the main risk is that they will
displace the oxygen in the air which is necessary for breathing (risk of suffocation).
Ensure good ventilation

In order to prevent occurrance of higher concentrations, work-places must be well
ventilated. The maximum working concentration must be observed.
Exhaust system
Opening windows and doors may not be sufficient, that means an exhaust system must be
installed at the point of exit if possible or close to the floor. This is particularly important
when working with open liquid coolants such as R 11 and R 113.
Do not smoke
Coolants can decompose in the heat of a cigarette. The substances thus produced are
toxic and should not be breathed in.
Do not let coolants escape during filling or repair work, but transfer to recycling
containers
If coolants are allowed to escape in closed rooms, higher concentrations can arise which
poses a risk to life due to narcotic effects or lack of oxygen.
Always transfer coolants from plants in need of repair into recycling containers for
temporary storage and, after the repair work, refill into the plant or return to the dealer.
10-466
If high concentrations of coolant are present in the air, use respiratory equipment
which is independent of the ambient atmosphere!
Filter masks with breathing filter A (solvents) can only remove coolant vapours to a small
extent. They may only be used if the concentration does not exceed 0.5 % vol. (see
respiratory equipment specifications). If the concentration is too high, there is a risk of
suffocation particularly in pits and shafts, since coolant vapours are heavier than air. In
case of doubt, always use respiratory equipment which is independent of the ambient
atmosphere.
Before carrying out welding and soldering work on cooling systems, remove
coolant from the relevant section of the plant and eliminate residue by blowing
through with air or nitrogen!
Decomposition products generated from the coolant are not only toxic but also have a
strongly corrosive effect, so that pipelines and parts of the plant may be attacked.
Pungent odour indicates decomposition of the coolant due to overheating: - leave

room immediately, ventilate well or use filter mask with breathing filter B (acidic
gases)!
If a pungent odour occurs, the above mentioned decomposition products have already
been generated. These substances should not be breathed in under any circumstances,
as this can damage the respiratory channels, lungs and other organs. A filter mask with
breathing filter B (acidic gases) provides effective protection against these decomposition
products. Observe the instructions for use!
First aid
1. In the event of contact with the eyes or mucous membranes, rinse out immediately
with plenty of running water and consult an eye specialist.
2. In the event of contact with the skin, remove wet clothing immediately and rinse
affected area of skin with plenty of water.
3. If coolant vapours are breathed in in higher concentrations, get the affected person
into the fresh air immediately. Summon a doctor. Administer oxygen in the event
of breathing problems. If the affected person can no longer breathe or cannot
breathe properly, bend head to back of the neck and resuscitate.
4. Information for the doctor: Higher concentrations of coolants can lead to a

restriction or loss of consciousness. Since coolants
make the heart sensitive to catecholamine, no
adrenomimetics should be administered.
A lung oedema can occur even after an indefinite latent
period if decomposition products have been inhaled.
10-467
10-468
OPERATION
10-469
CONTROLLER
WA 270-3 /
1. Rotary switch for van

2. Temperature control
3. Circulating air / Fresh air
4. Air distribution
5. Switch on lock
6. Switch ON / OUT
WA 320-3 up to SN H20560 /
WA 380-3 / WA 420-3 / WA 470-3
Operating mode selector switch
for setting air direction or defrosting
Air recycling mode switch
Temperature
control Air conditioning system
step-free switch
Fan switch ON/OFF
and various stages Control panel for
temperatures
• The set temperature remains stored with the following exceptions:
- If the machine has not been operated for longer than 1 week
- If the battery voltage is extremely low
• It is possible to generate overpressure in the cab by running fan at high level and
switching to fresh air setting to prevent penetration by dust.
10-470
HINT
• Only operate the air-conditioning when the engine is running.

• Run the air-conditioning for at least 10 minutes every month irrespective of
season. This prevents the compressor shaft seal from drying out.
Cab windows, doors and ventilation openings must be closed when operating the air-
conditioning, otherwise there is an excessive influx of heat which presents an effective
cooling of the cab. If the machine has been standing in the sun for a longer period of time,
we recommend airing the cab completely when starting up the engine by switching on the
air-conditioning and leaving the doors and windows open initially. This process can be
speeded up by increasing revving up engine.
Operation: WA 270-3 /
Switch on air-conditioner
1 Turn rotary switch (1) for fan to position "3".
2 Set temperature control (2) to "cold".
3 Set selector lever (3) to position "circulating air".
4 Push the switch (6) lock (5) down, hold in position and
press switch. The air-conditioning is now switched on
and the control lamp in the switch lights up.
Maximum cooling is achieved with this setting; even

more so if the engine is run at high rpm. Turn the fan
down a position as soon as the required temperature
has been reached and regulate further using the
temperature control. For low cooling requirements,
switch the fan to its lowest operating level.
5 Selector lever (4) is used for air distribution to the

rear window via air jets (7 and 8). These air jets can
be opened and closed individually. The flow direction
can be adjusted by changing position of vanes.
10-471
Operation: WA 320-3 up to SN 20560 /

WA 380-3 WA 420-3 WA 470-3
Temperature level
indicator lamp
1. FAN SWITCH
Via these switches, the air flow can be set to four
various levels.
This switch also acts as the main switch for the air
conditioner.
When the switch is pressed, the indicator lamp above
the respective switch lights up to indicate the air flow.
2. AIR CONDITIONER SWITCH

This is used to start or stop the cooling or
dehumidifying function. When the fan switch is turned
ON and the air conditioner switch is pressed, the
indicator lamp above the switch lights up.
When the switch is pressed again, the switch is
turned OFF and the indicator lamp goes out.
3. MODE SELECTOR SWITCHES

These are used to select the vents.
The following five vent modes are available: FACE,
FACE/FOOT, FOOT, FOOT/DEF, DEF.
After pressing one of these switches, the indicator
lamp above lights up to display the vent mode.
10-472
4. FRESH/RECIRC SELECTOR SWITCH
This switch is used to select between recirculating the air

inside the cab or taking in fresh air from outside.
When the RECIRC position is selected, the indicator lamp
above the switch lights up.
When the switch is pressed again, the indicator lamp goes
out, and fresh air is taken in.
5. TEMPERATURE CONTROL SWITCH
The temperature can be adjusted steplessly from low to high.
The temperature level indicator lamps light up to display the

temperature of the air coming from the vents. The more the
blue lamps light up, the lower the temperature.
The color of the indicator lamp changes while the switch is

being pressed. When the temperature reaches the desired
level, release the switch to set the temperature.
The settings for each mode are retained in memory even when be starting switch is turned
OFF. However, in the following cases, the settings must be made again:
• When the machine has been out of use for more than
7 days
• When the battery voltage is extremely low
• When there has been abnormal interference from

outside
• When the fan switch is turned OFF (the setting is not

kept in memory with only the air conditioner switch
active)
If the air conditioner is used together with the FRESH position, the inside of the cab will be
pressurized and this will prevent the entry of dust. The higher the position of the fan switch, the
more effective the pressurizing.
10-473
SETTINGS
Switch 1 2 3 4 5
Switch for air Operating mode Fresh/Circulating Temperature

Operating state Fan switch
conditioner selector switch air switch control
Fast HI ON HEADROOM RECIRC All blue

Cool
More than half
Normal HI-LO ON HEADROOM FRESH
are blue
More than half

Demoisturise, heat HI-LO ON LEGROOM FRESH
are red
Fast HI OFF LEGROOM RECIRC All red

Heat
More than half
Normal HI-LO OFF LEGROOM FRESH
are red
More than half

Defrost HI ON DEFROSTER FRESH
are red
Ventilate and pressurise HI-LO OFF HEADROOM FRESH All blue
3 4
1 5 Temperature 2
control lamp
Set the temperature control switch to the maximum temperature in order to improve the
performance of the system during defrosting and demoisturizing.
Set the operating mode switch to LEGROOM at the same time.
The air flow can be directed to HEADROOM or switched off when the ventilating mode is
switched on.
Do not switch to ventilating mode HEADROOM if the ventilation slots are closed.
10-474
MAINTENANCE
MAINTENANCE TIMETABLE
VISUAL INSPECTION (once a month)
Drive belts Tension, condition
Compressor Leaks, unusual noises
Magnetic clutch Function
Condenser Damage, dirt
Condensation outlet underneath the

Dirt, blockages
vaporiser
Coolant Filling level in inspection glass
FUNCTIONAL TESTS (once a year)
High pressure, low pressure High pressure: Low pressure:
Emission temperature at air vents At maximum output:
Compressor control ON and OFF switching points
Condenser fan Rotational direction, noises
Air distribution, air circulation system Emission, control
Magnetic clutch Dirt, oil soiling
EXCHANGE (every 2 years)
Replace filter dryer, suck off coolant, dispose in an environmentally safe manner
and fill the system with new coolant
10-475
MAINTENANCE INSTRUCTIONS
Always disconnect the battery if parts of the air conditioning system are to be removed.
Keep the system free of moisture and dust.
Always seal cable glands immediately with cap plugs when disconnecting cables.
Only remove plugs or caps just before reconnecting cables or lines.
Apply a few drops of low temperature oil to the contact surface of the O-ring or cone nut
before connecting a hose or line.
Always use two spanners when tightening a connection in order to prevent it from twisting.
A disposal unit must be connected when draining the cooling section of the system.
REGULAR MAINTENANCE
The air conditioning system must be switched on at least once a month for a brief time
(approx. 10 min) so that the compressor is lubricated.
The following maintenance work must be carried out at the beginning, middle and end of a
cooling period:
- Check V-belt tension and compressor fastening.
- Check coolant level

+ The coolant must flow through the filter dryer's inspection glass free of bubbles with
the engine running and air conditioner at maximum output (max. blower setting, top
idling speed, setting "cold").
- Clean the condenser:

+ The fins of the condenser must not be operating at excessive pressure as this could
deform the fins and reduce the cooling output.
Have an inspection of the air conditioning system carried out at least once a year by your
workshop.
The individual components should be kept closed as long as possible when

installing because of the very strong hygroscopic behaviour of the PAG oil
in the compressor.
10-476
INSTRUCTIONS FOR FILLING
• Filling the air conditioning system should only be carried out by a specialist for air
conditioning systems.
For this reason, only a few instructions are provided here for filling the air condition-
ing systems installed in WA-3 models.
• Use only original-coolant R134a and original PAG oil.
Mixing with other coolants or oils can result in the destruction of the air
conditioning system.
• The valves on the testing manometer should be closed (manometer valves turned
clockwise) when fastening the snap-fit connectors to the system. The central valve
connection for selecting vacuum pump or filling canister connection is therefore
closed.
Caution: An ambient temperature of at least 20°C (room/air) is required for a correct

evacuation.
10-477
EVACUATION
- Connect ball valves
- Set vacuum meter to 100 mbar
- Evacuate, min. 45 minutes
VACUUM TEST
- Check the vacuum meter after 10 minutes for pressure increase
+ A pressure increase is not permitted.
In the event of pressure increase

- Fill system with approx. 200 g
- Look for leakage points using leak finder
- repair leaks
- Start siphoning off.
No pressure rise
- Fill system
SIPHONING OFF COOLANT

- Close ball valves.
- Siphon off coolant into a measuring container; a certain amount of compressor oil will
also be siphoned off at the same time.
- The same amount of compressor oil as was siphoned off with the coolant must be
replaced with new compressor oil.
- Extracted coolant and compressor oil must be disposed of in accordance with
regulations.
- The siphon pressure gauge must indicate slight over-pressure before opening the drain
valve in order to avoid any air being sucked in.
FILLING
- Set prescribed Quantity on fill unit or weigh
- Commence filling
- Start engine
- Check on inspection glass of filter dryer
+ The filling is OK when the coolant flows
without bubbles.
FILLING QUANTITIES (R134a)
- WA 270-3 1000 g
- WA 320-3 1500 g
- WA 380-3 1500 g
- WA 420-3 1500 g
- WA 470-3 1500 g
10-478
CHECKING COOLANT LEVEL

• Run the air conditioning system at maximum output
for 5 - 10 minutes. Touch the high pressure section
and the low pressure section of the compressor or
the high pressure pipe and the low pressure pipe
connecting element with your hand. At the same
time, check the flow of coolant (R134a) through the
inspection glass for correct level of coolant.
Cooler condition Normal Abnormal
Temperature of high High pressure pipie is hot. High pressure pipe is Amost no difference in
and low Low pressure pipe is cold. warm. Low pressure pipe temperature between high
pressures pipes Clear difference in is cold. Little difference in and low pressure pipes.
temperature temperature
Sight glass Almost transparent. All Bubbles are always visible. Opaque substance is
bubbles disappear if the Sometimes becomes visible in the fluid.
engine speed is increased transparent, or white
or reduced. bubbles appear.
Pipe connections Properly connected Some parts contaminated Some parts heavily stained
with oil. with oil.
General condition of Coolant level correct, no There may be a leak Almost all coolant has
cooler abnormalities. somewhere. leaked out.
Ready for use. Call service repair shop for Contact service repair
inspection. shop immediately.
CHECKING THE COMPRESSOR OIL LEVEL

• Check, top up or change if:
- Compressor, vaporizer, condenser or drier have to be changed.
- Coolant leaks from coolant circuit.
- Problems occur with the oil in the coolant circuit.
- The connectors from compressor or dryer was opened.
10-479
COMPRESSOR OIL CHANGE
1. Remove compressor from the vehicle.
2. Drain the oil into a measuring beaker.

After the oil has flown out through the line, drain off any residual oil at the drain outlet
by turning several times by hand.
3. Check the oil for impurities.
4. Screw in drain plug with new washer and tighten. MA = 13-15 Nm.
5. Fill up with new compressor oil to same amount as measured quantity of drained oil.
EXCHANGE OF MAGNETIC CLUTCH
If the magnetic clutch is faulty
- Remove compressor
- Remove old clutch from compressor
- Connect new clutch to compressor
- Install compressor
- Switch on air conditioning system
- Operate compressor in neutral
- Switch air conditioning on for 10 seconds and off for 10 seconds at least 10 times,
check function of new clutch while doing so.
10-480
EXCHANGE OF COMPRESSOR
- Drain off coolant and dispose it in accordance with regulations.

- Remount the hoses and close them with cabs.
- Remount the compressor.
The compressor has to be installed within the range shown in the figure.
If installed outside this range, the compressor will be adversely affected.
This compressor is equipped with a pressure feed lubrication system which cannot
function properly if the compressor is installed outside this range.
Installing of a new compressor:
- The new compressor is filled with 150cm³ PAG oil and nitrogen gas (N2).
1. Loosen the discharge side connector's cab, release the nitrogen gas (N2) from
the compressor gently, close the connectors immediately.
Note: No compressor oil should escape!
2. Rotate the compressor several times by hand to distribute the oil.
3. Replace the compressor under compliance of the ranges shown in the figure above.
Adjust the clearance using the specified shims.
4. Remove the cabs and connect the hoses immediately.
The PAG oil is highly hygroscopic.

Single components must therefore be closed until they are installed.
5. Filling (see page 10-478).
10-481
Service operations
right wrong wrong

Fit the nuts and
unions tightly
against the base
of the companion
pieces, then
O-ring Pipe bulge hand tighten the
nut as much as
possible to
prevent cross-
Apply oil thoroughly to these threading.
areas.
Cone packing connections Fit the nuts and

unions tightly
Armature against the base
Cupper seal of the companion
pieces, then hand
Seal cone tighten the nut as
much as possible
to prevent cross-
threading.
Always use a
back-up wrench
and tighten fittings
to the specified
torque. The torque
wrench should be
used on the fitting
which is being
tightened.
10-482
ELECTRICAL SYSTEM
10-483
CONTROLLER: WA 320-3 up to SN 20560 /

WA 380-3 WA 420-3 WA 470-3
Plug assignment
Section Clamp Designation Function

G1 1 +24V terminal 30 +24V
H10 2 Motor connection shutter right +/- 0V or +24V
H10 3 Motor connection shutter right +/- +24V or 0V
H7 4 Water valve +24V terminal 15 +24V
H7 5 Water valve control voltage 0V to +9V
H12 6 Motor connection shutter left +/- 0V or +24V
H12 7 Motor connection shutter left +/- +24V or 0V
H15 8 Air recycling/Fresh air +24V terminal 15 +24V
G4 9 +24V terminal 15 +24V
H5 10 Digital - Earth Earth
H5 11 Thermometer Off: 29.7k Ω On: 23.7kΩ
H11 13 Shutter right, slider position 2 Earth input
G12 14 Background lighting +24V input
G5 15 Fan stage 4 Earth output
H15 16 Recycling air/Fresh air Recycling air = 24V / Fresh air = 0V
G8 19 Clutch Earth output
G13 20 Shutter left, slider position 3 Earth input
G6 21 Condenser fan Earth output
G10 22 Shutter right, slider position 4 Earth input
H4 27 Digital - Earth Earth
H4 28 Analogue - Earth Earth
H13 31 Shutter left, slider position 4 Earth input
H8 35 D+ +24V input
Function
Head room Foot area
Shutter position Head room & Foot area & Front screen
foot area front screen
Shutter left à ---------- 20 32 34 End position
Shutter left à End position 31 20 32 ----------
Shutter right ß ---------- 33 13 30 End position
Shutter right ß End position 22 33 13 ----------
10-484

10-485

10-486
Connection for control of servomotor: circulating air / fresh air

Pin Colour Connector
1 red (r) + Supply line (18-32 Volt)
2 brown (br) Ground
3 white/red (w/r) not used
4 white/black (w/b) Circulating air (24 Volt)
5 white (w) not used
6 blue (bl) not used
Page 10-485, Section K15
Connection for control of servomotor: warm air / cold air

Pin Colour Connector
1 red (r) not used
2 brown (br) Ground
3 white/red (w/r) + Supply line (18-32 Volt)
4 white/black (w/b) not used
5 white (w) Analogous entrance
6 blue (bl) not used
Page 10-485, Section K7
Connection for motor pins

Pin Colour Pin Colour
Connector
motor motor control control
1 green (g) 1 green (g) Poti ground
2 grey (gr) 2 grey (gr) Poti + 5 Volt
3 yellow (y) 3 yellow (y) Poti exit
4 NC 4 --- ---
5 brown (br) 5 brown (br) Motor
6 white (w) 6 white (w) Motor
Connector pins for the servomotors
10-487
Circuit diagram / Pin assignment

WA 270-3 /
Section Name
39 Y 293 Solenoid valve, compressor
40 K 292 Relay
40 B 296.1 Press. switch, heat exchanger
41 S 54.2 Switch, cooling
41 M 296 Fan, heater / cooler
42 S 54.1 Switch, fan (heater / cooler)
43 S 293.1 Thermostat
44 M 297 Fan with thermostat
10-488
30
15
Wiring Diagram Masse

Signal
Air Conditioner 31
31
39 40 41 42 43 44
WA 270-3 /
10-489
Technical data
Heating
Type Water / Air
Nominal voltage 24 Volt
Air flow rate max. 600 m³/h
Heat output Q 100 6.5 kW
Fan stages 4
Power consumption max. 10 amperes
Air conditioning unit

Type Coolant / Air
Cooling output 5.5 kW
Fan stages 4
Power consumption max. 10 amperes
Coolant R134a
Air recycling filter

Type Pleated polyester spun bond fleece
Filter area 0.3315 m²
Filter gauge Class: (BIAU) U
Number 2
Fresh air filter

Type Pleated polyester spun bond fleece
Filter area 1.6 m²
Filter gauge Class EU4
Number 2
Miscellaneous Washable
Condenser
Type Coolant / Air
Number 2
Heat output 6 kW
Fan stages 1
Power consumption max. 4.7 amperes
Coolant R134a
10-490
Technical data
Compressor
Type Seltec TM - 15H
Max. speed 6000 rpm
Delivery rate 147 cm³
Rotational direction Clockwise or anti-clockwise
Coolant R134a
Type of oil ZXL100PG (PAG oil)
Filling quantity 150 cm³
Weight 7 kg
Power consumption max. 3.75 amperes
Filter drier
Content 0.7 litres
Filtration Up to particle size > 6 micrometer
Water absorption of drying element (plug) 16 g
Coolant R134a
Weight 1 kg
Filling quantities
WA270-3 1000 g
WA320-3 1500 g
WA380-3 1500 g
WA420-3 1500 g
WA470-3 1500 g
Pressure and safety switches

Low pressure: Shut-off pressure = 2.0 bar
Switch-on pressure = 3.5 bar
High pressure: Shut-off pressure = 25 bar

Switch-on pressure = 18 bar
Magnetic clutch
Switching capacity 3.5 amps 13 VDC
10-491
10-492
FAULT DIAGNOSIS
10-493
PRECONDITIONS
3 4 13
II
I
• Preconditions for the start of fault diagnosis
a) Optimum power supply present
b) Fuses OK
- Fuse cassette I no. 13 (20A) - Operating element memory function
- Fuse cassette II no. 3 (20A) - Condenser fan, compressor clutch, pressure

switch
no. 4 (20A) - Vaporizer fan
10-494
FAN
OFF LO O OO HI
- Beep tone
- Control lamp on yes
- Air flow rate corresponds with O. K.
level setting
no
Control faulty? yes

exchange
no
Relay fault? yes

exchange
no
Cable set faulty? yes

exchange
10-495
OPERATING MODE SWITCH
- Beep tone
- Control lamp on yes
- Air flow on right channel O. K.
no
Control faulty? yes

exchange
no
Control actuator yes

exchange
faulty?
no
yes repair, exchange

Cable set faulty?
if necessary
10-496
AIR RECYCLING MODE
- Beep tone
- Control lamp on
- Air suction through air recycling yes
filter, possibly visual check of shutter O. K.
position (remove filter)
no
Check shutter for yes repair, exchange

air recycling box if
mechanical fault
necessary
no
Control faulty? yes

exchange
no
Control yes
actuator faulty? exchange
yes
Cable set faulty? exchange
10-497
TEMPERATURE SETTING
- Beep tone
- The more control lamps yes
are on, the warmer the air O. K.
- Check water valve function
no
Mech. fault?
Visual check of actuator, rods, yes exchange,
water valve, feed, return repair
no
Control faulty? yes

exchange
no
Control actuator yes

exchange
faulty?
yes exchange,
Cable set faulty?
repair
10-498
AIR CONDITIONING MODE
A/C
- Beep tone
- Control lamp on
- Fan min. stage 1 yes
- Noticeable cooling of air O. K.
no
No coolant in yes Look for leaks,

system repair and refill
no
Control faulty? yes

exchange
no
Compressor yes
exchange
faulty?
Check clutch,
apply 24 V to compressor
connection
Cable set, relay, yes exchange,

pressure switch faulty? repair
10-499
10-500
Troubleshooting
Checks prior to trouble shooting:
- Check belt tension
- Check condenser
- Check condenser blower, rotation direction right
- Compressor switches on and off
- Compressor clutch OK
- Function of air vents OK
- Coolant level OK (inspection glass)
- Condensation drain away
- Air temperature OK
10-501
Cause Fault recognition Remedy

Low pressure too high - System too full - Clean condenser or replace
High pressure too high - Condenser is dirty or blocked - Repair blower or replace
- Blower faulty or wrong
rotational direction
- Condenser blocked
Low pressure too low - Dryer blocked - Replace dryer

High pressure too high - Faulty expansion valve - Replace expansion valve
- Compressor faulty - Replace compressor
Low and high pressure the same - Compressor faulty - Check drive belt - belt pulley
- magnetic clutch, if all
correct, proceed as for
"Compressor does not switch
on"
Low pressure too low - Faulty expansion valve - Replace expansion valve
High pressure normal - Dirty or blocked vaporiser - Clean or replace vaporiser
Low pressure too low - Expansion valve faulty - Replace expansion valve
High pressure too low - Not enough coolant - Refill air conditioning system
- Insufficient cooling effect - Evacuate system, replace
only for short time; water in dryer
system, expansion valve iced - Replace dryer and expansion
up as a result valve
- Dryer or expansion valve - Check the ON and OFF
partially blocked times of the compressor
- Vaporiser iced up - Adjust or replace the
- Thermoswitch not working thermoswitch
Compressor switches on and off at - Loose contact in the - Check electrical system (air
speed electrical system conditioner switch,
- Coolant pressure too high thermostat)
- Check air conditioning
system pressure and refill if
necessary
Compressor constantly running as - Thermostat not working - Check whether sensor lead
well has been pushed into the
vaporiser correctly
- Check whether the sensor
lead is okay
- Adjust or replace thermostat
Compressor does not switch on - Not enough coolant in system - Check air conditioning
- Air conditioning system system pressure and refill if
power supply interrupted necessary
- Check electrical system
Condenser fan not working - Fault in the electrical system - Check electrical system
- Fan faulty - Repair fan or replace
10-502
Cause Fault recognition Remedy

System leaking - O-ring connection leaking - Check pipe and line
- Compressor shaft seal connections
leaking - Check pipes and lines
- Hose/line leaking - Check whether magnetic
clutch belt pulley is oily
Cooling output too low - Vaporiser iced up - Check whether sensor lead
has been pushed into the
vaporiser correctly
lead is okay
Cooling output drops after a while - Compressor not switching off - Check whether compressor
- Thermostat not working switches on and off
- Check whether sensor lead
vaporiser correctly
lead is okay
Air conditioning system not - Power supply interrupted - Check electrical system
working - Not enough coolant in the - Check filling level
system - Check magnetic clutch,
- Magnetic clutch faulty replace if necessary
White smoke emerging from the - Vaporiser iced up - Check whether compressor
air vents - Thermostat set too cold switches on and off
- Check whether sensor lead
vaporiser correctly
lead is okay
Windows fogged up - Circulating air flaps not - Check whether the circulating
working or not working air system is working properly
properly - Check that the condensation
- Condensation unable to drain drain hose is not blocked and
away is correctly laid
Bad smell coming from air - Condensation not draining - Check that the condensation
conditioning system away drain hose is not blocked and
is correctly laid
10-503
10-504
20 TESTING AND ADJUSTING
Standard value table for engine ......................... 20-2 Measuring accelerator pedal .................... 20-137
Standard value table for chassis .......................20-4 Basic adjustment of accelerator pedal ... 20-138-1
Test certificate ...................................................20-8 Measuring operating force, travel of
Standard value table for electrical system ....... 20-12 speed lever .............................................. 20-139
Tools for testing, adjusting and Measuring stall speed............................... 20-140
troubleshooting .............................................. 20-101 Measuring torque converter, transmission,
Up to SN WA380H20500: parking brake oil pressure ....................... 20-142
Adjusting valve clearance .............................. 20-103 Method of operating emergency
Measuring compression pressure ................. 20-107 manual spool ............................................ 20-144
Measuring blow-by pressure ......................... 20-109 Measuring clearance ............................... 20-146
Testing and adjusting fuel injection timing ...... 20-111 between tire and wheel ............................. 20-146
Measuring intake air pressure ....................... 20-113 Measuring steering oil pressure ............... 20-149
Measuring engine oil pressure ...................... 20-114 Measuring operating force, travel of
Measuring engine speed ............................... 20-115 brake pedal .............................................. 20-151
Measuring stall speed.................................... 20-116 Measuring brake performance ................. 20-152
Testing the fan belt tension ............................ 20-118 Testing brake oil pressure ........................ 20-153
Measuring turbocharger clearance ............... 20-119 Testing for brake disk wear ...................... 20-154
Turbocharger wastegate actuator Bleeding air from brake system................ 20-155
- visual inspection ......................................... 20-120 Measuring parking brake performance .... 20-156
Turbocharger wastegate actuator- Manual release method for parking
functional checking ....................................... 20-122 brake ....................................................... 20-157
SN WA380H20501 and up: Testing wear of parking brake disk ........... 20-158
Adjusting valve clearance .............................. 20-123 Measuring work equipment control lever .. 20-159
Measuring compression pressure ................. 20-124 Measuring work equipment
Measuring blow-by pressure ......................... 20-125 hydraulic pressure ................................... 20-161
Testing and adjusting fuel injection timing ...... 20-126 Measuring PPC-valve pressure ................ 20-163
Measuring exhaust color ............................... 20-129 Measuring work equipment ...................... 20-167
Measuring intake air pressure Testing and adjusting bucket positioner .... 20-169
(boost pressure) ........................................... 20-130 Testing and adjusting boom kick-out ......... 20-170
Measuring exhaust gas pressure ................... 20-131 Adjusting main monitor ............................. 20-172
Measuring engine oil pressure ...................... 20-132 Gas side test and topping up gas
Measuring engine speed ............................... 20-133 pressure .................................................. 20-173
Testing and adjusting fan belt tension ............ 20-134 Hydraulic accumulator ............................. 20-175
Method for adjusting engine stop cable ......... 20-135
« When using the standard value table to make judgement for testing and adjusting, and troubleshooting, the following
precautions are necessary.
1. The standard values in the table are the values for a new machine and are given as reference values for the time when
the machine is shipped from the factory. These values should be used as a guide when estimating wear and tear after
the machine is operated, and when carrying out repairs.
2. The permissible values given in the table are values estimated based on the results of various tests carried out on the
machines shipped from the factory, so they should be used together with the information on the repair condition and
other information such as the operating history of the machine when judging the condition of the machine.
3. These standard values do not form a basis for judging claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins and
blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people near the
machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is
still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE


Engine S6D108
Item Measurement conditions Unit Standard value Permissible value
High idling 2,450 ± 50 2,450 ± 100

Engine Speed Low idling rpm 785 ± 25 785 ± 50
Rated speed 2,200 2,200
Exhaust temperature All speed
°C Max. 650 700
(Turbine inlet temp.) (intake air temp. 20°C)
Intake resistance All rated output mmHg 950 – 1,200 750
At sudden acceleration Max. 6.0 7.0

Exhaust gas color Bosch
At high idling index Max. 1.0 2.0
Intake valve 0.34 –

Valve clearance mm
(cold) Exhaust valve 0.66 –
Compression pressure Oil temperature: Min. 2.9 2.4

(SAE 30 oil) 40-60°C bar
(engine speed: (Min. 30) (24)
250-300 rpm)
At rated output
Blowby pressure
(SAE 30 oil) mmH2O Max. 80 160
(Water temperature:
Operating range)
(Water temperature:
Operating range)
At high idling 0.29 – 0.49 0.21

(SAE 30) (3.0 – 5.0) (2.1)
Oil pressure At low idling MPa Min. 0.12 0.07
(SAE 30) (bar) (Min. 1.2) (0.7)
At high idling 0.25 – 0.44 0.18
(SAE 10W) (2.5 – 4.5) (1.8)
At low idling Min. 0.1 0.07
(SAE 10W) (Min. 1.0) (0.7)
Whole speed range
Oil temperature (inside oil pan) °C 90 -110 120
°
Fuel injection timing Before top dead center (degree) 22 22 ± 1
Deflection when pressed

with finger force of
Fan betlt tension approx. 6kg mm 5 - 10 5 - 10
(alternator pulley -
Fan pulley)
20-2
STANDARD VALUE TABLE FOR ENGINE


Engine S6D114E-1
Item Measurement conditions Unit Standard value Permissible value
High idling 2,410 ± 50 2,410 ± 100

Engine Speed Low idling rpm 785 ± 25 785 ± 50
Rated speed 2,200 2,200
Exhaust temperature All speed
°C Max. 700
(Turbine inlet temp.) (intake air temp. 20°C)
Exhaust gas color At sudden acceleration Bosch Max. 2,5

index
Valve clearance Intake valve 0.30 –

(cold) mm
Exhaust valve 0.61 –
At rated output
Blowby pressure
(SAE 30 oil) mmH2O Max. 164 226
(Water temperature:
Operating range)
(Water temperature:
Operating range)
At high idling 2,1 - 3,5 Min. 2,1

(15W40) bar
Oil pressure At low idling

(15W40) 0,7 - 2,2 Min. 0,7
Whole speed range

Oil temperature (inside oil pan) °C 90 -110 125
°
Fuel injection timing Before top dead center (degree) 16
Deflection when pressed

with finger force of
Fan betlt tension approx. 6kg mm 8 - 11
(alternator pulley -
Fan pulley)
20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Cate- Permissible
gory Item Measurement conditions Unit Standard value value
Torque converter stall • Engine water temperature 2,290 ± 50 2,290 ± 100
gauge: Green range
Engine
Hydraulic stall • Torque converter oil rpm 2,300 ± 100 2,300 ± 200
temperature: 60 – 80°C
Full stall • Hydraulic oil 1830 ± 200 1830 ± 300
Operating force N 58.8 – 73.5 108

(kg) (6 – 7.5) (11)
Accelerator pedal
α1 48 —
Operating angle deg.
α2 31 ± 3 —
Stopper height L1 mm 51 ± 5 —
+4.9 +0.5
Directional lever
Operating N – FORWARD N 5.9 –2.9 ( 0.6 –0.3 ) 13.7 (1.4)

force (kg)
N – REVERSE 5.9 +4.9
–2.9 (0.6
+0.5 )
–0.3 13.7 (1.4)
N – FORWARD 40 ± 10 40 ± 20
Travel mm
N – REVERSE 40 ± 10 40 ± 20
1st à 2nd • Engine stopped 59 +4.9 (0.6 +0.5 )

–2.9 –0.3 13.7 (1.4)
• Torque converter oil
Operating 2nd à 3rd temperature: 60 – 80°C N +4.9 (0.6 +0.5 )
5.9 –2.9 13.7 (1.4)
force (kg) –0.3
Speed lever
3rd à 4th 5.9 +4.9

–2.9 (0.6+0.5
–0.3 ) 13.7 (1.4)
1st ↔ 2nd 40 ± 10 40 ± 20
Travel 2nd ↔ 3rd mm 40 ± 10 40 ± 20

3rd ↔ 4th 40 ± 10 40 ± 20
High idling 2.9 ± 0.15 2.9+0.15 (30+1.5

Priority (30 ± 1.5) –0.29 –3.0 )
pressure Low idling 2.7 ± 0.15 2.7+0.15 +1.5 )
(28–2.5
(28 ± 1.5) –0.25
Transmission valve
Torque High idling 0.44 ± 0.05 0.44+0.05 (4.5+0.5

converter (4.5 ± 0.5) –0.1 –1.0 )
• Engine water temperature
outlet port Low idling gauge: Green range 0.34 ± 0.08 0.34+0.08 +0.8 )
(3.5–1.2
pressure MPa (3.5 ± 0.8) –0.12
• Torque converter oil (bar) 0.98 ± 0.1
Pilot pressure temperature: 60 – 80°C 0.98+0.1 +1 )
(10 –2
(10 ± 1) –0.2
• Work mode selector switch 2.3 ± 0.2
Clutch High idling 2.3+0.2 +2 )
(23 –4
on High mode (from (23 ± 2) –0.39
pressure SN WA380H20987 and up) 2.1 ± 0.34
Low idling 2.1+0.34 +3.5
–0.69 (21.5–7.0 )
(21.5 ± 3.5)
Parking brake 2.7 ± 0.15
pressure Low idling 2.7+0.15 +1.5 )
(28–2.5
(28 ± 1.5) –0.25
20-4

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Cate- Item Measurement conditions Unit Standard value Permissible

gory value
• Tire inflation pressure:
A Specified pressure Max. 2.5 —
Fitting of wheel
lock ring
Tire
B mm Max. 4.5 —
Clearance of wheel C 2 – 12 —
lock ring
• Engine stopped
Play • Machine facing straight mm 30 – 70 30 – 100
to front
Steering wheel
Operating force • Flat, horizontal, straight, N 9.8 – 14.7 34.3

dry paved road surface (kg) (1.0 – 1.5) (3.5)
• Hydraulic oil
Low idling temperature: 45 – 55°C 3.7 ± 0.5 5.0
Operating • Work mode selector switch
time on High mode (from Sec.
High idling SN WA380H20987 and up) 2.7 ± 0.5 5.0
Steering valve Frame
Clearance between front mm 25 ± 2 —

frame and rear frame
• Engine speed: High idling MPa
Relief pressure • Hydraulic oil 20.6 –+0.98 +10
0 . 2 9(210 – 3 ) 20.6 ± 1.96(210 ± 20)
temperature: 45 – 55°C (bar)
• Work mode selector switch
on High mode (from
SN WA380H20987 and up)
• Engine speed: Low idling
Operating force • Hydraulic oil N 294 ± 29.4 421,7
temperature: 45 – 55°C (kg) (30 ± 3) (43)
• Work mode selector switch
on High mode (from
Play 5 ± 0.5 —
α1 deg. 45 —
Operating angle
α2
Brakes
15 ± 1 —
• Flat, horizontal, straight, dry

paved road surface
• Speed when applying brake:
20 km/h, braking delay: 0.1 sec.
Performance • Brake pedal operating force: m Max. 5 Max. 5
265N(27kg)
Specified pressure
• Hold 4.9 MPa (50bar) MPa Max. 0.34 Max. 0.34

Drop in hydraulic pressure for 5 minutes (bar) (Max. 3.5) (Max. 3.5)
Wear of disc • Thickness of disc mm 8.0 ± 0.15 7.2
20-5


gory value
Specified pressure
Parking brake
• Flat paved road

Performance with 1/5 (11°20’) grade — Stopped —
• Dry road surface
Machine at operating condition
Wear of disc • Thickness of disc mm 3.2 ± 0.08 2.83
Max. 23.5 35.3

HOLD à RAISE (Max. 2.4) (3.6)
Max. 15.7 23.5
RAICE à HOLD (Max. 1.6) (2.4)
Max. 24.5 37.3
HOLD à LOWER (Max. 2.5) (3.8)
Boom
Operating force
37.3
LOWER à HOLD —
(3.8)
N Max. 34.3 52
LOWER à FLOAT
Work equipment control lever
(kg) (Max. 3.5) (5.3)

Max. 14.7 22.6
FLOAT à HOLD (Max. 1.5) (2.3)
HOLD à DUMP Max. 23.5 35.3

(Max. 2.4) (3.6)
• Engine speed: Low idling Max. 23.5 35.3
Bucket HOLD à TILT • Hydraulic oil (Max. 2.4) (3.6)
TILT à HOLD Max. 14.7 22.6
(Max. 1.5) (2.3)
HOLD à RAISE 67 ± 15 67 ± 30
Boom HOLD à LOWER 53 ± 15 53 ± 30

Travel
HOLD à FLOAT mm 67 ± 15 67 ± 30
HOLD à DUMP 60 ± 15 60 ± 30
Bucket
HOLD à TILT 60 ± 15 60 ± 30
• Hydraulic oil
Main control
+0.98 +10 +0.98 +10

valve
Relief pressure temperature: 45 – 55°C 20.6- 0,29 (210 - 3 ) 20.6- 0,29(210- 3 )

• Engine speed: Hiigh idling MPa
• Work mode selector switch (bar) +0.39 +4 +0.39 +4
valve
PPC
Relief pressure on High mode (from 2.94 (30 ) 2.94- 0.19 (30 - 2 )
0 0
Boom lifting time 5.5 ± 0.3 1) Max. 8.7
Work equipment speed
Work equipment
Boom lowering time 3.3 ± 0.5 2) Max. 5.0

• Hydraulic oil
Bucket dumping time • Engine speed: High idling Sec. 1.4 ± 0.3 3) Max. 2.1
• Steering valve: Neutral
At full stroke • No load 1.8 ± 0.3 Max. 2.7
Bucket • Work mode selector switch
tilting
time on High mode (from
Bucket horizontal SN WA380H20987 and up) 1.2 ± 0.3 Max. 1.8
SN WA380H20501 and up:

1)
5.1 ± 0.3
2)
3.0 ± 0.5
3)
1.5 ± 0.3
20-6


gory value
• Hydraulic oil
Hydraulic drift
Retraction of boom temperature: 45 – 55°C

equipment
cylinder rod • Leave for 5 minutes after Max. 14.0 –

Work
stopping engine then mm

measure for next 15 minutes
Retraction of bucket • Bucket empty, boom, bucket
cylinder rod Max. 36.0 –
horizontal
• No load
Clearance of bucket
Proximity
3–5 —
switch
positioner switch • Hydraulic oil

temperature: 45 – 55°C mm
Clearance of boom 3–5 —
kick-out switch
Accumulator 20 14
ALS
• Hydraulic oil
bar
Working pressure temperature: 45 – 55°C 98 +5 103
20-7

TESTING AND ADJUSTING TEST CERTIFICATE
Test certificate WA 380 - 3

Chassis no. Engine no. Owner
Engine output / rpm. Nominal Actual

1 Rated output ( kW/HP) 140 / 190
2 Low idle speed 760-810
3 High idle speed, no load 2400-2500
4 Stall speed against torque converter 2240-2340
5 Stall speed against hydraulics 2200-2400
6 Stall speed against torque converter and hydraulics 1630-2030
Operating temp ° C Nominal Actual

7 Engine (in operating temperature) 80 - 85
8 Torque converter 60 - 80
9 Hydraulic oil 45 - 55
Operating pressure bar. At high idling Nominal Actual

10 Working hydraulic pressure (max) 203 - 220
11 Cut-off pressure 160 - 165
12 PPC pressure 30 + 4
13 Steering pressure 207 - 220
14 Torque converter outlet pressure 4.0 - 5.0
15 Clutch pressure 23 ± 3
16 Accumulator gas press., operating / parking brake 35 / 15
Working times in sec. At high idling Nominal Actual

17 Lift, bucket empty 5.0 - 5.6
18 Bucket dump, boom highest position 1.1 - 1.7
19 Tilt back, boom highest position 1.5 - 2.1
20 Lower, bucket empty, 2.8 - 3.8
21 Lower, bucket empty, in float position 2.2 - 3.2
22 Steering, end to end 2.2 - 3.2
Gear change speeds ( km / h )

23 Up (2 - 3) 8 - 12
24 Up (3 - 4) 14 - 20
25 Down (4 - 3) 18 - 12
26 Down (3 - 2) 12 - 8
Hydraulic drift test

27 Lift cyl. (15 min) 14mm
28 Bucket cyl.(15 min) 36mm
All pressures and timings to be measured with the machine at working temp. Sep. 97
20-8
From SN WA380H20501
Test certificate WA 380 - 3


1 Rated output ( kW/HP) 141 / 192
2 Low idle speed 760-810
3 High idle speed, no load 2360-2460
4 Stall speed against torque converter 2210-2310
5 Stall speed against hydraulics 2170-2270
6 Stall speed against torque converter and hydraulics 1630-2030
Operating temp ° C Nominal Actual

7 Engine (in operating temperature) 80 - 85
Operating pressure bar. At high idling Nominal Actual

11 Cut-off pressure 160 - 165
14 Torque converter outlet pressure 4.0 - 5.0
15 Clutch pressure 23 ± 3
Working times in sec. At high idling Nominal Actual

20 Lower, bucket empty, 2.8 - 3.8
21 Lower, bucket empty, in float position 2.2 - 3.2
22 Steering, end to end 2.2 - 3.2

23 Up (2 - 3) 8 - 12
24 Up (3 - 4) 14 - 20
25 Down (4 - 3) 18 - 12
26 Down (3 - 2) 12 - 8

27 Lift cyl. (15 min) 14mm
28 Bucket cyl.(15 min) 36mm
All pressures and timings to be measured with the machine at working temp. Jan. 98
20-9

TEST CERTIFICATE WA 380 - 3H


1 Rated output ( kW / HP) 141 / 192
2 Low idle speed 760 - 810
3 High idle speed, (no load) High mode 2360 - 2460
4 Economy mode 2185 - 2215
5 Stall speed against torque converter (High mode) 2210 - 2310
6 Stall speed against hydraulics (High mode) 2170 - 2270
7 Stall speed against torque converter and hydraulics (High mode) 1630 - 2030
Operating temp ° C
8 Engine (in operating temperature)
Operating pressure bar. / at high idling

12 Cut-off pressure High mode 160 - 165
13 Standard / Economy mode max. 20
16 Torque converter outlet pressure 4-5
17 Clutch pressure 21 - 25
Working times in sec. / at high idling (High mode)

22 Lower, bucket empty, to ground 2.8 - 3.8
23 Lower, bucket empty, to ground (in float position) 2.2 - 3.2
24 Steering, end to end, at high idling 2.2 - 3.2

25 Up (2 - 3) / High mode 8 - 12
26 Up (2 - 3) / Economy mode 5-9
27 Up (3 - 4) / High mode 14 - 20
28 Down (4 - 3) / High mode 12 - 18
29 Down (3 - 2) / High mode 8 - 12
Final speed (Tires 20.5-25) ( km / h )

30 1. Gear / High mode 6-8
31 2. Gear / High mode 10 - 13

32 Lift cylinder (15 min) (measured at piston rod) max. 14 mm
33 Bucket cylinder (15 min) (measured at piston rod) max. 36 mm
All pressures and timings to be measured with the machine at working temperature. November 1999
20-10

20-11
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

Connector Inspec. Measurement

Name of component No. method Judgement table conditions
If the condition is as shown in the table Turn starting
Short connector
below, the sensor is defective. switch ON.
Short connector Disconnect

connected Monitor goes off connector.
CN R06
Radiator water CN RO6 disconnected Monitor lights up
level sensor
Check continuity
below, the sensor is normal. switch ON.
Oil level, Disconnect

water level normal Continuity connector.
Oil level,
water level abnormal No continuity

chassis ground

Connect to
Chassis ground Disconnect

connected Monitor goes off connector.
CN E10
disconnected Monitor lights up
Engine oil CN E10
level sensor If the condition is as shown in the table Turn starting
Check continuity
below, the sensor is normal. switch OFF.
Engine oil level Disconnect

normal Continuity connector
Engine oil level
abnormal No continuity

Torque converter oil below, the sensor is normal. switch OFF.
resistance
temperature sensor CN T07

Measure
Normal temperature
(25°C) Approx. 38 - 48 kΩ
Engine water CN E06
temperature sensor 100°C Approx. 3.6 - 3.9 kΩ

resistance

Measure
Fuel level sensor CN R07

Full Approx. 8 - 11 Ω Disconnect.
connector
Empty Approx. 85 - 95 kΩ
When engine is running Start engine.

(half throttle or above)
Measure
voltage
Alternator è 27,5 - 29,5 V

« If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
20-12
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Connector Inspec. Measurement

Name of component No. method Judgement table conditions

chassis ground
Connec to
Terminal wiring Monitor goes off
harness disconnected
Connected to Monitor lights up

Engine oil pressure CNE 11 chassis ground
sensor
If the condition is as shown in the table Start enginge.

below, the sensor is normal. Disconnect
connector.
continuity
Check
Oil pressure above No continuity

0.7 bar
Oil pressure below Continuity
0.3 bar

Short connector
Short connector Monitor goes off

connected
Brake ACC CN B08
CN B08, CN B13 Monitor lights up
disconnected
Low pressure switch CN B13 If the condition is as shown in the table Turn starting
Check continuity
Disconnect
connector.
Oil pressure above Continuity
60 bar
Oil pressure below No continuity
40 bar
20-13
Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method conditions
If the condition is as shown in the table 1) Turn starting

resistance
Measure
Engine water CNE 05 Normal temp. Approx. 2 kΩ 2) Disconnect
temperature sensor (male) (25°C) Between CNE05 CNE05.
Main monitor
Pre-heating 5°C (male) – GND Approx. 4 kΩ

resistance
Measure
below, it is normal. switch OFF.

Speed sensor CNT06
(male) Between (1) – (2) 500 – 1000 Ω 2) Disconnect CNE06.
If the condition is within the range shown 1) Turn starting

in the table below, it is normal. switch OFF.
resistance
Measure
F solenoid CNT01 Between (1) – (2) 48 - 58 kΩ 2) Disconnect

(male) Between (1) – connector.
chassis Min. 1 MΩ

resistance
Measure
R solenoid CNT02 Between (1) – (2) 48 - 58 kΩ 2) Disconnect

Transmission controller

chassis Min. 1 MΩ

resistance
Measure
H-L solenoid CNT03 Between (1) – (2) 48 - 58 kΩ 2) Disconnect

chassis Min. 1 MΩ

resistance
Measure
Speed solenoid CNT04 Between (1) – (2) 48 - 58 kΩ 2) Disconnect

chassis Min. 1 MΩ

resistance

Measure
Modulation valve CNT012

solenoid (male) Between (1) – (2) 12 - 15 Ω 2) Disconnect
Between (1) – connector
chassis Min. 1 MΩ
20-14
Sys- Name of Connector Inspection Judgement table Measurement conditions

tem component No. Method
If the condition is as shown in the 1) Turn starting
table below, it is normal. switch OFF.
resistance
Measure
Relief solenoid 2) Disconnect
for cylinder rod CNAF4 Between 20 - 40 Ω CNAF4.
E.C.S.S. controller (if equipped)
(male) –

resistance
Measure
High pressure 2) Disconnect
solenoid CNAF5 Between 20 - 40 Ω CNAF5.
(male) –

resistance
table below, it is normal. switch OFF.Low

Measure
pressure 2) Disconnect
solenoid CNAF6 Between 20 - 40 Ω CNAF6.
(male) –

2) Disconnect
Oilpressure Continuity CNAF7.
resistance
Measure
Pressure switch CNAF7 above 5,4 MPa

(male) (55 bar) Between
Oilpressure – No
below 4,4 MPa Continuity
(45bar)
If the condition is within the range 1) Turn starting

shown in the table below, it is normal. switch OFF.
resistance
Measure
Speed sensor CNTO6 2) Disconnect

(male) Between CNT06.
– 500 - 1000 Ω
20-15

From SN WA380H20501
Name of component Connector Inspection Judgment table Measurement

No. method conditions
Short connector
Short connector
connected Monitor goes off
CN R06 Monitor lights up

XR6 disconnected
Radiator water level between
sensor B255
and If the condition is as shown in the table Turn starting
Check continuity
XR2 (11) below, the sensor is normal. switch OFF.

Oil level,
water level normal Continuity
Oil level, No continuity

water level abnormal

chassis ground

Connect to
Chassis ground
CN E10 Monitor lights up

XB398 disconnected
between
Engine oil level sensor B398
and If the condition is as shown in the table Turn starting
Check continuity
X111 below, the sensor is normal. switch OFF.

Engine oil level
normal Continuity
Engine oil level No continuity

abnormal

resistance
Torque converter oil

Measure
XT07 Normal temperature

temperature sensor Approx. 38 – 48 kΩ
(25°C)
Engine water
temperature sensor XB13
100°C Approx. 3.6 – 3.9 kΩ

resistance

Measure
+1
Fuel level sensor XR7 Full Approx. 10 – 3Ω
Empty Approx. 85 – 95 KΩ
When engine is running Start engine

Measure
voltage
Alternator — (half throttle or above) à 27.5 – 29.5 V

20-16

Connector Inspection Measurement

Name of component Judgment table
chassis ground
Connect to
Connected to
chassis ground Monitor lights up
Engine oil pressure
sensor XB19 If the condition is as shown in the table Start engine.
Check continuity
below, the sensor is normal.

70 KPa (0.7 bar)
Oil pressure below
30 KPa (0.3 bar) Continuity
Check continuity

Brake ACC XB304 below, the sensor is normal. switch OFF.
Disconnect
Oil pressure above Continuity connector.
60 bar
Oil pressure below
40 bar No continuity
20-17

Judgment table
Between When engine is running 1) Start engine.
Measure
voltage
Alternator alternator (half throttle or above) à 27.5 – 29.5 V
terminal R If the battery is old, or after starting in cold
and chassis areas, the voltage may not rise for some time.

Measure resist- below, it is normal. switch OFF.
Main monitor
2) Disconnect
Engine water XB14
ance Normal tem- Approx. 2 kΩ CNE05.
temperature sensor perature (25°C) Between CNE05
(male) – GND
Pre-heating 5°C Approx. 4 kΩ
resistance

Measure

Speed sensor XT06 2) Disconnect
Between (1) – (2) 500 – 1000 Ω CNE06.

resistance

Measure
2) Disconnect
F solenoid XT01 connector.
Between (1) – (2) 46 – 58 kΩ
Between (1) – chassis Min. 1 MΩ

resistance
Measure
2) Disconnect
R solenoid XT02 connector.
Between (1) – (2) 46 – 58 kΩ


resistance

Measure
2) Disconnect
H-L solenoid XT03 connector.
Between (1) – (2) 46 – 58 kΩ

resistance
Measure
2) Disconnect
Speed solenoid XT04 connector.
Between (1) – (2) 46 – 58 kΩ

resistance
Measure
2) Disconnect
Modulation valve XT12
solenoid Between (1) – (2) 12 – 15 Ω connector.
20-18

Judgment table
resistance
Measure
Relief solenoid for XF4 2) Disconnect
ALS controller (if equipped)
cylinder rod Between (1) – (2) 20 Ω CNAF4.
resistance
Measure If the condition is as shown in the table 1) Turn starting
Low pressure XF6 2) Disconnect
solenoid
Between (1) – (2) 20 Ω CNAF6.
resistance

Measure

Speed sensor XE228 2) Disconnect
Between (1) – (2) 500 – 1000 Ω CN06.
20-19

Name of component Connector Inspection Judgment table Measurement

Short connector
Short connector
XR06 Monitor lights up

disconnected
Radiator water level
sensor XR6 If the condition is as shown in the table Turn starting
Check continuity

Oil level,
water level normal Continuity
Oil level, No continuity

water level abnormal

chassis ground

Connect to
Chassis ground
CN E10 Monitor lights up

disconnected
Engine oil level sensor XB398
Check continuity

Engine oil level
normal Continuity
Engine oil level No continuity

abnormal

resistance
Torque converter oil

Measure
XT07 Normal temperature

temperature sensor Approx. 38 – 48 kΩ
(25°C)
Engine water
temperature sensor XB13
100°C Approx. 3.6 – 3.9 kΩ

resistance

Measure
+1
Fuel level sensor XR7 Full Approx. 10 – 3Ω
Empty Approx. 85 – 95 KΩ
When engine is running Start engine

Measure
voltage
Alternator — (half throttle or above) à 27.5 – 29.5 V

20-20

Connector Inspection Measurement

Name of component Judgment table
chassis ground
Connect to
Connected to
chassis ground Monitor lights up
Engine oil pressure
sensor XB19 If the condition is as shown in the table Start engine.
Check continuity
below, the sensor is normal.

70 KPa (0.7 bar)
Oil pressure below
30 KPa (0.3 bar) Continuity
Check continuity

Brake ACC XRB304 below, the sensor is normal. switch OFF.
Disconnect
Oil pressure above Continuity connector.
60 bar
Oil pressure below
40 bar No continuity
20-21


Judgment table
Between When engine is running 1) Start engine.
Measure
voltage
Alternator alternator (half throttle or above) à 27.5 – 29.5 V
terminal R If the battery is old, or after starting in cold
and chassis areas, the voltage may not rise for some time.

Measure resist- below, it is normal. switch OFF.
Main monitor
2) Disconnect
Engine water XB14
ance Normal tem- Approx. 2 kΩ XB14.
temperature sensor perature (25°C) Between XB14
(male) – GND
Pre-heating 5°C Approx. 4 kΩ
resistance

Measure

Speed sensor XT06 2) Disconnect
Between (1) – (2) 500 – 1000 Ω XT06.

resistance

Measure
2) Disconnect
F solenoid XT01 connector.
Between (1) – (2) 46 – 58 kΩ

resistance
Measure
2) Disconnect
R solenoid XT02 connector.
Between (1) – (2) 46 – 58 kΩ


resistance

Measure
2) Disconnect
H-L solenoid XT03 connector.
Between (1) – (2) 46 – 58 kΩ

resistance
Measure
2) Disconnect
Speed solenoid XT04 connector.
Between (1) – (2) 46 – 58 kΩ
20-22


Judgment table
resistance
Measure
Relief solenoid for XF4 2) Disconnect
ALS controller (if equipped)
cylinder rod Between (1) – (2) 20 Ω XF4.
resistance
Measure If the condition is as shown in the table 1) Turn starting
Low pressure XF6 2) Disconnect
solenoid
Between (1) – (2) 20 Ω XF6.
resistance

Measure

Speed sensor XB228 2) Disconnect
Between (1) – (2) 500 – 1000 Ω XB228.
20-23

20-24

TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Check or measurement item Symbol Part No. Part Name Remarks

Digital display
Engine speed A 799–203–9000 Multi–tachometer L : 60 – 2,000rpm
H : 60 – 19,999rpm
Coolant, oil, and exhaust 799–101–1502 Digital temperature gauge —

temperatures B
799–201–1110 Wiring harness Measure exhaust temperature
Pressure gauge
799–101–5002 Analog hydraulic tester 2.45, 5.88, 39.2, 58.8 MPa
(25, 60, 400, 600 bar)
Oil pressure C Pressure gauge
790–261–1203 Digital hydraulic tester 49.0 MPa (500 bar)
799–401–2320 Hydraulic gauge 1.0 MPa (10 bar)
1 795–502–1590 Compression gauge 0 – 6.9 MPa (0 – 70 bar)

Compression pressure Kit Part No. 795–502–1205
D
2 795–502–1370 Adapter —
1 799–201–1511 Tool
2 799–201–1541 Gauge
Blowby pressure E Kit Part No.
3 799–201–1571 Tube 799–201–1504
4 799–201–1450 Adapter
Commercially Feeler gauge
Valve clearance F available —
Discoloration 0 – 70 % (with
1 799–201–9000 standard color)
Handy smoke checker (Discoloration % x 1/10 =.. Bosch
Exhaust color G index)
Commercially —
2 available Smoke meter
Intake air pressure H 799–401–2310 Pressure gauge 1,500mmHg

Troubleshooting of wiring
harnesses and sensors I 799–601–8000 T–adapter —
Measuring voltage and Commercially

resistance values J available Tester —
Operating force K 79A–264–0020 Push-pull scale 0 – 294N (0 – 30kg)

Commercially
Clearance measurement L available Thickness gauge —
Commercially
Pushing angle M available Angle gauge —
Commercially
Pushing force N available Push gauge —
Commercially
Stroke O available Scale —
Brake oil pressure P 793–605–1001 Brake test kit —

Commercially
Length measurement Q available Slide calipers —
Commercially
Speed R available Stop watch —
20-101
20-102
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Lift and remove the engine hood.

Remove the air crossover tube if the engine is equipped
so.
Disconnect the support clamps and hose clamp. Re-

move the crankcase vent tube and any other parts that
would prevent removal of the valve cover.
Remove the valve cover.
Tool:
1/2 Inch Drive, 3377381 Barring Gear
Locate Top Dead Center (TDC) for Cylinder Number 1

by rotating the crankshaft slowly while pressing on the
engine timing pin.
20-103
When the engine timing pin engages the hole in the Camshaft-
camshaft gear, Cylinder Number 1 is at TDC on the gear
compression stroke.
Timing pin
Be sure to disengage the engine timing pin after

Housing
locating TDC to prevent damage to the engine
timing pin.
Feeler Gauge
Intake Clearance: 0.30 mm [0.012 inch]
Exhaust Clearance: 0.61 mm [0.024 inch]
Check/set valves with engine cold - below 60°C
The clearance is correct when some resistance is

“felt” when the feeler gauge is slipped between the
valve stem and the rocker lever.
Tool:
14 mm, Flatbiade Screwdriver
Check/adjust the valves indicated for STEP A

(I = Intake; E = Exhaust).
After tightening the rocker lever lock nut, check the

valve clearance to make sure the valve clearance has
not changed.
Torque Value: 24 Nm
20-104
Mark the vibration damper and rotate the crankshaft

360 degrees.
Be sure the engine timing pin is disengaged to

prevent damage to the engine timing pin.
Set the valves indicated for STEP B.
After tightening the rocker lever lock nut, check the

valve clearance to make sure the valve clearance has
not changed.
Torque Value: 24 Nm
Install the rubber seal into the groove in the valve cover.
Start the installation at the overlap area shown in the
illustration. Do not stretch the rubber seal.
Install new sealing o-rings on the capscrews.
Install the valve cover and wastegate sensing tube.
Torque Value: 24 Nm
20-105
Install the crankcase vent tube and secure with the

support clamps and hose clamp.
A = 24 Nm
B = 43 Nm
Install the air crossover tube and any other parts previ-
ously removed to gain access to the valve cover.
Install the engine hood.
20-106
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
When measuring the compression pressure, be careful

not to touch the exhaust manifold or muffler, or to get
your clothes caught in the fan, fan belt or other rotating
parts.
« Warm up the engine (oil temperature: 40 - 60°C)

before measuring the compression pressure.
Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEARANCE.
Due to variables such as starter and battery condi-

tions that affect engine cranking speed, it is difficult
to establish an absolute value for compression pres-
sure; however, the following values can be used as
guidelines:
• New engine (cranking speed @ 250 RPM):

24 bar
• Used engine (cranking speed @ 250 RPM):

20 bar
It is recommended that the compression pressure be

checked on all cylinders and then compared. All cylin-
ders should be within 690 kPa [100 psi] of each other.
Piston Ring Sealing
If the compression is low but can be increased signifi-

cantly by squirting oil into the cylinder, the cause of low
compression is inadequate sealing between the rings
and the cylinder walls.
Intake and Exhaust Valve Sealing
If the compression is low on one or more non-adjacent

cylinders and the pressure cannot be increased by oil-
ing the rings, poor valve sealing is to be suspected.
20-107
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
Valve leakage is often audible from the intake and ex-

haust manifold.
Cylinder Head Gasket Sealing
If the compression is low on adjacent cylinders and the

pressure cannot be increased by oiling the rings, the
cylinder head gasket is probably leaking between the
cylinders.
Low compression on a single cylinder can be

caused by an external leak or a leak to a coolant
passage. A leak to a coolant passage of this magni-
tude will also result in coolant in the cylinder.
A compression leak to the coolant will normally be de-

tected by loss of coolant as the coolant is blown from
the cooling system.
Service Tip: Remove the drive belt from the water pump.
Run the engine for 1 to 2 minutes and check for coolant
being blown from the radiator.
20-108
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
The engine crankcase pressure, often referred to as

engine blowby, is an important factor that indicates when
the piston rings have achieved the correct finish and fit.
Rapid changes of blowby or values that exceed specifi-
cation more than 50 percent indicate that something is
wrong. The engine test must be discontinued until the
cause has been determined and corrected.
Blowby is generally recorded in liters/minutes.
Install the Cummins Part No. 3822566 Engine Blowby

Tool, to the crankcase breather tube in the valve cover.
Install a water manometer to the engine blowby tool.
Use the Blowby Conversion chart to convert the ma-

nometer reading to liters/minutes.
« A pressure gauge can be used to record the engine

blowby.
Minimum Gauge Capacity: 1270 mm H20

[50 inches H20]
Blowby Check Tool
3822566 Used with manometer, Part No. ST-111-3,

to measure the engine crankcase pressure.
Manometer
ST-111-3 Used with the blowby check tool to

measure engine crankcase pressure.
Test specifications:
Coolant temperature: 100°C
New engine (L/min) Used engine (L/min)
Blowby: 6CT8.3 113 226
6CTA8.3 113 226
All engines built after ESN 21087046 164 226
The blowby checking tool, Cummins P/N 3822566, has a special 7.67mm orifice that must be used to
obtain an accurate reading.
20-109
Blowby Conversion Chart (7.67 mm [0.302 in] Orifice
Inches Liters / Minute

of
Water
1 50
2 84
3 103
4 119
5 133
6 145
7 155
8 164
9 172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
17 222
18 226
19 229
20 235
21 239
22 242
23 246
24 248
20-110
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING

by rotating the crankshaft slowly while pressing on the
engine timing pin.
The fuel injection pump also has a timing pin (1), lo-
cated in the governor housing, to position the fuel injec-
tion pump shaft to correspond with TDC for cylinder
number 1. After the fuel injection pump is installed, the
timing pin is to be reversed and stored in the housing
(2).
Remove the timing pin access plug.
Remove the timing pin.
20-111
If the timing tooth is not aligned with the timing pin hole,
rotate the pump shaft until the timing tooth aligns.
Reverse the position of the timing pin so the slot of the

timing pin will fit over the timing tooth in the fuel injec-
tion pump.
Install and secure the timing pin with the access plug.
20-112
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRES-

SURE (BOOST PRESSURE)
For turbocharged engines, measure the restriction just

before the turbocharger. Measure just before the intake
manifold for naturally aspirated engines.
Replace the air cleaner element when the restriction

reaches the maximum limit at rated engine power and
speed.
Naturally Aspirated Turbocharged

50.8cm H20 63.5cm H20
[20 in. H20] [25 in. H20]
Maximum allowable intake restriction (compressor inlet)

(with dirty air filter element)
6CT8.3, 6CTA8.3 ......................................................................................................... 63.5cm H20 [25 in. H20]
Maximum turbocharger exhaust restriction (turbine outlet)

at rated speed and load
6CT8.3 ............................................................................................................................. 75 mm Hg [3 in. H20]
6CT8.3, 6CTA8.3 .......................................................................................................... 100cm H20 [40 in. H20]
Charge Air Cooler, if fitted .......................................................................................................... 21 kPa [3 psi]
20-113
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
Check the oil gauge and sending unit to make sure they
are operating correctly by verifying the pressure with a
manual gage.
Check the following for defects:
• Electrical wiring broken

• Sending unit malfunction
• Plumbing loose or broken
If a sending unit malfunction is found:
• Use a master gauge of known accuracy to verify

the reading of the suspect gauge.
• Connect the line from the master gauge to the main

oil rifle on the fuel pump side of the engine.
• Replace the sending unit if it is defective.
20-114
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
« Measurement conditions
• Engine water temperature: Within green range on

engine water temperature gauge
• Hydraulic oil temperature: 45 – 55°C
• Engine speed: High idling
• Work mode selector switch on High mode
(from SN WA380H20987 and up)
• Torque converter oil temperature: 60 – 80°C
« Apply the testing tool to the 3rd fuel injection line

and take the tool to the cab.
Apply the parking brake and put blocks under the

tires.
Be careful not to touch any hot or rotating parts.
1. Start the engine, and run the engine at low idling.
2. Check engine rpm at low and high idling.
20-115

TESTING AND ADJUSTING MEASURING STALL SPEED
MEASURING STALL SPEED


« Apply the testing tool to the 3rd fuel injection line

and take the tool to the cab.
« Check that low idling and high idling are the stand-
ard values.
« Check that the engine speed is the standard value.
If it is not within the standard range, check for loose
linkage or play.

tires.
Be careful not to touch any hot or rotating parts.
TORQUE CONVERTER STALL SPEED
« Before carrying out the measurement, always dis-

connect the connector from the speedometer sen-
sor wiring.
1. Start the engine and run at low idling.
2. Release the parking brake.
3. Place the speed lever at the highest position for

FORWARD or REVERSE.
4. Use the brakes to stop the machine, then use multi-

tachometer A to measure the speed when the en-
gine is run at high idling.
« Turn transmission cut-off selector switch (2) OFF

and use the left brake.
(Check that the pilot lamp goes out.)
« Do not keep the stall condition for more than 20
seconds. Make sure that the torque converter
oil temperature does not exceed 120°C.
20-116

HYDRAULIC STALL SPEED
1. Start the engine and run at high idling.
2. Operate the lever to the DUMP or LIFT position to

operate the cylinder to the end of its stroke and
actuate the relief valve in the main control valve.
3. Use multi-tachometer A to measure the engine

seconds. Operate the control lever quickly.
FULL STALL SPEED
• Measure the engine speed when the torque con-

verter stall and hydraulic stall are both carried out at
the same time.
« Before measuring the full stall, check that the
torque converter stall and hydraulic stall speeds
are normal.
If either of the stall speeds are abnormal, cor-
rect the problem and measure again.
20-117
TESTING AND ADJUSTING TESTING THE FAN BELT TENSION
TESTING THE FAN BELT

TENSION
Measure the belt deflection at the longest span of the

belt. Maximum Deflection: 9.5 to 12.7 mm [318 to 112
inch].
The Cummins belt tension gauge ST-1293 can be

used.
Tension Limit: 80 - 110 lbs
The belt tensioner is spring loaded and must be

pivoted away from the belt. Pivoting in the wrong
direction can result in damage to the belt tensioner.
After raising the tensioner arm to removelinstall the

belt, check the torque on the tensioner capsrew.
Torque Value: 43 Nm
20-118
TESTING AND ADJUSTING TURBOCHARGER
MEASURING TURBOCHARGER
CLEARANCE
Be careful not to touch any hot parts.

.
1. Stop the engine.
2. Measure clearance at the end of the shaft.
Tool No.: ST-537
Clearance (A) mm
* min 0,10
max 0,16
** min 0,03
max 0,08
* Turbocharger up to SN 840637
** Turbocharger SN 840638 and up
3. Measuring shaft radial-clearance.
Clearance (B) mm
min 0,21
max 0,46
Replace the turbocharger if clearance exceeds maxi-

mum limits of tolerance.
For details, refer to the Turbocharger Shop Manual,
Bulletin No. 3810321.
20-119
TESTING AND ADJUSTING WASTEGATE
TURBOCHARGER WASTEGATE
ACTUATOR - VISUAL INSPECTION
Before making any adjustments to the wastegate,

refer to the information in the Turbocharger Shop
Manual, Bulletin No. 3810321.
1. Inspect the lever pin.

Replace the turbine housing if pin is worn excessivly.
2. Inspect the valve and valve seat for cracks or ero-

sion.
Replace the turbine housing if worn excessivly.
3. Actuate the lever by hand to be shure that the shaft

moves freely and is not seized. Check for exces-
sive movement between shaft and bushing.
Replace the turbine housing if shaft and bushing
are worn excessivly.
4. Visually inspect the wastegate actuator hose for

cracks and holes.
Replace hose if damaged.
20-120
5. Visually inspect the wastegate mounting bracket,

actuator rod and lever for damage. A bent wastegate
mountig bracket, actuator rod or lever can cause
damage and must be replaced.
20-121
TURBOCHARGER WASTEGATE
ACTUATOR
- FUNCTIONAL CHECKING
1. Connect regulated air pressure and an accurate

pressure gauge to the capsule.
2. Apply 1,8 bar to make sure the wastegate is

functioning properly.
The actuating rod should move approximately 5mm
without sticking or air leakage.
« A small amount of travel when air pressure is

first applied is normal, the tolerance is being
removed from the system.
Replace the actuator if no movement of the actuator

rod and lever is detected.
Refer to the Turbocharger Shop Manual, Bulletin

No. 3810321, before disassembling the wastegate!
20-122
ADJUSTING VALVE CLEARANCE ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

1. Lift and remove the engine hood.
2. Disconnect the two dust indicator wires (1), then
disconnect intake connector (2).
3. Remove air cleaner assembly (3).
4. Remove intake connector (4), then remove cylinder
head cover (5).
5. Turn the crankshaft forward, watch the function of
the 6th cylinder's intake valve, and line up the
"1.6TOP" line (6) on the crank pulley with the pointer
(7).
6. If the 1st cylinder is at the upper compression dead
point, adjust the valves indicated with "l" in the
valve layout table, then turn the crankshaft 360° in
the forward direction and adjust the valves indi-
cated with "¡".
« Valve arrangement
Cylinder no. 1 2 3 4 5 6
Intake valve l l ¡ l ¡ ¡
Exhaust valve l ¡ l ¡ l ¡
To adjust, insert filler gauge F between locker

lever (8) and valve stem (9), adjust the adjust
screw (10) so that it turns gently, then tighten
locknut (11).
• Valve clearance (when cold)
Intake side: 0.34
Exhaust side: 0.66
Locknut: 44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
« Set the 1st cylinder to the upper compression
dead point, adjust the 1st cylinder, turn 120°,
and adjust the valve clearance for all cylinders
in this way in the order of ignition.
• Order of ignition: 1 - 5 - 3 - 6 - 2 - 4
« After tightening the locknut, check the valve
clearance once again.
20-123
ADJUSTING VALVE CLEARANCE MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
When measuring the compression pressure, be

careful not to touch the exhaust manifold or muffler,
or to get your clothes caught in the fan, fan belt or
other rotating parts.
« Warm up the engine (oil temperature: 40 – 60°C)

before measuring the compression pressure.
1. Adjust the valve clearance.

For details, see ADJUSTING VALVE CLEARANCE.
2. Remove spill tube (1) and disconnect fuel injection
pipe (2).
3. Remove nozzle holder (3) and pull out nozzle as-

sembly (4).
« Be careful not to let dirt or dust get in.
4. Install adapter D2 in the mount of the nozzle holder

of the cylinder to be measured, and tighten to the
specified torque.
Nozzle holder mounting bolt
: 44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
5. Connect compression gauge D1 to adapter D2.
6. Disconnect connector (6) of stop motor (5), set to

the NO INJECTION position, then crank the engine
with the starting motor and measure the compres-
sion pressure at the point where the pressure gauge
indicator remains steady.
« If the adapter mount is coated with a small
amount of oil, it will reduce leakage.
« For details of the standard value for the com-
pression pressure, see STANDARD VALUE TA-
BLE FOR ENGINE.
20-124
MEASURING BLOW-BY
PRESSURE
« Raise the coolant temperature to the operating range

before measuring the blow-by pressure.
1. Install tools E4 and E1 to the tip of engine breather

hose (1), then connect tools E3 and E2.
2. Run the engine at the rated output and measure the

blow-by pressure.
When measuring the blow-by pressure, be care-

ful not to touch any high temperature parts or
rotating parts.
« The blow-by should be measured with the en-

gine running at rated output.
• When measuring in the field, a similar value
can be obtained at stall speed.
• If it is impossible to check at rated output or
stall speed, measure at high idling. In this case,
the blow-by value will be about 80% of the value
at rated output.
« Blow-by varies greatly according to the condi-
tion of the engine. Therefore, if the blow-by
value is considered abnormal, check for prob-
lems connected with defective blow-by, such as
excessive oil consumption, defective exhaust
gas color, and prematurely dirty or deteriorated
oil.
20-125

FUEL INJECTION TIMING
There are two methods for testing and adjusting the
injection pump fuel injection timing, as follows:
• "Mark alignment adjustment" for mounting the injec-
tion pump on the original engine without repairing it.
• "Delivery valve adjustment" for injection pumps which
have been repaired or replaced.
« When using "delivery valve adjustment", the deliv-
ery valve copper gasket and O ring must be re-
placed with new ones. Prepare these new parts
beforehand.
« Refer to the section "Adjusting Valve Clearance"
and set the 1st cylinder to the upper compression
dead point before testing and adjusting.
Testing and adjusting using "mark alignment adjustment"

1. With the 1st cylinder at the top position, turn the
crankshaft 30 to 40° in the reverse direction.
2. Gently turn the crankshaft in the forward direction
and align the crankshaft pulley's injection timing line
(1) with the pointer (2).
3. Check that line a on the injection pump side is
aligned with line b on the injection pump drive case
side.
« If they are not aligned, loosen long-hole nut (3)
and pump installation nut (4), move the injec-
tion pump, align the lines, then tighten the nuts.
Nut (3): 66.7 ± 7.8 Nm (6.8 ± 0.8 kgm)
Testing and adjusting using "delivery valve adjustment"

1. Remove the 1st cylinder fuel injection tube (5).
2. Remove delivery valve holder (7).
20-126
3. Remove spring (8) and delivery valve (9) from deliv-

ery valve holder (7), then reassemble delivery valve
holder (7).
4. Set the fuel control lever to the full-speed position,
operate the priming pump, slowly turn the crank-
shaft forward, and check the position at which the
flow of fuel from the delivery valve holder stops.
5. At the position at which the fuel flow stopped, check
that the crankshaft pulley injection timing line (1)
and pointer (2) are aligned.
« If the injection timing line has moved past the
pointer
: The injection timing is slow.
« If the injection timing line has not reached the
pointer
: The injection timing is fast.
« If the injection timing is off, use the following proce-

dure to adjust it.
1) With the 1st cylinder at the top position, turn the
2) Gently turn the crankshaft in the forward direc-
tion and carefully align the pulley injection tim-
ing line (1) with the pointer (2).
3) Loosen the injection pump installation flange
long-hole nut (3) and pump installation nut (4),
operate the priming pump, turn the pump side
flange little by little, and stop at the position
where fuel stops flowing from the delivery valve
holder.
4) Tighten the injection pump installation flange's
long-hole nut and the pump installation nut.
« Retest the injection timing and check that it

is accurate.
5) Align marks a and b and stamp.
« After testing and adjusting, do not forget to reas-

semble the spring and delivery valve.
« Always replace the delivery valve's copper gasket
and O ring with new ones.
20-127
« Refer to the section "Adjusting Valve Clearance"

and set the 1st cylinder to the upper compression
dead point before testing and adjusting.
Testing and adjusting using "mark alignment adjustment"

1. With the 1st cylinder at the top position, turn the
2. Gently turn the crankshaft in the forward direction
and align the crankshaft pulley injection timing line
(1) with the pointer (2).
3. Check that line a on the injection pump side is
aligned with line b on the injection pump drive case
side.
« If they are not aligned, loosen long-hole nut (3)
and pump installation nut (4), move the injec-
tion pump, align the lines, then tighten the nuts.
Nut (3): 66.7 ± 7.8 Nm (6.8 ± 0.8 kgm)
20-128
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

« When measuring in the field when there is no air or
power supply, use smoker the checker; when re-
cording official data, use the smoke meter.
Measuring with handy smoke checker G1
When measuring the exhaust gas color, be careful

not to touch the exhaust pipe or any other high
temperature part.
« Warm up the engine (oil temperature: 60°C) before

measuring the exhaust gas color.
1) Fit filter paper in tool G1.
2) Insert the exhaust gas intake port into the ex-
haust pipe, accelerate the engine suddenly, and
at the same time operate the handle to catch
the exhaust gas on the filter paper.
3) Remove the filter paper and compare it with the
scale provided to judge the condition.
Measuring with smoke meter G2
When measuring the exhaust gas color, be careful

not to touch the exhaust pipe or any other high
temperature part.
« Warm up the engine (oil temperature: 60°C) before

measuring the exhaust gas color.
1) Insert the probe into the outlet port of the ex-
haust pipe, then tighten the clip to secure it to
the exhaust pipe.
2) Connect the probe hose, accelerator switch plug,
and air hose to tool G2.
« The pressure of the air supply should be
less than 1.5 MPa (15 kg/cm2).
3) Connect the power cord to the AC100V outlet.
« When connecting the cord, check first that
the power switch is OFF.
4) Loosen the cap nut of the suction pump, then fit
the filter paper.
« Fit the filter paper securely so that the ex-
haust gas does not leak.
5) Turn the power switch.
6) Accelerate the engine suddenly, and at the same
time, depress the accelerator pedal and oper-
ate the relief valve to catch the exhaust gas
color on the filter paper.
7) Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (10
sheets or more) inside the filter paper holder,
and read the indicated value.
20-129
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRES-

SURE (BOOST PRESSURE)
When removing or installing the measuring equip-

ment, be careful not to touch any high temperature
parts.
1. Remove intake air pressure measurement plug (1)

(PT 1/8) and install coupler (2) of oil pressure gauge
kit C.
2. Connect oil pressure measurement hose (3) to cou-

pler (2) and pressure gauge H (1500 mmHg).
When carrying out the measurement, be care-

rotating parts.
Note:
Run the engine at a mid-range speed or above, and
use the self-seal portion of the gauge to bleed the
oil from inside the hose.
• Insert the gauge about half way, and repeatedly
open the self-seal portion to bleed the oil.
« The gauge does not work if there is any oil

inside the hose, so always be sure to bleed all
the oil.
3. Run the engine at the rated speed and measure the

pressure indicated by the gauge.
20-130
TESTING AND ADJUSTING MEASURING EXHAUST GAS TEMPERATURE
MEASURING EXHAUST GAS

PRESSURE
The temperature sensor is installed to the exhaust

manifold, so if the machine has been operated, wait
for the manifold to cool down before installing the
sensor.
« Raise the coolant temperature to the operating range

before measuring.
1. Remove plug (1) from the exhaust manifold, then

install temperature sensor (2).
• Temperature sensor : 6215-11-8180 (cable
length: 610 mm), or 6215-11-8170 (cable length:
490 mm)
2. Connect to digital temperature gauge B with wiring

harness .
Measurement procedure
1. Measuring at torque converter stall
« If the exhaust gas temperature is measured
only at torque converter stall, and this is contin-
ued until the sensor core heats up and a stable
value is obtained, the torque converter will over-
heat.
1) Use the full stall (torque converter stall + hy-
draulic relief) to raise the exhaust gas tempera-
ture .
2) From the above condition, cancel the hydraulic
relief, and carry out only torque converter stall.
(The temperature will start to go down. If it
does not go down and continues to go up, make
the temperature setting at 1) higher.)
3) When the temperature starts to go down, record
the stable temperature.
2. When measuring maximum value for exhaust gas
temperature
Carry out actual work and measure the maximum
value when operating.
« Use the PEAK mode function (the maximum
value can be recorded) of the temperature
gauge.
20-131
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
When measuring, be careful not to let your clothes

get caught in any rotating part.
« Always stop the engine before removing or install-

ing any oil pressure sensor or oil pressure gauge.
« When measuring the oil pressure, always measure
at the specified oil temperature.
1. Remove plug.
2. Install coupler (1) on the oil pressure release
port.
3. Attach hose (2) to coupler (1) and install tool C
(gauge: 0.98 MPa (10 bar)).
4. Start the engine and measure the oil pressure.
20-132
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

When removing or installing the measuring equip-

ment, be careful not to touch any high temperature
parts.
« Measure the engine speed under the following con-

ditions.
1) Coolant temperature: Within operating range
2) Torque converter oil temperature : 60 – 80°C
3) Hydraulic oil temperature : 45 – 55°C
1. Remove cap (1) from speed pick-up port, then in-

stall adapter of tachometer A.
2. Connect tachometer A and the adapter with the

cable.
When carrying out the measurement, be care-

rotating parts.
3. Start the engine, and measure the engine speed

when the engine is at low idling and high idling.
« When measuring items other than the above
(during torque converter stall), see the proce-
dure for each item.
20-133
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FAN

BELT TENSION
Testing the fan belt tension

1. Apply a force of approximately 6 kg to the fan belt
midway between the fan pulley and alternator pulley
and check its deflection "a".
• Belt deflection a : 5 to 10 mm
Adjusting the fan belt tension

1. Loosen the alternator assembly installation bolt and
nut (1) and belt tension adjustment bolt (2).
2. Move the alternator using a pipe, etc., check the
belt (3) tension, then first tighten the adjustment
nut, then the alternator installation bolt.
20-134
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
METHOD FOR ADJUSTING

ENGINE STOP CABLE
1. Temporarily install ball joint (3) to cable (2) of en-

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

the engine stop position (no injection of fuel), and
temporarily assemble the cable (2) to the bracket
(5).
When this is done, secure the cable at a point
where stop lever (4) contacts engine STOP stop-
per, and temporarily assemble to the bracket with
locknuts (6),(7).
« Engine stop motor (1) is at the engine STOP
position with cable (2) pulled.
« Stop lever (4) of the fuel injection pump is at
the RUN position when the lever is free (it is
pulled by a spring to the RUN side).
3. Adjust stop lever (4) of the injection pump and STOP

stopper at the stop end so that clearance a is 0.5 –
2.5 mm.
Adjust with nut (6),(7) which secures the cable to
the bracket or carry out fine adjustment by chang-
ing the depth that ball joint (3) is screwed in.
20-135
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
4. Tighten all nuts and bolts. « Problems caused by improper adjustment of

engine stop motor cable
5. Turn the engine starting switch repeatedly to
• When engine stop motor • Engine does not
the ON and OFF positions, and check that the
cable is pulled and clear- stop
engine stop motor and cable work smoothly,
ance between stop lever
then carry out the following checks again.
and STOP stopper is too
large
1) Check visually that there is slack in the en-
• When cable is free and • Engine does not
gine stop motor cable when the engine is
clearance between stop give full output be-
running, and that the stop lever of the fuel
lever and RUN stopper is cause of drop in
injection pump has returned fully to the RUN
too large amount of fuel in-
position.
jected
2) Check that the clearance between the stop
lever (4) and stopper at the STOP end is
0.5 – 2.5 mm when the engine is stopped.
« With the engine stop motor, there are built-

in limit switches at both ends of the cable
stroke.
« Engine stop motor stroke: 35 mm

Fuel injection pump stop lever stroke:
30 mm
« When the engine is running, there is slack

in the engine stop motor cable, and the
RUN position is maintained by the action of
a spring (this is frequently built into the fuel
injection pump).
« There is a loose spring inside the engine

stop motor, and this absorbs the error in
the stop motor when the engine is stopped.
However, if this is absorbed by the loose
spring in the engine stop motor, force is
brought to bear on the injection pump, so
depending on the machine model, this sys-
tem may not be possible to use.
With such models, there is a danger of prob-
lems arising with the injection pump if the
clearance between the stop lever and the
stopper at the STOP end is set to 0 when
the engine is stopped.
20-136
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR
PEDAL
OPERATING FORCE OF ACCELERATOR PEDAL
1. Measuring
1) Set push-pull scale K at a position 150 mm
from pedal fulcrum a.
« Put the center of push-pull scale K in con-
tact with a point 150 mm from the pedal
fulcrum.
2) Start the engine, then measure the maximum

value when the pedal is moved from the pushed
position (low idling) to the end of its travel (high
idling).
2. Testing
1) Stop the engine.
2) Disconnect cable (1) at the bottom of the accel-
erator pedal and check that there is no heavi-
ness in the accelerator pedal linkage.
3) Connect cable (1) at the bottom of the pedal,
detach cable (2) at the injection pump connec-
tion, and check that there is no heaviness in the
cable.
Cable joint nut:
13.7 ± 0.98Nm(1.4 ± 0.1kgm)
« Carry out the above inspection, and adjust or

replace parts if necessary. Then carry out the
measurement of the operating force again to
check that it is within the standard value.
20-137
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
OPERATING ANGLE OF ACCELERATOR PEDAL
1. Measuring
1) Stop the engine.
2) Put angle gauge M in contact with the accelera-

tor pedal, and measure operating angle α (α =
α1 – α2) when the pedal is operated from low
idling position α1 to high idling position α2.
2. Adjusting
1) Remove the cover at the bottom of the cab, and
open the inspection cover of the engine hood.
2) Loosen nut (1), and adjust bolt (2) so that in-

stalled height L of the accelerator pedal stopper
is within a range of 51 ± 5 mm.
3) Loosen locknut (3) and adjust the length of the

cable so that the injection pump governor lever
contacts the high idling stopper when the accel-
erator pedal is depressed (high idling).
« Check that the injection pump governor con-
tacts the low idling stopper when the accel-
erator pedal is let back to the low idling
position.
« Adjust the travel of the governor lever with
joint (4).
Cable joint nut: 13.7 ± 0.98 Nm
(1.4 ± 0.1 kgm)
« After carrying out the above adjustment,
measure each part again and check that it
is within the standard value.
20-138
TESTING AND ADJUSTING BASIC ADJUSTMENT OF ACCELERATOR PEDAL
BASIC ADJUSTMENT
OF ACCELERATOR PEDAL SN WA380H20987 and up
(5)
• Engine water temperature: Within green range
on engine water temperature gauge
• Torque converter oil temperature: 60 – 80°C ‘A’
• When the work mode selector switch is on high or

standard mode, the solenoid (5) underneath the cab
platform is dead. In this case, the drawbar (4) is
pushed by resilience against the stop screw (1).
• The accelerator pedal stop (2) stands at right angle (4)
to the accelerator pedal.
Method of testing and adjusting

1. Switch to work mode "high" or "standard". The
accelerator pedal stop (2) must stand at right angle
to the accelerator pedal.
1
2. Check the measurement 'A' on the solenoid (5). 2 (Std / Hi mode)
Measurement 'A' = 117 mm. If necessary, the 2 (Eco mode)
drawbar (4) of the solenoid (5) must be adjusted 3
according measurement 'A'.
3. Switch to the work mode "economy". In switch

4
position "economy" the solenoid (5) has current
flow and will attract. This causes the drawbar (4) to
attract and the accelerator pedal stop (2) to turn
around 90° into travel direction.
4. Check the maximum engine speed. It must be at 5

2200 ±15 rpm. If the maximum engine speed is not
within the tolerance, the height of the accelerator
pedal stop (2) must be adjusted.
5. Loosen the lock-nut (6) and turn the accelerator

pedal stop (2) at least 180° to the left or right until
the engine speed stands by 2200 ±15 rpm.
6. Tighten the lock-nut (6).
7. Switch to the work mode "standard" or "high" and

check the maximum engine speed. It must be about
2360 - 2460 rpm.
NOTE:
With full speed (accelerator pedal on stop), the
lever on the injection pump must not be connected
to the stop.
20-139
20-138-1

20-138-2
20-140

TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER
• Engine stopped
Block the tires securely.
OPERATING FORCE OF SPEED LEVER
1. Stop the engine.
2. Install push-pull scale K or a spring balance to the

center of the control lever knob, and measure the
operating force when the lever is pulled in the direc-
tion of operation.
« Carry out the measurement for each speed
range.
TRAVEL OF SPEED LEVER
1. Stop the engine.
2. Make mark a at the center of the control lever knob,

and measure the travel when the lever is operated
in the direction of operation.
20-139
MEASURING STALL SPEED


« Check that low idling and high idling are the stand-
ard values.
« Before measuring each stall speed, install multi-
tachometer A to speed pickup port (1) on the en-
gine block.
« Check that the engine speed is the standard value.
If it is not within the standard range, check for loose
linkage or play.

tires.
TORQUE CONVERTER STALL SPEED
« Check that the tires are chocked and release the

parking brake.
1. Start the engine and run at low idling.

Before carrying out the measurement, always
disconnect connector (3) from speedometer
sensor (2) wiring.
2. Place the speed lever at the highest position for

FORWARD or REVERSE.
3. Use the brakes to stop the machine, then use multi-

tachometer A to measure the speed when the en-
gine is run at high idling.
« Turn transmission cut-off selector switch OFF
(Check that the pilot lamp goes out.)
seconds. Make sure that the torque converter
oil temperature does not exceed 120°C.
20-140
HYDRAULIC STALL SPEED
1. Start the engine and run at high idling.
2. Operate the bucket (4) or boom lever (5), set the

cylinder to the stroke end, and activate the work
equipment valve relief valve.
3. Use multi-tachometer to measure the engine

seconds. Operate the control lever quickly.
FULL STALL SPEED
« Before carrying out the measurement, always

disconnect connector (3) from speedometer sen-
sor (2) wiring.
• Measure the engine speed when the torque con-

verter stall and hydraulic stall are both carried out at
the same time.
« Before measuring the full stall, check that the
torque converter stall and hydraulic stall speeds
are normal.
If either of the stall speeds are abnormal, cor-
rect the problem and measure again.
20-141
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
MEASURING TORQUE CON-

VERTER, TRANSMISSION,
PARKING BRAKE OIL PRES-
SURE


tires.
Preparatory work
« The following preparatory work is necessary when

measuring all oil pressures.
• Remove cover (1) on the left side of the rear
frame.
• Turn transmission cut-off selector switch (2) OFF
(Check that the pilot lamp is OFF.)
• Remove the plug from the measurement port of
the transmission valve.
• Install hydraulic tester kit C to the measurement
port, extend the gauge to the operator’s com-
partment, then start the engine and measure
the pressure.
« Check that no oil is leaking from any connection.
« After removing the measurement plug, always coat

the plug with adhesive.
plug: Sealing agent (LG–1)
20-142
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
Measuring procedure
1. Priority pressure
1) Measuring port (P1, PT1/8)
2) Start the engine and measure the pressure at
low and high idle.
2. Torque converter output pressure

2) Start the engine and measure the pressure at
low and high idle.
3. Pilot pressure
2) Start the engine and measure the pressure.
4. Clutch pressure
2) Start the engine, set the forward/reverse lever
to neutral, and measure the pressure when the
gear shift lever is operated.
5. Parking brake pressure

2) Start the engine and measure the pressure when
the parking brake is released.
20-143
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
METHOD OF OPERATING
EMERGENCY MANUAL SPOOL
Outline
The transmission valve is controlled electrically, but if

there should be any failure in the electrical system, or if
there is any failure in the solenoid valve or spool and
the machine cannot move, it is possible to operate the
emergency manual spool to move the machine.
This operation of the spool is designed only for use

if the machine cannot be moved because of a fail-
ure in the transmission control, and it is necessary
to move the machine from a dangerous working
area to a safe place where repairs can be carried
out.
This spool must not be operated except when there
has been a failure.
When carrying out this operation, keep strictly to

the order of operation and pay careful attention to
safety when moving the machine.
To prevent the machine from moving, lower the

bucket to the ground, apply the parking brake, and
put blocks under the tires.
Always stop the engine before operating the spool.
1. Remove cover (1) from the left side of the rear

frame.
2. Remove lock plate (2) from emergency manual spool

(3) of the transmission valve.
« The lock plate can be removed simply by loos-
ening the mounting bolts.
3. Operate emergency spool (3) to the operating posi-

tion according to the direction of movement of the
machine (forward or reverse).
• REVERSE: Push in the spool until it enters the
detent.
a = Approx. 8 mm
b = Approx. 8 mm
• FORWARD: Pull the spool until it enters the

detent.
20-144
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
4. Check that the area around the machine is safe,

then remove the blocks from under the tires.
5. Sit in the operator’s seat and depress the left brake

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

and slowly let the brake pedal out to start the ma-
chine.
When the engine is started, the transmission is also

engaged and the machine will start, so always check
carefully that the area around the machine and in
the direction of travel is safe, and keep the brake
pedal depressed fully when starting the engine.
7. After moving the machine, stop the engine, then

apply the parking brake and put blocks under the
tires.
8. Return the manual spool to the neutral position and

install the lock plate.
20-145
TESTING AND ADJUSTING MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
MEASURING CLEARANCE
BETWEEN TIRE AND WHEEL
• Tire inflation pressure: Specified pressure
Method of measuring
1. Fitting of wheel lock ring
Using feeler gauge, measure dimensions A and B
at four places around the circumference.
2. Clearance of wheel lock ring

Measure dimension C.
20-146
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
MEASURING OPERATING FORCE OF STEER-

ING WHEEL
• Road surface: Flat, horizontal, dry paved surface

• Engine speed: Low and high idling (bucket empty)
Measurement method
1. Install push-pull scale K to the steering wheel knob.
2. Start the engine.

« After starting the engine, raise the bucket approx.
400 mm and remove the safety bar.
3. Pull push-pull scale K in the tangential direction and

measure the value when the steering wheel moves
smoothly.
« Avoid measuring when the steering wheel starts
to move.
20-147

TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
MEASURING OPERATING TIME FOR

STEERING WHEEL

• Engine speed: Low and high idling
Measurement method

« After starting the engine, raise the bucket approx.
400 mm and remove the safety bar.
2. Operate the steering wheel to the end of its

stroke to turn the machine to the left or right.
3. Measure the time taken to operate the

steering wheel to the end of the stroke to the
right (left).
« Operate the steering wheel as quickly as
possible without using force.
« Carry out the measurements both at low idling
and high idling, and to both the left and right.
MEASURING STEERING STOP TRAVEL
1. Start the engine (cold or warm).

2. Operate the steering wheel to the end of its stroke to
turn the machine to the left or right.
3. Stop the engine.
4. Turn the stop travel bolt until the head of the bolt
touches the top of the valve.
5. Start the engine und turn the steering wheel until the
machine sets in a straight line.
6. Stop the engine; loosen stop travel bolt 8,5 turns
(approx. 15mm) and lock bolt.
7. Carry out the measurements to both the left and
right side.
20-148

TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
MEASURING STEERING OIL

PRESSURE
• Hydraulic oil: 45 – 55°C

METHOD OF MEASURING MAIN RELIEF PRES-

SURE
Loosen the oil filler cap to release the pressure

inside the hydraulic tank, then turn the steering
wheel several times to release the remaining pres-
sure inside the piping.
1. Apply safety bar (1) to the frame.
2. Remove measurement plug (2) for the right turn

steering circuit.
3. Install hydraulic tester kit C to the measurement

port.
4. Start the engine, run the engine at high idling, then

turn the steering wheel to the right and measure the
pressure when the relief valve is actuated.
« To measure the pressure when turning the steer-
ing wheel to the left, remove the plug for the left
turn steering circuit.
20-149

TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
Adjusting
Always stop the engine before adjusting the pres-

sure.
1. Stop the engine.
2. Loosen locknut (5), then turn adjustment screw (6)

to adjust.
« Pressure adjustment for one turn of adjustment

screw: Approx. 14.8 MPa (151 bar)
« Turn the adjustment screw to adjust the set
pressure as follows.
« Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
20-150
TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING
FORCE, TRAVEL OF BRAKE
PEDAL

Operating force of pedal

1. Fit push gauge N to your foot.
« Set the push gauge at a position 150 mm from
the pedal fulcrum.
2. Start the engine and measure the pedal pushing

force at low idle.
Travel of pedal
1. Fit push gauge N to your foot.
« Set the push gauge at a position 150 mm from
the pedal fulcrum.
2. Start the engine and measure the pedal pushing

angle at low idle with a pedal pushing force of 294N
(30 kg).
3. Install angle gauge M on the brake pedal and meas-

uring pushing angle α with a pushing force of 294N
(30 kg). It is also possible to measure α1 and α2 and
calculate α = α1 – α2.
Pedal play

2. Push the brake pedal lightly by hand, and measure
pedal angle α3 when the pedal starts to become
heavy.
20-151
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
MEASURING BRAKE
PERFORMANCE
• Travel speed: 20 km/h when brakes are applied
• Delay in applying brakes: 0.1 sec
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position

and drive the machine.
3. When the travel speed reaches 20 km/h, depress

the left brake pedal with the specified operating
force.
Specified operating force: 265N (27 kg)
« Before carrying out this operation, determine
the run-up path and the point for applying the
brakes, then apply the brakes when the ma-
chine reaches that point.
« Switch the transmission cut-off switch ON when
carrying out this operation.
4. Measure the distance from the point where the

brakes were applied to the point where the machine
stopped.
« Repeat this measurement three times and take
the average.
20-152
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
TESTING BRAKE OIL PRESSURE

• Engine water temperature: Within engine water tem-
perature gauge green range
• Testing pressure: 4.9 MPa (50 bar)
Apply the parking brake and chocks the tires.
Measuring procedure
1. Stop the engine.
2. Disconnect brake tube (1) on the side to be meas-
ured.
3. Disconnect union (2), install joint and attach
hydraulic test kit C
.
« Use the O-ring installed on the union. (O- ring:
07002-02034)
« Connect the hydraulic test kit quick coupler.
4. Loosen bleeder screw (3) and bleed the air.
« Bleed the air by activating pump .
5. Tighten bleeder screw (3), activate pump , in-
crease the pressure to 4.9 MPa (50 bar), then
tighten stop valve .
6. Let sit for five minutes with pressure applied and
check the pressure decrease.
* Do not move the hose while the pressure is
being measured, as this will cause pressure
fluctuations.
* After testing, activate pump and lower the
pressure of hydraulic test kit C before removing
the test kit.
* When testing is completed, install the brake
tube and bleed the air from the brake circuit.
20-153
TESTING AND ADJUSTING TESTING FOR BRAKE DISC WEAR
TESTING FOR BRAKE DISK WEAR
• Engine water temperature: Within engine water tem-
perature gauge green range
Apply the parking brake and chocks the tires.
Measuring
1. Loosen drain plug (1) and drain the axle oil.
Axle oil: 32 l
2. Install measuring plug (2).
3. Lightly press the brake pedal.

« Check that the piston is pressed against the
disc.
4. Insert gauge plug (5) between the plates (3) and

check the wear of disc (4).
« For gauge plug (5), use the oil level plug at-
tached to the axle housing.
« Note that forcing in the gauge plug may dam-
age the springs (6).
• The disc has not reached its usage limit if there
is a clearance when the gauge plug is inserted.
• If there is no clearance in the gauge plug or if it
cannot be inserted, the disc has reached its
usage limits.
5. Fasten the drain plug and supply axle oil to the

specified level through the oil supply port.
Axle oil: 32 l
20-154
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE SYSTEM
BLEEDING AIR FROM BRAKE

SYSTEM
Apply the parking brake and securely chocks the
tires.
Securely apply the boom drop prevention prop.
• Remove the front frame front cover (1).

1. Bleeding air from front axle brake circuit
1) Once pressure has accumulated in the accu-
mulator, stop the engine, insert vinyl hose (3)
into the front axle bleeder screw (2) and place
the other end in a container.
2) Press the brake pedal, loosen the bleeder screw

and bleed the air. Slowly release the brake pedal
after tightening the bleeder screw.
3) Repeat this operation until there are no air bub-

bles in the fluid coming from the vinyl hose,
then press the pedal in fully and tighten the
bleeder screw while oil is flowing out.
4) Use the same procedure to bleed the air from

the other side.
« If the accumulator pressure drops, start the
engine to increase it.
2. Bleeding air from rear axle brake circuit

Bleed the air from rear axle brake circuit in the
same way as for the front.
« When air bleeding is completed, set the engine
to low idle, check the hydraulic oil level, and
add oil if necessary.
20-155
TESTING AND ADJUSTING MEASURING PARKING BRAKE PERFORMANCE
MEASURING PARKING BRAKE

PERFORMANCE
• Road surface: Flat, dry paved road surface with
slope of 1/5 grade (11°20').
• Machine: Operating condition
Measurement method
1. Start the engine, set the machine facing in a straight

line, then drive the machine up a 1/5 grade slope
with the bucket empty.
2. Depress the brake, stop the machine, set the direc-

tional lever to the neutral position, then stop the
engine.
3. Turn the parking brake switch ON, then gradually

release the brake pedal and check that the ma-
chine is held in position.
« When the engine is stopped, the parking brake
is automatically switched ON.
« Carry out the measurement in two ways: Once
with the machine facing uphill, and once more
with the machine facing downhill.
20-156
TESTING AND ADJUSTING MANUAL RELEASE METHOD FOR PARKING BRAKE
MANUAL RELEASE METHOD

FOR PARKING BRAKE
« The parking brake is controlled by hydraulic pres-
sure, so if there should be any failure in the sole-
noid valve and it becomes impossible to release the
parking brake, it is possible to release it manually to
move the machine.
The manual release of the parking brake is de-

signed only to move the machine from a dangerous
working area to a safe place where repairs can be
carried out. This method must not be used except
when there has been a failure.

bucket to the ground and put blocks under the tires.
Always stop the engine before carrying out this pro-

cedure.
1. Loosen bolt (1), then remove lock plate (2) from

bolt (3) (3 places).
2. Tighten bolts (3) at 3 places in turn as far as the

mounting position for the plate at portion “a”, then
install lock plate (2) at portion “a”.
« Tighten all three bolts uniformly a little at a time.
« Bolt (3) pushes piston and releases the parking
brake.
3. Tighten bolt (1) to secure lock plate (2) in position.
20-157
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
TESTING WEAR OF PARKING

BRAKE DISK
« If the parking brake becomes weak, measure the
piston stroke as follows.

bucket to the ground and put blocks under the tires.
Always stop the engine before carrying out this pro-

cedure.
1. Loosen bolt (1), then remove lock plate (2) from

parking brake manual release bolt (3) (3 places).
2. Measure dimension “a” with the three manual re-

lease bolts (3) in contact lightly with brake pistons
(4).
3. Tighten the three manual release bolts (3) in turn

and measure dimension “b” when brake piston (4)
is pushed in fully.
« Piston stroke (L) = a – b
L = Max. 7.4
« If the piston stroke is greater than 7.4 mm,

check thickness W of brake disc (5). For de-
tails, see DISASSEMBLY AND ASSEMBLY,
REMOVAL OF PARKING BRAKE DISC.
• Dimension W: Min 2.83 mm
20-158
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
MEASURING WORK EQUIP-

MENT CONTROL LEVER
Install the safety bar to the frame.
Measurement method
1. Operating force of work equipment control lever
Install push-pull scale K to the work equipment con-
trol lever and measure the operating force.
« Install the push-pull scale to the center of the
knob.
« Operate the control lever at the same speed as
for normal operations, and measure the mini-
mum value for the force needed to operate the
knob.
2. Travel of work equipment control lever

Measure travel at each position when operating the
work equipment control lever.
« Mark the lever knob and use scale to measure.
20-159
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
Adjusting
1. Remove cover (1).
2. With solenoid (6) pulled, fix the solenoid in position

so that the clearance between cam (3) and roller (4)
is dimension a.
Dimension a: 0 – 0.5 mm
« Set the bucket lever and boom lever at the
HOLD position.
« If cam (3), roller (4), or spring (5) are broken,
replace them before adjusting.
3. Boom lever
Operate the boom lever and adjust the length of rod
(2) so that roller (4) is dimension b at the notch at
both ends of cam (3).
Dimension b: 0 – 1 mm
4. Bucket lever
Operate the lift lever and adjust the length of rod (2)
so that roller (7) is dimension C at the notch at both
ends of cam (8).
Dimension C: 0 – 1 mm
20-160
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASURING WORK EQUIP-

MENT HYDRAULIC PRESSURE
Work equipment relief valve pressure measuring proce-

dure
« Raise bucket tip "a" 30 to 50 mm and ground the
bucket at point "b", then stop the engine.
« After operating the levers, check that both points
"a" and "b" on the bottom of the bucket are touching
the ground.
Loosen the oil supply cap to release the pressure
inside the hydraulic oil tank, then operate the con-
trol levers two or three times to release any pres-
sure remaining in the piping.
1. Remove bucket cylinder circuit oil pressure meas-

uring plug (1).
2. Install hydraulic test kit C to the measuring port.

« Check that there is no oil leakage from any
joints.
« Use a hose which is long enough to reach the
operator's seat.
3. Start the engine, raise the boom about 400 mm, tilt
back the bucket using the control lever, and meas-
ure the pressure when the relief valve is activated.
« Be careful not to apply any sudden pressure to

the pressure gauge.
When removing the hydraulic pressure gauge, re-

lease the pressure inside the circuit in the same
way as when it was installed.
20-161

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
Adjusting work equipment relief valve pressure
Be sure to stop the engine when adjusting the pres-

sure.
1. Raise the boom, set the boom prop, and remove

front frame inspection cover (1).
Set the prop securely.
2. Remove the relief valve cap nut (2).
3. Loosen lock nut (3), and turn adjust screw (4) to

adjust.
screw:
Approx. 3.5 MPa (bar)
20-162
TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
MEASURING PPC-VALVE
PRESSURE
Up to Serial number: WA380H20470
• Engine water temperature : Within engine water
temperature gauge green range
• Hydraulic oil temperature : 45 to 55°C
• Engine speed : High idle
Apply the parking brake and blocks the tires.
Measuring
1. Raise boom (1), set boom prop (2), set the bucket
to an angle of approximately 45° (not to the maxi-
mum dump position) and remove front cover (3).
Set the prop securely.
2. Stop the engine, loosen the oil supply cap, release
the pressure inside the hydraulic oil tank, then stroke
the bucket control lever between the tilt and neutral
positions at least 40 times to completely release the
accumulator pressure.
« Be sure to stop the engine before operating the
lever.
« After the accumulator pressure is completely
released, set the bucket lever to the dump posi-
tion and check that the bucket does not dump.
3. Remove the work equipment dump cylinder circuit
pressure measurement plug (4).
4. Install hydraulic test kit C to the measuring port.
• Connect the hose after installing the hydraulic
test kit 90° elbow to the measuring port.
• Check that there is no oil leakage from any
joints.
• Use a hose which is long enough to reach the
operator's seat.
5. Start the engine, raise the boom about 400 mm, tilt
back the bucket using the control lever, and meas-
ure the pressure when the relief valve is activated.
• Be careful not to apply any sudden pressure to
the pressure gauge.
lease the pressure inside the circuit in the same Serial Number: WA380H20384 and up
• Connect test kit at the T-connector in the
hydraulic piping to the acc. charge valve.
20-163
Adjusting
Always stop the engine when adjusting the oil pres-

sure.
« The PPC relief valve is installed on the left front of

the rear frame.
1. Loosen locknut (2), then turn adjustment screw (3)

to adjust.
screw:
Approx. 1.79 MPa (18.3 bar)
20-164
MEASURING PPC VALVE

PRESSURE
Serial number: WA380H20471 and up
Ports:
T M22 x 1,5
P, VA, HA, PPC, Orbitrol M16 x 1,5
Me1, Me2 M14 x 1,5
Me3 G 1/4
max. flow 62 l/min
max. pressure 110 bar
Pressure regulating valve:

Switch on press. 70 +8 bar
Switch off press. 100 -8 bar
1. Decompression spindel
2. Decal
3. Strainer
J. Pressure regulating valve
• Engine water temperature : Within engine water
temperature gauge green range
• Hydraulic oil temperature : 45 to 55°C
• Engine speed : High idle
Apply the parking brake and blocks the tires.
Measuring
1. Install the safety bar (4) to the frame.
2. Stop the engine, loosen the oil supply cap to release
the pressure inside the hydraulic oil tank and oper-
ate the bucket lever at least 40 times to release
accumulator pressure completly.
« Be sure to stop the engine before operating the
lever.
« After the accumulator pressure is completely
released, set the bucket lever to the dump posi-
tion and check that the bucket does not dump.
3. Remove plug at measuring port (Me3).
4. Install hydraulic test kit to the measuring port (Me3).
« Check that there is no oil leakage from any
joints.
« Use a hose which is long enough to reach the
operator's seat.
20-165
5. Start the engine and measure.

• Be careful not to apply any sudden pressure to
the pressure gauge.
lease the pressure inside the circuit in the same
Adjusting
Always stop the engine when adjusting the oil pres-

sure.
« The PPC relief valve is installed near the articulation

center at the rear frame.
1. Loosen locknut and turn adjustment screw to adjust.

« Adjust pressure at pressure regulating valve.
LOOSEN to DECREASE pressure.
20-166
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
MEASURING WORK
EQUIPMENT
• Steering position: Neutral
• No load
Measurement method
1. Boom RAISE time
Set the bucket at the lowest position from the ground
with the bucket tilted back fully, then raise it and
measure the time taken for the bucket to reach the
maximum boom height.
2. Boom LOWER time

Set the bucket horizontal, then lower the boom from
the maximum height and measure the time taken
for the bucket to reach the lowest position from the
ground.
3. Bucket DUMP time

Raise the boom to the maximum height, and meas-
ure the time taken to move the bucket from the tilt
position (bucket fully tilted back) to the dump posi-
tion (bucket fully tipped forward).
4. Bucket TILT time

1) Raise the boom to the maximum height, and
measure the time taken to move the bucket to
the tilt position (bucket fully tilted back).
2) Set the bucket horizontal to the ground and
measure the time taken to move the bucket
from the horizontal position to the tilt position
(bucket fully tilted back).
20-167

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
MEASURING HYDRAULIC DRIFT WORK EQUIP-

MENT
• Stop the engine, leave for 5 minutes, then measure
for 15 minutes.
• Boom: Horizontal
• Bucket: Horizontal
• No load
Apply the safety lock to the work equipment control

levers.
Never go under the work equipment.
Measurement method
1. Set the boom and bucket in a horizontal position,
then stop the engine.
2. Leave for 5 minutes, then start the measurement.

3. Wait for 15 minutes, then measure retraction amount
A of the bucket cylinder rod and retraction amount
B of the boom cylinder rod.
A: Retraction amount of bucket cylinder rod

B: Retraction amount of boom cylinder rod
20-168
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER

BUCKET POSITIONER
Testing
1. Stop the engine and check that the clearance be-
tween switch (1) and angle (2) is the standard value.
2. Start the engine, run at idling and check the actua-

tion position.
(Check three times and take the average value.)
Adjusting
1. Lower the bucket to the ground, operate the bucket
to the desired digging angle, then return the lever to
HOLD and stop the engine.
2. Adjust nut (4) of switch (1) so that clearance a from

the tip of switch protector (3) to the switch sensing
surface is the standard value, then secure the switch
in position.
« Clearance a: 0.5 – 1.0 mm
Switch mounting nut: 17.7 ± 2 Nm
(1.8 ± 0.2 kgm)
3. Using shims, adjust the switch protector so that the

clearance b between the switch (1) sensing surface
and angle (2) is the standard value, then secure the
switch in that position.
« Check that the switch sensing surface and the
angle are not in contact.
« Adjust with shims so that the clearance be-
tween the switch sensing surface and the angle
is the standard value at the full stroke of the
angle, then lock in position.
« After adjusting, operate the bucket lever and
check that the bucket positioner is actuated at
the desired position.
« Check that the switch sensing surface and an-
gle do not slip from the center, then lock them
in position.
« Clearance b: 3 – 5 mm
20-169
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT

BOOM KICK-OUT
Testing
1. Stop the engine, and check that the clearance be-
tween switch (1) and plate (2) is the standard value.
2. Start the engine, run at high idling, and check the

actuation position.
(Check three times and take the average value.)
Adjusting
1. Raise the boom to the desired position and mark it
at the position where the center of the switch is at
the lower end of the plate.
Be sure to apply the safety lock to the control lever.
2. Lower the boom and stop the engine.
3. Adjust the plate position so that the center of switch

(1) is aligned with the lower end of plate (2) as
marked, then lock in position.
Switch installation bolt:
17.7 ± 2.0 Nm (1.8 ± 0.2 kgm)
4. Adjust the switch so that the clearance a between

the switch (1) sensing surface and plate (2) is the
standard value, then secure the switch in that posi-
tion.
« Clearance a: 3 to 5 mm
« After adjusting, operate the boom lever and
check that the kick-out is actuated at the de-
sired position.
20-170
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT
Proximity switch actuation pilot lamp (red)

The proximity switch is equipped with a pilot
lamp which shows when it is being actuated, so
use this when adjusting.
Proximity switch
actuation Lights up Goes out
pilot lamp
When detector is positioned at detection When detector has moved away from
Detector position
surface of proximity switch detection surface of proximity switch
Bucket
positioner
Boom kick-out
20-171
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
ADJUSTING MAIN MONITOR

(SPEEDOMETER MODULE)
• The speedometer on the main monitor is a common
part for all machines, and the input signal for the
travel speed differs according to the machine, so it
is necessary to adjust the monitor for use with the
particular model.
• In addition, the tire diameter also differs according
to the type of tire fitted, so it is necessary to adjust
to give the correct travel speed.
• It is also necessary to change the switches if the
optional E.C.S.S. (Electronically Controlled Suspen-
sion System) is installed.
Adjustment procedure
• Turn off the power, then remove the main monitor
and adjust the switches at the back of the speedom-
eter.
1. Setting machine model
1) Remove the rubber caps from dipswitches (1),
(2), (3), and (4) at the back of the speedometer.
2) When the rubber cap is removed, a rotary switch
can be seen inside. Using a flat-headed screw-
driver, turn this switch to adjust it to the settings
in the table below.
Tire size
Switch 20,5 x 25 (695) 23,5 x 25 (760)
1 1 (4)* 2 (4)*
2 B (5)** 5 (2)**
3 0 0
* SN WA380H20501 and up
** SN WA380H20987 and up
3) When the cap is removed from dipswitch (4) at

the back of the speedometer, an ON/OFF switch
can be seen.
Adjust the setting if the E.C.S.S. (Electronically
Controlled Suspension System) is installed. S1 - Model selection
S2 - Tire correction
S3 - km/h or MpH
Switch 4 S4 - Attachment
WA380
Switch
Reference: Amount of correction for switch (2)
No. without with with manual with work
attachment ECSS / ALS gear shift mode Switch posi-
tion 0 1 2 3 4 5 6 7
selector
1 ON ON ON OFF Amount of
2 ON ON ON ON correction (%) +14 +12 +10 +8 + 6 +4 +2 +0
3 ON OFF ON ON
4 ON ON OFF ON Switch posi-
tion 8 9 A B C D E F
4) After completing the adjustment, fit the rubber caps Amount of

correction (%) 0 –2 –4 –6 –8 –10 –12 –14
securely and install the main monitor.
20-172

TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC SYSTEM
GAS SIDE TEST AND TOPPING UP THE GAS PRESSURE
Note:
If a filling unit, as shown ,

DFM (9), and a pressure
table are available, then
the test can be carried out
in the machine. To carry
out this care must be taken
to check that there is no
hydraulic pressure on the
hydraulic side of the
accumulators. If the accumulators are to be
checked out off the machine , then there is no
need for the special mounting tool (2).
Accumulator pressure test, gas side:
Follow the following instructions :
a) Remove the protection cap (10) from the gas

connector M28 X 1.5 on the accumulator (1)
and check that the connector is clean.
b) Release the gas fill screw (11) using a 6mm

allen key approx. ¼ turn.
c) Close the release screw (12), on the filling

unit, fully.
d) Fit the filling unit (9) without the hose (13) to

the gas connection. Check that the O-ring
(14) is in position and sitting correctly in the
grove. Attention ! The check valve (15) only
works when the hose (13) is fitted in position.
e) After fitting the filling unit (9), feed the key

(16) by turning the handle (17) back and fore
into the gas fill screw (11). Open the release
screw slowly by turning clockwise, so that gas
from the accumulator can enter the filling unit.
The gas pressure can be read on the pres-
sure gauge. At ambient temp, the pressure
read is the gas pressure.
f) If the pressure, read at ambient temp., is more g) Remove the filling unit (9) from the accumu-
than 17 bar, close the gas fill screw (11) using lator. Tighten the gas filling screw (11) using
the handle (17) and the key (16). Open the an allen key to 20 +5 Nm.. Fit the protection
release screw (12) and release the gas pres- cap back on the gas connector (10) M28 x
sure in the fill unit. 1.5mm.
20-173

TOPPING UP THE GAS PRESSURE
• Use only dry, technically clean nitrogen from stand-

ard nitrogen gas bottles.
Important safety note:

• Do not fill directly from the gas bottle with DFM
filling unit. The use of improvised adapters is not
allowed. When using the DMF filling unit always use
a purpose built pressure reducing valve set (bottle
pressure to 200 bar, regulating pressure 20 bar).
h) As in a) to c)
i) Connect the filling unit (9) to the hose (13), M28 x

1.5. Check that the O-ring (14) is correctly fitted in
its grove. Connect the hose, connector (19), to the
gas bottle pressure reducing valve((21), connector
(20). The gas bottle valve (22) and the pressure
reducing valve out-let (23) are closed.
j) Slowly open the gas bottle valve (22) and allow the
gas to flow at the desired pressure (adjusting valve
(24)). Pressure gauge (25) shows the filling pres-
sure, pressure gauge (26) the gas bottle pressure.
The pressure reducing valve out-let (23) is open.
k) Feed the key (16) by turning the handle (17) back

and fore into the gas fill screw (11) and then open
slowly in clockwise direction. Keep the pressure
reducing valve out-let (23) open until the Pressure
gauge (18) on the filling unit (9) shows the desired
pressure. Allow time for the temp. to stabilise. Close
the pressure reducing valve out-let (23) and the
gas bottle valve (22). If the pressure drops because
of temp. equalising, repeat the topping up opera-
tion. Allow an extended stabilising time.
l) As in f) and g).
Renewing the Usit-ring (27)
• The Usit-ring seals the gas fill screw (11). If it is

suspected that the Usit-ring is leaking or as a pre- as in steps h) to l).
ventive measure (long life) it is to be changed, then
the gas pressure in the accumulator has to be Pressure warning system
dropped to zero by following steps a) to e) and
opening the release screw (12).Now remove the • The gas fill screw (11) is provided with a
filling unit (19) and remove the gas fill screw (11). release grove. If the screw is opened, gas
Renew the Usit-ring (27) making sure that the con- flows out and causes a hissing noise as a
nector and surrounding is clean and not damaged. warning that gas pressure is present.
After fitting a new Usit-ring to the accumulator gas
fill screw (11), renew the accumulator gas pressure
20-174

HYDRAULIC ACCUMULATOR
Service:
• Service of the ALS accumulators should be carried

out every 1000 hrs or once a year. The service
consists of checking the gas pressure and eventu-
ally topping up. Also regular checks for leaks and
condition of the mountings should be carried out. If
the gas pressure is found to be under 17 bar (at
ambient temp.), see also the table opposite, then
the pressure must be topped-up, according to the
following instructions, to 20 bar, or the hydraulic
accumulator must be changed completly.
Gas pressure check from the hydraulic side
Note:
• With a gas pressure check, from the hydraulic
side, with two or more accumulators, it is not pos-
sible to check the condition of individual accumula-
tors. If one accumulator losses all its gas pressure
it will not show up in this check as long as the other
accumulators have gas pressure. Because of this it
is only recommended to carry out this type of test
with individual accumulators that have been removed
from the system. The position nos., in brackets
refer to the fig. on the next page.
Press.
• The individual accumulators (1) should be mounted

in the special holder (2), 206-1036-011-001, and
secured with 4 screws (3) M8 x 80. Care should be
taken to check that one of the 2 SAE ¾” standard
connections (4) is sealed with plug (5) M20 x 1.5. A
When filling: a full off in pressure rise speed
test pump (7) (hand pump) should be fitted to the
other SAE connector (6) along with a pressure test
When releasing: a sudden drop in pressure to
gauge (8). When the test pump is operated oil will
zero
enter the accumulator. Because oil can not be
compressed the pressure on the gauge will rise
rapidly, see graph diagram. When the gas pres- Accumulated volume
sure is reached, the pressure rise speed, in the
accumulator, falls off to a slower curve. This is seen
as an almost constant pressure on the pressure
gauge. When this point is reached the gas pres-
sure in the accumulator is the same as that shown
on the gauge. The pressure is equivalent to gas
pressure P0ϑ at a test temp ϑ in ° C.
• If the test temp. ϑ is different to the ambient temp. Safety note:

(20°C = 293 K) then the read gas pressure P0ϑ Damaged hydraulic accumulators must be
must be calculated (pressure absolute). exchanged completly!
20-175

MEMO:
20-176

TROUBLESHOOTING
Points to remember when troubleshooting ............................................................................................ 20-202

Sequence of events in troubleshooting .................................................................................................. 20-203
Precautions when carrying out maintenance ......................................................................................... 20-204
Handling connectors ............................................................................................................................... 20-211
Checks before troubleshooting .............................................................................................................. 20-212
Method of using troubleshooting charts ................................................................................................. 20-213
Connector types and mounting locations, connector pin arrangement diagram ................................... 20-222
Connection table for connector pin numbers ........................................................................................ 20-231
Troubleshooting of engine system (S mode) ......................................................................................... 20-251
Troubleshooting of main monitor system (M mode) ............................................................................... 20-351
Troubleshooting of maintenance monitor system (K mode) ................................................................... 20-401
Troubleshooting of electrical system (E mode) ...................................................................................... 20-451
Troubleshooting of transmission controller system (A mode) ................................................................ 20-501
Troubleshooting of hydraulic and mechanical system (Chassis related) (T mode) ............................... 20-551
Troubleshooting of ECSS (Electronically Controlled Suspension System) (D mode) ........................... 20-601
20-201

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any
unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the
engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the
internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of
possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to 4) Check the stroke of the control valve spool.
disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered to
failure occurs: be necessary.
• Parts that have no connection with the failure or 4. Confirming failure
other unnecessary parts will be disassembled. • Confirm the extent of the failure yourself, and
• It will become impossible to find the cause of judge whether to handle it as a real failure or as
the failure. a problem with the method of operation, etc.
It will also cause a waste of manhours, parts, or oil « When operating the machine to reenact the
or grease, and at the same time, will also lose the troubleshooting symptoms, do not carry out
confidence of the user or operator. any investigation or measurement that may
For this reason, when carrying out troubleshooting, make the problem worse.
it is necessary to carry out thorough prior investiga- 5. Troubleshooting
tion and to carry out troubleshooting in accordance • Use the results of the investigation and inspec-
with the fixed procedure. tion in Items 2 – 4 to narrow down the causes
2. Points to ask user or operator of failure, then use the troubleshooting flow-
1) Have any other problems occurred apart from chart to locate the position of the failure exactly.
the problem that has been reported? « The basic procedure for troubleshooting is
2) Was there anything strange about the machine as follows.
before the failure occurred? 1) Start from the simple points.
3) Did the failure occur suddenly, or were there 2) Start from the most likely points.
problems with the machine condition before this? 3) Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? • Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred before? will occur again.
3. Check before troubleshooting To prevent this, always investigate why the prob-
1) Check the oil level lem occurred. Then, remove the root cause.
2) Check for any external leakage of oil from the
piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first ask Ring Ring

the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the problem.
• Condition of failure
• Work being carried out at the time of the TEW00182
failure
• Operating environment
• Past history, details of maintenance, etc. Breakdown
Step 2 TEW00183
Determining probable location of cause
Step
1) Look at the troubleshooting section of the shop
manual to find locations of possible causes. Repair at jobsite
Hurray !
It's repaired
TEW00184
Step 3 TEW00185
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in the

shop manual and prepare the necessary tools. Step 7
• T-adapter • Pinpoint locations of failure (carry out
• Hydraulic pressure gauge kit, etc. troubleshooting)
2) Look in the parts book and prepare the neces- • Decide action to take
sary replacement parts.
TEW00186
1) Before starting troubleshooting, locate and re-
pair simple failures.
• Check before starting items
• Other check items
Step 8 2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart that
Repair at workshop matches the symptoms, and carry out trouble-
shooting.
TEW00187
Machine Step 6
volume Re-enacting failure
• Drive and operate the machine to confirm the

Shop manual condition and judge if there is really a failure.
TEW00188
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of fail-
ure.
• Was there anything strange about the machine

before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?
TEW00190
20-203
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a
long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance
and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with
correct repair procedures for mechatronics and is
aimed at improving the quality of repairs. For this
purpose, it gives sections on “Handling electric equip-
ment” and “Handling hydraulic equipment”
(particlularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLING ELEC-

TRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connect-ing
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protector or tubes
used for protecting the wiring. Compared with
other electrical components fitted in boxes or
cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water, heat,
or vibration. Furthermore, during inspection and
repair operations they are frequently removed
and installed again, so they are likely to suffer
deformation or damage. For this reason, it is
necessary to be extremely careful when han-
dling wiring harnesses.
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely TEW00191
to occur because the male connector is not Improper insertion
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
TEW00192
20-204
(2) Defective compression or soldering of con-

nectors
The pins of the male and female connec-
Improper compression
tors are in contact at the compressed ter-
minal or soldered portion, but there is ex-
cessive force on the wiring, and the plating
peels to cause improper correction or break-
age.
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with TEW00193
a crane with the wiring still connected, or a
heavy object hits the wiring, the compres-
sion of the connector may be lost, or the
soldering may be damaged, or the wiring
may be broken.
(4) High pressure water entering connector

The connector is disigned to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector depending on the direction of the
water jet.
The connector is designed to prevent water TEW00194
from entering, but at the same time, if the
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited
by the water, so if any water gets in, imme-
diately dry the connector or take other ap-
propriate action before passing electricity
through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating
surface between the male and female pins,
the oil will not let the electricity pass, so TEW00195
there will be defective contact.
If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or
blow dry with air, and spray it with a contact
restorer.
« When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
« If there is water or oil in the air, it will
increase the contamination of the points,
so clean with air from which all the wa-
ter and oil has been removed.
TEW00196
20-205
2) Removing, installing, and drying connectors and

wiring harnesses
Disconnecting connectors
(1) Hold the connectors when disconnecting. Press lightly
When disconnecting the connectors, hold when removing
the connectors and not the wires. Lock stopper
For connectors held by a screw, loosen the
screw fully, then hold the male and female
connectors in each hand and pull apart. For
connectors which have a lock stopper, press
TEW00197
down the stopper with your thumb and pull
the connectors apart.
(2) Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
Connecting connectors
(1) Check the connector visually.
a. Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
b. Check that there is no deformation, de-
TEW00198
fective contact, corrosion, or damage
to the connector pins.
c. Check that there is no damage or break-
age to the outside of the connector.
« If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
« If there is any damage or breakage,
replace the connector.
20-206
(2) Fix the connector securely.

Align the position of the connector cor-rectly,
then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper clicks
into position. Cliks into position
TEW00199
(3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct
position.
« When blowing with dry air, there is dan-
ger that the oil in the air may cause
improper contact, so clean with air from
which all the water and oil has been
removed. TEW00200
Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connec-tor must be
washed in water, do not use high pressure wa-
ter or steam directly on the wiring harness. If
water gets directly on the connector, do as fol-
lows.
(1) Disconnect the connector and wipe off the
water with a dry cloth.
« If the connector is blown dry with air,
there is the risk that oil in the air may
cause defective contact, so avoid blow- TEW00196
ing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
« Hot air from the dryer can be used, but
be careful not to make the con-nector
or related parts too hot, as this will cause
deformation or damage to the connec-
tor.
TEW00202
20-207
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
« After completely drying the connector,
blow it with contact restorer and reas-
semble. T-adapter
3) Handling control box
TEW00203
(1) The control box contains a microcomputer

and electronic control circuits.
These control all of the electronic circuits
on the machine, so be extremely careful
when handling the control box.
(2) Do not open the cover of the control box
unless necessary.
(3) Do not place objects on top of the control
box.
(4) Cover the control connectors with tape or a
vinyl bag.
(5) During rainy weather, do not leave the con- TEW00204
trol box in a place where it is exposed to
rain.
(6) Do not place the control box on oil, water,
or soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand)
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
TEW00205
TEW00206
20-208
2. POINTS TO REMEMBER WHEN HAN-

DLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equip-
ment. TEW00207
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling TEW00208

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
TEW00209
20-209
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the hy-
draulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil Flushing oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
TEW00210
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEW00211
20-210
TROUBLESHOOTING HANDLING CONNECTORS
HANDLING CONNECTORS
1. When removing the connectors from the clips, pull
the connector in a parallel direction to the clip.
« If the connector is twisted to the left and right or
up and down, the housing may break.
TBW00484
Stopper
TBW00485
2. When disconnecting male and female connectors,

release the lock and pull in parallel with both hands.
« Never try to pull out with one hand.
TBW00486
3. When the wiring harness clamp of the connector

has been removed, always return it to its original
condition and check that there is no looseness of
the clamp.
TBW00487
20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Remedy

standard
1. Check fuel level, type of fuel — Add fuel
2. Check for dirt or water in fuel — Clean, drain
Lubricant, coolant
3. Check hydraulic oil level — Add oil

4. Check filter (hydraulic, transmission, torque converter) — Replace
Checks before starting
5. Check oil level — Add oil

6. Check engine oil — Add oil
7. Check coolant level — Add water
8. Check clogging of dust indicator — Clean or check
Electrical components
9. Check for loose or corroded battery terminals or wiring — Tighten or replace

10. Check for loose or corroded alternator terminals or wiring — Tighten or replace
11. Check for loose or corroded starting motor terminals or wiring — Repair or replace
12. Check operation of gauges — Repair or replace
Hydraulic, mechanical
13. Check for abnormal noise or smell — Repair

14. Check for oil leakage — Repair
components
15. Bleed air from system — Bleed air

16. Check effect of brakes — Adjust or repair
17. Check battery voltage (engine stopped) 24 – 26V Repair or replace
18. Check battery electrolyte level — Add electrolyte or
replace
Other check items
19. Check for discolored, burned, or bare wiring — Replace

Electrical components
20. Check for missing wiring clamps, hanging wires — Repair

21. Check for water on wiring — Dry place affected by
(check carefully for water at connectors and terminals) water
22. Check for broken or corroded fuses — Replace
23. Check alternator voltage (engine running at over half throttle) — Replace
(If the battery charge is low, it may reach approx. 25 V 28.5 – 29.5V Repair or check
immediately after starting)
24. Noise when battery relay is operated — Replace
(turn starting switch ON-OFF)
20-212
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting code No. Component
S-OO Troubleshooting of engine
M-OO Troubleshooting of main monitor
K-OO Troubleshooting of maintenance monitor
E-OO Troubleshooting of electrical system
A-OO Troubleshooting of transmission controller
T-OO Troubleshooting of hydraulic and mechanical system
D-OO Troubleshooting of ECSS (Electronically Controlled Suspension System)
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode
(problem with the machine). (See Example (1))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according to the
model, component, or problem. In such cases, the failure mode (problem) is further divided into
sections marked with small letters (for example, (a)), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item
in the failure mode. (See Example (2))
3) Method of following troubleshooting chart YES
• Check or measure the item inside NO
, and according to the answer follow either the YES line
or the NO line to go to the next . (Note: The number written at the top right corner of
the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy column on
the right. (See Example (3))
• Below the [ ] there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the are correct or the answer to the question inside the is
YES, follow the YES line; if the judgement value is not correct, or the answer to the question is
NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is
mistaken, there is danger that it may cause mistaken judgement, or the equipment may be
damaged. Therefore, before starting inspection or measurement, always read the instructions
carefully, and start the work in order from Item 1).
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items
are given at the top of the page and marked with «. (See Example (4))
The precautions marked « are not given in the , but must always be followed when carrying out
the check inside the .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number
connection. When carrying out troubleshooting, see this chart for details of the connector pin number
and location for inspection and measurement of the wiring connector number appearing in the
troubleshooting flow chart for each failure mode (problem).
20-213
< Example >

(1) M-15 Abnormality in buzzer
(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check)
Cause Remedy
(3) Defective contact, or

Yes disconnection in wiring After inspection,
1 harness between CNL06 repair or replace
(female) (8) and CNL43
Does buzzer (male)
sound ? 2 Yes
Defective buzzer Replace
Is valtage between
CNL42 (female) and
1) Turn starting
No chassis Defective contact, or
switch ON After inspection,
ground normal ? disconnection in wiring
repair or replace
No harness between CNL42
2) Contact CNL43 1) 20 - 30 V (female) and CNFS(2) male
(female) to
chassis ground 2) Turn starting
switch ON
(4)
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
20-214
20-215
3. Using troubleshooting chart for engine-related failure
This troubleshooting chart is divided into three sec-

tions: questions, check items, and troubleshooting. The
questions and check items are used to pinpoint high
probability causes that can be located from the failure
symptoms or simple inspeciton without using trouble-
shooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final
confirmation.
[Questions]
Sections + in the chart on the right corresponds
to the items where answers can be obtained from
the user. The items in are items that can be
obtained from the user, depending on the user’s
Causes
level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under in the
chart on the right correspond to this.
The serviceman narrows down the causes from in-
formation that he has obtained from the user and
the results of that he has obtained from his own
inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of prob-
ability, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check items].
Questions
Check items
shooting
Trouble-
20-216
The basic method of using the troubleshooting chart is

as follows.
Items listed for [Questions] and [Check items] that have
a relationship with the Cause items are marked with ¡,
and of these, causes that have a high probability are
marked with .
Check each of the [Questions] and [Check items] in
turn, and marked the ¡ or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for that
item to make final confirmation of the cause. Cause
1. For [Confirm recent repair history] in the [Ques-
n)
ctio
tions] Section, ask the user, and mark the Cause
inje
column with ∆ to use as reference for locating
the cause of the failure. However, do not use
ve
e
le
enc
ozz
ssi
this when making calculations to narrow down
xce
rfer
nt
nn
the causes.
er
e
p (e
2. Use the ∆ in the Cause column as reference for
inte
em
ing
ind
c t i o
pum
r el
tim
cyl
[Degree of use (Operated for long period)] in
inje
er,
e
the [Questions] section as reference. As a rule,
arg
ng,
tion
n
tion
ed
lea
do not use it when calculating the points for
och
n ri
jec
eiz
c
ir c
inje
locating the cause, but it can be included if
turb
isto
n
d, s
da
er i
necessary to determine the order for trouble-
tive
rn p
gge
gge
zed
rop
shooting.
fec
Wo
Clo
Sei
Clo
Inp
De
>>1 Confirm recent repair history
>>2 Degree of use Operatred for a long period
20-217
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air Causes
• Improper condition of fuel injection
)
tion
• Excessive injection of fuel
ead
d)
jec
ize
dh
e in
r se
eat
r an
siv
nge
es
rge
nce
ces
le
alv
, plu
cha
ozz
ere
(ex
e, v
rbo
ack
nt
nn
terf
mp
me
ing
ce
alv
nde
p (r
r
ctio
t
le
r, in
ran
u
ele
en
tim
of v
f
um
cyli
np
f
mu
inje
twe
lea
rge
ner
tion
np
ctio
act
,
ged
g
ec
e
cha
ed
lea
ctio
n rin
b
jec
t
inje
con
alv
air
eiz
log
Legend
ir c
rbo
inje
er in
isto
er v
d, s
f
: Possible causes (judging from Questions and check items)
d, c
tive
eo
da
tive
d tu
tive
: Most probable causes (judging from Questions and Check items)
rn p
rop
gge
rop
kag
gge
she
fec
fec
ize
ffec
: Possible causes due to length of use (used for a long period)
Imp
Imp
Lea
Wo
Cru
Clo
De
Clo
De
Se
: Items to confirm the cause.
De
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
starting engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Troubleshooting
Speed of some cylinders does not change when operating

on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy, or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-218
Five causes
Step 1
Clarify the relaitionship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of ¡ and marks where the hori-

zontal lines for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element: ¡
(2) Air leakage between turbocharger
and head: ¡¡
(3) Clogged, seized injection nozzle: ¡
(4) Defective contact of valve, valve seat: ¡
(5) Worn piston ring, cylinder: ¡
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting area
and carry out the troubleshooting item marked l.
The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return to
normal.
20-219
4. Method of using matrix troubleshooting tables

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to
locate the causes of failures in the machine. The troubleshooting tables are divided broadly into categories
for the main components, such as the steering system and work equipment hydraulic system. Follow the
procedure given below and carry out troubleshooting to locate the problems accurately and swiftly.
Step 1. Questioning the operator

The questions to ask the operator are given
below the failure symptom. If the answers to 1. Steering does not work ¨ Symptom [Example]
the questions match the information given, fol-
low the arrow to reach the probable cause of Ask the operator about the following points.
the failure. • Did the steering suddenly stop working?
Consider the contents of the questions and con- à Breakage in steering equipment
sult the table while proceeding to Steps 2 and 3 • Had the steering gradually been becom-
to grasp the true cause. ing heavy? à Internal wear of steering
equipment, defective seal
Step 2. Checks before troubleshooting
Before starting the main troubleshooting and Checks before starting [Example]
measuring the hydraulic pressure, first check
the Checks before Starting items, and check for • Is the oil level and type of oil in the hy-
oil leakage and loose bolts. These checks may draulic tank correct?
avoid time wasted on unnecessary troubleshoot- • Is there any leakage of oil from the steer-
ing. ing control valve?
The items given under Checks before Starting
are items which must be considered particularly
for that symptom before starting troubleshoot-
ing. [Example 1]
Step 3. Using cross-reference table Remedy

1) Operate the machine to carry out the checks No.
Problem
in the troubleshooting item column.
1 Steering does not work to the left or right.
Mark the items where the results match the
symptom. 2 Same as item 1, but abnormality is actuated of work equipment.
« It is not necessary to follow the trouble- 3 Steering can only be operated to one side.
shooting checks in order; follow an or- 4 Steering wheel is heavy and cannot be turned.
der which is easiest to carry out trou-
bleshooting.
2) Find the appropriate cause from the cause
column. If the symptom appears, the ! marks
on that line indicate the possible causes. [Example 2]
(For item No. 2 in the table on the right, the
possible causes are c or e.)
If there is only one o:
ses
Carry out the other troubleshooting items

Cau
(where the same cause is marked with !),

a b c d e
check if the symptom appears, then repair.
If there are two os: Remedy
C A
Go on to Step 3) to narrow down the possi- Problem
ble causes. 1
20-220
3) Operate the machine and check the trouble-

shooting items other than those in 1).
es
s
Operate the machine and check the items in
Cau
the same way as in 1), and if the symptom
a b c d e
appears, mark that item. (In the chart on the
right, the symptom appears again for item 5). Remedy
C A
4) Find the appropriate cause from the cause col- Problem
umn. In the same way as in Step 2), if the 1
symptom appears, the ¡ marks on that line 2
indicate the possible causes. (For item No.5 in
3
the table on the right, the possible causes are b
or e.) 4
5
5) Narrow down the possible causes. Applicable troubleshooting item located in Step 3).
There is one common cause among the causes Applicable troubleshooting item located in Step 1).
located in Steps 2) and 4). (One cause marked
¡ appears on the line for both items.) This
cause is common to both the symptoms in trou- Ignore these causes
ses
bleshooting Steps 1) and 3).
Cau
« The causes which are not common to both
troubleshooting items (items which are not a b c d e Common causes
marked ¡ for both symptoms) are unlikely Remedy
causes, so ignore them. C A
Problem
(In the example given on the right, the 1
causes for Troubleshooting Item 2 are c or
2
e, and the causes for Troubleshooting Item
5 are b or e, so cause e is common to 3
both.) 4
6) Repeat the operations in Steps 3), 4) and 5) 5
until one cause (one common cause) remains.
« If the causes cannot be narrowed down to
one cause, narrow the causes down as far
ses
as possible.
Cau
7) Remedy a b c d e
If the causes are narrowed down to one com- Remedy Action to take
mon cause, take the aciton given in the remedy C A
Problem
column. 1
The symbols given in the remedy column indi-
2
cate the following:
X: Replace, ∆: Repair, A; Adjust, C: Clean 3
20-221
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATION

• The Address column in the table below shows the address in the connector arrangement drawing (3-
dimensional drawing)
(1/3)
Con- Con- No. Con- Con- No.
nector nector of Mounting location nector nector of Mounting location
No. Type pins No. Type pins
CNA18 SWtype 8 Servo motor left CNGR1 M type 4 Intermediate connector
CNB01 X type 2 Condenser motor left CNGW1 M type 3 Working lamp
CNLR1 S type 12 Floor wiring harness
CNB03 (Con- 2 Front washer motor
nector) SWP Floor wiring harness
CNLR2 14
type
CNB04 (Con- 2 Rear washer motor
nector) SWP Floor wiring harness
CNLR3 8
CNB07 X type 2 Condenser motor right type
SWP CNLR4 SWP 14 Floor wiring harness
CNBR1 14 Bulkhead wiring harness
type type
CNC01 M type 6 Front wiper motor CNLR5 X type 4 Floor wiring harness
CNC02 M type 4 Radio CNLR6 L type 2 Floor wiring harness
CNC03 M type 2 Working lamp right CNR05 X type 2 Brake pressure
CNC04 M type 2 Working lamp left CNR06 X type 2 Radiator level sensor
CNR07 X type 2 Fuel level sensor
CNC05 (Con- 4 Warning lamp
nector) Combination lamp
CNR08 M type 4
(Con- rear left
CNC06 2 Room lamp
nector) Combination lamp
CNR09 M type 4
CNC07 M type 4 Rear wiper motor rear right
CNCL1 S type 12 Instrument wiring harness
CNR18 (Con- 2 Reverse light
CNCL2 S type 16 Air condenser nector)
CNCL3 S type 8 Air condenser
CNR19 (Con- 2 Reverse light
SWP nector)
CNE03 8 Engine stop motor
type CNR25 X type 2 Brake oil pressure
Engine water temp. sensor CNT01 X type 2 F solenoid
CNE06 X type 2
CNT02 X type 2 R solenoid
CNE08 — 1 Pre-heating CNT03 X type 2 Hi-Lo solenoid
CNE09 — 2 Pre-heating CNT04 X type 2 Speed solenoid
SWP CNT06 X type 2 Speed sensor (kmh)
CNER1 14 Engine wiring harness
type Torque converter oil
CNT07 X type 2
temperature sensor
CNER2 SWP 8 Engine wiring harness
type CNT10 X type 2 Pressure switch
CNF01 M type 4 Head lamp right Flow control
CNT11 X type 2
CNF02 M type 4 Combination lamp
front right SWP
CNTL1 8 Floor wiring harness
Combination lamp type
CNF03 M type 4
front left SWP
CNTL2 8 Floor wiring harness
CNF04 M type 4 Head lamp left type
CNF05 X type 3 Bucket positioner CNT12 X type 2 Proportional solenoid
CNF06 X type 3 Boom kick-out CNT08 X type 2 Pressure switch parking brake
CNFR1 S type 10 Wiring harness
front frame
CNFR2 X type 4 Wiring harness

front frame
20-222
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
Connector pin arrangement diagram (1/3)
CNB07 CNB03 CNB04 CNGW1

CNB01
CNC07 CNR06
CNC06
CNLR1 CNR09
CNLR2 CNBR1
CNGR1
CNC04
CNLR3
CNLR4 CNC03 CNE06
CNC05
CNLR5 CNR18
CNLR6 CNC02
CNR19
CNC01
CNTL1 CNTL2
CNCL1
Z
CNCL3
CNCL2
CNA18
CNR08
CNF01
CNF02
CNR07
CNE08
CNF06
CNE09
CNE03
CNF05 CNER1
CNER2
CNT05
CNT04
CNT03
CNT02 CNT01
CNT12
CNT07
CNT06
CNFR1
CNT08
CNFR2
CNF04
CNT11 TBW00712
CNF03 CNT10
20-223
(2/3)
Con- Con- No. Con- Con- No.
nector nector of Mounting location nector nector of Mounting location
No. Type Pins No. Type Pins
CNA5 M type 2 Thermistor
MIC
SWP CNL29 type 21 Transmission controller
CNA6 14 Air mix servo motor
type
CNA7 M type 6 Blower motor
AMP040
CNA8 S type 16 Air conditioner CNL30 20 Transmission controller
connector
CNA9 — 4 Ventilator relay (MAIN)
CNA10 — 4 Ventilator relay (Hi) AMP040
CNL31 16 Transmission controller
connector
CNA11 — 4 Ventilator relay (M2)
CNA12 — 4 Condenser relay (Hi) CNL48 — 5 Bucket relay
CNA13 — 4 Ventilator relay (M1) CNL49 — 5 Boom relay
CNA14 — 4 Condenser relay CNL52 — 5 Warning relay
CNA15 — 4 Air condit. compress. relay CNL53 — 5 Brake light relay
CNCL1 S type 12 Floor wiring harness CNL55 — 5 Horn relay
CNCL2 S type 16 Air conditioner CNL56 — 5 Pre-heating relay
CNCL3 S type 8 Air conditioner CNL57 — 5 Neutral relay
CNFS1 L type 2 Fuse box CNL60 — 6 Front working lamp relay
CNFS2 S type 12 Fuse box CNL61 — 6 Rear working lamp relay
CNFS3 M type 6 Fuse box CNL62 — 5 Engine stop relay
CNFS4 L type 2 Fuse box CNL63 — 1 Horn switch
CNFS5 M type 6 Fuse box CNL64 — 5 Engine oil pressure relay
CNFS6 M type 6 Fuse box CNL67 — 5 Reverse lights
CNL09 — 4 Starting switch CNL80 — 5 Air clogging relay
SWP Transmission combination CNL200 — 6 Parking brake neutral
CNL02 6
type switch TDR1 — 6 Transmission control
CNL03 SWP 6 Transmission combination TDR2 — 6 Transmission control.
type switch
CNL04 SWP 14 Transmission combination

type switch
CNL05 AMP040 20 Main monitor

connector

connector

connector

connector
CNL18 AMP040 16 Maintenance monitor

connector
CNL19 AMP040 8 Maintenance monitor

connector
CNL21 (Con- 2 Maintenance monitor

nector)
CNL22 (Con- 2 Maintenance monitor

nector)
20-224
Relay location up to SN WA380H20500
20-225

Relay location from SN WA380H20501 up to H20836

(Relay label see page 10-412)
Note: The Connector indication CN has changed into X for the actual wiring harness.
CNL52
K163.1
CNTDR2
K163.2
CNTDR1
CNL200
CNL49
K67.1
CNL48
K67.2 CNL60
CNL57 CNL56
CNL67
CNL55
TD1-TD4
CNL53 CNL61
CNL44 Z CNL80
Forward CNL64 TD5-TD8
(Fahrtrichtung)
CNFS1
CNFS2
CNL18 CNL22 Z CNFS3
CNL19 CNFS4
CNL21 CNFS5
CNFS6
CNL31
CNL30 CNA8
CNL29
CNA14
CNL03 CNA9
CNL09
CNA11
CNL02
CNL06 CNA10
CNL07
CNA13
CNL08
CNA12
CNL05
CNA15
CNL63
CNA5
CNCL1 CNA7
CNCL2 CNA6
CNCL3
CNL04
Relais_A
20-226

Relay location: SN WA380H20837 and up

(Relay label see page 20-230)
Note: The Connector indication CN has changed into X for the actual wiring harness.
Alteration from SN WA380H20987 and up: K101

Relay K218 (Reserve) replaced by K67 KTDR2
K161.1 KTDR1
Relay K443 (Selection work mode) K200
K414 K139
K209
(K218) K432
K443
K208 K282
K385
K8 K159
V118.1 K433
K165
Z V118.3
K337 K262
Forward K19 V118.2
(Fahrtrichtung)
CNFS1
CNFS2
CNL18 CNL22 Z CNFS3
CNL19 CNFS4
CNL21 CNFS5
CNFS6
CNL31
CNL30 CNA8
CNL29
CNA14
CNL03 CNA9
CNL09
CNA11
CNL02
CNL06 CNA10
CNL07
CNA13
CNL08
CNA12
CNL05
CNA15
CNL63
CNA5
CNCL1 CNA7
CNCL2 CNCL3 CNA6
CNL04
Relais_m2
20-227
Connector pin arrangement diagram (3/3) Up to SN WA380H20500
(3/3)
Con- Con- No.
nector nector of Mounting location
No. Type Pins
CNE04 X type 3 RPM sensor
CNE05 (Con- 1 Water temperature

nector) sensor (pre-heating)
CNE06 X type 2 Water temperature

sensor (Display)
CNE08 — 1 Pre-heating (WA 380-3H)
CNE09 X type 2 Pre-heating (WA 380-3H)
CNE10 X type 1 Engine oil level sensor
CNE11 — 1 Engine oil pressure sensor
CNE12 X type 1 Compressor clutch

CNE13 X type 2 Starting motor
CNE15 — 1 Alternator B
CNE16 — 1 Alternator R
CNE17 — 1 Alternator E
CNE19 (Con- 1 Dust indicator

nector)
CNE20 (Con- 1 Dust indicator

nector)

type

type
20-228

CNE08
CNE09
CNE11
CNE19
CNE20
CNE06
CNE04
CNE05
To rear frame harness
CNE15 CNER1
CNE16
CNE17
CNER2
CNE13
To battery
, terminal
CNE12
CNE10
TBW00724
20-229
Relay location from SN WA380H20501

Relay location: SN WA380H20837 and up

Alteration from SN WA380H20987 and up:
Relay K218 (Reserve) replaced by
Relay K443 (Selection work mode)
Reserve 7 (K218)
Selection
work mode K443
20-230
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

« The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
No. X type connector

of
pins Male (female housing) Female (male housing)
TEW00219 TEW00220
1
1
2
2
TEW00221 TEW00222
1 3 3 1
2 2
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-231
No. AMP040 type connector

of
4 8 8 4
1 5 5 1
TEW00227 TEW00228
6 12
12 6
12
1 7 7 1
TEW00229 TEW00230
8 16 16 8
16
1 9 9 1
TEW00231 TEW00232
10 20 20 10
20
1 11 11 1
TEW00233 TEW00234
20-232
No. SWP type connector

of
1 4 4 1
3 6 6 3
TEW00235 TEW00236
1 5 5 1
4 8 8 4
TEW00237 TEW00238
1 4 8 11 11 8 4 1
14
3 7 10 14 14 10 7 3
TEW00239 TEW00240
20-233
No. M type connector

of
1 1
2 2
TEW00241 TEW00242
2 3 3 2
1 1
TEW00243 TEW00244
3 2 3 1
1
4 2
TEW00244 TEW00246
1 4 4 1
3 6 6 3
TEW00247 TEW00248
20-234
No. S type connector

of
1 5 5 1
4 8 8 4
TEW00249 TEW00250
1 6 6 1
10
5 10 10 5
TEW00251 TEW00252
12 5 6 1
12
6 1 TEW00253 12 5 TEW00254
16 7 8 1
16
8 1 TEW00255 16 7 TEW00256
20-235
No. L type connector

of
pins Male (male housing) Female (female housing)
1 1
6
2 2
TEW00257 TEW00258
No. MIC type connector

of
1 11
11 1
12 21
21 21 12
TEW00259 TEW00260
No. Diode type connector

of
1 1
2
2
2
TEW00261 TEW00262
20-236
No. Simple connector (ring connector)

of
TEW00263 TEW00264
TEW00263 TEW00265
20-237
20-238
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
S- 1 Starting performance is poor (Starting always takes time) ........................................................ 20-253

S- 2 Engine does not start ................................................................................................................. 20-254
(1) Engine does not turn ........................................................................................................... 20-254
(2) Engine turns but to exhaust gas comes out (Fuel is not being injected) ........................... 20-255
(3) Exhaust gas comes out but engine does not start (Fuel is being injected) ........................ 20-256
S- 3 Engine does not pick up smoothly (Follow-up is poor) ............................................................. 20-257
S- 4 Engine stops during operations .................................................................................................. 20-258
S- 5 Engine does not rotate smoothly (hunting) ................................................................................ 20-259
S- 6 Engine lacks output(no power) ................................................................................................... 20-260
S- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-261
S- 8 Oil consumption is excessive (or exhaust gas is blue) .............................................................. 20-262
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-263
S-10 Fuel consumption is excessive ................................................................................................... 20-264
S-11 Oil is in cooling water, or spurts back, or water level goes down ............................................ 20-265
S-12 Oil pressure lamp lights up (drop in oil pressure) ..................................................................... 20-266
S-13 Oil level rises .............................................................................................................................. 20-267
S-14 Water temprautre becomes too high (overheating) ................................................................... 20-268
S-15 Abnormal noise is made ............................................................................................................. 20-269
S-16 Vibration is excessive ................................................................................................................. 20-270
20-251
20-252
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)

General causes why starting performance is poor
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
(At ambient temperature of – 10°C or below, use ASTM D975
No. 1, and – 10°C or above, use ASTM D975 No. 2 diesel fuel.) Causes
« Battery charging rate.
Charging rate
ck)
Ambient 100% 90% 80% 75% 70%
er
ath syste er stu

temperature
ain
20°C 1.28 1.26 1.24 1.23 1.22
ine p str
g
eat
m
fue , plun
0°C 1.29 1.27 1.25 1.24 1.23
ole
es
y
tter
r
er h
pu
alv
–10°C 1.30 1.28 1.26 1.25 1.24
ck
l
inje ion no ed ba
el t ng, a p (ra
r el lve, v
mg
tra
t
• The specific gravity should exceed the value for the charging rate
De ctive l filter emen

cle t of va r
e
e, c jection iming
tac ylinde
ir in
d p primi
ps
bre
zzl
m
of 70% in the above table.
at
u
tive gula ug
um
fec e inje terior
air
p
• In cold weather the specific gravity must exceed the value for the
tor
t
alte tor
,
c
pl
n
ane
ank
rna
ng,
ctio
charging rate of 75% in the above table.
ow
gi
e
ct
fee
or d
log
n ri
gge e con
l
ue
g
Legend
re
in
air
isto
d fu
tive
df
De ctive
tive
tive
Lea ctive
v
tiv
d
e
kag
rn p
gge
t
fec
gg
fec
fec
fec
fec
fe
fe
fe
Clo
Wo
Clo
De
De
De
De
De
De
De
clo
: Items to confirm the cause
Gradually became worse
Ease of starting Starts when warm
Questions
Indicator lamp does not light up

Replacement of filters has not been carried out according to
operation manual
Battery charge lamp is ON
Starting motor cranks engine slowly
Engine does not pick up smoothly, and combustion is irregular
Check items
Mud is stuck to fuel tank cap

When engine is cranked with starting motor
1) Little fuel comes out even when injection pump sleeve
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
Leakage from fuel piping

When air element is inspected directly, it is found to be
clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
Troubleshooting
be clogged
Heater mount does not become warm
Voltage is 26 - 30V betweem alternator terminal B and Yes
terminal E with engine at low idling No
Either specific gravity of electrolyte or voltage of battery is low
When control rack is pushed, it is found to be heavy or does
not return (when blind plug at rear of pump is removed, it
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-253
TROUBLESHOOTING S-2
S-2 Engine does not start Causes
(1) Engine does not turn
ire
rw
General causes why engine does not turn
oto
• Internal parts of engine seized
itch
n
pm
it
ctio
« If internal parts of the engine are seized,
ircu
sw
o
nne
ry
t
es
carry out troubleshooting for “Engine
fety
gc
atte
gin
l co
stops during operations”.
rtin
r sa
tor
db
f en
ch
ina
mo
• Failure in power train
sta
yo
rate
wit
oto
nt o
erm
e la
• Defective electrical system
top
ela
of
gs
erio
gm
ry r
me
ry t
s
ty r
ing
rtin
ne
r
et
rtin
ust
a tte
gea
atte
Legend
afe
wir
or d
ngi
sta
sta
adj
b
s
ring
e
tive
tive
tiv e
tive
tive
tive
tive
tive
tive
ken
fec
fec
fec
fec
fec
fec
fec
fec
fec
Bro
De
De
De
De
De
De
De
De
De
Questions
Condition of horn when starting Horn does not sound
switch is turned ON Horn sound level is low
Rotating speed is slow
Makes grating noise

When starting switch is turned to
START, pinion moves out, but Soon disengages again
Makes rattling noise and
does not turn
When starting switch is turned to START, pinion does not
move out
Check items
When starting switch is turned to ON, there is no clicking sound

Carry out troubleshooting for defective wiring of starting circuit
Battery terminal is loose
When starting switch is turned to ON, linkage does not move
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low
For the following conditions 1) - 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are

Troubleshooting
3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of
starting motor are connected, engine starts
5) There is no 24V voltage between battery relay terminal B
and terminal E
When ring gear is inspected directly, tooth surface is found
to be chipped
Does not move even when engine stop motor linkage is
disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
–
20-254
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust gas comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust gas comes out
• Supply of fuel impossible
• Supply of fuel is extremely small Causes
• Improper selection of fuel (particularly in winter)
)
zed
Standards for use of fuel
sei
Ambient temprature
ger
Type of fuel
ey
–22 –4 14 32 50 68 86 104 122°F
ole
ft, k
n
–30 –20 –10 0 10 20 30 40 50°C
plu
rh
n
sha
isto
ck,
the
ASTM D975 No.2
r
a
g
rive
pp
r
rea
r
pin
ain
oto
(
ine
Diesel fuel
mp
pum
pd
l pi
b
pm
r
stra
ASTM D975 No.1
, st
u
air
um
fue
np
sto
eed
ter
d
ank
np
um
ctio
use
ing
l fil
ine
rn f
Legend
ctio
el t
dp
eak
inje
fue
eng
uel
rok
el
e
inje
d fu
f fu
d fe
d, l
er f
tive
d, b
ed
tive
gge
ken
ko
gge
rop
gge
gg
fec
fec
ize
Lac
Imp
Clo
Bro
Clo
Clo
Clo
De
De
Se
Exhaust gas suddenly stops coming out (when starting again)

Questions
operation manual
Fuel tank is found to be empty
There is leakage from fuel piping
When starting switch is turned ON, linkage does not move
When fuel filter is drained, fuel does not come out
When engine is cranked with starting motor,
1) Injection pump coupling does not rotate

Check items
2) No fuel comes out even when fuel filter air bleed plug is
loosened
3) No fuel spurts out even when injection pipe sleeve is

loosened
Rust and water are found when fuel is drained
Check injection pump directly
not return
Troubleshooting
Check feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
be clogged
Does not move even when engine stop motor linkage is
disconnected
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
20-255
TROUBLESHOOTING S-2
Causes
(3) Exhaust gas comes out but engine does not start
.)
etc
(Fuel is being injected)
k)
ver
tuc
r , le
ay
rs
General causes why exhaust gas comes out but engine does
spr
cke
ge
m
not start
lun
e
, ro
ste
ve
hol
k, p
lve
i
• Lack of rotating force due to defective electrical system
l sy
ect
her
(va
tery
rac
f
r
fue
, de
r
ine
nt
de
eat
m
ner
bat
me
e
ir in
a
mp
zle
ylin
yst
r
str
ir b
trai
ele
ed
es
noz
pu
• Improper selection of fuel
g, a
c
ps
a
ter,
riat
valv
ner
lug
g,
tion
d
ank
gin
tion
pum
use
rin
eto
l fil
wp
lea
ken
Legend
log
el t
jec
inje
or d
fue
ton
uel
ir c
glo
ed
ro
e, c
d fu
d in
,b
d fe
er f
da
pis
tive
ed
tive
tive
tive
kag
gge
gge
gge
rop
gge
gg
fec
rn
fec
fec
fec
Lea
Wo
Clo
Imp
Clo
Clo
Clo
Clo
De
De
De
De
Suddenly failed to start
When engine is cranked, abnormal noise is heard from
around head
Questions

operation manual
Rust is found when fuel is drained
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not
contact stopper
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve
Check items
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
starting engine, temperature of some cylinder is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
Troubleshooting
found to be clogged
be clogged
When air element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or pump
is heavy
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Clean
Clean
Clean
Remedy
–
20-256
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick up
smoothly
y
• Improper fuel used
pra
t
es
sea
e
ctiv
hol
nce
ve
efe
val
her
ere
ger
r
g
ne
e, d
nt
ipin
ve,
eat
terf
lun
ner
r
rai
me
nde
ce
val
el p
zzl
r
pp
r, in
trai
ir b
, st
ele
ran
i
o
c yl
um
t of
ps
g fu
a
rge
ter
n
ner
lea
ank
tion
ng,
np
pum
tac
l fil
cha
kin
lea
ec
Legend
n ri
ctio
el t
jec
con
fue
a
alv
ir c
rbo
ed
e
d fu
d in
isto
inje
d, l
er v
d fe
da
tive
d tu
ed
rn p
gge
gge
gge
gge
zed
gge
rop
gg
fec
ize
Clo
Imp
Clo
Clo
Wo
Clo
Clo
Sei
Clo
De
Se
operation manual
Questions

Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)

When fuel filter, strainer are inspected directry, they are
found to be clogged
be clogged
Troubleshooting

not return
does
When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-257
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during opera-
tions
• Seized parts inside engine
Causes
• Overheating
« If there is overheating and insufficient
ck)
tc)
output, carry out troubleshooting for over-
stu
er e
heating.
ger
lev
• Failure in power train
lun
rod
er,
ole
« If the engine stops because of a failure
k, p
ring
ey
ock
pum ther h
ing
n
ft, k
t
in the power train, carry out troubleshoot-
isto
in
bea
rac
e, r
ect
me
tra
g
ne
sha
pp
ing for the chassis.
pin
p(
rea
v
onn
ner
aft
rai
qui
er
( va
pum
l pi
trai
trai
ir b
ive
ksh
ow
nc
, st
ry e
fue
tem
ps
sp
isto
ear
ran
pd
ter
ed
a
tion
ank
i
pum
uxil
ing
sys
ssi
d fe
dg
dc
l fil
um
dp
Legend
c
el t
pa
eak
nje
cha
ize
ize
fue
ize
el p
ize
ve
ed
el
pum
d fu
i
, se
, se
, se
val
, se
d fe
d, l
f fu
tive
u
e in
ed
f
gge
gge
ken
ken
ken
ken
ken
ken
gge
ko
ken
gg
fec
ilur
Clo
Lac
Bro
Clo
Bro
Bro
Bro
Bro
Clo
Bro
Bro
Clo
De
Fa
Abnormal noise was heard
and engine stopped suddenly
Condition when engine Engine overheated and stopped
stopped Engine stopped slowly
Questions
There was hunting and

engine stopped
Fuel gauge lamp lights up
operation manual
When feed pump is operated, there is no response or it is heavy
Engine turns, but stops when transmission control lever is
operated
Does not turn at all
Check items
Carry out troubleshooting in chassis volume
Try to turn by hand using Turns in opposite direction

barring tool Moves amount of backlash
Shaft does not turn
Metal particles are found when oil is drained
Remove oil pan and check directly

Troubleshooting
When gear train is inspected, it does not turn

Turns when pump auxiliary equipment is removed
found to be clogged
be clogged
Check feed pump directly
When control rack is pushed, it is fond to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
Remedy
–
Add
20-258
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
• Air in fuel system
• Defective governor mechanism Causes
• Defective engine throttle controller mecha-
p
um
zle
nism
dp
noz
fee
(engine throttle controller type)
nd
and
pa
e
pum
ck
hol
nk
l ra
l ta
or
er
r
ern
rno
fee
fue
ntro
ath
r
ine
gov
ove
en
en
ner
bre
f co
tra
we
we
of g
trai
f
nt o
bet
bet
no
r, s
air
low
ps
on
me
uit
atio
uit
e
ank
pum
t
rati
irc
o
circ
l fil
ust
o
Legend
per
el t
in c
is t
ope
fue
ir in
adj
ed
el
d fu
o
, air
ed
d fe
f fu
d, a
tive
ed
tive
tive
spe
gge
eed
ko
gge
ge
gee
fec
fec
fec
g
Low
Clo
Lac
Clo
Clo
Clo
Clo
De
De
De
Occurs at certain speed range
Occurs at low idling
Condition of hunting Ocuurs even when speed is

Questions
raised
Ocuurs on slopes
operation manual
Rust is found when fuel is drained
When feed pump is operated,
1) No response, light, return is quick

Check items
1) No response, light, return is normal

Engine speed sometimes rises too high
Engine is sometimes difficult to stop
When governor lever is moved it is found to be stiff
When injection pump is tested, governor is found to be
improperly adjusted
Troubleshooting
does not return
be clogged
found to be clogged
Adjust
Adjust
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Remedy
Add
20-259
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output Causes
ent
stm
y
pra
• Improper fuel used
dju
eat
es
(if non-specified fuel is used, output drops)
ole
ea
es
ctiv
e
er h
ctiv
alv
• Lack of output due to overheating
enc
efe
ger
er
« If there is overheating and insufficient
e, v
efe
ath
g
rfer
ent
e, d
ain
pin
ner
lun
er
e, d
alv
bre
inte
output, carry out troubleshooting for over-
em
ce
ind
l pi
r
zzl
trai
pp
, st
of v
ran
kag
r el
air
heating.
fue
cyl
o
er,
ps
um
ter
l ea
ane
arg
ank
act
r lin
pum
tion
ng,
np
ing
l fil
ec
Legend
och
ont
cle
n ri
el t
ctio
eak
e
jec
fue
al v
ed
lev
c
turb
ir
d fu
isto
d in
inje
d fe
d, l
er v
da
tive
ed
uel
rn p
gge
gge
gge
gge
zed
gge
zed
rop
gg
fec
nt f
Clo
Imp
Wo
Clo
Clo
Clo
Clo
Sei
Clo
Sei
De
Be
Suddenly
Power was lost
Gradually
Questions

operation manual
Black
High idling speed under no load is normal, but speed
Check items
suddenly drops when load is applied

There is hunting from engine (rotation is irregular)
High idling speed of engine is low

When trubocharger is rotated by hand, it is found to be heavy
found to be clogged
Troubleshooting
When feed pump strainer are inspected directly, it is found

to be clogged
dose not return
When lever is placed at FULL position, it does not contact
stopper
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-260
TROUBLESHOOTING S-7
S-7 Exhaust gas is black

(incomplete combustion)
General causes why exhaust gas is black
e d)
)
tion
eiz
ead
jec
er s
dh
e in
t
ung
r an
sea
siv
rge
, pl
nce
ve
ce s
le
cha
ack
val
ozz
ere
(ex
rbo
p (r
nt
ve,
nn
terf
ce
er
me
g
mp
u
min
val
um
r
lind
ctio
ran
t
ffle
r, in
ele
en
u
np
np
t of
n ti
lea
mu
y
inje
twe
rge
c
ner
ctio
ctio
ng,
ctio
ec
tac
ged
r be
cha
ed
lea
Legend
n ri
alv
con
inje
inje
nje
eiz
log
f ai
ir c
rbo
er v
isto
d, s
er i
d, c
eo
da
tive
tive
tive
d tu
rn p
rop
rop
gge
kag
gge
she
fec
fec
fec
ize
Imp
Imp
Lea
Cru
Wo
Clo
Clo
De
De
De
Se
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Suddenly
Power was lost
Gradually
Check items

Exhaust noise is abnormal
Muffler is crushed

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust gas color returns to normal
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-261
TROUBLESHOOTING S-8
S-8 Oil consumption is

excessive (or exhaust gas is
blue)
« Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-
sive
• Abnormal combustion of oil
• External leakage of oil
• Wear of lubrication system
Causes
ger
har
boc
c.
, et
Tur
eal
ead
ce
ler
urfa
tem
ns
ose
er h
r
oo
line
oke
sys
al s
er h
il c
lind
er
lug
), b
r, o
, se
ke
ath
lind
, cy
end
in p
ide
nta
d
ing
bre
filte
eal
r en
pan
, cy
, gu
mi
dra
pip
ine
ar s
r or
e
oil
ring
o
ring
low
tern
urb
ler
oil
oil
oil
r
n re
the
Legend
in f
m
coo
at b
om
om
at t
ton
om
e (s
fro
rea
ton
e
ed
rok
e fr
e fr
pis
e fr
oil
eal
db
eal
alv
uck
pis
ge
b
kag
kag
kag
ken
ken
rn s
rn v
rn s
gge
aka
st s
rn,
rn

Lea
Lea
Lea
Wo
Bro
Bro
Wo
Wo
Wo
Wo
Clo
Du
Le

Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Exhaust gas is blue under light load
Abnormally excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty

with oil
Inside of turbocharger intake pipe is dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
Troubleshooting
clogged with dirty oil

There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Check rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty
with oil
Replace
Replace
Replace
Repalce
Repalce
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
20-262
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Intake of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper combustion
• Improper oil used Causes
• Operation under excessive load
end
ine
urb
er t
e
ube
pip
arg
er t
ain
er
och
ath
ind
r dr
e
ve
uid
turb
bre
cyl
age
ck
val
eg
er
r
bla
ng,
er,
filte
l at
chr
Legend
fety
ool
alv
ath
s is
n ri
sea
rbo
e, v
il c
oil
a
re
s
t ga
isto
d tu
do
db
alv
tive
tive
ed
rn p
aus
gge
gge
gge
rn v
gg
fec
fec
Exh
Clo
Wo
Clo
Clo
Clo
Wo
De
De
Questions

Black
Abnormally excessive
Carry out troubleshooting for "Exhaust is black"
Amount of blow-by gas

None
Check items
Oil filter caution lamp stays on even when oil pressure rises
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
When breather element is inspected directly, it is found to be clogged with

Troubleshooting
dirty oil, or hose is broken
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be catching or
broken
Replace
Replace
Replace
Repalce
Repalce
Clean
Clean
Clean
Remedy
20-263
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

Causes
General causes why fuel consumption is excessive
• Leakage of fuel
r
filte
)
tion
)
ton
e
uel
jec
kag
(pis
e in
g, f
r lin
mp
pin
ssiv
r
ove
eve
r
u
nge
y
l pi
dp
xce
pra
min
dc
el l
plu
fue
fee
p (e
le s
hea
f fu
n ti
mp
om
ide
ozz
nt o
um
ctio
de
u
s
e fr
np
np
nsi
l in
me
inje
n
ctio
kag
ctio
ctio
el i
sea
ust
Legend
l
fue
f fu
inje
inje
inje
adj
lea
oil
eo
er
tive
tive
tive
tive
tive
nal
rop
kag
fec
fec
fec
ter
fec
fec
Imp
Lea
De
De
De
Ex
De
Confirm recent repair history De

Questions
More than for other machines of
same model
Condition of fuel consumption
Gradually increased
Suddenly increased
Black
Exhaust gas color
White
There is irregular combustion
When exhaust manifold is touched immediately after starting engine,

Check items
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Injection pump test shows that injection amount is excessive
Speed of some cylinders does not change when operating on reduced

Troubleshooting
cylinders
When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found to be
incorrect
Remove feed pump and check directly
When engine speed is measured, low idling speed is found to be high

Replace
Replace
Adjust
Adjust
Adjust
Repair
Repair
Repair
Remedy
20-264
S-11 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
• Internal leakage in lubrication system
• Internal leakage in cooling system
Causes
ing
pitt
by
ed
ain
ck
aus
r
line
blo
g
r
er t
-rin
sc
er
of
pow
ole
e, O
ind
ket
on
g, h
cyl
gas
usi
cor
for
-rin
s in
r
ad
ler
ler
rot
Legend
, he
rO
coo
coo
ack
p
nt
line
d
hea
l cr
oil
oil
icie
ken
ken
rna
ken
ken
uff
Inte
Bro
Bro
Bro
Ins
Bro

Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white

Check items
Excessive air bubbles inside radiator, spurts back
Hydraulic oil, torque converter transmission oil is cloudy white
When hydraulic oil, torque converter transmission oil is drained, water

is
found
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage
Remove cylinder head and check directly

Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-265
S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Standards for engine oil selection

Selection of oil SAE number according
to ambient temperature
Type of oil
–22 –4 14 32 50 68 86 104 122°F
–30 –20 –10 0 10 20 30 40 50°C
Causes
SAE 30
SAE 10W
Diesel fuel
pan
SAE 10W-30
oil
ing
ide
pan
pip
or
SAE 15W-40
ins
ens
g
oil
lic
zin
an
or
e
ipe
rau
re s
alv
ens
ide
bra
il p
e
il p
hyd
alv
v
ins
l
ssu
el s
rna
in o
ipe
tor
no
oil
p
ef v
r
hed
ner
filte
pum
jou
pre
ula
p
lev
Legend
oke
in
oil
on
reli
trai
reg
rus
ing
oil
oil
el
oil
i
oil
r
nt
t
d, b
suc
, fu
ds
ear
g, c
tive
tive
tive
cie
tive
ed
tive
gge
gge
rn b
ter
ken
kin
gg
fec
uff
fec
fec
fec
fec
Wa
Lea
Clo
Clo
Clo
Bro
Ins
Wo
De
De
De
De
De

Dregree of use Operated for long period
Questions
Replacement of filter has not been carried out according to

operation manual
Caution lamp lights up
Lights up at low idling
Condition when oil pressure Lights up at low, high idling
lamp lights up Lights up on sloes
Sometimes lights up
There is clogging, leakage from hydraulic piping (external)
Check items
Oil level sensor lamp lights up

When oil level in oil pan is checked, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Carry out troubleshooting for
When oil filter is inspected directly, it is found to be clogged

Troubleshooting

Oil pump rotation is heavy, there is play
There is catching of relief valve, regulator valve, spring, or
"Oil level rises"
valve guide is broken

When oil level sensor is replaced, oil pressure sensor lamp
goes out
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
Add
20-266
S-13 Oil level rises

« If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
• Water in oil (cloudy white)
• Fuel in oil (diluted, and smells of diesel fuel) Cause
er)
• Entry of oil from other component
al
e)
mb
typ
es
ent
er
cha
ing
cov
ctiv
ipm
ge
ion
pitt
e
flan
t
ead
bus
equ
f
, de
by
com
eh
p(
ade
y
ole
m
xilia
pre
sid
ve
er h
sm
u
rfac
g
g in
ing
np
lee
r au
-rin
k
ath
loc
ole
lud
ipin
ctio
er s
eat
e, O
al s
po
(inc
er b
g, h
bre
at s
r se
inje
old
pum
ket
cor
rom
-rin
mp
ind
le h
gas
t
a
s
ide
r pu
d re
cyl
rO
ler
rmo
el f
l of
Legend
ead
ozz
coo
ins
line
ide
age
f fu
ea
ate
the
d, h
n
es
ins
eo
dw
tive
oil
dam
ged
tive
tive
hea
ctiv
kag
ken
cks
gge
fec
ma
fec
fec
ken
rn,
efe
Cra
Lea
Bro

Clo
De
Wo
De
Da
De
Bro
D
Questions
There is oil in radiator cooling water

Exhaust gas is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
When water pump breather hole is clean, water comes out
Check items
Oil level goes down in clutch, TORQFLOW transmission, or

damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Remove water pump and check directly

Check rear seal directly
When pump auxiliary equipment is removed, seal is found
to be broken
Remove injection pump and check directly
There is improper contact of thermostat seat valve
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
20-267
Causes
S-14 Water temperature becomes too high
(overheating)
ing
pitt
re
General causes why water temperature becomes too high
n)
atu
by
ope
• Lack of cooling water (deformation, damage of fan)
per
ley
ade
e
aug
not
• Drop in heat dissipation efficiency
tem
pul
sm
fan
re g
• Defective cooling circulation system
oes
fan
oil
ole
ter
er
tor
atu
ool
• Rise in oil temperature of power train
t
e
ter
t (d
wa
e
g, h
dia
orn
alv
k
per
gas
il c
« Carry out troubleshooting for chassis.
ver
e
sta
d ra
g, w
re v
cor
-rin
ing
tem
no
con
ead
rmo
p
rO
ool
she
ssu
um
tor
pin
Legend
oke
ter
d, h
ue
dia
line
er p
the
nt c
pre
u
slip
wa
r
r
torq
d, b
d, c
d ra
hea
wat
tive
ged
cie
tive
tive
elt
gge
gge
gge
e in
ken
uffi
ken
fec
nb
ma
fec
fec
Clo
Clo
Clo
Ris
Bro
Ins
Bro
De
Da
De
Fa
De
Suddenly overheated
Condition of overheating
Questions
Always tends to overheat
Rises quickly
Water temperature gauge Does not go down from red
range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated

Check items
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through

Water is leaking because of cracks in hose or loose clamps
Belt tension is found to be slack
Power train oil temperature enters red range before engine
water temperature
Carry out troubleshooting for chassis
Temperature difference between top and bottom radiator

tank is excessive
Temperature difference between top and bottom radiator
tank is slight
Troubleshooting
When water filler port is inspected, the core is found to be clogged
When a function test is carried out on the thermostat, it does
not open even at the cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set

pressure is found to be low

Replace
Replace
Repalce
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
–
Add
20-268
Causes
S-15 Abnormal noise is made
.)
)
n)
ion
etc
d)
sitio
ize
d
jec
er,
hea
f po
« Judge if the noise is an internal noise or an
r se
lev
e in
ut o
and
external noise.
nge
e
t
bel
er
siv
c
ran
do
ock
General causes why abnormal noise is made
r
plu
rge
ces
an
ce
oar
le
lea
r
• Abnormality due to defective parts
e, r
n
of f
a
ozz
ck,
line
x
ere
och
ec
gb
e
ash
• Abnormal combustion noise
(ra
alv
p(
nn
ce
alv
idin
terf
er
turb
l
n
v
pum
p
k
• Air sucked in from intake system
lind
ctio
of v
(
ere
div
r, in
bac
um
g
tem
en
hin
, cy
er (
inje
terf
np
ent
twe
rge
tion
rain
bus
sys
uffl
ring
ctio
, in
m
cha
r be
ed
jec
ar t
Legend
t
ed
em
jus
fan
eiz
ve
inje
rbo
f ai
ton
eiz
e
d
val
sid
i
d, s
er g
er a
ed
eo
tive
g, s
d tu
tive
pis
t in
ken
form
gge
rop
kag
rop
sin
fec
fec
ize
rn
fec
Imp
Bro
Imp
Lea
Wo
Clo
Mis
De
De
De
Se
De

Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred

Color or exhaust gas
Black
Metal particles are found in oil filter


Check items
Abnormal noise is loud when accelerating engine
Vibrating noise is heard from around muffler

When trubocharger is rotated by hand, it is found to be heavy
Remove gear cover and check directly

Troubleshooting
When control rack is pushed, it is found to be heavy or does not return
Fan is deformed, or belt is loose
Remove cylinder head cover and check directly
When muffer is removed, abnormal noise disappers

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Repair
Remedy
20-269
S-16 Vibration is excessive

« If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion
Causes
n)
k
ctio
tuc
rain
inje
n
c) s
r)
hio
e
er t
mp
cus
, et
ive
pow
(da
ess
ver
ken
ring
and
r le
aft
exc
bro
bea
t sh
h
cke
e
p(
ts,
las
gin
g
ain
tpu
bol
hin
um
, ro
ack
e n
,m
bus
u
ing
np
lve
een
nb
o
rod
unt
e
am
ctio
(va
ilot
trai
w
sid
mo
ing
bet
Legend
r, c
rt p
t in
inje
tem
ear
ect
ine
nce
ent
o
par
er g
upp
onn
sys
tive
eng
nm
ala
ken
rn s
rop
rn c

rn b
alig
fec
se
lve
Imp
Bro
Loo
Mis
Wo
Wo
Wo
De
Va

Questions
Suddenly increased
Condition of vibration
Gradually increased

Metal particles are found in oil filter
Check items
Oil pressure is low at low idling
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust gas is black

Remove oil pan and check directly?

Remove side cover and check directly
Troubleshooting
Check directly for worn support pilot, play

Check directly for loose engine mounting bolts, broken cushion
Check inside of output shaft (damper) directly

When radial runout, face runout are measured, they are
found to be outside standard value
Remove front cover and check directly

Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Remedy
20-270
TROUBLESHOOTING OF
MAIN MONITOR SYSTEM
(M MODE)
Trouble data display ................................................................................................................................ 20-353
M- 1 Main monitor does not work ....................................................................................................... 20-357

M- 2 When starting switch is turned ON and engine is started immediately,
all lamps stay lighted up ............................................................................................................. 20-358
M- 3 Speedometer display does not work properly ............................................................................ 20-359
M- 4 Abnormality in shift indicator
(a) Stays at N even when directional lever is at F ................................................................... 20-360
(b) Stays at N even when directional lever is at R ................................................................... 20-360
(c) Does not display N even when directional lever is at N and displays R when
directional lever is at F ........................................................................................................ 20-360
(d) Does not display N even when directional lever is at N and displays F when
directional lever is at R ........................................................................................................ 20-361
(e) Does not display 1st, 4th ..................................................................................................... 20-361
(f) Does not display 3rd, 4th .................................................................................................... 20-362
(g) Does not display 2nd, 3rd ................................................................................................... 20-362
(h) Does not display 1st, 2nd .................................................................................................... 20-363
M- 5 High beam does not light up ...................................................................................................... 20-364
M- 6 Turn signal display does not light up
(a) L.H. turn signal does not light up ........................................................................................ 20-365
(b) R.H. turn signal does not light up ........................................................................................ 20-365
M- 8 Abnormality in preheating system (QGS)
(a) Does not carry out preheating ............................................................................................ 20-366
(b) Always carries out preheating for 1 minute ........................................................................ 20-367
(c) Preheating stays on ............................................................................................................. 20-367
(d) Preheating time becomes shorter, or is unstable ................................................................ 20-368
M- 9 Night lighting does not light up ................................................................................................... 20-369
M-10 Abnormality in front working lamp
(a) Neither monitor display nor front working lamp light up ...................................................... 20-370
(b) Working lamp lights up but monitor display does not light up ............................................ 20-370
(c) Monitor lights up but working lamp does not light up .......................................................... 20-370
M-11 Abnormality in rear working lamp
(a) Neither monitor display nor rear working lamp light up ...................................................... 20-371
(b) Working lamp lights up but monitor display does not light up ............................................ 20-371
(c) Monitor lights up but working lamp does not light up .......................................................... 20-371
M-12A Abnormality in transmission cut-off (WA320-3H manual gear shift)
(a) When monitor switch is pressed, cut-off function is not switched and
display is not given .............................................................................................................. 20-373
(b) Monitor display goes out but cut-off stays on ..................................................................... 20-373
(c) Monitor display lights up but cut-off function is not actuated ............................................. 20-374
M-12B Abnormality in transmission cut-off (WA-3H automatic transmission)
(a) When monitor switch is pressed, cut-off function is not switched and
display is not given .............................................................................................................. 20-375
(b) Monitor display goes out but cut-off function is actuated when pedal
is depressed ......................................................................................................................... 20-375
(c) When monitor display is turned off, cut-off function is always actuated ............................ 20-375
(d) Cut-off function is always actuated regardless of monitor display ...................................... 20-375
(e) Monitor display lights up but cut-off function does not work .............................................. 20-376
20-351
M-13 Abnormality in parking brake dragging warning
(a) When parking brake is applied, buzzer sounds (intermittently) even when
directional lever is at N, and caution lamp flashes ............................................................. 20-377
(b) When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N .......................... 20-377
M-14 When parking brake dragging warning is given, buzzer and caution lamp
are actuated continuously, or they are not actuated
(a) Actuated continuously .......................................................................................................... 20-378
(b) Not actuated ......................................................................................................................... 20-378
M-15 Abnormality in buzzer
(a) Buzzer does not sound when starting switch is turned ON (during self-check) ................. 20-379
(b) Buzzer always sounds ......................................................................................................... 20-379
M-17 Abnormality in failure display mode
(a) Does not enter failure display mode ................................................................................... 20-381
(b) Time for time elapsed since failure on failure display mode does not advance ................ 20-281
M-20 Buzzer does not sound because of transmission controller ...................................................... 20-382
M-21 Abnormality in emergency steering normal display
(a) Emergency steering normal display does not light up ........................................................ 20-383
(b) Emergency steering normal display stays lighted up .......................................................... 20-383
M-22 Abnormality in emergency steering actuation display
(a) Emergency steering actuation display does not light up ..................................................... 20-384
(b) Emergency steering actuation display stays lighted up ...................................................... 20-384
M-23 Abnormality in auto greasing system (KOMATSU auto greasing system only)
(a) Forced greasing cannot be carried out ............................................................................... 20-385
(b) Monitor display flashes rapidly ............................................................................................ 20-385
(c) When no more grease remains, monitor display flashes rapidly ........................................ 20-385
(d) Monitor display flashes slowly .............................................................................................. 20-386
(e) Monitor display goes out ...................................................................................................... 20-386
M-24 Abnormality in ECSS system
(a) Display does not change when switch is pressed .............................................................. 20-387
(b) Monitor display lights up but ECSS function does not work ............................................... 20-387
M-26B Failure code is not sent to main monitor (abnormality in network) ........................................... 20-388
20-352
TROUBLESHOOTING TROUBLE DATA DISPLAY
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main monitor is
used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2. Abnormality in failure action code

This code informs the operator directly of the Example: When action code CALL is displayed
abnormality, and takes action, such as stopping

the machine immediately. SPEED
There are four types of action code: E00,

E01+CALL (E01 and CALL are displayed alter- km/h Action code
nately), E03+CALL, and CALL. If a failure
occurs suddenly, one of these codes is shown
on the action code display.
For details of the action taken by operator for TDW00283
the action codes, see Item 4.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible Example: When failure code "41" has occurred
27 hours before
to tell from this code which system in which
controller has failed, so carry out troubleshoot- Failure code
SPEED
ing for the applicable controller.
For failures that have occurred, the failure code
and the time elapsed since failure are displayed Time elapsed
since failure
to make it easy to check failures that are not
occurring at present.
The failure codes for failures that are now oc-
TDW00283
curring flash, and the codes for failures that are
not occurring light up.
For details of the method of operating and trans-
ferring data to the trouble data display mode,
see STRUCTURE AND FUNCTION for the main
monitor.
Note: If the engine is not stopped, it is impos-
sible to switch to the trouble data dis-
play mode, so the codes for failures
which can only be detected when the
engine is operating light up.
For the correspondence between the failure
codes for each controller and the failed system,
see Item 5.
20-353
4. Action code table
Action code: "Epp+ CALL" means that Epp and CALL are displayed alternatly
Transmission control system

Action Alarm Action by
code Problem system Action of maschine Buzzer operator
Speed sensor Does not shift gear Normal operation

system automatically (gear possible using
E00 No
(disconnection) must be shifted manually) manual gear
shifting
H-L solenoid, Transmission range fixed Travel under own

speed solenoid (1st - 3rd, depending power possible,
system on case) call for service after
E01 + Yes moving to a
CALL safe place

Shift lever system Neutral (F,R solenoids Actuate emergency

output OFF) manual spool, open
modulation solenoid
Directional solenoid Neutral (F,R solenoids, manually. This action
E03 + system modulation solenoids Yes makes it possible to
CALL output OFF) travel under own
Moulation solenoid Neutral (F,R solenoids, power. Call for service
system modulation solenoids
output OFF)
Wiring harness on return Neutral (F,R solenoids, Stop machine imme-

side of modulation solenoid modulation solenoids diately, turn starting
CALL short circuit with output OFF), possible Yes switch OFF, then call
power source that controller is burnt out for service
20-354
5. Failure code chart
Transmission control system ECSS control system
10 Modulation solenoid system d0 Relief solenoid system
11 Modulation solenoid system High pressure solenoid

d1 system
12 F solenoid valve system Low pressure solenoid

d2 system
13 R solenoid valve system d3 Speed sensor system
14 H-L solenoid valve system Abnormality in model

d4 selection
16 Speed solenoid system
Directional lever input

20
system
21 Speed lever input system
22 Speed sensor input system
23 Engine speed input system
20-355
WA320-3H Automatic
4. Action code table

Action code: "Epp+ CALL" means that Epp and CALL are displayde alternatly
Transmission control system

Action Alarm Action by
code Problem system Action of maschine Buzzer operator
Speed sensor Does not shift gear Normal operation

E00 system automatically (gear No possible using
(disconnection) must be shifted manually) manual gear shifting
H-L solenoid, Transmission range fixed Travel under own

E01 +
speed solenoid (1st - 3rd, depending Yes power possible,
CALL
system on case) call for service
Actuate emergency
Shift lever system Neutral (F,R OFF)
manual spool.
E03 +
Yes Possible to travel
CALL
Directional system Neutral (F,R OFF) under own power.
Call for service
Stop machine imme-
CALL Neutral (F,R OFF), possible
Short circuit Yes diately, starting switch
that controller is burnt out
OFF, call service
5. Failure code chart
Transmission control system ECSS control system

12 F solenoid valve system
d0 Relief solenoid valve
13 R solenoid valve system
d1 High pressure solenoid system
14 H-L solenoid valve system
d2 Low pressure solenoid system
16 Speed solenoid system
d3 Speed sensor system
20 Directional lever input system
d4 Abnormality in model selection
21 Speed lever input system
22 Speed sensor input system
23 Engine speed input system
20-356
TROUBLESHOOTING M-1
M-1 Main monitor does not work

Cause Remedy
YES Defective main monitor Replace

1
Is voltage between Defective contact, or
CNL05 (1), (2) and disconnection in wiring
(3) normal ? 2 YES After inspection,
harness between CNL05
repair or replace
Is there continuity (female) (1), (2) and
1) 20 - 30 V between CNL05 CNFS2 (9)
2) Turn starting NO (female) (3) and
switch ON. chassis ground? Defective contact, or
disconnection in wiring After inspection,
1) Turn starting NO harness between CNL05 repair or replace
switch OFF. (female) (3) and CNLR2 (11)
2) Disconnect
CNL05.
Power source
Maintenance monitor Buzzer
Battery relay
CNL05
1 CNFS2 CNFS1 CNLR6

Fuse Slow blow fuse
2 9 2 1
CNE02
3
CNLR5
3
CNL06
16
CNL07 CNLR11
12
20-357
TROUBLESHOOTING M-2
M-2 When starting switch is turned ON and engine is started

immediately, all lamps stay lighted up
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (4) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
NO harness between CNL05 repair or replace
1) 20 - 30 V
(female) (4) and CNL57 (3)
2) Turn starting
switch START.
Neutral relay
Start signal,
neutral signal
Starting motor
CNL57
1 2 3 5 6 CNL04
CNL05
3 N Speed lever
Starting
4
CNLR5
8
Neutral
2
CNR10
Rear frame GND
CNL09
3
Starting switch
20-358
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly

« Check that the gap between the speed sensor and gear is normal.
Cause Remedy
2 YES
Is resistance
YES between CNL07
(female) (1) and Defective contact, or
1 (2) normal ? disconnection in wiring
After inspection,
Is resistance harness between CNL07
1) 500Ω - 1 kΩ NO repair or replace
between CNT06 (female) (1), (2) - CNTL2
(male) (1) and (2) 2) Turn starting (1), (2) - CNT06 (1), (2)
normal? switch OFF.
3) Disconnect
1) 500Ω - 1 kΩ CNL07.
2) Turn starting Defective speed sensor Replace
NO
switch OFF.
3) Disconnect
CNL06.
Speedometer
CNL07 CNTL2 CNT06 Speed sensor
1 1 1
2 2 2
20-359
TROUBLESHOOTING M-4
M-4 Abnormality in shift indicator

« Check that the transmission shifts.
Cause Remedy
(a) Stays at N even when directional lever is at F
1 YES
Is voltage between
CNL08 (7) and
1) 20 - 30 V
2) Turn starting
switch ON.
3) Directional
lever: F
(b) Stays at N even when directional lever is at R
1 YES
Is voltage between
CNL08 (8) and
1) 20 - 30 V (female) (8) and CNL04 (4)
2) Turn starting
switch ON.
3) Directional
lever: R
(c) Does not display N even when directional lever is

at N and displays R when directional lever is at F
1 YES
Is voltage between
CNL08 (8) and
chassis ground Contact of power source with
normal? wiring harness between
After inspection,
CNL08 (female) (8) and
1) 0 - 5 V NO repair or replace
CNL04 (4), or defective
control lever
2) Turn starting
switch ON.
3) Directional
lever: N
20-360
TROUBLESHOOTING M-4
(d) Does not display N even when directional lever

Cause Remedy
at N and displays F when directional lever is at R
1 YES
Is voltage between
CNL08 (7) and
chassis ground Contact of power source
normal? with wiring harness between
After inspection,
control lever
2) Turn starting
switch ON.
3) Directional
lever: N
(e) Does not display 1st, 4th

(WA320-3H with manual gear shift)
1 YES
Is voltage between
CNL05 (12) and
1) 20 - 30 V NO harness between CNL05 repair or replace
2) Turn starting
switch ON.
3) Speed lever: 1
WA-3H with automatic transmission

1 YES
Is resistance between
CNL05 (female) (12)
and chassis ground Defective contact, or
harness between CNL05 repair or replace
1) Disconnect NO (female) (12) and CNL29
CNL05. (11)
2) 50 - 70 Ω
20-361
TROUBLESHOOTING M-4
Cause Remedy
(f) Does not display 3rd, 4th
1 YES
Is voltage between
CNL05 (13) and
1) 20 - 30 V NO harness between CNL05 repair or replace
2) Turn starting (female) (13) and CNL04 (7)
switch ON.
3) Speed lever: 3
1 YES
CNL05 (female) (13)
1) Disconnect NO (female) (13) and CNL29
CNL05. (10)
2) 50 - 70Ω
(g) Does not display 2nd, 3rd

1 YES
Is voltage between
CNL05 (12) and
chassis ground Contact of power source
normal? with wiring harness between
After inspection,
2) Turn starting control lever
switch ON.
3) Speed lever: 2
Relationship between monitor H : 20 30 V

input signal and display L : 0V
CNL05(12) CNL05(13) Display
H L 1
L L 2
L H 3
H H 4
20-362
TROUBLESHOOTING M-4
Cause Remedy
(h) Does not display 1st, 2nd
1 YES
Is voltage between
CNL05 (13) and Contact of power source
chassis ground with wiring harness between
normal? CNL05 (female) (13) and After inspection,
CNL04 (7), or defective repair or replace
1) 0 - 5 V NO
transmission lever
2) Turn starting
switch ON.
3) Speed lever: 2
Transmission lever
WA320-3H with manual gear shift CNL04
Transmission range
2 F
CNL05 4 R
12 5 1ST
13 7 3RD
CNL08 CNTL1 CNT03

Hi-Lo
7 5 1
8 6 2
FORWARD relay REVERSE relay CNT04

SPEED
CNL66 CNL67
1
5 5
2

CNL29 CNL30
Transmission lever
10 11 1 12 CNL04
Transmission range
2 F
CNL05 4 R
12 1ST
13 3RD
CNL08 CNTL1 CNT03

Hi-Lo
7 5 1
8 6 2
Buckup lamp relay CNT04

SPEED
CNL54
1
20-363
TROUBLESHOOTING M-5
M-5 High beam does not light up

« Before starting troubleshooting, check that the lamp bulb is not blown.
Cause Remedy
2 YES
Is there continuity
YES between CNL06
(female) Defective contact, or
1 chassis ground? disconnection in wiring After inspection,
Is voltage between 1) Turn starting NO harness between CNL06 repair or replace
CNL06 (12) and switch OFF. (female) (13) and CNL02 (3)
chassis ground 2) Disconnect
normal? CNL06.
3) Dimmer switch:
1) 20 - 30 V Defective contact, or
H beam
2)Turn starting disconnection in wiring After inspection,
switch ON. NO harness between CNL06 repair or replace
(female) (12) and CNFS2
(2)
Hi beam
CNL06 CNFS2
12 2
13 1
CNL02
2 Lamp switch
Dimmer switch
CNLR1 CNFR1 CNF01
10 4 2
R.H. head lamp
8 2 3
20-364
TROUBLESHOOTING M-6
M-6 Turn signal display does not light up

« Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not
blown.
Cause Remedy
(a) L.H. turn signal does not light up

1 YES
Is voltage between
CNL06 (14) and
1) Repeat 0V and NO harness between CNL06 repair or replace
20 - 30 V. (female) (14) and CNL03 (4)
2) Turn starting
switch ON.
(b) R.H. turn signal does not light up

1 YES
Is voltage between
CNL06 (15) and
1) Repeat 0V and
20 - 30 V.
(3)
2) Turn starting
switch ON.
To turn signal lamp
Turn signal
CNL06 CNL03 Turn signal switch

L
14 4
B
15 3
CNL12
B
Hazard switch
E
Turn signal unit
20-365
TROUBLESHOOTING M-8
M-8 Abnormality in preheating system (QGS) (WA380-3H)

(a) Does not carry out preheating

« Check that the water temperature is below 5°C. Cause Remedy
(1) Monitor display also does not light up
2 YES
Defective monitor panel Replace
YES CNL05 (female) (7)
and chassis ground Wiring harness between
1
normal? CNL05 (female) (7) - CNLR4
After inspection,
Is resistance (2) - CNER1 (8) - CNE05
between CNE05 1) Disconnect NO repair or replace
(female) short circuiting with
(male) and chassis CNL05.
chassis ground
ground normal? 2) Turn starting
switch OFF.
1) Disconnect 3) Min. 4kΩ Defective engine water
CNE05. temperature sensor Replace
NO
2) Turn starting
switch OFF.
3) Min. 4kΩ
(2) Only monitor display lights up

YES
Defective glow plug Replace
2
Is voltage between
YES CNE07 and
chassis ground 3 YES
normal? Defective heater relay Replace
Is voltage between
1) 20 - 30 V CNE08 and
1
NO chassis ground Defective contact, or
Is voltage between normal? disconnection in wiring After inspection,
2) Turn starting
CNE09 (1) and (2) harness between CNE08 repair or replace
switch ON. 1) 20 - 30 V NO
normal? and slow blow fuse
2) Turn starting Defective contact, or
1) 20 - 30 V switch ON. disconnection in wiring
harness between CNL56 (3)
2) Turn starting
- CNLR4 (7) - CNER1 (4) - After inspection,
switch ON.
NO CNE09 (female) (1), or repair or replace
between CNE09 (female)
(2) - CNER2 (5) - chassis
ground
20-366
TROUBLESHOOTING M-8
(b) Always carries out preheating for 1 minute Cause Remedy

« Check that the water temperature is below 10°C.
2 YES
1
normal? disconnection in wiring
Is resistance
After inspection,
between CNE05 1) Max. 8 kΩ NO repair or replace
(female) (7) - CNLR4 (2) -
(male) and chassis 2) Turn starting CNER1 (8) - CNE05 (female)
ground normal? switch OFF.
3) Disconnect
1) Max. 8 kΩ CNE05. Defective engine water
temperature sensor Replace
NO
2) Turn starting
switch OFF.
3) Disconnect
CNE05.
(c) Preheating stays on

YES
1
3 YES
Does preheating Defective preheating relay Replace
stop? Is voltage between
YES CNL06 (4) and
2 chassis ground Wiring harness between
1) Turn starting normal? CNL06 (female) (4) and After inspection,
switch ON.
Does preheating 1) 20 - 30 V NO CNL56 (2) short circuiting repair or replace
NO stop? 2) Turn starting with chassis ground
2) Disconnect
CNL06. switch ON. Contact of power source
1) Turn starting with wiring harness between After inspection,
switch ON. NO CNL56 (3) - CNLR4 (7), repair or replace
CNL05 (19)
2) Remove
preheating
relay.
20-367
TROUBLESHOOTING M-8
Cause Remedy
(d) Preheating time becomes shorter, or there is variation
3 YES
Is voltage between
YES CNL05 (3) and
2 chassis ground Defective contact of wiring
normal? harness between CNL05 (3) After inspection,
1) Max. 0.1 V NO - CNLR5 (3) - CNR11 - repair or replace
and chassis ground 2) Turn starting chassis ground
1 normal? switch ON. Defective contact of wiring
Is resistance harness between CNL05
1) Are temperature After inspection,
between CNE05 (female) (7) - CNLR4 (2) -
and resistance repair or replace
(male) and chassis value as shown
NO CNER1 (8) - CNE05, or
ground normal? in table below? leak from chassis ground
2) Turn starting
1) Are temperature switch OFF. Defective engine water
and resistance temperature sensor Replace
value as shown NO
in table below?
2) Turn starting
switch OFF.
Table (Tolerance ± 0.5 kΩ)
Temperature(°C) 10 8 6 4 2 0 2 4
Resistance value(kΩ) 7.7 7.1 6.5 6.0 5.5 5.1 4.7 4.3
Starting motor SWR2 signal

Preheating
CNL05 CNLR4 CNER1 CNE09

Slow blow fuse
19 7 4 1 + 24 V
CNE08
2
CNL06 CNER2
CNE09
4
CNL56 Glow plug
5
1 2 3 5 6
Preheating relay
Starting switch
CNL09
2 BR
Water temperature signal CNLR5 Battery ⊕

CNL05 3
3 CNLR4 CNER1 CNE05

7 2 8
Engine water
temperature sensor
20-368
TROUBLESHOOTING M-9
M-9 Night lighting does not light up

« Before starting troubleshooting, check that the lamp bulb is not blown.
Cause Remedy
1 YES
Is voltage between
CNL05 (16) and
1) 20 - 30 V
(female) (16) and CNFS2
(5)
2) Turn starting
switch ON.
3) Turn side lamp

switch ON.
Side lamp (right)
Side
CNL05 CNFS2
16 5
Lighting switch
CNL02
5
20-369
TROUBLESHOOTING M-10
M-10 Abnormality in front working lamp

« Before starting troubleshooting, check that the monitor lighting is lighted up.
Cause Remedy
(a) Neither monitor display nor front working lamp light up
Defective contact, or
YES disconnection in wiring After inspection,
harness between CNL60 (1) repair or replace
- CNL05 (17), CNCL1 (7)
1 YES Defective front working lamp

Is voltage between Replace
3 relay
CNL60 (1) and Is voltage between
chassis ground YES CNL60 (6) and Defective contact, or
normal? chassis ground 4 YES disconnection in wiring After inspection,
1) 0 - 3 V normal? Is voltage between harness between CNL06 (1) repair or replace
2) Turn starting 2 CNL06 (1) and and CNL60 (6)
1) 0 - 3 V
switch ON. Is voltage between
2) Turn starting NO chassis ground
CNL60 (2), (5) and normal?
switch ON.
NO chassis ground Defective main monitor Replace
normal? 1) 0 - 3 V NO
2) Turn starting
1) 20 - 30 V switch ON. Defective contact, or
2) Turn starting disconnection in wiring After inspection,
switch ON. harness between CNL60 repair or replace
NO
(2), (5) - CNFS5 (1)
(b) Working lamp lights up but monitor display does not light up
1 YES
Is voltage between
CNL05 (17) and
1) 20 - 30 V
2) Turn starting
switch ON.
(c) Monitor lights up but working lamp does not light up

disconnection in wiring
harness between CNL60 (1) After inspection,
- CNCL1 (7) - front working repair or replace
lamp, or blown working lamp
bulb
20-370
M-11 Abnormality in rear working lamp

« Before starting troubleshooting, check that the monitor lighting is lighted up.
Cause Remedy
(a) Neither monitor display nor rear working lamp light up
YES After inspection,
harness between CNL61 (1)
- CNL05 (18), CNLR1 (12) repair or replace
1 YES Defective rear working lamp

Is voltage between relay Replace
3
CNL61 (1) and
Is voltage between
chassis ground YES CNL61 (6) and Defective contact, or
normal?
chassis ground 4 YES disconnection in wiring After inspection,
1) 20 - 30 V normal? Is voltage between harness between CNL06 (2) repair or replace
2) Turn starting
2 and CNL61 (6)
1) 0 - 3 V CNL06 (2) and
switch ON. Is voltage between
CNL61 (2), (5) and 2) Turn starting NO chassis ground
switch ON. normal?
NO chassis ground Defective main monitor Replace
normal? 1) 0 - 3 V NO
2) Turn starting
switch ON. Defective contact, or
(2), (5) - CNFS5 (2)
(b) Working lamp lights up but monitor display does not light up
1 YES
Is voltage between
CNL05 (18) and
harness between CNL05 After inspection,
1) 20 - 30 V NO (female) (18) and CNL61 repair or replace
2) Turn starting (1)
switch ON.
(c) Monitor lights up but working lamp does not light up Defective contact, or
- CNLR1 (12) - rear repair or replace
working lamp, or blown
working lamp bulb
20-371
F Working lamp relay

CNL60
Working lamp F
CNL05 5 6 1 2 3 4 CNCL1
to front working lamp
17 7
CNL06 CNFS5
1 1 + 24 V
R Working lamp relay

CNL61
Working lamp R
CNL05 5 6 1 2 3 4 CNLR1
To rear working lamp
18 12
CNL06 CNFS5
2 2 + 24 V
20-372
TROUBLESHOOTING M-12A
M-12A Abnormality in transmission cut-off

(a) When monitor switch is pressed, cut-off function is Cause Remedy

not switched and display is not given
(b) Monitor display goes out but cut-off function stays

on
3 YES
A
Is voltage between
YES CNL65 (1) and
2 chassis ground Defective contact, or
YES CNL65 (2) and NO harness between CNL65 (1) repair or replace
1) 20 - 30 V
chassis ground and CNFS2 (8)
1 normal? 2) Turn starting Defective contact, or
Is voltage between
1) 0 - 3 V switch ON. disconnection in wiring After inspection,
CNL06 (3) and
chassis ground
2) Turn starting (female) (3) and CNL65 (2)
normal?
switch ON.
1) 0 - 3 V
NO
2) Turn starting
switch ON.
5 YES Defective transmission cut-
Replace
Is voltage between off relay
YES CNL65 (5) and
1) 20 - 30 V NO harness between CNL65 (5) repair or replace
4 2) Turn starting and CNL12 (female) (2)
Is voltage between switch ON.
CNL65 (3) and 3) Turn parking
A chassis ground switch OFF.
normal? 4) Remove cut - off
relay.
1) 20 - 30 V 5) Stop machine
cut - off function.
2) Turn starting Defective contact, or
switch ON. disconnection in wiring After inspection,
NO harness between CNL65 (3) repair or replace
3) Turn parking and CNL12 (female) (1)
switch OFF.
20-373
TROUBLESHOOTING M-12A
(c) Monitor display lights up but cut-off function is not actuated Cause Remedy
YES
Defective cut-off relay Replace
2
Is voltage between
YES CNL65 (2) and
chassis ground 3 YES
normal? Defective main monitor Replace
1
1) 20 - 30 V Does cut-off
Does cut-off
NO function work? Wiring harness between
function work? 2) Turn starting CNL06 (female) (3) and After inspection,
switch ON. 1) Turn starting NO CNL65 (2) short circuiting repair or replace
switch ON. with chassis ground
1) Turn starting 2) Disconnect Contact of wiring harness
switch ON. CNL06. between CNL65 (3) and (5), After inspection,
NO or defective cut-off switch repair or replace
2) Remove cut - off
relay.
Transmission cut-off relay CNL65
Transmission cut-off
CNFS2
CNL06 +24V
CNL04 Transmission lever
CNL08
CNL12 Transmission cut-off switch
Parking
brake
switch CNTL1
F solenoid
R solenoid
Neutralizer relay FORWARD relay REVERSE relay

CNL58 CNL66 CNL67
TDW00297
20-374
TROUBLESHOOTING M-12B
M-12B Abnormality in transmission cut-off

(WA-3H with automatic transmission)
(a) When monitor switch is pressed, cut-off function is not Cause Remedy
switched and display is not given
(b) Monitor display goes out but cut-off function is actuated

when pedal is depressed Defective contact, or
1 YES After inspection,
Is voltage between repair or replace
CNL06 (3) and (female) (16)
chassis ground
normal?
1) 0 - 3 V NO
2) Turn starting
switch ON.
3) Disconnect
CNL12.
(c) When monitor display is turned off, cut-off function is

always actuated Defective contact, or
2 harness between CNL12
repair or replace
Is there continuity
YES between CNL12 (female) (16)
1
chassis ground? disconnection in wiring
Is there continuity After inspection,
between CNL12 1) Disconnect harness between CNL12
NO repair or replace
(male) (1) and CNL12. (female) (2) and chassis
(2) ? ground
1) Disconnect Defective transmission cut-

Replace
CNL12. NO off switch
(d) Cut-off function is always actuated regardless of

monitor display
1 YES Defective transmission
Replace
Is voltage between controller
CNL30 (16) and Defective contact, or
chassis ground disconnection in wiring
normal? harness between CNL30 After inspection,
1) 0 - 3 V NO (female) (16) - CNL06 repair or replace
(female) (3), CNL12
(female) (1)
20-375
Cause Remedy
(e) Monitor display lights up but cut-off function does not work
YES Defective transmission cut-

Replace
off switch
1
Does cut-off YES

function work? Defective main monitor Replace
2
1) Disconnect Does cut-off

CNL12.
NO function work? 3 YES Defective transmission
Replace
2) Turn starting
Is voltage between controller
switch ON.
1) Disconnect CNL30 (16) and Wiring harness between
CNL06. NO chassis ground CNL06 (female) (3) -
2) Turn starting normal? CNL30 (female) (16) - After inspection,
switch ON. 1) Disconnect NO CNL12 (female) (1) short repair or replace
CNL 12. circuiting with chassis
2) Disconnect ground
CNL06.
3) Turn starting
switch ON.
4) 20 - 30 V
CNL30
16
Cut-off signal
CNL06 CNL12 Transmission cut-off switch
3 1
20-376
M-13 Abnormality in parking brake dragging warning

(a) When parking brake is applied, buzzer sounds Cause Remedy

(intermittently) even when directional lever is at N, and
caution lamp flashes
1 YES
Is voltage between
CNL05 (8) and
1) 20 - 30 V
2) Turn starting
switch ON.
(b) When parking brake is applied, buzzer does not sound

and caution lamp does not light up even when
directional lever is at position other than N
« Check that the synchronous flash signal is normal.
YES
1
Is voltage between
CNL05 (8) and Contact of power source with
chassis ground 2 YES wiring harness between After inspection,
normal? CNL05 (female) (8) and repair or replace
Is resistance
between CNL05 CNL04 (female) (3)
1) 0 - 5 V
2) Turn starting NO (male) (8) and (3)
switch ON. normal?
1) 3 kΩ - 4 kΩ NO
2) Turn starting
switch OFF.
3) Disconnect Neutral relay
CNL05.
Start signal,
neutral signal
Starting motor
CNL57
1 2 3 5 6 CNL04
CNL05
3 N Speed lever
Starting
4
CNLR5
8
Neutral
2
CNR10
Rear frame GND
CNL09
3
Starting switch
20-377
M-14 When parking brake dragging warning is given, buzzer and

caution lamp are actuated continuously, or they are not actuated
Cause Remedy
(a) Actuated continuously
2 YES Defective maintenance

monitor Replace
YES Does buzzer stop
and lamp go out? Defective contact, or
1 disconnection in wiring
After inspection,
1) Turn starting NO repair or replace
Does buzzer stop switch ON. (female) (5)
and lamp go out? 2) Connect CNL19
(female) (5) to
chassis ground.
1) Turn starting
switch ON. Defective main monitor Replace
2) Connect CNL07 NO
(6) to chassis
ground.
(b) Not actuated

Replace
monitor
YES Do buzzer and
1 lamp work? Wiring harness between
CNHL19 (female) (5) short After inspection,
Do buzzer and 1) Turn starting NO repair or replace
circuiting with chassis
lamp work? switch ON. ground
2) Disconnect
1) Turn starting CNL19.
switch ON. NO
2) Disconnect
CNL07.
Synchronous flashing signal
CNL07 CNL19
6 5
20-378
M-15 Abnormality in buzzer

Cause Remedy
(a) Buzzer does not sound when starting switch is turned
ON (during self-check)
YES
1 (female) (8) and CNL43
(male)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
1) Turn starting CNL42 (female) and
switch ON. NO chassis ground Defective contact, or
2) Contact CNL43 normal? disconnection in wiring After inspection,
(female) to 1) 20 - 30 V NO harness between CNL42 repair or replace
chassis ground. 2) Turn starting (female) and CNFS2 (9)
switch ON.
(b) Buzzer always sounds
YES
Defective main monitor. Replace
1
Does buzzer stop? YES Go to Troubleshooting for

-
2 maintenance monitor
1) Turn starting Does buzzer stop? Wiring harness between

switch ON. 3 YES CNL06 (female) (8) and
NO After inspection,
2) Disconnect CNL43 (male) short
repair or replace
CNL06. circuiting with chassis
1) Turn starting Does buzzer stop? ground
switch ON. NO
2) Disconnect
CNL19. Defective buzzer Replace
1) Turn starting NO
switch ON.
2) Disconnect
CNL43.
CNL19 CNL42
CNFS2 9
Buzzer output 4 Buzzer
+ 24 V
CNL06 Maintenance monitor CNL43

8
20-379
20-380
M-17 Abnormality in failure display mode

Cause Remedy
(a) Does not enter failure display mode
1 YES
Is voltage between
CNL05 (5) and Contact of power source
chassis ground with wiring harness between
normal? CNL05 (female) (5) - After inspection,
1) 0 - 5 V NO CNLR4 (6) - CNER1 (9) - repair or replace
2) Turn starting alternator terminal R, or
switch ON. defective alternator
(b) Time for time elapsed since failure on failure

display mode does not advance
1 YES
Is voltage between
CNL05 (5) and Defective contact, or
chassis ground disconnection in wiring
normal? harness between CNL05
After inspection,
(female) (5) - CNLR4 (6) -
CNER1 (9) - alternator
2) Start engine. terminal R, or defective
alternator
Charge
Alternator
CNL05 CNLR4 CNER1
5 6 9 R
CNE16
20-381
TROUBLESHOOTING M-19, M-20
M-20 Buzzer does not sound because of transmission controller
Cause Remedy
Go to
2 YES Defective transmission Troubleshooting
Is resistance between controller for transmission
YES CNL31 (female) (15) controller
1 and chassis ground Defective contact, or
Does buzzer 1) 1kΩ - 2kΩ NO repair or replace
sound? 2) Turn starting (female) (15)
switch ON.
1) 0 - 3 V
2) Turn starting Defective main monitor Replace
switch ON. NO
CNL34
Transmission controller buzzer 7
CNL08 CNL31
6 15
3.3 K
20-382
M-21 Abnormality in emergency steering normal display

Cause Remedy
(a) Emergency steering normal display does not light up
YES Defective emergency

steering normal sensor Replace
1
Is there continuity
between CNT10
(male) (1) and 2 YES
(2)? Defective main monitor Replace
Is voltage between
1) Disconnect CNL05 (10) and
Wiring harness between
CNT10. NO chassis ground
normal? CNL05 (female) (10) -
2) Turn starting After inspection,
CNTL1 (2) - CNT10 (female)
switch ON. 1) 20 - 30 V NO repair or replace
(1) short circuiting with
2) Turn starting chassis ground
switch ON.
(b) Emergency steering normal display stays lighted up
3 YES
Is voltage between
YES CNL05 (10) and
2 normal? disconnection in wiring After inspection,
Is there continuity harness between CNL05 repair or replace
1) 0 - 2 V NO (female) (10) - CNTL1 (2) -
YES between CNT10
(female) (2) and 2) Turn starting CNT10 (female) (1)
1 chassis ground? switch ON.
Is there continuity 1) Disconnect disconnection in wiring
between CNT10 After inspection,
CNT10. harness between CNT10
(male) (1) and NO repair or replace
(female) (2) - CNTL1 (8) -
(2)? chassis ground
1) Disconnect
Defective emergency
CNT10. Replace
NO steering normal sensor
2) Turn starting
switch ON.
Emergency steering normal
CNL05 CNTL1 CNT10 Emergency steering

normal sensor
10 2 1
8 2
20-383
M-22 Abnormality in emergency steering actuation display

Cause Remedy
(a) Emergency steering actuation display does not light up
YES Defective emergency

Replace
1 steering function sensor
Is there continuity
between CNT11
(male) (1) and 2 YES
(2)? Defective main monitor Replace
Is voltage between
1) Disconnect CNL05 (11) and
Wiring harness between
CNT11. NO chassis ground
normal? CNL05 (female) (11) -
CNTL1 (1) - CNT11 (female)
switch ON. 1) 20 - 30 V NO repair or replace
switch ON.
(b) Emergency steering actuation display stays lighted up
3 YES
Is voltage between
YES CNL05 (11) and
chassis ground Wiring harness between
2 normal? CNL05 (female) (11) -
After inspection,
Is there continuity CNTL1 (1) - CNT11 (female)
YES between CNT11 (1) short circuiting with
(female) (2) and
switch ON.
1 chassis ground?
Is there continuity 1) Disconnect disconnection in wiring
between CNT11 After inspection,
CNT11. harness between CNT11
(male) (1) and NO repair or replace
(female) (2) - CNTL1 (8) -
(2)? chassis ground
1) Disconnect
Defective emergency
CNT11. Replace
NO steering actuation sensor
2) Turn starting
switch ON.
Emergency steering actuation
CNL05 CNTL1 CNT11 Emergency steering

actuation sensor
11 1 1
8 2
20-384
M-23 Abnormality in auto-greasing system

(KOMATSU auto-greasing system only)
Cause Remedy
(a) Forced greasing cannot be carried out

Go to
2 YES operation maintenance
manual for handling –
Is voltage
auto-greasing system
YES between CNGRE
(1) and chassis
1 ground normal ? disconnection in wiring After inspection,
Is voltage NO harness between CNL06 repair or replace
1) 0 - 3 V
between CNL06 (female) (5) and CNGRE (1)
2) Turn starting
(6) and chassis switch ON
ground normal ? 3) Turn auto-greasing
1) 0 - 3 V switch ON
switch ON NO
3) Turn auto-greasing
switch ON
(b) Monitor display flashes rapidly (2 times/sec)
YES
1
Is voltage
between CNL08 Defective contact, or
(5) and chassis 2 YES disconnection in wiring After inspection,
ground normal ? harness between CNL08 repair or replace
Is voltage
between CNGRE (female) (5) and CNGRE (3)
1) 0 - 30 V
2) Turn starting NO (3) and chassis Go to
switch ON ground normal ? operation maintenance
NO manual for handling –
1) 0 - 30 V
2) Turn starting auto-greasing system
switch ON
(c) When no more grease remains, monitor display flashes

rapidly (2 times/sec)
YES
1
Is voltage
between CNL07 Defective contact, or
(11) and chassis disconnection in wiring
ground normal ? harness between CNL07
Is voltage repair or replace
(female) (11) and CNGRE
1) 20 - 30 V between CNGRE (2)
2) Turn starting NO (2) and chassis
Go to
switch ON ground normal ?
operation maintenance
1) 20 - 30 V NO manual for handling –
switch ON
20-385
Cause Remedy
(d) Monitor display flashes slowly (1 time/sec)

Go to
operation maintenance
manual for handling –
auto-greasing system
(e) Monitor display goes out

YES
1
Is voltage
between CNL07 Contact of power source
(11) and chassis 2 YES with wiring harness After inspection,
ground normal ? between CNL07 (female) repair or replace
Is voltage
between CNGRE (11) and CNGRE (female) (2)
1) 0 - 3 V
2) Turn starting NO (2) and chassis Go to
switch ON ground normal ? operation maintenance
NO manual for handling –
1) 0 - 3 V
switch ON
Relationship between input signal

and display
CNL07(11) CNL08(5) Display

Rapid flashing
L L (2 times/sec)
Slow flashing
H L (1 time/sec)
H H OFF
L H ON
Auto-greasing
CNL06 CNGRE
CNL07
A 11
CNL08
P
20-386
M-24 Abnormality in ECSS system

Cause Remedy
(a) Display does not change when switch is pressed
(b) Monitor display lights up but ECSS function does not

work
Go to
2 YES Troubleshooting
Defective ECSS controller
Is voltage between for ECSS
YES CNDP2 (1) and controller
1 chassis ground Defective contact, or
CNL06 (7) and 1) 0 - 3 V NO harness between CNL06 (7) repair or replace
chassis ground 2) Turn starting and CNDP2 (1)
normal? switch ON.
1) 0 - 3 V
2) Turn starting NO
switch ON.
ECSS
CNL06 CNDP2
7 1
20-387
M-26B Failure code is not sent to main monitor

(abnormality in network)
« Set dipswitch 3 at the rear of the main monitor to F.
Cause Remedy
2 YES Applicable controller is

Replace
Is voltage normal defective
YES between pins of Defective contact, or
connectors in disconnection in wiring
table below? harness between CNL08 After inspection,
1
1) Repeat 0 V and NO (female) (1)(3), CNL08 repair or replace
Is voltage (female)(2)(4) - applicable
between CNL08 12 V
2) Turn starting connector pins
(male) (1) and (2)
normal ? switch ON
3) Disconnect connector
1) Repeat 0 V and to be measured
12 V
switch ON NO
3) Disconnect
CNL08
Table
Connector Pin No.
CNL29 CNL30 Between (1) (9)
CNL29
CNL30 Transmission controller
CNL08 CNDP2
ECSS
20-388
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor does not work ..................................................... 20-402
(a) All lamps on maintenance monitor do not light up for 3 seconds ....................................... 20-402
(b) Some lamps do not light up ................................................................................................. 20-403
K- 2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out ........................................................................................................................ 20-403
K- 3 When engine is started immediately after starting switch is turned ON
(within 3 seconds), all lamps on maintenance monitor do not go out ....................................... 20-404
K- 4 When starting switch is turned ON (engine stopped), CHECK items flash ............................... 20-405
(a) Engine oil level display flashes ............................................................................................ 20-405
(b) Engine water level display flashes ....................................................................................... 20-406
K- 5 When starting switch is turned ON (engine started), CAUTION items flash ............................. 20-407
(a) Engine oil pressure display flashes ..................................................................................... 20-407
(b) Battery charge level display flashes .................................................................................... 20-408
(c) Brake oil pressure display flashes ....................................................................................... 20-409
(d) Air cleaner display flashes ................................................................................................... 20-410
K- 6 CAUTION items are flashing but alarm buzzer does not sound ............................................... 20-411
K- 7 There is no abnormality in monitor display but alarm buzzer sounds ....................................... 20-412
K- 8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp)
does not light up ........................................................................................................................ 20-413
(a) CHECK lamp ....................................................................................................................... 20-413
(b) CAUTION lamp .................................................................................................................... 20-413
K- 9 There is no abnormality in maintenance monitor display but
warning lamp (CHECK lamp, CAUTION lamp) lights up ........................................................... 20-414
(a) CHECK lamp ....................................................................................................................... 20-414
(b) CAUTION lamp .................................................................................................................... 20-414
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up) ........................................................... 20-415
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays
lighted up .................................................................................................................................... 20-416
K-12 Service meter does not work ..................................................................................................... 20-417
K-13 Service meter is running even when engine is stopped ............................................................ 20-417
K-14 Abnormality in gauge items ........................................................................................................ 20-418
(a) Abnormality in fuel gauge .................................................................................................... 20-418
(b) Abnormality in engine water temperature gauge ................................................................. 20-419
(c) Abnormality in torque converter oil temperature gauge ...................................................... 20-420
20-401
TROUBLESHOOTING K-1
K-1 When starting switch is turned ON, all lamps on maintenance

monitor do not light up for 3 seconds, maintenance monitor does
not work
« Always connect any disconnected connectors before go-

ing on the next step.
(a) All lamps on maintenance monitor do not light up for 3 Cause Remedy
seconds
YES Defective maintenance Replace
monitor module
disconnection in wiring Repair wiring
YES harness between CNL18 harness,
1 3 (female) (1), (2) - CNFS2 replace or
Is voltage Is voltage between (9) - fuse box - CNFS1 replace fuse
between CNL18 YES CNFS1 (female) (2) (male) (2), or blow fuse
(1),(2) - (3) and chassis
normal? ground normal?
2 1) 20 - 30 V harness between CNFS1 harness,
1) 20 - 30 V
Is there continuity 2) Disconnect (female) (2) - CNLR6 (1) - replace or
2) Turn starting NO
between CNL18 CNFS1. slow blow fuse - battery replace fuse
switch ON.
(female) (3) and 3) Turn starting relay, or blow fuse
NO
chassis ground? switch ON.
1) Turn starting disconnection in wiring Repair wiring
switch ON. harness between CNL18 harness or
2) Disconnect NO (3) - CNLR4 (12) - chassis replace
CNL18. ground
Battery relay
CNL18 Fuse box Slow blow fuse
1 CNFS2 10A CNFS1 CNLR6 80A

2 9 2 1
3
CNLR4 Battery terminal
12
20-402
TROUBLESHOOTING K-1, K-2
Cause Remedy
(b) Some lamps do not light up
Defective maintenance
monitor module Relace
K-2 When starting switch is turned ON, all lamps on maintenance

monitor light up but do not go out
Cause Remedy
Go to troubleshooting of –
main monitor
20-403
TROUBLESHOOTING K-3
K-3 When engine is started immediately after starting switch is turned

ON (within 3 seconds), all lamps on maintenance monitor do not
go out
Cause Remedy
1
YES
When starting Defective maintenace Replace
engine, is voltage monitor module
between CNL19
(female (1) and Defective contact, or
chassis ground disconnection in wiring Repair wiring
normal? harness between CNL19 harness or
NO replace
1) 20 - 30 V (female) (1) and neutral
2) Disconnect relay
CNL19.
3) Start engine.
4) Measure when
starting motor is
turning.
CNL09
CNL19 3
1
C
Starting switch
6 5 3 2 1
CNL04
CNL57 3 N Speed lever
Neutral relay
20-404
TROUBLESHOOTING K-4
K-4 When starting switch is turned ON (engine stopped), CHECK items

flash
(a) Engine oil level display flashes Cause Remedy

« Before starting troubleshooting, check the engine oil level again.

Replace
Is there continuity monitor module
YES between CNL18
1 (female) (13) and Defective conact, or
chassis ground? disconnection in wiring Repair wiring
Is there continuity
harness between CNL18 harness or
between CNE10 1) Turn starting NO (female) (13) - CNLR4 (4) - replace
(male) (1) and switch off. CNER1 (3) - CNE10
chassis ground? 2) Disconnect (female) (1)
CNL18.
Defective engine oil lever Replace
1) Turn starting NO sensor
switch off.
2) Disconnect
CNE10.
CNL18 CNLR4 CNER1 CNE10 Engine oil lever sensor
13 4 3 1
20-405
TROUBLESHOOTING K-4
(b) Engine water level display flashes Cause Remedy

« Before starting troubleshooting, check the engine
water level again.

Replace
YES between CNL18
2 chassis ground disconnection in wiring Repair wiring
Is there continuity NO harness between CNL18 harness or
YES between CNR06 1) Turn starting
(female) (8) - CNLR3 (2) - replace
(female) (1) and switch OFF.
CNR06 (female) (1)
1 chassis ground 2) Disconnect
CNL18. Defective contact, or
Is there continuity Repair wiring
1) Turn starting disconnection in wiring
between CNR06 harness or
switch OFF. harness between CNR06
(male) (2) and NO replace
(1)? 2) Disconnect (female) (2) and chassis
CNR06. ground
1) Turn starting
switch OFF. Defective radiator water Replace
2) Disconnect NO level sensor
CNR06.
CNL18 CNLR3 CNR06 Radiator water level sensor
8 2 1
20-406
TROUBLESHOOTING K-5
K-5 When starting switch is turned ON (engine started), CAUTION

items flash
Cause Remedy
(a) Engine oil pressure display flashes
YES Defective engine oil Replace

pressure sensor
1
Does display go 3 YES Defective maintenance
monitor module Replace
out when ring Is there continuity
terminal is YES between CNL18
removed? (female) (10) and
chassis ground?
1) Start engine. 2 harness between CNL18 harness,
Is voltage between
1) Disconnect NO (female) (10) - engine oil replace, or
ring terminal and CNL18. pressure relay - chassis replace relay
2) Turn starting ground, or defective relay
NO chassis ground switch OFF.
removed?
Contact off ground with
1) 20 - 30 V
wiring harness between Repair wiring
2) Remove ring
terminal. ring terminal - CNER1 (2) harness,
3) Start engine. NO - CNLR4 (3) - engine oil replace, or
pressure relay, or replace relay
defective relay
CNL18 CNLR4 CNER1 Ring terminal

10 3 2
Engine oil pressure sensor
+24V
6 5 3 2 1
Enginge oil pressure relay

CNL64
20-407
TROUBLESHOOTING K-5
Cause Remedy
(b) Battery charge level display flashes

Replace
Is voltage between monitor module
YES CNL18 (female)
1 (12) and chassis Disconnection in wiring
ground normal? harness between CNL18 Repair wiring
Is voltage between (female) (12) - CNLR4 (6) - harness or
alternator terminal R 1)20-30V NO CNER1 (9) - alternator replace
and chassis
2)Startengine. terminal R
ground normal?
1)20-30V Defective alternator Replace

2)Startengine. NO

12 6 9 2 R Starting motor
R Alternator
CNR04
2 CNR12
1 1
Battery relay
20-408
TROUBLESHOOTING K-5
Cause Remedy
(c) Brake oil pressure display flashes
YES Defective maintenance

4 Replace
monitor module
Is voltage
YES between CNL18 Defective contact, or
ground normal? harness between CNL18 Repair wiring
(female) (11) and CN41 harness,
replace, or
3 1) Start engine. NO (female) (2), or between replace diode
Is there continuity 2) 0 - 3 V CN41 (female) - CNLR2
YES between CNB13 (8) - CNBR1 (6) - CNB13
(female) (2) and (female) (1), or defective
chassis ground? diode
1) Turn starting
2
switch OFF. Defective contact, or
Is there continuity 2) Disconnect
YES between CNB08 disconnection in wiring Repair wiring
CNB13. harness between CNB13 harness or
(male) (1) and
(2)?
NO (female) (2) and CNB08 replace
(female) (1), or between
1
1) Start engine. CNB08 (female) (2) -
Is there continuity 2) Disconnect CNBR1 (1) - chassis ground
between CNB13 CNB08.
(male) (1) and Defective brake
(2)? accumulator charge oil Replace
NO
pressure switch (CNB08
1) Start engine. end)
2) Disconnect
CNB13. Defective brake Replace
accumulator charge oil
NO
pressure switch (CNB13
end)
CN41
CNL18 2 1 CNLR2 CNBR1 CNB13
11 8 6 1
4 2
Brake accumulator oil

CNB08 pressure switch
20-409
TROUBLESHOOTING K-5
Cause Remedy
(d) Air cleaner display flashes
YES Defective dust indicator Replace

sensor
1 YES
Defective maintenance Replace
3
monitor
Does display go Is there continuity
YES between CNL18
out? Defective contact, or
(female) (15) and disconnection in wiring
chassis ground? harness between CNL18 Repair wiring
1) Start engine. 1) Turn starting (female) (15) and CNL80 harness,
2
2) Disconnect switch OFF. NO (female) (3), or between replace, or
CNE19. Is voltage between 2) Disconnect CNL80 (female) (6) - CNLR5 replace relay
CNE19 (female) (1) CNL18. (2) - chassis ground, or
NO and chassis ground defective dust indicator
normal? relay
1) Turn starting
switch ON. Short circuit, or contact of
Repair wiring
2) Disconnect wiring harness between
harness,
CNE19. CNE19 (female) (1) - CNER1
replace, or
3) 20 - 30 V NO (5) - CNLR4 (5) - CNL80
replace relay
(female) (2) with chassis
ground, or defective dust
indicator relay
+24V
CNL18 CNLR4 CNER1 CNE19 Dust indicator
15 5 5 1
CNER2 CNE20
5 1
6 5 3 2 1
CNLR5
2
Dust indicator relay

CNL80
20-410
TROUBLESHOOTING K-6
K-6 CAUTION items are flashing but alarm buzzer does not sound
« The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
Cause Remedy

2 monitor module
YES Does buzzer sound

when CNL19 (female) Defective contact, or
pin (4) is connected 3 YES disconnection in wiring Replace
to chassis ground? Does buzzer sound harness between CNL19
1
when CNL43 (female) (female) (4) and CNL43
Is voltage between 1) Turn starting pin (1) is connected (male) (1)
switch ON. NO
CNL42 (female) (1) to chassis ground?
and chassis Defective buzzer Replace
ground normal? 1) Turn starting NO
switch ON.
1) 20 - 30 V Defective contact, or Repair wiring
2) Disconnect disconnection in wiring harness or
CNL42. harness between CNL42 replace
NO
3) Turn starting (female) (1) - CNFS2 (9) -
switch ON. +24V
+24V
CNFS2 CNL42 Alarm buzzer
9 1
Maintenace monitor
CNL19 CNL43
4 1
Main monitor
CNL06
8
20-411
TROUBLESHOOTING K-7
K-7 There is no abnormality in monitor display but alarm buzzer

sounds
« Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause Remedy
YES Defective buzzer Replace

1
Is there continuity
between CNL43 Contact of chassis ground Repair wiring
(female) (1) and 2 YES with wiring harness harness or
chassis ground?
Is there continuity between CNL19 (female) replace
1) Turn starting between CNL19 (4) and CNL43 (male) (1)
switch OFF. NO (female) (4) and
2) Disconnect chassis ground?
CNL43. Defective maintenance Replace
1) Turn starting NO monitor module
switch OFF.
2) Disconnect
CNL19.
+24V
CNFS2 CNL42 Alarm buzzer
9 1
Maintenace monitor
CNL19 CNL43
4 1
Main monitor
CNL06
8
20-412
TROUBLESHOOTING K-8
K-8 CAUTION items are flashing but warning lamp (CHECK lamp,
CAUTION lamp) does not light up
« Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause Remedy
(a) CHECK lamp
YES Defective maintenance

1 Replace
monitor module
Does check lamp
light up when
CNL19 (female) pin Defective contact, or
2 YES Repair wiring
(2) is connected to disconnection in wiring
chassis ground? Does check lamp harness or
light up when replace
1) Disconnect CNL06 (male) pin
CNL19. NO (female) (10)
(10) is connected to
2) Turn staring chassis ground?
1) Disconnect
NO
CNL06.
2) Turn staring
switch ON.
(b) CAUTION lamp

1
Does check lamp
monitor module
light up when
CNL19 (female) pin Defective contact, or Repair wiring
(3) is connected to
2 YES
disconnection in wiring harness or
chassis ground? Does check lamp harness between CNL19
light up when replace
1) Disconnect (female) (3) and CNL06
CNL06 (male) pin
CNL19. NO (9) is connected to
(female) (10)
2) Turn staring chassis ground?
1) Disconnect NO
CNL06.
2) Turn staring
switch ON.
Maintenace monitor Main monitor

CNL19 CNL06
2 10
3 9
20-413
TROUBLESHOOTING K-9
K-9 There is no abnormality in maintenance monitor display but

warning lamp (CHECK lamp, CAUTION lamp) lights up
« Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause Remedy
(a) CHECK lamp
Contact of chassis ground Repair wiring
1 YES with wiring harness harness or
between CNL19 (female) replace
Is there conitnuity
between CNL 19 (2) and CNL06 (female)
(female) (2) and (10)
chassis ground?
Defective maintenance Replace
NO monitor module
1) Turn starting
switch OFF.
2) Disconnect
CNL19.
(b) CAUTION lamp
Contact of chassis ground Repair wiring

1 YES harness or
with wiring harness
Is there conitnuity between CNL19 (female) replace
between CNL 19
(3) and CNL06 (female) (9)
(female) (3) and
chassis ground?
NO Defective maintenance Replace

1) Turn starting monitor module
switch OFF.
2) Disconnect
CNL19.
Maintenace monitor Main monitor

CNL19 CNL06
2 10
3 9
20-414
TROUBLESHOOTING K-10
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up)
« Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause Remedy
1 YES Disconnection in wiring Replace

Is voltage harness of lamp holder
between CNL21
(female) (1) and Defective contact, or Repair wiring
(2) normal? disconnection in wiring harness or
1) 20 - 30 V NO harness between CNL21 replace
2) Diconnect (female) (1) and CNFS2 (5)
CNL21.
3) Turn starting
switch ON.
4) Turn lamp
switch ON.
Fuse box
Lighting +24V
CNL21 CNFS2 10A
1 5 CNL02 Lamp switch
2 2 4 1
5
CNLR5
20-415
K-11 Night lighting lights up even when lamp switch is OFF, night
lighting stays lighted up
Cause Remedy
Contact of +24V with

wiring harness between Repair wiring
2 YES CNFS2 (male) (4) - fuse harness or
Is voltage between box - CNFS2 (5) - CNL21 replace
YES CNFS2 (female) (4) (female) (1)
and chassis
Contact of +24V with
ground normal? Repair wiring
1 wiring harness between
1) 0 V CNL02 (female) (5) and harness or
NO replace
Is lamp switch 2) Disconnect CNFS2 (female) (4)
normal? CNFS2.
3) Turn lamp
switch ON.
1) Turn starting 4) Turn starting
switch OFF. switch ON.
Defective lamp switch Replace
2) Disconnect NO
CNL02.
3) Check that
continuity
between CNL02
(male) (1) and
(5) is as shown
in table below
when lamp
switch is turned
ON-OFF.
Switch Continuity
ON Continuity
OFF NO continuity
Fuse box
Lighting +24V
CNL21 CNFS2 10A
1 5 CNL02 Lamp switch
2 2 4 1
5
CNLR5
20-416
TROUBLESHOOTING K-12, K-13
K-12 Service meter does not work

Cause Remedy
YES Defective service Replace

meter
1 Defective contact, or
YES disconnection in wiring Repair wiring
Is voltage harness or
between CNL22 3 harness between CNL22
(female) (2) - CNLR4 (6) - replace
(female) (2) and Is there continuity
(1) normal? YES between CNL22 CNER1 (9) - alternator
(female) (1) and terminal R
1) 20 - 30 V 2 chassis ground? Defective contact, or
2) Start engine. Is voltage between disconnection in wiring Repair wiring
1) Turn starting
3) Disconnect alternator terminal harness between CNL22 harness or
switch ON. NO
CNL22. NO R and chassis (female) (1) - CNLR5 (2) - replace
ground normal? 2) Disconnect
chassis ground
CNL22.
1) 20 - 30 V Defective alternator Replace
2) Start engine. NO
K-13 Service meter is running even when engine is stopped

Cause Remedy
1 YES
Defective service meter Replace
Is voltage
between CNL22
(female) (2) and Defective alternator, or Replace
(1) normal? contact of wiring harness alternator, or
NO between CNL22 (female) repair, replace
1) 0 -4 V (2) - CNLR4 (6) - CNER1 wiring harness
2) Turn starting (9) alternator terminal R
switch ON. with +24V
3) Disconnect
CNL22.

2 6 9 2 R Starting motor
1
CNLR5
service meter
2 R Alternator
20-417
K-14 Abnormality in gauge items

(a) Abnormality in fuel gauge

« Before carrying out troubleshooting, check the fuel
Cause Remedy
level again.
(1) Little or nothing is displayed in the display area
YES
Defective fuel sensor Replace
1
Does fuel gauge monitor module Replace
Is there continuity
show FULL? YES between CNL18
1) Disconnect
2 chassis ground? disconnection in wiring Repair wiring
CNR07. Is there continuity harness between CNR07 harness or
2) Connect short between CNR07 1) Turn starting NO (female) (1) - CNLR4 (10) - replace
connector to switch OFF. CNL18 (female) (6)
(female) (2) and
CNR07 (female). NO 2) Connect short
3) Turn starting chassis ground? connector to
switch ON. CNR07 (female).
1) Turn starting 3) Disconnect
switch OFF. CNL18.
2) Disconnect Defective contact, or
CNR07. Repair wiring
harness or
NO harness between CNR07
replace
(female) (2) and chassis
ground
(2) Display always shows FULL and does not move
YES
Defective fuel sensor Replace
1
Do all display Contact of chassis ground
areas on fuel with wiring harness Repair wiring
gauge go out? 2 YES between CNR07 (female) harness or
Is there continuity (1) - CNLR4 (10) - CNL18 replace
1) Disconnect between CNR07 (female) (6)
CNR07. (female) (1) and
2) Turn starting
NO
chassis ground?
switch ON. Defective maintenance
Replace
switch OFF.
2) Disconnect
CNR07.
Fuel sensor
CNL18 CNLR4 CNR07

6 10 1
20-418
(b) Abnormality in engine water temperature gauge

Cause Remedy
(1) Nothing is displayed in the display area
YES Defective engine water

Replace
1 temperatur sensor
Does engine water
temperature gauge Contact of chassis ground
with wiring harness Repair wiring
display minimum 2 YES
between CNE06 (female) harness or
level? Is there continuity
(1) - CNER1 (6) - CNLR4 replace
1) Disconnect between CNE06
(female) (1) and (1) - CNL18 (female) (4)
CNE06. NO
2) Turn starting chassis ground?
switch ON. Defective maintenance Replace
1) Trun starting NO monitor module
switch OFF.
2) Disconnect
CNE06.
(2) Display shows lowest level and does not move
YES Defective engine water

temperatur sensor Replace
1
Do all display 3 YES Defective maintenance
areas on engine Replace
water temperature YES between CNL18
gauge go out? (female) (4) and Defective contact, or
2 chassis ground? Repair wiring
1) Disconnect Is there continuity harness between CNE06 harness or
CNE06. 1) Trun starting NO replace
between CNE06 (female) (1) - CNER1 (6) -
2) Connect short switch OFF.
connector to NO (female) (2) and CNLR4 (1) - CNL18
CNE06 (female). chassis ground? 2) Connect short
(female) (4)
3) Turn starting connector to
switch ON. 1) Trun starting CNE06 (female).
switch OFF. 3) Disconnect Defective contact, or
2) Disconnect CNL18. disconnection in wiring Repair wiring
CNE06. harness between CNE06 harness or
NO (female) (2) - CNER1 (7) - replace
chassis ground
CNL18 CNLR4 CNER1 CNE08 Water temperature sensor
4 1 6 1
7 2
20-419
(c) Abnormality in torque converter oil temperature gauge

Cause Remedy
(1) Nothing is displayed in the display area
YES Defective torque converter Replcae

1 oil temperature sensor
Does torque converter
oil temperature gauge Contact of chassis ground
display minimum with wiring harness Repair wiring
2 YES
level? between CNT07 (female) harness or
Is there continuity replace
(1) - CNTL2 (4) - CNL18
1) Disconnect between CNT07
(female) (5)
CNT07. NO (female) (1) and
2) Turn starting chassis ground? Defective maintenance
switch ON. Relace
switch OFF.
2) Disconnect
CNT07.
(2) Display shows lowest level and does not move
YES Defective torque converter

Replace
oil temperature sensor
1
Do all display areas 3 YES Defective maintenance
on torque converter Replace
oil temperature YES between CNL18
gauge go out? (female) (5) and Defective contact, or
2 chassis ground? disconnection in wiring Repair wiring
1) Disconnect
CNT07. Is there continuity harness between CNT07 harness or
2) Connect short 1) Turn starting NO (female) (1) - CNTL2 (4) - replace
between CNT07
connector to switch OFF. CNL18 (female) (5)
CNT07 (female). NO (female) (2) and 2) Connect short
3) Turn starting chassis ground? connector to
switch ON. CNT07 (female).
1) Turn starting 3) Disconnect
switch OFF. CNL18.
2) Disconnect Defective contact, or
CNT07. disconnection in wiring Repair wiring
harness between CNT07 harness or
NO (female) (2) - CNTL2 (5) - replace
CNLR4 (12) - chassis
ground
CNT02 CNT07 Torque converter oil

CNL18 temperature sensor
5 4 1
12 5 2
CNLR4
20-420
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
E- 1 Engine does not start ................................................................................................................. 20-452

(a) Starting motor does not turn ................................................................................................ 20-452
(b) Starting motor turns ............................................................................................................... 20-456
E- 2 Engine does not stop ................................................................................................................... 20-458
E- 3 Engine stops when machine is traveling .................................................................................... 20-458
WA320-3H with manual transmission only:

E- 8 Transmission does not work normally ........................................................................................ 20-459
(a) Problem in common circuit for transmission (always stays in 2nd) ................................... 20-461
(b) Problem in H-L circuit .......................................................................................................... 20-461
(c) Problem in speed circuit ...................................................................................................... 20-462
(d) Problem in 4th circuit (does not enter 4th) ......................................................................... 20-462
(e) Contact in H-L circuit .......................................................................................................... 20-464
(f) Contact in speed circuit ....................................................................................................... 20-466
(g) Contact in 4th circuit (always stays in 4th) ......................................................................... 20-468
(h) Problem in FORWARD circuit (REVERSE is normal) ........................................................ 20-470
(i) Problem in REVERSE circuit (FORWARD is normal) ........................................................ 20-472
(j) Problem in common circuit for FORWARD and REVERSE
(does not travel forward, parking brake is normal) ............................................................. 20-474
(k) Contact in FORWARD circuit .............................................................................................. 20-476
(l) Contact in REVERSE circuit ............................................................................................... 20-478
(m) Problem in common circuit for FORWARD and REVERSE ............................................... 20-480
E- 9 Kick-down switch does not work ................................................................................................ 20-482
E-10 Kick-down works only when kick-down switch is ON ................................................................ 20-484
E-11 Kick-down operation cannot be canceled .................................................................................. 20-484
(a) Not canceled even when directional lever is moved from F to N or R ............................... 20-484
(b) Not canceled even when speed lever is moved from 2nd to other position
(becomes 4th) ............................................................................................................................ 20-486
E-12 Kick-down switch is actuated by mistake when traveling in 2nd ............................................... 20-488
20-451
TROUBLESHOOTING E-1
E-1 Engine does not start

« When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out
checks, always turn the starting switch OFF before starting.
« When connecting the T-adapter (or socket adapter), connect to the connector specified as CN¡∆( ).
« After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return
to the original condition before going on to the next check.
(a) Starting motor does not turn
YES
YES
3
5
Is voltage between
YES starting motor Is voltage between
YES both battery relay
terminal (E) and
chassis 20 - 30 V? terminals and
chassis 20 - 30 V?
1) Turn starting
1) Turn starting
switch ON 4 NO
switch ON
Is actuating sound
2) Check voltage
heard from battery
NO relay ? between chassis
and both YES
terminals
2 1) Turn starting connected by
Is there continuity switch thick cable 6
YES between starting ON OFF Is voltage 20 - 30V
motor terminal (E) between both
and chassis? connection terminals of
NO CNR12 and CNR13 of
B battery relay?
1) Turn starting
switch OFF 1) Turn starting
1 switch ON
NO
Is voltage between
CNE13 (female)
(1) and chassis
20 - 30 V ?
1) Disconnect
CNE13
NO
2) Directional
lever: Neutral
Go to A on next page
3) Turn starting NO
switch to
START
20-452
TROUBLESHOOTING E-1
Cause Remedy
Defective starting motor

assembly Replace
disconnection in cable After inspection,
between battery relay and repair or replace
starting motor
• If answer is NO for both

terminals: Defective
contact or disconnection After inspection,
in wiring harness repair or replace
between battery and
battery relay
• If answer is NO for one
terminal: Defective Replace
battery relay
Defective battery relay Replace
harness between starting
switch terminal BR-CNL09
YES (2) - CNLR4 (9) - CNR03 After inspection,
7 (diode) - CNR12 (female) repair or replace
Is voltage between or defective contact, or
starting switch disconnection in wiring
terminal BR and harness between CNR13
chassis 20 - 30 V ? and chassis ground
Defective starting switch Replace

1) Turn starting NO
switch ON.
After inspection,
disconnection in starting
repair or replace
motor ground cable
20-453
TROUBLESHOOTING E-1
YES
YES
3
Is voltage between
YES CNL57 (female)
(5) and chassis 5 YES
1
20 - 30 V? YES Is voltage between
Does starting 4 starting switch
motor turn when 1) Disconnect terminal C and
A Is voltage between
CNL57 chassis 20 - 30 V?
relay is replaced? starting switch
NO terminal B and 1) Turn starting NO
1) Replace neutral 2) Turn starting chassis 20 - 30 V? switch to
relay (CNL57) switch to START START
with stop lamp 1) Turn starting
relay (CNL53) switch OFF
NO
2) Directional lever:
Neutral
3) Turn starting 2
switch to START Is voltage between
CNL57 (female) 8 YES
NO (1) and (2) Is voltage between
20 - 30 V ?
YES CNL04 (3) and
chassis 20 ? 30 V?
1) Disconnect
CNL57
NO
1) Connect T-
2) Directional lever: 7 adapter to
Neutral
Is voltage between CNL04
YES CNL04 (female) 2) Directional lever:
3) Turn starting
(1) and chassis Neutral
switch to START
20 - 30 V? 3) Turn starting
switch ON
1) Disconnect
CNL04 9 YES
6
2) Turn starting Is actuating sound
Is there continuity heard from battery
between CNL57 switch ON NO relay?
Go to B on
NO (female) (2) and
chassis? previous
1) Turn starting NO page
1) Turn starting switch ON OFF
switch OFF
2) Disconnect
CNL57
NO
20-454
TROUBLESHOOTING E-1
Cause Remedy
Defective neutral relay Replace
(female) (3) - CNLR4 (8) - repair or replace
CNR01, 02 (diode) - CNER1
(10) - CNE13 (female) (1)
harness between starting After inspection,
switch terminal C - CNL09 repair or replace
(3) - CNL57 (female) (5)
Defective starting switch Replace
harness between starting
switch terminal B - CNL09 After inspection,
(1) - CNFS3 (4) - fuse - repair or replace
CNFS3 (6) - CNLR5 (1) -
CNR17 - slow blow fuse
30A - battery relay
(female) (3) and CNL57 repair or replace
(female) (1)
Defective directional lever

Replace
switch
harness between battery
relay - slow blow fuse 80A -
repair or replace
CNR15 - CNLR6 (1) -
10
CNFS1 (2) - fuse - CNFS2
Is voltage between (8) - CML04 (female) (1)
both battery relay
terminals and • If answer is NO for both
chassis 20 - 30 V? terminals: Defective contact
or disconnection in wiring
1) Turn starting harness between battery After inspection,
switch ON and battery relay repair or replace
2) Check valtage NO
• If answer is NO for one
between chassis terminal: Defective battery
and both relay
terminals
connected by Defective contact, or
thick cable. disconnection in wiring
After inspection,
repair or replace
(female) and chassis ground
ground
20-455
TROUBLESHOOTING E-1
(b) Starting motor turns
YES
YES
3 YES
1
YES Is voltage between
CNE03 (7) and
Does engine stop
chassis 20 - 30 V ?
motor work ?
1) Connect T-
1) Turn starting adapter to 4
CNE03 YES
switch ON
OFF and check Does engine stop
2) Turn starting
visually. switch ON motor work when
NO relay is replaced ? 6
Is there continuity
1) Replace engine YES between CNL62
2 stop relay (female) (2) and
(CNL62) with
Is voltage between Stop lamp relay chassis?
CNE03 (female) (CNL53) 5 1) Turn starting
NO (4) and chassis 2) Turn starting Is voltage between switch OFF
20 - 30 V ? switch ON CNL62 (female)
OFF and check 2) Disconnect
1) Turn starting visually NO (1) and chassis CNL62 NO
switch OFF 20 - 30V ?
2) Disconnect 1) Disconnect
CNE03 CNL62
2) Turn starting
switch ON NO
NO
20-456
TROUBLESHOOTING E-1
Cause Remedy
Defective adjustment of wire

between engine stop motor Adjust
and lever
Defective engine stop motor,

or defective contact, or
harness between CNE03 repair or replace
(female) (8) - CNER2 (5) -
chassis ground
Defective engine stop relay Replace
YES
Defective engine stop motor Replace
7
Is there continuity
between CNE03 Defective contact, or
(female) (5) and disconnection in wiring
(7) ? harness between CNE03
(female) (5) - CNER2 (3) -
1) Disconnect CNLR3 (5) - CNL62 (female) After inspection,
CNE03 NO (5), or between CNE03 repair or replace
(female) (7) - CNER2 (4) -
2) Turn starting CNLR3 (6) - CNL62 (female)
switch ON (3)
(female) (2) and chassis repair or replace
ground
(female) (2)
Blown fuse, or defective

contact, or disconnection in
wiring harness between After inspection,
CNF2 (female) (11) - CNLR repair or replace
(3) - CNER2 (1) - CNE03
(female) (4)
20-457
TROUBLESHOOTING E-2, E3
E-2 Engine does not stop
Cause Remedy
Defective adjustment
YES
and stop lever
1
YES
Does engine stop Defective engine stop motor Replace
motor work?
2 disconnection in wiring
1) Turn starting harness between CNE03
Is voltage between
switch ON (female) (3) - CNER2 (2) -
CNE03 (7) and (8)
OFF and check CNLR3 (4) - CNL62
visually NO 20 - 30 V ? YES After inspection,
(female), or between
CNL62 (female) (3) - repair or replace
1) Connect 3 CNLR3 (6) - CNER2 (4) -
T-adapter to CNE03 (female) (7)
CNE03 (engine Is voltage between
or defective relay
stop motor CNE03 (3) and (8)
(CNL62)
connector) NO 20 - 30 V ?
pin) 4 YES Defective engine stop motor Replace
1) Connect Is voltage between
2) Turn starting T-adapter to
switch OFF CNE03 (4) and (8) Defective contact, or
CNE03
NO 20 - 30 V ? disconnection in wiring
harness between CNE03
(female) (4) - CNER2 (2) -
switch OFF 1) Connect NO CNLR3 (3) - CNFS2 repair or replace
T-adapter to
(female) 11, or blown fuse
CNE03
E-3 Engine stops when machine is traveling
« Check if the starting motor turns. If it does not turn, check

E-1(a) (Engine does not start).
Defective adjustment
YES
1 and stop lever
Does engine stop YES

motor work ? Defective engine stop motor Replace
2
Does voltage between
1) Turn starting CNE03 (7) and (8)
switch ON NO switch between 0V and 3 YES
OFF and check 20 - 30 V ? Defective engine stop relay Replace
Is voltage between
visually
CNL62 (female) (2) Defective contact, or
1) Connect
T-adapter to NO and (female) (1) 20 disconnection in wiring
- 30 V ? harness between starting After inspection,
CNE03
NO switch terminal BR - CNL09 repair or replace
1) Disconnect
2) Turn starting (2) - CNL62 (female) (1)
CNL62 (engine
switch ON stop relay)
OFF
2) Turn starting
switch ON
20-458
TROUBLESHOOTING E-8
E-8 Transmission does not work normally

(WA320-3H manual gear shift)
« When carrying out troubleshooting of the transmission system, stop the machine on flat ground.
Cause Remedy
If condition is as shown in
Table 2 - 1 (transmission is
always in 2nd) Problem in common circuit
Go to E-8(a)
for transmission
Table 1 or Table 2 - 2
Problem in H-L circuit Go to E-8(b)
2 Table 1 or Table 2 - 3
Problem in speed circuit Go to E-8(c)
Travels in both Check voltage If condition is as shown in Table
FORWARD and between CNT03 (1) 2 - 4 or Table 2 - 5 or Table 2 -
REVERSE. (female) and chassis 6 (does not enter 4th)
and between CNT04 Problem in 4th circuit Go to E-8(d)
(1) (female) and
chassis. If condition is as shown in
Table 2 - 7
1) Disconnect Contact in H - L circuit Go to E-8(e)
CNT03 and
CNT04 If condition is as shown in
2) Turn parking Table 2 - 8
switch ON Contact in speed circuit Go to E-8(f)
3) Turn parking If condition is as shown in
1 switch ON Table 2 - 9 (transmission is
OFF always in 4th)
Does machine 4) Operate speed Contact in 4th circuit Go to E-8(g)
?
travel forward and lever with
directional lever If condition is as shown in
in reverse? at FORWARD, Table 3 or Table 4 - 1
NEUTRAL, and (REVERSE is normal) Problem in FORWARD
REVERSE to circuit Go to E-8(h)
1) Start engine
check condition If condition is as shown in
2) Turn parking Table 3 or Table 4 - 2
switch ON Travels in only (FORWARD is normal) Problem in REVERSE
OFF circuit Go to E-8(i)
FORWARD or
REVERSE, or 3 If condition is as shown in
3) Operate directional does not travel Table 4 - 3 (does not travel in Problem in common circuit
lever FORWARD Check voltage either direction)
REVERSE in either between CNT01 (1) for FORWARD and Go to E-8(j)
direction. (female) and chassis REVERSE
and between CNT02 Table 4 - 4 (REVERSE is
(1) (female) and normal) Contact in FORWARD
chassis. circuit Go to E-8(k)
1) Disconnect Table 4 - 5 (FORWARD is
CNT01 and normal) Contact in REVERSE circuit
CNT02 Go to E-8(l)
2) Turn parking If condition is as shown in
switch ON Table 4 - 6 (does not travel in
3) Turn parking either direction) Problem in common circuit
switch ON for FORWARD and Go to E-8(m)
OFF REVERSE
4) Operate directional lever with speed lever
in all positions (1st to 4th) to check condition
Go to applicable item.
20-459
TROUBLESHOOTING E-8

¡: 0 0.5 V
l: 20 30 V
(H L) (Speed)
Between Between Between Between Between Between Between Between
CNT03 CNT04 CNT03 CNT04 CNT03 CNT04 CNT03 CNT04
Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1)
mission chassis chassis mission chassis chassis mission chassis chassis mission chassis chassis
range ground ground range ground ground range ground ground range ground ground
1 ¡ l 1 ¡ ¡ 1 ¡ l 1 ¡ ¡
2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡
3 l ¡ 3 ¡ ¡ 3 ¡ ¡ 3 l ¡
4 l l 4 ¡ ¡ 4 ¡ l 4 l ¡
Table 1 (normal) Table 2-1 (abnormal) Table 2-2 (abnormal) Table 2-3 (abnormal)
Between Between Between Between Between Between

CNT03 CNT04 CNT03 CNT04 CNT03 CNT04
Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1)
mission chassis chassis mission chassis chassis mission chassis chassis
range ground ground range ground ground range ground ground
1 ¡ l 1 ¡ l 1 ¡ l
2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡
3 l ¡ 3 l ¡ 3 l ¡
4 ¡ ¡ 4 l ¡ 4 ¡ l
Table 2-4 (abnormal) Table 2-5 (abnormal) Table 2-6 (abnormal)

Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1)
mission chassis chassis mission chassis chassis mission chassis chassis
range ground ground range ground ground range ground ground
1 l l 1 ¡ l 1 l l
2 l ¡ 2 ¡ l 2 l l
3 l ¡ 3 l l 3 l l
4 l l 4 l l 4 l l
(F) (R)
Between Between Between Between Between Between Between Between
CNT01 CNT02 CNT01 CNT02 CNT01 CNT02 CNT01 CNT02
Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1)
tional chassis chassis tional chassis chassis tional chassis chassis tional chassis chassis
lever ground ground lever ground ground lever ground ground lever ground ground
FORWARD l ¡ FORWARD ¡ ¡ FORWARD l ¡ FORWARD ¡ ¡

REVERSE ¡ l REVERSE ¡ l REVERSE ¡ ¡ REVERSE ¡ ¡
Table 3 (normal) Table 4-1 (abnormal) Table 4-2 (abnormal) Table 4-3 (abnormal)

Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1)
tional chassis chassis tional chassis chassis tional chassis chassis
lever ground ground lever ground ground lever ground ground
FORWARD l l FORWARD l ¡ FORWARD l l

REVERSE ¡ l REVERSE l l REVERSE l l
20-460
TROUBLESHOOTING E-8

(a) Problem in common circuit for transmission (always stays in 2nd)
Cause Remedy
Problem in H-L circuit and

1 YES
speed circuit –
Is voltage between • Go to E-8 (b), E-8 (c)
CNL04 (5)(6)(7)(8)
and chassis as
shown in table?
Defective speed lever switch Replace
1) Connect NO
T-adapter to
CNL04
2) Turn starting switch ON

3) Shift speed lever and check
l: 20 30 V
¡: 0 0.5 V
Transmission
Between Between Between Between
range CN04(5) chassis CN04(6) chassis CN04(7) chassis CN04(8) chassis
1 l ¡ ¡ ¡
2 ¡ l ¡ ¡
3 ¡ ¡ l ¡
4 ¡ ¡ ¡ l
(b) Problem in H-L circuit
Cause Remedy
YES
Defective H - L solenoid Replace
2
Is voltage between
YES CNT03 (female) Defective contact, or
(1) and chassis 3 YES After inspection,
20 - 30 V ? repair or replace
Is voltage between (female) (7) - CNTL1 (5) -
1 1) Disconnect CNL04 (7) and CNT03 (female) (1)
CNT03 NO chassis 20 - 30V?
Is there continuity
between CNT03 2) Turn starting Defective speed lever switch Replace
(female) (2) and switch OFF 1) Connect NO
T-adapter to
chassis ? CNL04
2) Turn starting
1) Disconnect switch ON
CNT03 3) Speed lever: 3rd Defective contact, or
2) Turn starting disconnection in wiring
harness between CNT03 After inspection,
switch OFF
NO (female) (2) and chassis repair
ground
20-461
TROUBLESHOOTING E-8

(c) Problem in speed circuit
Cause Remedy
YES
Defective speed solenoid Replace
2
Is voltage between
YES CNT04 (female) Defective contact, or
(1) and chassis 3 YES disconnection in wiring
After inspection,
20 - 30 V ? harness between CNL04
repair or replace
1 Is voltage between (female) (5) - CNTL1 (6) -
Is there continuity 1) Disconnect CNL04 (5) and CNT04 (female) (1)
CNT04 NO chassis 20 - 30 V?
between CNT04
(female) (2) 2) Turn starting Defective speed lever switch Replace
chassis ? switch ON 1) Connect NO
T-adapter to CNL04
1) Disconnect 3) Speed lever: 1st 2) Turn starting switch ON Defective contact, or
CNT04 3) Speed lever: 1st disconnection in wiring
After inspection,
harness between CNT04
2) Turn starting NO repair or replace
switch OFF (female) (2) and chassis
ground
(d) Problem in 4th circuit (does not enter 4th)
1 YES
After inspection,
(female) (8) - CN37 -
repair or replace
Is voltage between CNTL1 (male) (6) or CNL04
CNL04 (8) and (female) (8) - CN38 -
chassis ground 20 CNTL1 (male) (5)
- 30V?
1) Connect Defective speed lever switch Replace
NO
T-adapter
to CNL04
2) Turn starting
switch ON
3) Speed lever: 4th
20-462
20-463
TROUBLESHOOTING E-8

(e) Contact in H-L circuit
YES
1
Is voltage between
CNT03 (female) YES
(1) and chassis
20 - 30 V ?
1) Disconnect
CNT03
2) Disconnect 2
CNTL1
Is there continuity
3) Turn starting between CNTL1 YES
switch ON NO (female) (5) and
(3)(4)(6)?
1) Turn starting
switch OFF
2) Disconnect 3
CNT03 Is voltage between
CNTL1 (male) (5) YES
3) Disconnect
CNTL1 NO and chassis 20 -
30 V ?
1) Disconnect
CNTL1
2) Disconnect
4
CNL04 Is there continuity
between CNTL1
3) Turn starting
switch ON NO (male) (5) and
(3)(4)(6)?
1) Turn starting YES

switch OFF
2) Disconnect 5
CNTL1 Is there continuity
3) Disconnect between CNL04
CNL04 NO (female) (7) and
(1)(2)(3)(4)(6)?
1) Turn starting
switch OFF
NO
2) Disconnect
CNTL1
3) Disconnect
CNL04
4) Disconnect
CNL66
20-464
TROUBLESHOOTING E-8
(WA320-3H manual gear shift) Cause Remedy
Abnormal contact of wiring

After inspection,
(female) (1) and CNTL1
repair or replace
(female) (5) with +24 V
wiring harness

harness between CNTL1
(female) (5) and CNT03
(female) (1) with wiring harn.
between CNTL1 (female) (3) After inspection,
- CNT01 (female) (1), CNTL1 repair or replace
(female) (4) - CNT02 (female)
(1),
CNTL1 (female) (6) - CNT04
(female) (1)

harness between CNTL1 After inspection,
(male) (5) and CNL04 (male) repair or replace
(7) with +24 V wiring harness

(male) (5) and CNL04
between CNTL1 (male) (3) - After inspection,
CNL66 (female) (2), CNTL1 repair or replace
(male) (6) - CNL04
(female) (5)

(male) (5) with wiring
(male) (1) - CNFS2 (female)
(8) or CNL04 (female) (2) After inspection,
CNL66 (female) (5) or repair or replace
CNL04 (female) (3) - CNL57
(female) (1) or CNL04
(female) (4) - CNL67 (female)
(5) or CNL04 (female) (6) -
CNL66 (3)
Defective transmission
control switch Replace
20-465
TROUBLESHOOTING E-8

(f) Contact in speed circuit
YES
1
Is voltage between
CNT04 (female) YES
(1) and chassis
20 - 30 V ?
1) Disconnect
CNT04
2) Disconnect 2
CNTL1
Is there continuity
switch ON NO (female) (6) and
(3)(4)(5)?
1) Turn starting
switch OFF
2) Disconnect 3
CNT04 Is voltage between
CNTL1 (male) (6) YES
3) Disconnect
CNTL1 NO and chassis 20 -
30 V ?
1) Disconnect
CNTL1
2) Disconnect
4
between CNTL1
3) Disconnect
CNL04 NO (male) (6) and
(3)(4)(5)?
4) Turn starting
switch ON 1) Turn starting YES
switch OFF
2) Disconnect 5
CNTL1 Is there continuity
(1)(2)(3)(4)(6)?
4) Disconnect
CNL04
1) Turn starting
switch OFF
NO
2) Disconnect
CNTL1
3) Disconnect
CNL68
4) Disconnect
CNL04
5) Disconnect
CNL66
20-466
TROUBLESHOOTING E-8
(WA320-3H manual gear shift) Cause Remedy

After inspection,
repair or replace
(female) (6) with +24 V
wiring harness

(female) (4) - CNT02 (female)
(1),
(female) (1)
(male) (6) and CNL04 repair or replace
(female) (5), CNL68 (female)
(4) with +24 V wiring harness

(male) (6) and CNL04 After inspection,
(female) (5) with wiring harn. repair or replace
between CNTL1 (male) (3) -
CNL66 (female) (2), CNTL1
(male) (4) - CNL04
(female) (7)

(male) (6) with wiring
(female) (1) - CNFS2 (female)
(8) or CNL04 (female) (2) After inspection,
CNL66 (female) (5) or repair or replace
(5) or CNL04 (female) (6) -
CNL66 (3)
After inspection,
control switch, or abnormal
repair or replace
contact of CNL68 (3) (4)
(male)
20-467
TROUBLESHOOTING E-8

(g) Contact in 4th circuit (always stays in 4th)
Cause Remedy
Abnormal contact of CNL04

1 YES (female) (8) - CN37 (female)
After inspection,
(2), CN38 (female) (2) with
+24 V wiring harness
CNL04 (female)
(8) and chassis
20 - 30 V ?
Defective speed lever switch Replace
NO
1) Disconnect
CNL04
2) Turn starting
switch ON
20-468
20-469
TROUBLESHOOTING E-8

(h) Problem in FORWARD circuit (REVERSE is normal)
2 YES
Is there continuity
YES between CNT01
(female) (2) and
chassis ?
1) Disconnect NO
CNT01
2) Turn starting
1 switch OFF YES
Is voltage between
CNT01 (female)
(1) and chassis
20 - 30V? 7 YES
1) Disconnect Is voltage between
CNT01 YES CNL66 (female) (5)
and chassis 20 -
2) Turn starting 3
switch ON 6 30V?
Is problem Is there continuity 1) Disconnect NO
3) Turn parking
switch ON removed when YES between CNL66 CNL66
OFF NO relay is replaced ? (female) (6) 2) Turn starting
switch ON
chassis? 3) Directional lever:
4) Dirctional 5
lever: 1) Replace FORWARD
FORWARD Is there continuity 1) Disconnect
FORWARD CNL66
solenoid relay YES between CNL66
(CNL66) with NO
REVERSE (female) (2) and 2) Turn starting
solenoid relay chassis? switch OFF
(CNL67) 4
1) Disconnect
2) Start engine Is voltage between CNL66
CNL66 (female)
3) Turn parking 2) Turn starting NO
switch ON NO (1) and chassis switch OFF
OFF 20 - 30V?
4) Dirctional 1) Disconnect
lever: FORWARD CNL66
2) Turn starting
switch ON NO
3) Turn parking
switch ON
OFF
20-470
TROUBLESHOOTING E-8
Cause Remedy
harness between CNT01 repair or replace
Defective FORWARD
solenoid Replace
Defective FORWARD relay Replace
After inspection,
repair or replace
(female) (5)

Replace
switch
After inspection,
repair or replace
(female) (2) - CNTL1 (3) -
CNT01 (female) (1)
After inspection,
repair or replace
(female) (1)
20-471
TROUBLESHOOTING E-8

(i) Problem in REVERSE circuit (FORWARD is normal)
2 YES
Is there continuity
YES between CNT02
(female) (2) and
chassis ?
1) Disconnect NO
CNT02
2) Turn starting
1 switch OFF YES
Is voltage between
CNT02 (female)
(1) and chassis
20 - 30V? 7 YES
1) Disconnect Is voltage between
CNT02 YES CNL67 (female) (5)
and chassis 20 -
2) Turn starting 3
switch ON 6 30V?
Is problem Is there continuity 1) Disconnect NO
3) Turn parking
switch ON removed when YES between CNL67 CNL67
OFF NO relay is replaced ? (female) (6) 2) Turn starting
switch ON
chassis? 3) Directional lever:
4) Dirctional 5
lever: 1) Replace REVERSE
REVERSE Is there continuity 1) Disconnect
REVERSE CNL67
solenoid relay YES between CNL67
(CNL67) with NO
FORWARD (female) (2) and 2) Turn starting
solenoid relay chassis? switch OFF
(CNL66) 4
1) Disconnect
2) Start engine Is voltage between CNL67
CNL67 (female)
3) Turn parking 2) Turn starting NO
switch ON NO (1) and chassis switch OFF
OFF 20 - 30V?
4) Dirctional 1) Disconnect
lever: REVERSE CNL67
2) Turn starting
switch ON NO
3) Turn parking
switch ON
OFF
20-472
TROUBLESHOOTING E-8
Cause Remedy
harness between CNT02 repair or replace
Defective REVERSE
solenoid Replace
Defective REVERSE relay Replace
After inspection,
repair or replace
(female) (5)

Replace
switch
After inspection,
repair or replace
(female) (2) - CNTL1 (4) -
CNT02 (female) (1)
After inspection,
repair or replace
(female) (1)
20-473
TROUBLESHOOTING E-8

(j) Problem in common circuit for FORWARD and REVERSE
(does not travel forward, parking brake is normal)
YES
2
Is voltage between
YES CNL04 (2), (4) -
chassis as shown in 3 YES
table? Is voltage between
CNL04 (female)
1) Connect
T-adapter to NO (1) and chassis
CNL04 20 - 30 V ?
2) Turn starting 1) Disconnect NO
1 switch ON CNL04
Is voltage between 3) Directional lever: 2) Turn starting

CNL66 (female) F N R switch ON YES
5
(1) and chassis Is problem removed
20 - 30 V? YES when short connector is
connected instead of
1) Disconnect transmission cut-off
CNL66 switch?
2) Turn starting 1) Connect short NO
switch ON connector to
4 CNL12 (female)
3) Turn parking
brake switch Is problem removed 2) Start engine YES
ON OFF
when transmission
3) Turn transmission
NO cut-off switch is cut-off selector
turned OFF? switch ON
1) Start engine
YES
6 9
Is voltage between
Is problem YES CNL58 (female)
removed when (3) and chassis
NO relay is replaced?
8 20 - 30 V?
1) Replace Is there continuity 1) Disconnect

neutralizer relay YES between CNL58 CNL58
NO
(CNL58) with (female) (2) and
stop lamp relay 2) Turn starting
(CNL53) chassis? switch ON
7
2) Start engine Is voltage between 1) Disconnect
CNL58 (female) CNL58
NO (1) and chassis NO
2) Turn starting
20 - 30 V? switch OFF
1) Disconnect
CNL58
2) Turn starting NO
switch ON
3) Turn parking
brake switch
ON OFF
l: 20 30 V
¡: 0 0.5 V
Divectional
Between Between
lever CN04(2) chassis CN04(4) chassis
F l ¡
N ¡ ¡
R ¡ l
20-474
TROUBLESHOOTING E-8
Cause Remedy
Go to E-8 (h) and (i) –

switch Replace
harness between CNFS2 After inspection,
(female) (1)
Defective transmission cut-

off switch Replace
After inspection,
repair or replace
(female) (1), or between
CNL65 (female) (5)
Defective neutralizer relay Replace
(female) (5) and CNL12 After inspection,
(female) (1), or between repair or replace
CNL12 (female) (2) -
CNL66 (female) (1), CNL67
(female) (1)
(female) (3) - CNFS2 (8) - repair or replace
fuse - CNFS1 (male) (2)
(female) (2)
20-475
TROUBLESHOOTING E-8

(k) Contact in FORWARD circuit
YES
1 YES
Is problem
removed when
relay is replaced?
1) Replace
FORWARD relay 2
(CNL66) with F
working lamp Is voltage between
relay (CNL60) CNT01 (female) YES
NO (1) and chassis
2) Start engine 20 - 30 V ?
3) Turn parking 1) Disconnect
brake switch ON CNT01
OFF
2) Disconnect 3
4) Directional lever: CNTL1
FORWARD Is there continuity
switch ON
NO (female) (3) and
(4)(5)(6)?
1) Turn starting
switch OFF
2) Disconnect 4
CNT01
Is voltage between YES
3) Disconnect CNTL1 (male) (3)
CNTL1
NO and chassis
20 - 30 V?
1) Disconnect
CNTL1
2) Disconnect
CNL66 5
Is there continuity
3) Turn starting
switch ON between CNTL1
NO (male) (3) and
(4)(5)(6)?

switch OFF
2) Disconnect
CNTL1 6
3) Disconnect Is there continuity
CNL66 between CNL04
NO (female) (2) and (1)
(3)(4)(5)(6)(7)(8)?
1) Turn starting
switch OFF
2) Disconnect NO
CNL66
3) Disconnect
CNL04
20-476
TROUBLESHOOTING E-8

Cause Remedy
Defective FORWARD relay Replace

After inspection,
repair or replace
(female) (3) with +24V
wiring harness

(female) (5) - CNT03
(female) (1),
(female) (5)

After inspection,
repair or replace
wiring harness

(female) (2) with wiring
(male) (4) - CNL67 (female) repair or replace
(2),CNTL1 (male) (6) -
CNL04 (female) (5)

between CNL04 (female) (1) -
CNFS2 (female) (8), CNL04
(female) (3) - CNL57
(female) (1), After inspection,
repair or replace
(5) - CNTL1 (male) (6),
(7) - CNTL1 (male) (5),
CNL04 (female) (6) - CN37
(2) or CN38 (2)
Replace
control switch
20-477
TROUBLESHOOTING E-8

(l) Contact in REVERSE circuit
YES
1 YES
Is problem
removed when
relay is replaced?
1) Replace
REVERSE relay 2
(CNL67) with F
working lamp Is voltage between
relay (CNL60) CNT02 (female) YES
NO (1) and chassis
2) Start engine 20 - 30 V ?
3) Turn parking 1) Disconnect
brake switch ON CNT02
OFF
2) Disconnect 3
4) Directional lever: CNTL1
REVERSE Is there continuity
switch ON
NO (female) (4) and
(3)(5)(6)?
1) Turn starting
switch OFF
2) Disconnect 4
CNT02
Is voltage between YES
3) Disconnect CNTL1 (male) (4)
CNTL1
NO and chassis
20 - 30 V?
1) Disconnect
CNTL1
2) Disconnect
CNL67 5
Is there continuity
3) Turn starting
switch ON between CNTL1
NO (male) (4) and
(3)(5)(6)?

switch OFF
2) Disconnect
CNTL1 6
CNL67 between CNL04
NO (female) (4) and (1)
(2)(3)(5)(6)(7)(8)?
1) Turn starting
switch OFF
2) Disconnect NO
CNL67
3) Disconnect
CNL04
20-478
TROUBLESHOOTING E-8

Cause Remedy
Defective REVERSE relay Replace

After inspection,
repair or replace
wiring harness

(female) (5) - CNT03
(female) (1),
(female) (1)

After inspection,
repair or replace
wiring harness

(female) (2) with wiring
(male) (3) - CNL66 (female) repair or replace
(2),CNTL1 (male) (6) -
CNL04 (female) (5)

between CNL04 (female) (1) -
CNFS2 (female) (8), CNL04
(female) (1), After inspection,
repair or replace
(5) - CNTL1 (male) (6),
(7) - CNTL1 (male) (5),
CNL04 (female) (6) - CN37
(2) or CN38 (2)
Replace
control switch
20-479
TROUBLESHOOTING E-9

(m) Problem in common circuit for FORWARD and REVERSE
Cause Remedy
Contact of wiring harness

between CNT01 (female) (1)
YES and CNL66 (female) (2) with After inspection,
wiring harness between repair or replace
1 CNT02 (female) (1) and
CNL67 (female) (2)
Is there continuity
between CNT01 Contact of wiring harness
(female) (1) and between CNL04 (female) (2)
CNT02 (female) (1)? 2 YES and CNL66 (female) (5) with After inspection,
wiring harness between repair or replace
1) Turn starting Is there continuity
switch OFF between CNL04
CNL67 (female) (5)
NO (female) (2) and
2) Disconnect CNL04 (female) (4)?
CNT01 and Defective transmission
CNT02 NO control switch Replace
1) Turn starting
switch OFF
2) Disconnect
CNL04
20-480
20-481
TROUBLESHOOTING E-9
E-9 Kick-down switch does not work

(the regular F1 to F4 shifts normally)
YES
YES
2
Is problem
YES
removed when
relay is replaced?
1) Replace kick-
down realy
(CNL68) with
REVERSE
solenoid relay
(CNL67) 3 YES
2) Start engine
Is problem
removed when
NO relay is replaced? 6
Is there continuity
1) Replace YES between CNL15
FORWARD (female) 1)
1 soleniod realy CNL66 (female) (4)?
(CNL66) with
Is there continuity REVERSE 5
solenoid relay 1) Disconnect
between CNL15 CNL15 and
(CNL67) Is there continuity
YES between CNL68
(male) (2) ? 2) Start engine
(female) (5) 2) Turn starting
switch OFF NO
1) Disconnect CNL15 (female) (2)?
CNL15
4 1) Disconnect
2) Press kick-down CNL68 and
switch Is there continuity CNL15
3) Turn starting between CNL68
switch OFF 2) Turn starting
NO (female) (6) and switch OFF
NO
chassis ground?
1) Disconnect
CNL68
2) Turn starting
switch OFF NO
NO
20-482
TROUBLESHOOTING E-9
Cause Remedy
Defective kick-down relay Replace
Defective FORWARD
solenoid relay Replace
YES disconnection in wiring
After inspection,
repair or replace
Is voltage between
YES CNL68 (female) (female) (5)
(3) and chassis Defective contact, or
20 - 30V ? disconnection in wiring
7 After inspection,
1) Disconnect harness between CNL68
Is voltage between CNL68 (female) (3) and CNFS2
CNL66 (female) (female) (3)
2) Turn starting
(3) and chassis switch ON
20 - 30V ? Defective contact, or
1) Disconnect 9 YES After inspection,
CNL66 Is voltage between repair or replace
2) Speed lever: CNL04 (6) and (female) (6)
2nd NO chassis 20 - 30V?
3) Turn starting Defective speed lever switch Replace
switch ON 1) Connect NO
T-adapter to CNL04
2) Speed lever: 2nd Defective contact, or
3) Turn starting switch ON disconnection in wiring
(female) (4)
(female) (2)
After inspection,
repair or replace
ground
Defective kick-down switch Replace
20-483
TROUBLESHOOTING E-10, E-11
E-10 Kick-down works only when kick-down switch is ON (Kick-down

switch relay does not hold in position (self-holding function) )
Cause Remedy
1 YES
Defective kick-down relay Replace
Is problem Defective contact, or
removed when disconnection in wiring
relay is replaced? harness between CNL66
After inspection,
1) Replace kick- NO repair or replace
down relay
(CNL68) with (female) (2) - CNL68
REVERSE (female) (5)
solenoid relay
(CNL67)
2) Start engine
E-11 Kick-down operation cannot be canceled

(a) Not canceled even when directional lever is moved from F to N or R
Cause Remedy
1 YES Defective FORWARD Replace

solenoid relay
Is problem
removed when
relay is replaced? Contact of wiring harness
After inspection,
between CNL66 (female) (3)
1) Replace and (4)
FORWARD
solenoid relay
(CNL66) with
REVERSE
solenoid relay
(CNL67)
2) Start engine
20-484
20-485
TROUBLESHOOTING E-11

(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)
YES
1
Is there continuity YES
between CNL04
(female) (1) and
CNL04 (female) (6)?
2
1) Turn starting
switch OFF Is there continuity
between CNL04
YES
2) Disconnect
CNL04 (female) (6)?
3) Disconnect 3
CNL66 1) Turn starting
switch OFF Is voltage between
CNL66 (female) YES
2) Disconnect
CNL04 NO (3) and chassis
20 - 30 V ?
3) Disconnect
CNL66 1) Disconnect 4
CNL66 Is voltage between
2) Disconnect CNL66 (female)
CNL04 NO (4) and chassis YES
20 - 30 V?
3) Turn starting
switch ON 1) Disconnect 5
CNL66
Is voltage between
2) Disconnect CNL68 (female) YES
CNL68 NO (2) and chassis
3) Disconnect
20 - 30 V?
6
CNL15
1) Disconnect
4) Turn starting between CNL04
switch ON
2) Disconnect NO (female) (1) and
CNL15 CNL04 (female) (5)?
3) Turn starting
switch ON 1) Turn starting
switch OFF
2) Disconnect NO
CNL04
3) Disconnect
CNFT1
20-486

Cause Remedy

After inspection,
repair or replace
(female) (1) (6)

(female) (2) (6), or defective repair or replace
speed lever switch

and CNL66 (3) with +24V repair or replace
wiring harness

(female) (4) - CNL68 (female) After inspection,
(1) , CNL15 (female) (1) with repair or replace
+24 V wiring harness

(female) (2) - CNL68 (female) After inspection,
(5) - CNL15 (female) (2) with repair or replace
+24V wiring harness

(female) (1) (5) repair or replace

YES (4), CN37 (female) (1), After inspection,
7 CNTL1 (male) (6) with repair or replace
+24V wiring harness, or
Is voltage between
defective speed lever switch
CNL68 (female)
(4) and chassis
20 - 30V ? Abnormal contact of wiring
1) Disconnect harness between CNTL1 (6) After inspection,
CNL68. NO and CNT04 (1) with +24V repair or replace
2) Disconnect wiring harness
CNTL1.
3) Disconnect
CNL04.
4) Turn starting
switch ON
20-487
E-12 Kick-down switch is actuated by mistake when traveling in 2nd

« When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks,
always turn the starting switch OFF before starting.
Cause Remedy
YES
Defective kick-down switch Replace
1
Is there continuity
between CNL15 YES
(male) (1) and Defective kick-down relay Replace
CNL15 (male) (2) ? 2
CNL15 between CNL68 YES Contact of wiring harness
After inspection,
NO (male) (1) - (2) 3
repair or replace
2) Turn starting and (3) - (4) ? (2)
switch OFF
Is there continuity
3) Do not press
4 YES Contact of wiring harness
kick-down relay
kick-down (CNL68) NO (female) (1) and After inspection,
switch CNL15 (female) (2) ?
Is there continuity
repair or replace
2) Turn starting (2)
switch OFF 1) Disconnect between CNL68
CNL68 (female) (2) ? Contact of wiring harness
After inspection,
2) Turn starting between CNL68 (female) (3)
switch OFF NO (4) repair or replace
1) Disconnect
CNL68
3) Directional
lever: N 2) Turn starting
switch OFF
3) Directional
lever: N
20-488
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(A MODE)
OUTLINE .................................................................................................................................................. 20-502

1 Function ............................................................................................................................................... 20-502
2 When carrying out troubleshooting ..................................................................................................... 20-502
3 Failure code table ................................................................................................................................ 20-502
4 Table of troubleshooting modes and causes ....................................................................................... 20-503
A- 1 Troubleshooting code [10] Modulation valve solenoid system

(disconnection, short circuit) ...................................................................................................... 20-504
A- 2 Troubleshooting code [11] Short circuit in power source for
modulation valve solenoid system ............................................................................................... 20-505
A- 3 Troubleshooting code [12] F solenoid signal system ................................................................. 20-506
A- 4 Troubleshooting code [13] R solenoid signal system ................................................................. 20-506
A- 5 Troubleshooting code [14] Abnormality in H-L solenoid signal system ..................................... 20-507
A- 6 Troubleshooting code [16] Abnormality in speed solenoid signal system .................................. 20-508
A- 8 Troubleshooting code [20] Abnormality in directional lever signal system ................................ 20-510
A- 9 Troubleshooting code [21] Abnormality in speed lever signal system ....................................... 20-511
A-10 Troubleshooting code [22] Abnormality in travel speed signal system ...................................... 20-512
A-11 Troubleshooting code [23] Abnormality in engine speed signal ................................................ 20-513
A-12 Hold switch system ..................................................................................................................... 20-514
A-13 Kick-down switch system ........................................................................................................... 20-514
A-14 Kick-down output signal system ................................................................................................. 20-515
A-15 Transmission cut-off signal system ............................................................................................ 20-516
A-17 Buzzer signal system ................................................................................................................. 20-518
A-18 Network signal system ................................................................................................................ 20-519
A-19 Controller power source system ................................................................................................. 20-520
20-501
TROUBLESHOOTING OUTLINE
OUTLINE
1. Function
The control mechanism of the transmission con-
troller consists of the controller, sensors, input
switch, solenoid output, and buzzer output. The
controller receives the input signal, processes it,
and carries out the auto-shift control by control-
ling the solenoid to a transmission range that
matches the travel speed.
2. When carrying out troubleshooting

The controller has a troubleshooting function,
and when a failure is detected, the alarm buzzer
soands to warn the operator that there has been
a failure, and the display also shows the failure
code on the main monitor. However, failure
codes number A-12 to A-20 are no function to
display in the display area but are abnormality
in the control.
3. Failure code table
No. Failure code Failure No. Failure code Failure

Abnormality in modulation Abnormality in engine speed
A-1 10 A-11 23
solenoid signal system sensor signal system
Abnormality in modulation
A-2 11 A-12 Hold switch signal system
solenoid signal system
Abnormality in F solenoid Kick-down switch signal
A-3 12 A-13
signal system system
Abnormality in R solenoid Kick-down output signal
A-4 13 A-14
Abnormality in H-L solenoid Transmission cut-off signal
A-5 14 A-15
Abnormality in speed
A-6 16 A-16 Neutralizer signal system
solenoid signal system
A-17 Alarm buzzer signal system
Abnormality in directional
A-8 20 A-18 Network signal system
lever signal system
Abnormality in speed Abnormality in controller
A-9 21 A-19
lever signal system power source voltage
Abnormality in travel speed Abnormality in model
A10 22 A-20
sensor signal system selection wiring harness
20-502
TROUBLESHOOTING OUTLINE
4. Table of troubleshooting modes and causes
Cause of failure Related equipment
Engine speed sensor signal system

Travel speed sensor signal system
Controller power source voltage system

Model selection wiring harness system
Modulation valve solenoid system
Directional lever signal system
Transmission cut-off system
Alarm buzzer signal system

Speed lever signal system
Hold switch signal system
Neutralizer signal system

Kick-down signal system
Speed solenoid system
Network signal system

H-L solenoid system
R solenoid system
F solenoid system
Failure mode
Main monitor display failure code 12 13 14 16 10
11 20 21 22 23
Impossible to travel ¡¡ ¡¡ ¡¡ ¡
Auto-shift does not work ¡¡ ¡¡
Position of directional lever and
direction of travel do not match ¡
Machine travels forward when
directional lever is not at F position ¡
Machine travels in reverse when
directional lever is not at R position ¡
Transmission does not shift down in
accordance with travel speed ¡¡ ¡
Transmission does not shift up in
accordance with travel speed ¡¡
Transmission stays in same range as
speed lever regardless of travel speed ¡
There is excessive shock when shifting gear ¡ ¡ ¡
There is shift hunting when traveling ¡
There is shift hunting when shifting gear ¡ ¡
Transmission range cannot be
controlled with speed lever
¡
Shift cannot be held ¡

Transmission does not shift to 1st with ¡
kick-down switch
No power for scooping operations
when kick-down switch is ON
¡
Transmission is not cut off when left

brake is operated ¡
Machine can travel when parking brake

is applied ¡
Alarm buzzer does not sound when
travel direction is switched between ¡
forward and reverse when traveling at
high speed
Alarm buzzer does not stop ¡
Main monitor does not display
transmission controller information ¡
(alarm buzzer, failure code, etc.)
Model selection cannot be carried out ¡
20-503
TROUBLESHOOTING A-1
A-1 Troubleshooting code [10] Modulation valve solenoid system

(disconnection, short circuit)
« When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting
switch OFF.
Cause Remedy
2 YES
Defective controller Replace
Is insulation
YES between CNL29 Wiring harness between Repair wiring
3 YES CNL29 (female) (3), (14), harness, or
(female) (3) and
chassis normal ? CNTL2 (7), (8) - CNT12 replace
s insulation (19), (2) short circuiting
between CNT12 with chassis ground.
1) Disconnect
(male) (1) and
1 CNL29. NO chassis normal ?
2) Min. 1MΩ Defective modulation Replace
Is resistance 1) Disconnect NO solenoid valve
between CNL29 CNT12.
(female) (3) and (14) 4 YES 2) Min. 1MΩ Defective contact, Repair wiring
disconnection, or short harness, or
normal? Is resistance circuit in wiring harness replace
between CNT12 between CNL29 (female)
1) Disconnect (male) (1) and (2) (13), (14) - CNTL2 (7), (8)
NO
CNL29. normal? - CNT12 (1), (2)
2) 12 - 15 Ω
NO Defective modulation Replace
1) Disconnect
solenoid valve
CNT12.
2) 12 - 15 Ω
CNL 29 CNTL 2 CNTL 12 Modulation solenoid

Modulation solenoid (+)
Modulation solenoid (-) 14
20-504
TROUBLESHOOTING A-2
A-2 Troubleshooting code [11] Short circuit in power source for

modulation valve solenoid system
switch OFF.
Cause Remedy
3 YES
Is voltage between
2 YES CNT12 (male) (1) and
chassis normal?
Is voltage between Short circuit of solenoid Replace
YES
CNL29 (female) (14) power source
1) Disconnect NO
and chassis normal?
CNT12.
2) Max. 1V
1) Disconnect
3) Turn starting switch ON. Wiring harness between Repair wiring
CNL29 and
1 CNL29 (female) (14) - harness or
CNT12. CNTL2 (8) - CNT12 (2) - replace
Is voltage between NO
2) Max. 1V solenoid short circuiting
CNL29 (female) (3) and 3) Turn starting with power source
chassis normal? switch ON.
Wiring harness between Repair wiring

1) Disconnect CNL29 (female) (3) - harness or
CNL29 and NO
CNTL2 (7) - CNT12 (1) replace
CNT12. solenoid short circuiting
2) Max. 1V with power source
3) Turn starting switch ON.
CNL 29 CNTL 2 CNTL 12 Modulation solenoid

Modulation solenoid (+)
Modulation solenoid (-) 14
20-505
TROUBLESHOOTING A-3, A-4
A-3 Troubleshooting code [12] F solenoid signal system

switch OFF.
Cause Remedy
YES
· Defective contact, or
(female) (21) - CNTL1 (3)
Is resistance
- CNT01 (female) (1) or
between CNL29
short circuit with ground Repair wiring
(female) (21) and 2 YES
· Disconnection in wiring harness or
(19) normal? Is resistance harness between CNT01 replace
1) Disconnect between CNT01 (female) (2) and chassis
NO (male) (1) and (2)
CNL29 and
normal?
CNT1R Defective F solenoid Replace
(if equipped). 1) Disconnect NO
2) 46 - 58 Ω CNT01.
2) 46 - 58 Ω
A-4 Troubleshooting code [13] R solenoid signal system

Cause Remedy
YES
· Defective contact, or
Is resistance between (female) (20) - CNTL1 (4)
CNL29 (female) (20) - CNT02 (female) (1) or
Repair wiring
and (19) normal? 2 YES short circuit with ground
harness or
· Disconnection in wiring
Is resistance between replace
CNT02 (male) (1) and (female) (2) and chassis
1) Disconnect
NO (2) normal?
CNL29
(If equipped). Defective R solenoid Replace
2) 46 - 58 Ω 1) Disconnect CNT02. NO
2) 46 - 58 Ω
CNL 29
GND 19
R - solenoid CNTL 1 CNT02 R - solenoid
20
F - solenoid
21
CNT01 F - solenoid
CNTIR
F - solenoid
20-506
TROUBLESHOOTING A-5
A-5 Troubleshooting code [14] Abnormality in H-L solenoid signal

system
switch OFF.
Cause Remedy
YES
3 YES chassis ground and harness or
CNL29 (female) (10), replace
CNTL1 (male) (5),
Is resistance CNL05 (female) (13) short
YES between CNTL1 circuiting with chassis
(female) (5) and ground, or disconnection,
1 chassis normal ? defective contact
Repair wiring
· Wiring harness harness or
Is resistance NO between CNTL1 (female)
1) Disconnect replace
between CNL29 (5) and CNT03 (female)
(female) (10) and 2 CNTL1. (1) short circuiting with
(19) normal? 2) 46 - 58 Ω chassis ground, or
Is resistance disconnection, defective
between CNT03 contact
1) Disconnect · Disconnection in wiring
NO (male) (1) and (2)
CNL29, CNT1R harness between CNT03
(if equipped). normal? (female) (2) and chassis
2) 46 - 58 Ω 1) Disconnect
Defective H solenoid Replace
CNT03.
NO
2) 46 - 58 Ω
CNL29
GND
CNTL1 CNT03 H-L solenoid
H-L solenoid
Speed solenoid 11
GND 19 CNT04 Speed - solenoid
CNTIR
Speed solenoid
H-Lsolenoid
CNL05
12 Transmission range 1
20-507
TROUBLESHOOTING A-6
A-6 Troubleshooting code [16] Abnormality in speed solenoid signal

system
switch OFF.
Cause Remedy
YES
3 YES CNL29 (female) (11) - harness or
CNTL1 (female) (6), replace
Is resistance between CNL05 (female) (12) short
YES CNTL1 (female) (6) circuiting with chassis
ground, or disconnection,
and chassis normal ?
defective contact
1 Repair wiring
· Wiring harness harness or
Is resistance between NO between CNTL1 (female)
1) Disconnect replace
CNL29 (female) (11) (6) and CNT04 (female)
and (19) normal? 2 CNTL1.
2) 46 - 58 Ω chassis ground, or
disconnection, defective
CNT04 (male) (1) and contact
1) Disconnect
CNL29, CNT1R NO (2) normal? · Disconnection in wiring
(if equiped) harness between CNT04
and CNL05. (female) (2) and chassis
1) Disconnect
2) 46 - 58 Ω
CNT04. Defective speed solenoid Replace
NO
2) 46 - 58 Ω
CNL29
GND
CNTL1 CNT03 H-L solenoid
H-L solenoid
Speed solenoid 11
GND 19 CNT04 Speed - solenoid
CNTIR
Speed solenoid
H-Lsolenoid
CNL05
20-508
20-509
TROUBLESHOOTING A-8
A-8 Troubleshooting code [20] Abnormality in directional lever signal

system
« Check that there is no abnormality in the combination
switch for the directional and speed levers.
« Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
« Always connect any disconnected connectors before going
on the next step. Cause Remedy
« When disconnecting connectors to connect 3 YES
the T-adapter (or socket adapter), Is voltage between
always turn the starting · Wiring harness between
2 YES CNL30 (12) and (9) CNL30 (female) (12) -
switch OFF. normal? CNL04 (4) directional,
Is voltage between Repair wiring
YES CNL30 (1) and (9) speed lever switch short
harness or
normal? 1) Directional lever NO replace
ground or disconnection,
at R: 20 - 30 V defective contact
Other than R: 0 V · Wiring harness between
1) Directional lever 2) Turn starting CNL30 (female) (1) -
at F: 20 - 30 V CNL08 (female) (8) short
1 switch ON.
Other than F: 0 V circuiting with chassis
Is voltage between 2) Turn starting ground
CNL30 (11) and (9) switch ON.
normal?
· Wiring harness between
CNL30 (female) (1) - Repair wiring
1) Directional lever CNL04 (2) directional, harness or
at N: 20 - 30 V speed lever switch short replace
Other than N: 0 V circuiting with chassis
2) Turn starting ground or disconnection,
NO defective contact
switch ON.
CNL08 (female) (7) short
ground

Fuse 24 V CNL30 (female) (11) -
CNL04 (3) directional,
speed lever switch short Repair wiring
circuiting with chassis harness or
NO ground or disconnection,
replace
CNFS2 defective contact
Directional CNL05 (female) (8) short
CNL04 lever switch
ground
CNL30
Directional lever F
Speed lever 2 Main monitor
Speed lever 4
CNL08
Signal ground Transmission
Directional lever N 11 signal F input
Transmission
Directional lever R 12
signal R input
Speed lever 1 13
14
Speed lever 3 CNL05
Neutral
20-510
TROUBLESHOOTING A-9
A-9 Troubleshooting code [21] Abnormality in speed lever signal

system
Cause Remedy
YES
4
Is voltage
YES
between CNL30 Wiring harness between
(3) and (9) CNL30 (female) (3) -
Repair wiring
3 normal? CNL04 (8) - directional
harness or
speed lever switch short
Is voltage NO replace
YES between CNL30 circuiting with chassis
1) Speed lever
(14) and 4th: 20 - 30 V
defective contact
(9)normal? Other than 4th:
2
0V Wiring harness between
Is voltage 1) Speed lever 2) Turn starting
YES between CNL30 CNL30 (female) (14) - Repair wiring
3rd: 20 - 30 V swtich ON. CNL04 (7) - directional
(2) and (9) harness or
Other than 3rd: speed lever switch short replace
normal? 0V NO circuiting with chassis
2) Turn starting ground, or disconnection,
1) Speed lever
swtich ON. defective contact
2nd: 20 - 30 V
1
Other than 2nd:
Is voltage 0V
between CNL30 Wiring harness between
2) Turn starting CNL30 (female) (2) -
(13) and (9) swtich ON. Repair wiring
CNL04 (6) - directional harness or
normal?
speed lever switch short replace
1) Speed lever NO circuiting with chassis
1st: 20 - 30 V ground, or disconnection,
Other than 1st: defective contact
0V
2) Turn starting Wiring harness between
swtich ON. CNL30 (female) (13) -
CNL04 (5) - directional Repair wiring
speed lever switch short harness or
NO circuiting with chassis replace
Fuse 24 V ground, or disconnection,
defective contact
CNFS2
Directional
CNL04 lever switch
CNL30
Directional lever F
Speed lever 2 Main monitor
Speed lever 4
CNL08
Signal ground Transmission
Directional lever N 11 signal F input
Transmission
Directional lever R 12
signal R input
Speed lever 1 13
14
Speed lever 3 CNL05
Neutral
20-511
TROUBLESHOOTING A-10
A-10 Troubleshooting code [22] Abnormality in travel speed signal

system
switch OFF.
Cause Remedy
YES
YES Defective speed sensor Replace

1
Is resistance between Defective contact, or Repair wiring
CNL31 (female) (5) YES disconnection in wiring harness or
and (12) normal? 2 harness between CNL31 replace
(female) (4), (12) - CNTL2
Is resistance between (1), (2) - CNT06 (female)
CNT06 (male) (1) and (1), (2)
1) Disconnect CNL31
(2) normal? 3
2) 0.5 - 1 ΚΩ NO
Is insulation between
CNL31 (female) (4)
1) Disconnect CNT06 and (12) normal ? Wiring harness between Repair wiring
2) 0.5 - 1 ΚΩ NO CNL31 (female) (4), (12) harness or
- CNTL2 (1), (2) - CNT06 replace
NO (female) (1), (2) short
1) Disconnect CNL31
ciruiting with chassis
and CNT06
ground, short circuit
CNL31 Speed sensor

CNTL2 CNT06
Speed signal (+)
Engine speed siganl (+)
Speed signal (-) 12
To engine throttle controller

floor wiring harness
CNL07
14 Engine speed (+)
15 Engine speed (-)
Main monitor
CNL07
Speedometer (+)
Speedometer (-)
Tachometer (+)
20-512
A-11 Troubleshooting code [23] Abnormality in engine speed signal

« Check that there is no error message for the engine speed signal for the engine throttle controller.
switch OFF.
Cause Remedy
2 YES
Is continuity between
and (12) normal?
Defective contact, or Repair wiring
1 disconnection in wiring harness or
1) Disconnect CNL31, NO harness between CNL31 replace
Is insulation between
CNLGL and CNL07. (female) (5) and CNLGL
CNL31 (female) (5),
2) Short circuiting CNLGL (female) (14), (15). (female) (14)
(12) and chassis
normal?
1) Disconnect Wiring harness between Repair wiring

CNL31, CNLGL CNL31 (female) (5), (12) harness or
and CNL07. NO - CNL07 (female) (3), (2), replace
2) Min. 1 ΜΩ between CNL31 (female)
(5), (12) - CNLGL
(female) (14), (15) short
ground
CNL31 Speed sensor

CNTL2 CNT06
Speed signal (+)
Engine speed siganl (+)
Speed signal (-) 12

CNL07
14 Engine speed (+)
15 Engine speed (-)
Main monitor
CNL07
Speedometer (+)
Speedometer (-)
Tachometer (+)
20-513
TROUBLESHOOTING A-12, A-13
A-12 Hold switch system

switch OFF.
Cause Remedy
YES
1
Is continuity between Wiring harness between Repair wiring
CNL30 (female) (18) CNL30 (female) (18) and harness or
and chassis normal? 2 YES CNL15 (female) (3) short replace
CNL15 (male) (3) and
1) Disconnect defective contact.
NO (4) normal?
CNL30.
2) Hold switch Defective hold switch Replace
ON: Max. 1 Ω NO
OFF: Min. 1 ΜΩ
A-13 Kick-down switch system Cause Remedy

YES
1
Is continuity between Wiring harness between
CNL30 (female) (17) CNL30 (female) (17) and
and chassis normal? 2 YES CNL15 (female) (1) short Repair wiring
circuiting with chassis harness or
Is continuity between replace
CNL15 (male) (1) and
1) Disconnect defective contact
NO (2) normal?
CNL30.
2) Kick-down- switch Defective kick-down Replace
1) Disconnet NO switch
ON: Max. 1 Ω
CNL15.
OFF: Min. 1 ΜΩ
2) Kick-down switch
ON: Max. 1 Ω
OFF: Min. 1 ΜΩ
Kick-down switch Hold switch
CNL30 CNL15
17
Kick-down switch
Hold switch 18
20-514
A-14 Kick-down output signal system
« Check that the fuses of CNFS2 (10), CNFS5 (6) are not blown.
switch OFF.
Cause Remedy
2 YES Go to troubleshooting of
Is voltage between engine throttle controller
YES CNLGL2 (female) (2) Wiring harness between Repair wiring
and chassis normal? CNRES (female) (2) and harness or
CNLGL2 (female) (2) replace
short circuiting with
1) Disconnect CNLGL2 NO chassis ground, or
1 2) Starting switch ON: Max. 1 V disconnection, defective
3) Kick-down switch ON: 20 - 30 V contact.
Is voltage between
CNL31 (6) and
chassis normal? 3 YES
Is voltage between
1) Insert T-adapter CNL31 (female) (6)
NO Wiring harness between Repair wiring
and chassis normal?
2) Hold switch CNL31 (female) (6) and harness or
ON: Max. 1 Ω CNFS5 (female) (6) replace
3) Kick-down 1) Disconnect CNL31 NO short circuiting with
2) 20 - 30 V chassis ground, or
switch ON: disconnection, defective
10 - 15 V contact.
+ 25 V
CNFS5
CNRES
CNL31
Kick-down signal output
CNLGL2
Switch pump cut-off
Kick-down signal
20-515
A-15 Transmission cut-off signal system
switch OFF.
Cause Remedy
YES

CNL12 (female) (1) short
1 circuiting with chassis
Is continuity between ground, or disconnection,
CNL30 (male) (16) defective contact
and chassis normal? · Wiring harness between
CNL30 (female) (16) and Repair wiring
2 YES CNL06 (female) (3) short harness or
1) Disconnect circuiting with chassis replace
Is continuity between ground
CNL30. CNL12 (male) (1) and
2) Transmission (2) normal?
NO
cut-off switch
Defective transmission Replace
ON: Max. 1 Ω
NO cut-off switch
OFF: Min. 1 MΩ 1) Disconnect
CNL12.
2) Transmission
cut-off switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
CNL30
CNL12
Transmission cut-off switch 16
Transmission
cut-off switch
Main monitor
CNL06
3
Transmission cut-off
output
20-516
20-517
A-17 Buzzer signal system

« Check that the main monitor and alarm buzzer work properly.
switch OFF.
Cause Remedy
3 YES
and chassis normal ?
2 Short circuit between Repair wiring
CNL34 (female) and harness or
Is continuity between NO resistor, or replace
YES 1) Disconnect
CNL31 (female) (15) disconnection, defective
and chassis normal? CNL31 and CNL08.
contact
2) 4 - 7 ΚΩ
1 Defective contact, or Repair wiring
Is insulation CNL31 1) Disconnect disconnection in wiring harness or
(female) (15) and CNL31, CNL08 and NO harness between CNL31 replace
CNL34. (female) (15) and CNL08
chassis normal?
2) Short circuit CNL08 (female) (6)
(female) (6) - chassis
1) Disconnect 3) Max. 1 Ω
CNL31, CNL08 and
CNL34.
CNL31 (female) (15) - harness or
2) Min. 1 ΜΩ NO CNL08 (female) (6) - replace
CNL34 (male) (7) short
ground
+ 24 V
Main monitor
CNL42
CNL06
Caution buzzer
Buzzer output
CNL43
CNL31 CNL08
Buzzer signal output 15 Buzzer ON input
CNL34
Resistor
20-518
A-18 Network signal system

switch OFF.
Cause Remedy
4 YES
Is continuity
YES between CNL30
(female) (9), and
chassis Wiring harness between Repair wiring
3
normal ? harness or
Is insulation 1) Disconnect replace
NO CNL08 (female) (2), (4)
YES between CNL30 CNL30 and
(female) (9) and short circuiting with
CNL08.
chassis 2) Short circuit chassis ground
2 normal ? CNL08 (female)
(2), (4) with chassis
Is continuity 1) Disconnect ground.
YES between CNL29 CNL30 and 3) Max. 1 Ω
(female) (1), (12) CNL08.
and chassis CNL30 (female) (9) and harness or
normal ? 2) Min. 1 ΜΩ CNL08 (female) (2), (4) replace
NO short circuiting with
1) Disconnect
chassis ground
CNL29 and
1 CNL08.
Is insulation 2) Short circuit harness or
between CNL29
NO disconnection in wiring
CNL08 (female) replace
(female) (1), (12) harness between CNL29
(1), (12) -
and chassis (female) (1), (12) and
chassis.
normal ? CNL08 (female) (1), (3)
3) Max. 1 Ω
1) Disconnect Wiring harness between Repair wiring
CNL29 and CNL29 (female) (1), (12) harness or
CNL08. NO and CNL08 (female) (1), replace
2) Min. 1 ΜΩ (3) short circuiting with
chassis ground
Main monitor
CNL29 CNL08
Netzwork (+) Netzwork (+)
Netzwork (+) 12 Netzwork (-)

Netzwork (+)
CNL30 Netzwork (-)
Signal GND
20-519
A-19 Controller power source system

« Check that fuse for the transmission controller power source is not blown.
switch OFF.
Cause Remedy
YES
1
Short circuit with chassis Repair wiring
Is voltage between ground between CNL29 harness or
CNL29 (female) (8), (female) (8), (17), (18) replace
(17), 2 YES and CNFS5 (female) (6),
(18) -(9),(19) normal? or disconnection,
CNL29 defective contact
1) Insert T-adapter (female) (9),(19)and
NO
2) 20 - 30 V chassis normal?
NO disconnection in wiring harness or
1) Disconnect
CNL29. harness between CNL29 replace
2) Max. 1 Ω (female) (9), (19) - CNCL1
(female) (9), (12) - chassis
ground
+24 V
CNFS5
CNL29
Power source 24V
GND
Solenoid power source 17
Power source 24V 18

CNCL1
GND 19
12
20-520
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (CHASSIS RELATED)
(T MODE)
POWER TRAIN
T- 1 Machine does not start ............................................................................................................... 20-552
T- 2 Travel speed is slow, thrusting power is weak, lacks power on slopes .................................... 20-554
T- 3 Excessive shock when starting machine or shifting gear .......................................................... 20-556
T- 4 Excessive time lag when starting machine or shifting gear ....................................................... 20-557
T- 5 Torque converter oil temperature is high ................................................................................... 20-558
STEERING SYSTEM
T- 6 Steering wheel does not turn ..................................................................................................... 20-559
T- 7 Steering is heavy ....................................................................................................................... 20-560
T- 8 Steering wheel shakes or there is excessive shock .................................................................. 20-561
T- 9 Machine deviates to one side when traveling ............................................................................ 20-561
T-10 Turning radius is different between left and right ...................................................................... 20-561
BRAKE SYSTEM
T-11 Brakes do not work or braking effect is poor ............................................................................ 20-562
T-12 Brakes are not released or brakes drag .................................................................................... 20-563
WORK EQUIPMENT
T-14 Boom does not rise .................................................................................................................... 20-565
T-15 Boom movement is slow or boom lacks lifting power ............................................................... 20-566
T-16 When boom is raised, it moves slowly at a certain height ........................................................ 20-567
T-17 Bucket cannot be pushed with boom cylinder (bucket floats) ................................................... 20-567
T-18 Excessive hydraulic drift of boom .............................................................................................. 20-567
T-19 Boom shakes during operation .................................................................................................. 20-568
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE ...................... 20-568
T-21 Bucket does not tilt back ............................................................................................................ 20-569
T-22 Bucket movement is slow or tilt back lacks power .................................................................... 20-570
T-23 Bucket movement becomes slow during tilt-back operation ...................................................... 20-571
T-24 Bucket cannot be pushed with bucket cylinder.......................................................................... 20-571
T-25 Excessive hydraulic drift of bucket ............................................................................................. 20-571
T-26 Bucket shakes during loading operation .................................................................................... 20-572
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT ...................... 20-572
T-28 Boom, bucket control levers are heavy or do not move smoothl .............................................. 20-573
Explanation of symbols in Table

The following symbols are used on the Cause column to show the action to be taken to remove the cause.
X: Replace, ∆: Correct, A: Adjust, C: Clean
20-551
TROUBLESHOOTING T-1
POWER TRAIN
T-1 Machine does not start
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Internal part seized or broken
.)
Was there any abnormal noise when this
etc
happened?
eal,
e
r, s
Yes = Component broken.
alv
tato
ol v
Checks before troubleshooting
tc.)
p, s
ntr
Does the machine monitor function prop-
g, e
f co
um
erly?
in
eo
e, p
uf f
valv
Is the transmission oil level correct?
bin
, sc
lv e
Is the type of oil correct?
tur
tor
ght
f va
la
,
cau
ing
Is the transmission filter or strainer clogged?
egu
es
reli
nd
O)
e
ear
alv
er
dirt
Does the electrical circuit of the transmis-
ne
s
PT
ter
Cau
sur
e
io
e(
ver
(
tive
valv
trol
sion control work properly?
uct
er
res
lv
con
con
t
fec
ps
l va
ver
e
Is the transmission oil deteriorated? Does
oid
p
alv
e
um
ue
ch
n
cin
p (d
tro
len
issio
ol v
the oil smell of burning?
t
gp
f clu
con
r
f so
que
um
f to
ntr
p
sm
rgin
Is there any damage or leakage of oil that
um
gp
no
no
no
f co
ion
tor
an
a
gp
rgin
io
can be seen externally?
ratio
io
e tr
t ch
rat
eo
ide
rat
rat
rgin
cha
id
ope
in a
rific
Is the drive shaft broken?
ins
ope
ope
ope
ins
cha
do
e fo
ked
ge
kge
tive
Is the wheel brake or parking brake locked?
tive
tive
tive
ive
aka
gge
driv
suc
aka
fec
ect
fec
fec
fec
Bre
Clo
Bre
Def
De
De
De
De
No
Air
Charging Torque
pump converter Transmision control valve
a b c d e f g h i j
Remedy C
No. Problems
1 Does not start in any transmision range
2 Does not start in certain transmisssion ranges
3 Does not start when oil temperature rises

Torque converter stall speed does not go down to specified speed
4 in any transmission range
Torque converter stall speed does not go down to specified speed
5 in certain transmission ranges
7 Transmission clutch pressure does not rise in any speed range
8 Transmission clutch pressure does not rise in certain speed ranges

9 Metal particules (aluminium, copper, iron, etc.) stuck to filter or strainer
20-552
k
Exc
l
ess
iv e le
aka
De ge
fec of o
m
tive il fr
o per om
Me atio tran
cha n in sm
n
iss
Transmission
nis
che side ion
rS tra clu
Bre ch nsm tch
aka ade iss sha
ge n im ion ft s
ins c eal
o
ide Ge lutc por
t
valve
r ieb h ( tion
tran
sm e (La se ize (wo
Bre is sin g er, d,w rn,
aka ( o bro
ge b Z
TROUBLESHOOTING
ear ahn rn, ken

ins
ide in rad oil le )
acc
g, g
ear , Ge aka
um , hou h äus ge,
p
b
valve
ula
tor s ing e ) rok
valv ) en)
De
fec e (a
Accumulator Flow control

tive bno
ope rma
rat lw
ion ear
of f of s
low poo
con l po
tro rtio
l va n)
lve
(dir
t ca
ugh
t, s
cuff
ing
)
WA-3H automatic transmission
20-553
T-1
TROUBLESHOOTING T-2
T-2 Travel speed is slow, thrusting power is weak, lacks power on

slopes
Checking for abnormalities
Measure digging operations and speed
tc.)
when traveling on level ground and on
g, e
slopes, and check if there is actually an
arin
abnormality or whether it is just the feeling
.)
ve
etc
, be
tc.)
of the operator.
val
,
e
ing
r ol
tato
ol,
pr
ont
spo
p, s
sna
of c
,
ve
pum
hes
ng,
val
lve
ratc
shi
r va
e
rol
rbin
, bu
e, s
ont
lato
, tu
her
ring
Is there any oil leaking from the joints of the
of c
egu
g
e (w
piping or valves?
arin
eal
ve
er
end
ve
ses
val
r (s
Is there any dragging of the wheel brake or
(be
sur
val
val
tion
on
res
parking brake?
ter
Cau
trol
ert
lief
suc
lati
ver
hp
onv
n
Is the tire inflation pressure and tread pat-
r re
odu
pum
nc
con
lutc
ec
rte
tern normal?
of m
sio
of c
rqu
nve
que
ing
p
Is the method of operation correct?
mis
um
e to
arg
tion
ion
tor
c
gp
ans
t ch
sid
rat
que
ide
a
rgin
e tr
r
ope
in a
ope
e in
ins
tor
cha
sid
kag
ked
ge
tive
tive
tive
t in
tive
aka
suc
lea
fec
fec
fec
fec
fec
Bre
De
De
De
De
Oil
De
Air
Charging Torque Transmission

pump converter control valve
a b c d e f g h
Remedy
No. Problems
1 Abnormality in all transmission ranges
2 Abnormality in certain transmission ranges
When oil temperature is low, abnormal noise comes from

3
charging pump
4 Torque converter oil overheats
5 Abnormality in high idling and low idling speeds
6 Abnormality in each stall engine speed
7 Torque converter relief pressure is low
8 Low in every transmission range

Transmission
9 clutch pressure Low in certain transmission ranges
10 Indicator is unstable and fluctuates violently
11 Transmission oil level changes
Metal particles stuck to transmission as trainer

12
or torque converter filter

WA320-3H manual gear shift
20-554
C
i
valve
Clo
Control
g ged
j
orif
ice
of c
Lea ont
k
kag rol
eo val
f oi ve
Lea
l
l fro
kag ms
eo eal
f oi ring
C
Bre l fro
m
aka mt of t
ge ran
Torque converter,
ins ran sm
sm
TROUBLESHOOTING
iss
transmission circuit
Clo ide i ssi ion
n
gge tran
sm o nc clu
d tr
ans issio l utc tch
Clo mis n hp pag
s isto
o
sha
gge
d to
ion
bre n sea ft
rqu a the l
Exc
ess
ec
onv r
ive erte
p
lea
valve
kag r co
eo ole
Bre f oil
r ci
rcu
aka from it
Accumulator
ge
q
ins par
ide kin
acc gb
Lea um rak
es
r
kag ula eal
eo tor
v
Others
(wo
f oi alv rn,
De l fro e (ab bro
fec m nor ken
t in sea ma )
eng l of l we
ine
rela
sha
ft in a r of
ted wo spo
par rk e ol p
t q ui orti
pm on)
ent
and
ste
erin
gc
ircu
it p
um
p
20-555
T-2
TROUBLESHOOTING T-3
T-3 Excessive shock when starting machine or shifting gear

It is difficult to measure if the shock is exces-
sive or normal, so judge that the shock is ex-
ing
cessive in the following cases.
spr
When it is clear that the shock has become
urn
greater than before.
ret
ve
When the machine is compared with an-
er
ack
val
ind
other machine of the same class and the
hp
tor
cyl
shock is found to be greater.
lutc
ula
ack
reg
of c
p
ch
re
age
t
ssu
l u
of c
Is the engine idling speed too high?
eak
pre
Is there play in any of the drive shafts?
nce
, br
tch
ing
lve
fere
clu
ses
r va
ettl
um
ion
to s
lato
Cau
circ
iss
mu
nsm
ue
nd
nd
ccu
rou
ra
isto
of a
of t
ton
le a
pis
of p
o
ion
on
in h
tor
rati
rat
urn
dra
ula
ope
ope
ret
um
il
do
tive
tive
tive
acc
gge
fec
fec
fec
ck
Clo
Stu
De
De
De
Accumulator
Control valve Transmission valve
a b f g h
Remedy C
No. Problems
1 Shock is excessive in every transmission range
2 Shock is excessive in certain transmission ranges
3 Clutch pressure is too high
20-556
TROUBLESHOOTING T-4
T-4 Excessive time lag when starting machine or shifting gear

Was there excessive time lag? Was there
any abnormality in the travel speed or thrust-
ool
ing force? Was there any lack of power
r sp
when traveling up slopes?
cto
Yes = Go to T-2 Travel speed is slow, thrust-
ele
ing power is weak, lacks power on
al s
slopes
tion
ing
ring
rec
ol)
ve
spo
al r
f di
val
l
sea
t se
it o
o rn
and
ore
aft
haf
,w
ircu
, sh
rb
ing
ing
k, s
in c
l, o
s
ack
spr
Is there any oil leaking from the joints of the
hou
pac
dra
poo
hp
en
piping or valves?
ion
v
rok
e in
n, s
lutc
lutc
val
ses
iss
e (b
isto
alv
nc
nc
on
sm
valv
Cau
kv
lati
o
sio
of p
tran
i
iss
hec
odu
tor
i
sm
sm
ar
t of
ula
of c
of m
we
ran
ran
oin
um
e to
mt
mt
on
mj
ion
acc
i
l fro
l fro
l du
rat
l fro
rat
ide
e
ope
ope
f oi
f oi
f oi
rific
f oi
ins
eo
eo
eo
eo
do
tive
tive
ge
kag
kag
kag
kag
gge
aka
fec
fec
Lea
Lea
Lea
Lea
Clo
Bre
De
De
Transmission Accumulator
control valve Transmission valve
a c e f g h i j
Remedy C
No. Problems
1 Time lag is excessive in every transmission range
2 Time lag is excessive in certain transmission ranges
3 Clutch pressure is low in every transmission range
Clutch oil pressure is low in transmission ranges where time lag

4
is excessive
20-557
TROUBLESHOOTING T-5
T-5 Torque converter oil

temperature is high
Does oil temperature rise during torque con-
tc.)
p
um
g, e
verter stall and go down when there is no
it p
arin
ircu
load?
it
ircu
tc.)
, be
gc
Yes = Selection of transmission range
r, e
dc
erin
ring
Does oil temperature rise only when carry-
gge
ato
ste
nap
ing out scooping work?
, st
clo
and
g, s
Yes = Improvement in method of operation
ine
or
uit
shin
urb
ler
lve
circ
coo
p, t
, bu
r va
ent
um
ter
ing
lato
Are the radiator water level and fan belt
ipm
end
g, p
ver
al r
equ
tension correct?
reg
con
arin
tion
(se
ork
ve
ure
suc
(be
ter
es
que
val
in w
s
ver
res
s
nd
rter
tor
lief
Cau
con
pa
t
hp
haf
nve
om
r re
r
n
pum
t
the
lutc
par
s
ue
sio
r fr
o
e
l of
c
rea
orq
ert
is
nc
f ai
ted
ing
ue
sm
sea
p
nb
t
um
sio
con
torq
o
arg
rela
e
tran
Measure the torque converter oil tempera-
id
sio
ng
from
gp
mis
t ch
ins
ue
ide
mis
edi
ine
rgin
ide
ture. Is it actually high?
s
q
in a
f oil
tran
f oil
ins
ble
eng
ans
tor
ins
cha
Yes = Defective oil transmission gauge

eo
eo
ked
ge
d tr
tive
tive
tive
ge
t in
ive
kag
kag
aka
aka
gge
suc
fec
fec
ect
fec
fec
Lea
Lea
Bre
Bre
Def
Clo
De
De
De
De
Air
Charging Torque Trans- Torque converter,

mission transmission cicuit Others
pump converter
a b c d e f g h i j k
Remedy C
No. Problems
When oil temperature is low, abnormal noise comes from charging
1
pump
2 Abnormality in high idling and low idling speeds
3 Abnormality in each stall engine speed
Abnormality in travel speed, thrusting force, and gradeability in all

4
transmission ranges
Abnormality in travel speed, thrusting force, and gradeability in all

5
certain transmission ranges
6 Torque converter relief pressure is low
7 Low in every transmission range

Transmmision clutch
8 Low in certain transmission ranges
pressure
9 Indicator is unstable and fluctuates violently
10 Transmission oil level changes
11 Metal particles stuck to transmission straniner or torque converter filter
20-558
TROUBLESHOOTING T-6
STEERING SYSTEM
T-6 Steering wheel does not turn
Yes = Steering equipment damaged or
,
TO
broken
p, P
ve
Was there previously any symptom, such
um
al
gv
as heavy steering?
cp
erin
auli
Yes = Wear of internal parts of steer-
ste
ydr
ing equipment, defective seal
of h
ide
ns
l)
or p kage
se a
ct i
ump
fe
a
ton
Is the hydraulic oil level correct?
Bre
De
pis
en
es
Is there any part broken in the steering gear
rok
s
box or steering linkage?
Cau
(b
box
der
Has the safety bar been removed from the
ear
ylin
frame?
gg
p
gc
pum
Is the steering linkage properly adjusted?
erin
ve
erin
ste
val
ch
ste
swit
ide
ief
ide
ins
rel
ol
e
nd
valv
spo
s
ga
ge
t in
ng
and
aka
erin
eri
fety
fec
Dem
Ste
Bre
Ste
De
Hydraulic Sa
pump Valves Others
a b c d e f
Remedy
No. Problems
1 Steering wheel does not turn either to left or to right
2 In Item 1, mopvement of work equipment is abnormal
3 Steering wheel turns only to one side (left or right)
4 Steering wheel is heavy and cannot be turned
5 Oil pressure in steering circuit does not rise at all
There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-559
TROUBLESHOOTING T-7
T-7 Steering is heavy

Yes = Steering equipment damaged or
broken
as heavy steering?
Yes = Wear of internal parts of steer-
ing equipment, defective seal
e
alv
gv
p
um
ve
erin
lic p
val
ste
rau
ss
al)
Is there any abnormality in the steering gear
ide
ypa
hyd
e
ns
box mount, column, or linkage?
ins
b
tive
isto
ve
Is the stopper for the steering valve control
)
fec
nut
fec
mp
i
ect
e
lever properly adjusted?
De
orm
D
fro
f
, de
Is there any leakage of oil from the hydrau-
,w
ge
ide
ring
lic hoses, valves, or cylinders?
aka
eaa
ses
Is there any scuffing of the center hinge pin
l le
urn
i
x (b
r (o
ret
bearing or steering cylinder pin or bushing? Cau
nde
oil
r bo
Is the tire inflation pressure correct?
ulic
i
gea
cyl
p
a
pum
ring
ydr
ring
lve
at h
e
ch
er
tee
Measure the operating force of the steering
f va
ste
swit
ool
es
lter
wheel and the time taken to turn the steer-
elie
ide
il c
ol
e
nd
sid
d fi
alv
spo
do
gr
ing, and check the values in the Standard

ga
t in
t in
ty v
gge
erin
gge
and
erin
Value Table to check if there is any abnor-

fec
fec
fe
Dem
Clo
Ste
Clo
Ste
De
De
Sa
mality.
Tank -
pump Valves Others
a b c d e f g i
Remedy A C C
No. Problems
1 Steering is heavy when turned in both direction (left and right)
2 Steering is heavy when turned in one direction (left or right)
3 Steering is particularly heavy when engine is at low speed
4 Boom lifting speed is low when engine is runnig at full throttle
5 Steering is heavy and steering wheel jerks
6 Hydraulic oil overheats

7 Oil pressure in steering circuit is low
8 Oil pressure rises in return piping for steering cylinder
20-560
TROUBLESHOOTING T-8, T-9, T-10
T-8 Steering wheel shakes or there is excessive shock

olt)
t, b
Is there any abnormality in the steering gear
, nu
box mount, column, or linkage?
l
sea
Is there any play in the center hinge pin
n
al v
isto
bearing or steering cylinder pin or bushing?
gv
r, p
Is there any variation in the tire inflation
erin
nde
ste
pressure?
cyli
tive
Is the steering wheel play correct?
of
fec
ce
De
l
poo
fa
sur
or s
Operate at a safe place and check how the
ide
ect
ses
steering wheel shakes and under what con-
(ins
sel
ditions.
Cau
ve
er
In cases where the steering wheel is
val
nd
cyli
heavy but does not shake, go to
ing
eer
g
T-7 Steering is heavy.
erin
f st
ste
no
itio
e
sid
e
pos
valv
t in
ong
fec
ftey
De
Wr
Sa
Valves Cylinder
a b d
Remedy A
No. Problems
1 Chassis shakes when traveling on rough road surface
2 Shakes when steering is suddenly turned during operation travel
4 Chassis shakes when engine is started
T-9 Machine deviates to one side when traveling

Cause : Defective steering valve
Wrong position of spool
: Leakage of oil inside steering cylinder
: Variation in tire inflation pressure
T-10 Turning radius is different between left and right

Cause : Defective adjustment of steering linkage
Distribution to left and right, stopper lock position
(relief sound can be heard from valve when turning is completed)
20-561
TROUBLESHOOTING T-11
BRAKE SYSTEM
T-11 Brakes do not work or braking effect is poor
Yes = Brake equipment broken
xle
Did the problem gradually appear?
ea
sid
Yes = Deterioration of seal, wear of lin-
g in
ing, disc
nin
re
e li
ssu
rak
pre
of b
e
axl
gas
Is the brake pedal play correct?
ear
xle
ide
ent
ea
te w
ins
Is there any leakage of oil from the brake
fing
fici
sid
ng
ple
tube or connector?
suf
cuf
n in
lini
om
ses
, in
Is there any deformation of the tube?
), s
ke
e
isto
to c
e
eal
axl
alv
Cau
a
Is the tire inflation pressure and tread pat-
rge
e
f br
ep
axl
ns
ev
due
ide
cha
tern normal?
o
rak
sto
arg
ide
ins
ity
tion
lve
(for
of b
r pi
s
f ch
l
tion
rma
l in
por
a
lato
ev
Checks before abnormalities
no
mp
sea
ion
it
por
bno
ircu
tal
rak
mu
ratio
t pu
rat
Measure the braking force and compare with
me
ton
ke
er a
eb
ccu
ec
ope
pilo
ope
bra
the Standard Value Table to check if the
pis
ith
h
sid
rak
a
r ot
ct w
tive
tive
tive
tive
tive
tive
brakking effect is poor.
t in
in b
ar o
fec
nta
fec
fec
fec
fec
fec
fec
We
Air
De
De
De
De
De
Co
De
De
a b c d e f g h i j
Remedy
No. Problems
1 Resistance is low when brake pedal is depressed
2 Break pedal is heavy when it is depressed
3 Abnormal operating force is needed to obtain specified braking force
4 Abnormal noise is heard from axle brake when brake is applied
5 Machine cannot travel (lacks rimpull)
Jack up 4 wheels and set axles on stand. In F1, when brakes are
6
applied, only certain wheels rotate quickly
Air can be seen flowing out when air is bled from brake circuit.
7
Returns after air is bled.
8 Abnormal oil leakage is found when checking leakage of oil inside axle.
9 Many metal particles are found in axle oil
No abnormality in operating force of travel of brake pedal, but

10
braking effect is poor
11 Number of times of braking effect is small when engine is stopped
12 Accumulator is not charged, buzzer sounds
13 There is a time lag in effect of brake
20-562
T-12 Brakes are not released or brake drag

Does the brake pedal come back fully?
Is the praking brake fully released?

Is there any abnormal heat from the brakes?
Does the machine travel smoothly under
inertia on level ground?
e
axl
e
sid
ck)
xle
es
n in
stu
ea
s
isto
Cau
ton
sid
ep
(pis
g in
rak
ve
n
lini
of b
val
ke
ke
ion
ra
bra
rat
in b
ope
ide
lity
s
tive
ma
t in
nor
fec
fec
De
De
Ab
a b c
Remedy
No. Problems
1 Brake remains applied even when brake pedal is released
When brake pedal is released and oil is bled from air bleeder ,
2
circuit pressure goes down and brake is released
Jack up 4 wheels and set axles on stand. When engine is stopped

3 and parking brake is released, certain wheels are heavy when they
are rotated by hand
20-563
20-564
WORK EQUIPMENT
T-14 Boom does not rise
Yes = Equipment seized, damaged Was
there any abnormal noise when
this happened? (from where?)
as the speed becoming slow?
Yes = Wear of internal parts, deterio-
ration in spring
il
in o
air
ve
ssi
e
p
alv
Is the travel of the boom control lever and
ol)
um
xce
es
spo
ef v
p
spool properly adjusted?
ol
re
ch
s
lve
spo
l
om
reli
sea
Cau
po
swit
f va
(bo
nd
any
pum
ton
ool
and
e
ma
ody
r pis
reli
f sp
of m
f de
t of
eb
um
nde
f
n o
o
mp
por
no
ion
valv
lic p
ion
cyli
r pu
atio
p
ratio
rat
pum
ion
rat
rau
ide
oom
e fo
per
ope
uct
ope
ope
hyd
ins
PC
driv
db
ds
eP
tive
tive
ge
tive
ive
tiv
age
PTO
gge
ectiv
aka
fec
ect
fec
fec
fec
Dam
Clo
Bre
Def
De
Def
De
De
De
No
Steering Main control

Tank - pump valve
PPC valve valve Cylinder
a b c d e f g h i j
Remedy C
No. Problems
1 Bucket cannot be operated and boom cannot be raised
Chassis can be raised with boom but boom cannot be raised, or
2
bucket can be operated but boom cannot be raised
Boom can be raised when there is no load but cannot be raised

3
when there is a load
4 Abnormal noise comes from hydraulic pump
5 Excessive hydraulic drift of boom cylinder
When engine is running at full throttle, steering operation is too

6
light and fast
When engine is running at full throttle, steering operation is heavy

7
and slow
20-565
T-15 Boom movement is slow

or boom lacks lifting
power
Is the travel of the boom control lever and
main control valve spool properly adjusted?
ent
Is there any seizure of the work equipment
stm
linkage? (Is there any abnormal noise?)
nt
me
dju
ust
ea
il
adj
ctiv
in o
There is a strong connection between lifting
ive
efe
ol)
air
power and speed, so this problem first ap-
ect
s po
rd
ve
eo
def
pears as a lack of lifting speed. Measure
ssi
om
p
alv
xce
pum
or
the boom lifting speed when the bucket is
(bo
es
ef v
ve
re
ve
ody
loaded and use the Stand-
ch
val
Cau
ol
reli
po
val
swit
eal
eb
spo
ard Value Table to judge if there is any
off
pum
ns
lief
ain
l
valv
poo
nd
ut-
and
abnormality.
isto
f re
fm
pa
of c
of s
t of
ide
dem
p
um
no
der
por
ins
ion
on
on
lic p
o
n
ylin
i
i
ratio
rat
rat
ear
rati
rat
ion
rau
mc
ope
ope
ope
or w
ope
uct
ope
hyd
boo
ds
tive
tive
tive
tive
ge
tive
ive
age
gge
aka
fec
fec
fec
ect
fec
fec
Dam
Clo
Bre
Def
De
De
De
De
De
Tank - Steering PPC Main control Cut-off

pump valve valve valve Cylinder
valve
a b c d e f g h i
Remedy C A
No. Problems
Bucket tilting power and speed are abnormal and boom lifting
1
speed is slow
Bucket tilting power and speed are normal but boom lifting speed
2
is slow
As in Item 1, but lifting speed is particularly slow when oil

3
temperature rises

5
light and fast

6
and slow
7 Excessive hydraulic drift of cylinder
8 Relief pressure or relief valve in main control valve is low
9 Relief pressure or relief valve in main control valve is too high
20-566
TROUBLESHOOTING T-16, T-17, T-18, T-19
T-16 When boom is raised, it moves slowly at a certain height

Can any deformation be seen in the boom cylinder?
Cause
Swelling or internal damage to boom cylinder tube
« For other abnormalities when the boom is raised, go to "T-15 Boom movement is slow or boom
lacks lifting power."
T-17 Bucket cannot be pushed with boom cylinder (bucket floats)

See "T-15 Boom movement is slow or boom lacks lifting power."

Is the stroke of the boom spool in the main control valve properly adjusted?
Cause
Defective seating of suction valve at boom cylinder rod end of main control valve
Oil leakage from boom cylinder piston seal
T-18 Excessive hydraulic drift of boom

Yes = Dirt caught in valve, broken part
Yes = Worn parts
Is the boom spool at the neutral position?
Yes = Seized link bushing, defect in spool detent
Troubleshooting and Cause
When measuring the hydraulic drift, is there any sound of oil leakage from inside the boom cylinder?
Yes = Defective cylinder packing
T-19 Boom shakes during operation

When digging or leveling operations are carried out with the boom control lever at HOLD, the bucket and
boom move up and down to follow the shape of the ground.
Troubleshooting and Cause
Measure the hydraulic drift of the boom and check if it is possible to lift the chassis with the boom cylinder.
1. If the hydraulic drift of the boom cylinder is outside the standard value, go to "T-18 Excessive hydraulic
drift of boom."
2. If the chassis cannot be raised with the boom cylinder, go to "T-17 Bucket cannot be pushed with
boom cylinder."
3. If the hydraulic drift of the boom is normal, operate the boom several times, and operate the boom
cylinder to the end of its stroke. Is it now possible to raise the chassis with the boom cylinder?
Yes = Vacuum had formed inside cylinder
« However, if this problem appears frequently, the suction valve at the boom cylinder rod end is
defective.
20-567
T-20 Boom drops momentarily when control lever is operated from

HOLD to RAISE
Checking problem
When the engine is run at low idling and the boom control lever is operated slowly from HOLD to
RAISE, the boom goes down under its own weight. When the lever is operated fully to the RAISE
position, the condition returns to normal.
Cause
Defective seating of check valve for boom spool in main control valve
20-568
T-21 Bucket does not tilt back

Yes = Equipment seized, damaged
Was there any abnormal noise
when this happened? (from
where?)
as the speed becoming slow?
Yes = Wear of internal parts, deterio-
ration in spring
il
in o
air
Is the travel of the bucket control lever and
ve
ssi
spool properly adjusted?
e
p
ool)
alv
pum
xce
ses
ef v
t sp
ol
re
ch
spo
Cau
reli
po
cke
swit
l
sea
nd
pum
(bu
ain
and
ton
ma
of m
ody
r pis
f de
t of
p
um
eb
mp
alv
por
nde
no
ion
lic p
alv
r pu
ef v
ratio
cyli
rat
pum
ion
ev
rau
l
poo
e fo
ope
reli
uct
ket
ope
sid
hyd
PC
driv
buc
ds
e in
tive
eP
tive
tive
tive
ive
PTO
gge
ectiv
akg
ge
fec
ect
fec
fec
fec
Dam
Clo
Bre
Def
De
Def
De
De
De
No
Steering Main control

Tank - pump valve
PPC valve valve Cylinder
a b c d e f g h i j
Remedy C
No. Problems
1 Boom cannot be operated and bucket cannot be tilted back
Chassis can be raised with bucket but bucket cannot be tilted
2
back, or boom can be operated but bucket cannot be tilted back
Bucket can be tilted back when there is no load but cannot be

3
tilted back during digging or scooping operations
5 Excessive hydraulic drift of bucket cylinder

6
light and fast
When engine is running at full throttle, steering operation is

7
heavy and slow
20-569
T-22 Bucket movement is slow or tilt-back lacks power

Is the travel of the bucket control lever and
main control valve spool properly adjusted?
nd
Is there any seizure of the work equipment
me
linkage? (Is there any abnormal noise?)
otto
er b
lind
ent
t cy
Check if there is lack of tilt-back power dur-
stm
cke
nt
ing actual operations.
me
dju
t bu
Measure the operating speed of the bucket
ust
ea
e) a
adj
and use the Standard Value Table to check
il
ctiv
in o
valv
ive
if there is any abnormality
efe
air
ect
tion
rd
ve
def
suc
eo
ssi
ol)
p
alv
or
spo
xce
um
h
es
(wit
ve
ef v
ve
ool
hp
re
l
cke
sea
s
val
lve
val
p
c
Cau
reli
po
swit
ds
(bu
a
off
ton
lief
ty v
pum
ain
l
poo
nd
ma
ut-
r pis
ody
f re
afe
of m
pa
of c
f de
of s
t of
eb
of s
no
nde
um
no
por
valv
ion
ion
on
atio
lic p
cyli
n
ratio
ratio
rat
rati
rat
tion
ide
rau
per
ket
ope
ope
ope
ope
ope
uc
ins
hyd
buc
o
ds
tive
tive
tive
tive
ge
tive
tive
ive
ge
gge
aka
fec
fec
fec
ect
fec
ma
fec
fec
Clo
Bre
Def
De
De
De
De
De
De
Da
Tank - Steering Main control Cut-off
PPC valve Cylinder
pump valve valve valve
a b c d e f g h i j
Remedy C A
No. Problems
Boom lifting power and speed are abnormal and bucket tilt-back
1
power or speed are abnormal
Boom lifting power and speed are abnormal but bucket tilt-back
2
power or speed are abnormal
3 As in Item 1, but problem is particularly bad when oil temperature
rises

5
light and fast
6
and slow
7 Excessive hydraulic drift of bucket cylinder
8 Relief pressure or relief valve in main control valve is low
9 Relief pressure or relief valve in main control valve is too high
20-570
TROUBLESHOOTING T-23, T-24, T-25
T-23 Bucket movement becomes slow during tilt-back operation

Can any deformation be seen in the bucket cylinder?
Cause
Swelling or internal damage to bucket cylinder tube
For other abnormalities when the bucket is operated, go to "T- 22 Bucket movement is slow or tilt back
lacks power."
T-24 Bucket cannot be pushed with bucket cylinder

See "T-22 Bucket movement is slow or tilt back lacks power."

Is the stroke of the bucket spool in the main control valve properly adjusted?
Cause
Defective seating of safety valve (with suction valve) at bucket cylinder rod end of main control valve
Oil leakage from bucket cylinder piston seal
T-25 Excessive hydraulic drift of bucket

Yes = Dirt caught in valve, broken part
Yes = Worn parts

Is the bucket spool at the neutral position?
Yes = Seized link bushing, defect in spool detent

Use the Standard Value Table to check if the hydraulic drift of the bucket is actually excessive.
Cause
Oil leakage inside bucket cylinder
Defective seating of safety valve (with suction valve) at bottom end
Defective oil tightness of bucket spool
20-571
TROUBLESHOOTING T-26, T-27
T-26 Bucket shakes during loading operation

(Main control valve at HOLD)
Is there play in the work equipment linkage pin, bushing? (Is there any abnormal noise?)
Cause
Defective bucket cylinder piston seal
Defective operation of safety valve (with suction valve) at bucket cylinder rod end. If any other
problem occurs at the same time, carry out troubleshooting according to the nature of the problem.
T-27 Bucket dumps momentarily when control lever is operated from

HOLD to TILT
Checking problem
When the engine is run at low idling and the bucket control lever is operated slowly from HOLD to
TILT, the bucket dumps momentarily under its own weight. When the lever is operated fully to the
TILT position, the condition returns to normal.
Cause
Defective seating of check valve for bucket spool in main control valve
20-572
T-28 Boom, bucket control levers

are heavy or do not move
smoothly
s
bolt
ing
ol
unt
spo
Check the values in the Standard Value Table
mo
, lin
to check if the operating force of the lever is
and
lve
ver
ol
actually excessive.
f va
ody
s po
ol
l le
l
poo
spo
go
eb
tro
nd
s
lve
in
alv
ya
nd
con
ol
ten
a
a
spo
ol v
bod
ol v
dy
tigh
of
r
o
and
ol
ont
r
lve
eb
ion
ont
ven
spo
ses
in c
valv
c
or t
ody
v
une
ain
C
ve
a
gp
Cau
PP
eb
fm
PC
fm
val
ol
e
atin
l
P
spo
valv
o
f
poo
o
so
yd
rol
en
ss
ess
rot
es
ont
bod
e
dne
lve
trol
dne
etw
ndn
alv
of
in c
con
n
l
Cv
lve
oun
b
poo
rou
rou
v
ss
ce
ma
f va
trol
PP
ain
r
es
fne
-of-
ran
-of-
-of-
con
no
t in
of m
alv
t in
clea
stif
cut
cut
cut
Cv
atio
ugh
ugh
ain
tive
tive
re,
tive
ing
ive
t PP
form
nt m
t ca
t ca
izu
ect
fec
tch
fec
fec
Ben
Def
Se
Dir
Dir
Ca
De
De
De
De
Be
Lever PPC valve Main control valve
a b c d e f g h i j k
Remedy C
No. Problems
1 Lever are heavy when there is a load and oil pressure is high
2 Levers become heavy as oil temperature changes
Levers become heavy at places during operation regardless of oil

3
pressure or temperature
Levers are always heavy during operation regardless of oil

4
pressure or temperature
Levers are still heavy after control lever link is disconnect at
5
valve connection
20-573
20-574
TROUBLESHOOTING OF ECSS (ELECTRONICALLY
CONTROLLED SUSPENSION SYSTEM)
(D MODE)
Judgement Table for controller electrical system .................................................................................... 20-602
D- 1 ECSS does not work .................................................................................................................. 20-603

(a) Error code [d0] is displayed ................................................................................................ 20-604
(b) Error code [d1] is displayed ................................................................................................ 20-604
(c) Error code [d2] is displayed ................................................................................................ 20-605
(d) Error code [d3] is displayed ................................................................................................ 20-605
(e) Error code [d4] is displayed ................................................................................................ 20-606
(f) No abnormality display is given ........................................................................................... 20-606
D- 2 ECSS cannot be canceled ......................................................................................................... 20-610
D- 3 Output is turned ON
(travel speed does not become 5 km/h) (deviates around 5 km/h) ........................................... 20-611
D- 4 Output is turned ON when transmission is in 1st ...................................................................... 20-611
D- 5 Output is turned ON when transmission is in 4th ...................................................................... 20-612
D- 6 Controller LED code is not displayed ........................................................................................ 20-613
D- 7 ECSS is abnormal but main monitor does not give abnormality display ................................... 20-613
20-601
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

Error code Self-diagnosis table (abnormality display)
Solenoid Solenoid Solenoid Travel speed Model Troubleshooting

(relief) (high pressure) (low pressure) sensor selection code when no
abnormality
system system system system abnormality display is given
Failure mode d0 d1 d2 d3 d4
ECSS does not
work or does not D-1 (a) D-1 (b) D-1 (c) D-1 (d) D-1 (e) D-1 (f)
work properly
ECSS cannot be
canceled D-2
Output is turned
ON but travel
speed does not D-3
become 5 km/h
(deviates)
Output is turned
ON when
transmission is in D-4
1st
Output is turned
ON when
transmission is in D-5
4th
LED code display
is not given D-6
ECSS is abnromal
but main monitor
does not give D-7
abnormality
display
20-602
TROUBLESHOOTING D-1
D-1 ECSS does not work

« Carry out troubleshooting with the starting switch ON.
« Check that the ECSS switch on the main monitor is ON.
Cause Remedy
Displaying [d0]. Go to Item (a) -
Displaying [d1]. Go to Item (b) -
2 5
YES Wich code is

monitor Displaying [d2]. Go to Item (c) -
displaying?
1
Displaying [d3]. Go to Item (d) -
Is there an
abnormality
display
7
Displaying [d4]. Got to Item (e) -
Go to Item (f) -
NO
20-603
TROUBLESHOOTING D-1
(a) Error code [d0] is displayed

Cause Remedy
YES Replace
Defective controller
1
CNAL1 (female) (21) YES
and chassis ground Defective solenoid Replace
normal? 2
Is there continuity
1) Disconnect Disconnection in wiring
between CNAL1
CNAL 1. YES harness between CNAL1 After inspection,
NO (female) (21) and 3
chassis ground? (female) (21) - CNSAS (4) repair or replace
2) DC resistance: Is there continuity - CNAF4 (female) (1)
20 - 40 Ω 1) Disconnect between CNAF4
CNAL1. NO (female (2) and
chassis ground Disconnection is wiring
2) Disconnect harness between CNAF4 After inspection,
CNAF4. 1) Disconnect NO (female) (2) - CNTL1 (8) - repair or replace
CNAF4. CNCL1 (12) - chassis
3) Connect short ground
connector to
CNAF4 (female).
(b) Error code [d1] is displayed
YES
Defective speed sensor Replace
1
and chassis ground Defective controller Replace
normal? 2
Is there continuity
1) Disconnect between CNAL1
CNAL 1. (female) (20) and Disconnection in wiring
NO YES harness between CNAL1 After inspection,
chassis ground? 3
2) DC resistance: Is there continuity (female (20) - CNSAS (5) repair or replace
20 - 40 Ω 1) Disconnect between CNAF4 - CNAF5 (female) (1)
connector to
CNAF5 (female).
20-604
TROUBLESHOOTING D-1
(c) Error code [d2] is displayed

Cause Remedy
YES Replace
Defective controller
1
and chassis ground Defective solenoid Replace
normal? 2
Is there continuity
1) Disconnect Disconnection in wiring
between CNAL1
CNAL 1. YES harness between CNAL1 After inspection,
NO (female) (11) and 3
chassis ground? (female) (11) - CNSAS (6) repair or replace
2) DC resistance: Is there continuity - CNAF6 (female) (1)
20 - 40 Ω 1) Disconnect between CNAF6
connector to
CNAF6 (female).
(d) Error code [d3] is displayed

YES
Defective speed sensor Replace
1
Does error
display go off?
YES
2
Is there continuity
1) Connect short between CNAL3
connector to NO (female) (4) and
CNT06 (female). (12)?
Disconnection in wiring After inspection,
2) Turn starting 1) Disconnect harness between CNAL3 repair or replace
switch OFF CNAL3. NO (4) - CNSAS (9) or CNAL3 (if any other
ON. (12) - CNSAS (10) controller is
3) Connect short abnormal, check
connector to all wiring
CNT06 (female). harness for the
speed sensor
system)
20-605
TROUBLESHOOTING D-1
(e) Error code [d4] is displayed

Cause Remedy
2 YES
Is continuity of
YES wiring harness
Disconnection in wiring
normal? harness between CNAL2
1 After inspection,
(female) and CNAL4
1) Disconnect (male), or contact with
Is connection of
CNAL2. chassis ground
wiring harness
normal ? 2) Is continuity between CNAL2
(female) (1) - (4) and chassis Defective contact, or
1) Disconnect ground as shown in the table? disconnection in wiring
CNAL4. harness between CNAL4 After inspection,
2) Is continuity NO (female) and chassis repair or replace
between CNAL4 (female) ground, or contact with
(1), (2), (3), (5) - chassis ground as chassis ground
shown in the table?
Table
Connector CNAL4(female) CNAL2(female)
Model (5) (2) (3) (1) (1) (2) (3) (4)
WA320-3H No No No Yes No No No Yes
WA380-3H No No Yes No No No Yes No
WA420-3H No Yes No No No Yes No No
WA470-3H No Yes Yes Yes No Yes Yes Yes
(f) No abnormality display is given

(1) Does not work at all
YES Defective controller Replace
1
Is voltage
between CNAL2
(15) and chassis 2 YES Go to
ground normal? Defective main monitor troubleshooting
Is voltage between of main monitor
CNL06 (female) (7)
1) 0 - 3 V
2) Turn starting NO and chassis Disconnection in wiring
ground normal?
switch ON. harness between CNAL2 After inspection,
3) Turn main NO (female) (15) - CNDP2 (1) - repair or replace
1) 20 - 30 V CNL06 (female) (7)
monitor ECSS
switch ON.
2) Disconnect
CNL06.
20-606
TROUBLESHOOTING D-1
(2) Works when bucket is loaded but not when empty

Cause Remedy
Defective pressure switch

YES or defective chassis Replace
2 hydraulic system
Is there continuity
YES between CNAF7 Contact of chassis ground After inspection,
(male) (1) and 3 YES with wiring harness repair or replace
(2)? between CNAL2 (female)
1 I)s there continuity
between CNAL2 (8) - CNSAS (7) - CNAF7
1) Turn starting (female) (1)
NO (female) (8) and
Zeigt
Doesdie Kontroller-
controller switch ON.
chassis ground?
LED
LED55 an ? 55?
display 2) Disconnect Defective controller Replace
CNAF7. 1) Turn starting NO
3) Empty bucket. switch ON.
1) Turn starting
switch ON. Defective chassis –
2) Empty bucket. NO hydraulic system
(3) Works when bucket is empty but not when loaded
YES Defective chassis –

hydraulic system
1
3 YES Defective controller Replace
Does controller Is voltage
LED display 55? YES between CNAL 2 Defective contact, or
ground normal? harness between CNAL2
2 After inspection,
1) Turn starting (female) (8) - CNSAS (7) -
switch ON. Is there continuity 1) 0 - 3 V NO CNAF 7 (female) (1), or repair or replace
2) Load bucket. between CNAF7 2) Turn starting between CNAF7 (female)
NO (male) (1) and switch ON. (2) - CNSAS (8) - CNAL4
(2)? 3) Load bucket. (4) - chassis ground
1) Turn starting Defective pressure switch

switch ON. or defective chassis Replace
2) Disconnect NO hydraulic system
CNAF7.
3) Load bucket.
20-607
TROUBLESHOOTING D-1
D-1 (a), (b), (c) Related electric circuit diagram

Solenoid system
CNAL1 CNSAS
11 5 1
20 6 1 2
21 4 1 2
CNAF6
2
CNAF5
CNAF4
Solenoid 1 Solenoid 2 Solenoid 3

(relief) (high (low
pressure) pressure)
8 12
CNTL1 CNCL1
D-1 (d) Related electric circuit diagram

Speed sensor system
CNAL3 CNSAS CNTL2 CNT06 Speed sensor

Speed (+)
4 9 1 1
12 10 2 2
Speed (-)
D-1 (e) Related electric circuit diagram

Model selection system
CNAL2 CNAL4 WA320 WA380 WA420 WA470

a a a a a
1 5
For connections, see
diagrams on right
b b b b b
2 2
c c c c c
3 3
d d d d d
4 1
20-608
TROUBLESHOOTING D-1
D-1 (f-(1)) Related electric circuit diagram

ECSS operation switch and network
CNAL1 CNDP2 CNL08

Netzwork (+)
1 2 1
12 3
3 2
CNAL2 4
Netzwork (-)
9 1
CNL06
15
ECSS operation switch 7
D-1 (f-(2)), (f-(3)) Related electric circuit diagram

Pressure switch system
CNAL2 CNSAS CNAF7

Pressure switch
8 7 1
8 2
CNAL4
20-609
TROUBLESHOOTING D-2
D-2 ECSS cannot be canceled

« Check that the ECSS switch on the main monitor is OFF.
Cause Remedy
YES
1
Is voltage
between CNAL2 Contact chassis ground
(15) and chassis with wiring harness
ground normal? between CNAL2 (female)
Is there continuity (15) - CNDP2 (1) - CNL06 repair or replace
1) 20 - 30 V between CNAL2 (female) (7)
2) Turn starting NO (female) (15) and
switch ON. chassis ground?
Defective main monitor Go to
3) Turn main NO troubleshooting
1) Diconnect
monitor ECSS of main monitor
CNAL2.
switch OFF.
2) Disconnect
CNL06.
CNAL1 CNDP2 CNL08

Network (+)
1 2 1
12 3
3 2
CNAL2 4
Network (-)
9 1
CNL06
15
ECSS operation switch 7
20-610
TROUBLESHOOTING D-3, D-4
D-3 Output is turned ON (travel speed does not become 5 km/h)

(deviates around 5 km/h)
Cause Remedy
Defective speed sensor, Replace or

2 YES
or defective mount of adjust
speed sensor
YES Is monitor speed
1 display incorrect?
Is machine model Defective controller Replace

1) Start engine. NO
code normal?
Go to Troubleshooting –
1) Check LED NO D-1 (e)
display code.
2) See
STRUCTURE
AND FUNCTION
for details of the
codes.
D-4 Output is turned ON when transmission

is in 1st Cause Remedy
1 YES
CNAL2 (female) (14)
harness between CNAL2 repair or replace
1) Disconnect NO
(female) (14) - CNSAS (3)
CNAL2. - speed solenoid
2) 50 - 70 Ω

CNAL2 CNSAS CNTL1 CNL04
Hi/Lo
Standard 13 2 5 7
specification Directional,
machine speed switch
14 3 6 5
Speed
To solenoid
Hi/Lo
HYPER 13 2 5 10
specification Transmission
machine controller
14 3 6 11
Speed
To solenoid
20-611
TROUBLESHOOTING D-5
D-5 Output is turned ON when transmission is in 4th

Cause Remedy
1 YES
CNAL2 (female) (13)
harness between CNAL2 repair or replace
1) Disconnect NO
(female) (13) - CNSAS (3)
CNAL2. - Hi/Lo solenoid
2) 50 - 70 Ω

13 2 5 7
14 3 6 5

13 2 5 10
14 3 6 11
20-612
TROUBLESHOOTING D-6, D-7
D-6 Controller LED code is not displayed

Cause Remedy
YES
1 Defective contact, or
Ist die Spannungs- harness between CNAL1
versorgung normal ? (female) (8), (18) - CNDP1
YES CNDP1 (male) (1)
(female) (1)
2 and chassis
1) 20 - 30 V ground normal?
Is there coninuity Anormality in fuse box Repair
2) Measure voltage between CNAL1 NO
1) 20 - 30 V
between CNAL1
NO (female) (9), (19) - 1) Disconnect Defective contact, or
(8), (18) - (9), (19). chassis ground? disconnection in wiring
CNDP1.
harness between CNAL1 After inspection,
1) Disconnect (female) (9), (19) - CNSAS repair or replace
CNAL1.
NO
(1) - CNTL1 (8) - CNCL1
(12) - chassis ground
CNAL1 CNDP1
+ 24V
8 1 Fuse box
17
18
9 CNSAS CNTL1 CNCL1

19 1 8 12
GND
D-7 ECSS is abnormal but main monitor does not give abnormality
display
Cause Remedy
Check that the ECSS controller is displaying an error code.
Go to troubleshooting of –
main monitor
20-613
20-614
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL...................... 30- 3 Disassembly .......................................... 30- 77

PRECAUTIONS WHEN CARRYING OUT Assembly ............................................... 30- 86
OPERATION ............................................ 30- 4 TRANSMISSION CONTROL VALVE
SPECIAL TOOL LIST .................................... 30- 6 Removal ................................................. 30-103
STARTING MOTOR Installation ............................................. 30-105
Removal and Installation .......................... 30- 9 Disassembly .......................................... 30-112
ALTERNATOR Assembly ............................................... 30-114
Removal and Installation .......................... 30- 10 TRANSMISSION ACCUMULATOR VALVE
ENGINE OIL COOLER Disassembly .......................................... 30-117
Removal and Installation .......................... 30- 11 Assembly ............................................... 30-118
FUEL INJECTION PUMP DRIVE SHAFT
Removal ................................................... 30- 12 Disassembly .......................................... 30-121
Installation ............................................... 30- 13 Assembly ............................................... 30-124
WATER PUMP FRONT AXLE
Removal and Installation .......................... 30- 16 Removal ................................................. 30-126
TURBOCHARGER Installation ............................................. 30-128
Removal and Installation .......................... 30- 17 REAR AXLE
NOZZLE HOLDER Removal ................................................. 30-129
Removal and Installation .......................... 30- 18 Installation ............................................. 30-133
THERMOSTAT DIFFERENTIAL
Removal and Installation .......................... 30- 19 Disassembly .......................................... 30-135
CYLINDER HEAD Assembly ............................................... 30-140
Removal ................................................... 30- 20 AXLE HOUSING
Installation ............................................... 30- 25 Disassembly .......................................... 30-150
RADIATOR Assembly ............................................... 30-157
Removal ................................................... 30- 27 CENTER HINGE PIN
Installation ............................................... 30- 30 Removal ................................................. 30-167
ENGINE Installation ............................................. 30-171
Removal ................................................... 30- 31 STEERING GEAR
Installation ............................................... 30- 36 Removal ................................................. 30-174
TORQUE CONVERTER CHARGING PUMP Installation ............................................. 30-176
Removal ................................................... 30- 41 Disassembly .......................................... 30-177
Installation ............................................... 30- 42 Assembly ............................................... 30-178
TORQUE CONVERTER, TRANSMISSION STEERING VALVE
Removal ................................................... 30- 43 Removal ................................................. 30-181
Installation ............................................... 30- 47 Installation ............................................. 30-183
TORQUE CONVERTER Disassembly .......................................... 30-184
Disassembly ............................................ 30- 48 Assembly ............................................... 30-187
Assembly ............................................... 30- 50 STEERING CYLINDER
TRANSMISSION Removal ................................................. 30-190
Disassembly .......................................... 30- 53 Installation ............................................. 30-191
Assembly ............................................... 30- 63 BRAKE VALVE
TRANSMISSION CLUTCH PACK Removal ................................................. 30-192
30-1
Installation ............................................. 30-193 Removal ................................................. 30-247
RIGHT BRAKE VALVE (TANDEM) Installation ............................................. 30-248
Disassembly .......................................... 30-194 MAINTENANCE MONITOR
Assembly ............................................... 30-195 Removal and Installation ........................ 30-249
LEFT BRAKE VALVE (SINGLE) AIR CONDITIONER UNIT
Disassembly .......................................... 30-196 Removal ................................................. 30-250
Assembly ............................................... 30-197 Installation ............................................. 30-255
PARKING BRAKE DISC AIR CONDITIONER CONDENSER
Removal ................................................. 30-198 Removal ................................................. 30-256
Installation ............................................. 30-200 Installation ............................................. 30-257
HYDRAULIC TANK DRY RECEIVER
Removal ................................................. 30-201 Removal and Installation ........................ 30-258
Installation ............................................. 30-203 AIR CONDITIONER CONDENSER
HYDRAULIC FILTER COMPRESSOR
Removal and Installation ........................ 30-204 Removal and Installation ........................ 30-259
HYDRAULIC, STEERING, SWITCH,
PPC PUMP
Removal ................................................. 30-205
Installation ............................................. 30-208
MAIN CONTROL VALVE
Removal ................................................. 30-209
Installation ............................................. 30-211
Disassembly .......................................... 30-212
Assembly ............................................... 30-214
PPC VALVE
Removal ................................................. 30-217
Installation ............................................. 30-219
Disassembly .......................................... 30-220
Assembly ............................................... 30-221
BUCKET CYLINDER
Removal ................................................. 30-222
Installation ............................................. 30-224
BOOM CYLINDER
Removal ................................................. 30-225
Installation ............................................. 30-226
HYDRAULIC CYLINDER
Disassembly .......................................... 30-227
Assembly ............................................... 30-230
WORK EQUIPMENT
Removal ................................................. 30-233
Installation ............................................. 30-236
COUNTERWEIGHT
Removal and Installation ........................ 30-238
FUEL TANK
Removal ................................................. 30-239
Installation ............................................. 30-241
CAB, FLOOR FRAME
Removal ................................................. 30-242
Installation ............................................. 30-244
CAB
Removal ................................................. 30-245
Installation ............................................. 30-246
MAIN MONITOR
30-2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked ❈ 1 , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVAL OF O O O ASSEMBLY ................ Title of operation
................................................................. Precautions related to safety when carrying out the
operation
1. XXXX (1) ............................................ Step in operation
« .......................................................... Technique or important point to remember when re-
moving XXXX (1).
2. ∆ ∆ ∆ (2): ............................................ ❈ 1 Indicates that a technique is listed for use
during installation
3. oooo assembly (3)
.................................................... See Lubricant and Coolant Table
INSTALLATION OF O O O ASSEMBLY ........ Title of operation
• Carry out installation in the reverse
order to removal.
❈ 1 ................................................ Technique used during installation
« ................................................ Technique or important point to remember when install-
ing ∆ ∆ ∆ (2).
• Adding water, oil ................................ Step in operation
« ................................................ Point to remember when adding water or oil
................................................ Quantity of filling oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze, dispose of it correctly.

• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
« Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal Plug (nut end) Sleeve nut (elbow end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head Split flange
number (tube end)
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12 Taper 1/8
øD
ød
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 L
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30 DEW00401
27 07049-02734 27 22.5 34
30-4
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions for installation operations
• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with antifriction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
« When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping 100
mm from the end of its stroke.
3) Next, operate the steering, bucket, and boom cylinders 3 - 4 times to the end of their strokes, then stop
the engine and loosen air bleed plug (1) to bleed the air from the hydraulic tank. After bleeding the air,
tighten plug (1).
4 Following this, raise the engine speed, repeat the procedure in Step 3)
to bleed the air. Repeat this operation until no more air comes out from
the plug hole.
Plug : 11.3 ± 1.5 Nm (1.15 ± 0.15 kgm) 1
5) After doing this, run the engine at normal speed.
« When using the machine for the first time after repair or
long storage, follow the same procedure.
3. Precautions when completing the operations DLW00002
• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed
for repair, always bleed the air from the system after reassembling the parts.
« For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Nature of work Symbol Part No. Part Name Q’ty Remarks
1 793-305-1600 Lifting tool 2 Rear housing lifting tool
2 793-415-1210 Lifting tool 1 For F – R clutch
Disassembly, assembly of 3 793-415-1220 Lifting tool 1 For 1st, 2nd, 3rd 4th clutch
A
transmission assembly 793-415-1150 Plate 1
Removal, installation of
4 01010-51075 Bolt 4
parking brake disc
01580-11008 Nut 4
1 793-310-1300 Stand 1
2 793-310-1370 Guide pin 5
Plate 1 Removal, installation of

3 793-310-1330
Disassembly, assembly of end plate
transmission clutch pack B 4 01541-01260 Nut 2
assembly Bar 2
5 793-310-1360
6 793-415-1250 Seal holder 1 F–R Jig for settling
7 793-415-1130 Seal holder 1 1st – 4th piston seal
Mandrel 1 Positioning bearing of
1 793-422-1120 differential pinion
793-422-1100 Installer assembly 1
2
793-422-1130 • Plate 5
3 01016-30880 • Bolt 5 Insertion of brake piston

Disassembly, assembly of
C 01011-01010 • Bolt 5
differential assembly 4
01643-32060 • Washer 5
5 790-301-1720 • Joint 1
6 799-101-5002 Hydraulic tester kit 1

Checking for oil leakage
7 793-605-1001 Brake tester 1
8 790-101-1102 Pump assembly 1
1 790-101-2910 Puller 1 set Puller assembly:
Bolt 2 790-101-2900
2 790-101-2920
Removal of axle shaft
D 3 790-101-2930 Nut 2 bearing
axle housing assembly
4 793-422-1140 Seal support 2 Holder for oil seal when
press fitting oil seal
4-1 01016-30840 • Adjustment bolt 6
5 793-422-1110 Holder 1 For adjusting shim
30-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nature of work Symbol Part No. Part Name Q’ty Remarks
1 793-840-1310 Push tool 1
2 792-103-0400 Grip 1
3 790-101-1002 Pump 1
4 790-101-2102 Puller 1
Installation of center 5 790-101-2300 Push-puller 1 Press fitting of bearing
E
hinge pin
6 793-520-2370 Push tool 1
7 793-520-2350 Push tool 1
8 793-520-2540 Guide 1
9 793-520-2360 Bar 2
790-502-1003
or Cylinder repair stand 1
F 790-502-2000
790-101-1102 Pump 1
G Steering Removal, installation
790-330-1100 Wrench ass'y 1 Cylinder of round head
H Commercially Socket Steering Removal, installation
available (width across flats: 46) 1 Cylinder of nylon nut
790-101-5021 Grip 1 Press fitting of coil bushing
01010-50816 Bolt 1 Kit Part No.: 790-201-1702
I Bucket
790-201-1841 Push tool 1 cylinder
Steering
790-201-1751 Push tool 1 Cylinder
1 790-720-1000 Expander 1 Installation of piston ring
hydraulic cylinder 796-720-1680 Ring 1 Boom
07281-01589 Clamp 1 cylinder
J 796-720-1690 Ring 1 Bucket

2 cylinder
07281-01919 Clamp 1
796-720-1640 Ring 1 Steering

07281-00909 Clamp 1 cylinder
790-101-5021 Grip 1 Insertion of dust seal

01010-50816 Bolt 1 Kit Part No.: 790-201-1500
K Bucket, Boom
790-201-1650 Plate 1 Cylinder
Steering
790-201-1560 Plate 1 Cylinder
30-7
30-8
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
2
Disconnect the cable from the negative (–) terminal
of the battery.
1. Open engine hood side cover and lock in position.
2. Disconnect hose (1).

3
3. Disconnect wiring (2). 1
4
5
4. Disconnect wiring connector (3). DLW01859
5. Remove starting motor assembly (4). ❈1
INSTALLATION OF STARTING
MOTOR ASSEMBLY
• Carry out installation in the reverse order to re-

moval.
❈1
« When installing the starting motor assembly,
install ground connection (5) securely.
30-9
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
3
Disconnect the cable from the negative (–) terminal 4
of the battery. 1
1. Open engine hood side cover and lock in position.
2. Disconnect 3 set of wiring (1).

« Mark the wiring with tags to prevent mistakes
when assembling.
5
3. Loosen mounting bolt and nut (2), and adjustment 2
DEW01348
plate mounting bolt (3). ❈1
4. Move alternator assembly (5) towards engine, then

remove fan belt (4) from alternator assembly (5).
❈2
5. Remove mount bolt and nut (2), and adjustment plate
mounting bolt (3), then remove alternator assembly
(5).
INSTALLATION OF
ALTERNATOR ASSEMBLY

moval.
❈1 Mounting bolt
Adjust the belt tension. For details, see TESTING and nut
AND ADJUSTING, Testing and adjusting fan belt
tension.
❈2 DEW01349
To prevent interference with the fan belt, set with the

mount bolt and nut facing in the direction shown in
the diagram on the right when installing.
30-10
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1
1. Lift off engine hood assembly.
2. Remove fuel injection pump assembly. 2

For details, see REMOVAL OF FUEL INJECTION 3
PUMP ASSEMBLY.
3. Disconnect oil pressure sensor wiring (1).
4. Remove oil filter and head assembly (2) together

with tube (3). 5 DBW00009
5. Remove cooler pipe (4), then remove oil cooler

cover assembly (5).
7
5
6. Remove 4 nuts (6) from oil cooler cover assembly
(5), then remove cooler (7).
DBW00010
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY

moval.
• Refilling with water

Add water through the water filler to the specified
level. Run the engine to circulate the water through
the system. Then check the water level again.
30-11
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
3
1
1. Remove boost compensation tube (1).
2. Disconnect stop motor cable (2) and remove to-

5
gether with mounting bracket (3).
3. Disconnect accelerator cable (4) and remove to-

gether with mounting bracket (5).
2 4 DBW00000
4. Remove fuel filter and head assembly (6) together 8

7
with hoses (7) and (8). ❈1
DBW00006
5. Disconnect fuel hoses (9) and (10).

11
« After disconnecting hose (10), bend it and tie
with wire to prevent fuel from leaking out.
❈2
9
6. Disconnect 6 fuel injection pipes (11), and remove
lubrication tube (12). ❈3 12
7. Remove mounting bracket (14) at rear of fuel injec-
13 10
tion pump assembly (13), remove front mounting
bolts, then remove fuel injection pump assembly DBW00007
(13). ❈4
14
DBW00008
30-12
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
• Carry out installation in the reverse order to removal
❈1
Joint bolt : 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
❈2
Joint bolt : 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
❈3
Fuel injection pipe sleeve nut :
22.6 ± 2.9 Nm (2.3 ± 0.3 kgm)
❈4
Mounting bolt of fuel injection pump as-
sembly : 66.7 ± 7.8 Nm (6.8 ± 0.8 kgm)
• Adjust the injection timing.

For details, see TESTING AND ADJUSTING, Test-
ing and adjusting fuel injection timing.
30-13
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1 2
1. Drain engine coolant.
2. Remove radiator upper tube (1), then remove fan

guard (2).
DBW00011
3. Remove water temperature sensor connector (3)

from clip and disconnect. 3
4. Remove spill hose (4).
5. Remove thermostat housing assembly (5).
5
4 DBW00012
6. Loosen adjustment bolt (7) and mount bolt (8) of

9
alternator assembly (6), remove adjustment bolt, then
move alternator assembly (6) towards frame.
❈1
7. Remove fan (10) and spacer (11).
8. Loosen clamp of hose (12), then remove mounting
bolts, and remove water pump assembly (13). 10 7
6
DBW00013
INSTALLATION OF WATER
PUMP ASSEMBLY
13
• Carry out installation in the reverse order to re- 12
moval.
❈1
Adjust the belt tension. For details, see TESTING
AND ADJUSTING, Testing and adjusting fan belt
tension.
DBW00014
30-16
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1
2. Remove intake hose (1). ❈1
DBW00015
2 3
3. Remove muffler assembly (2), then remove lubrica-
tion inlet tube (3).
DBW00016
4. Disconnect lubrication return tube (4), and remove

turbocharger assembly (5). ❈2 5
4
DBW00017
INSTALLATION OF
TURBOCHARGER ASSEMBLY

moval.
Intake hose clamp :

8.8 ± 0.49 Nm (0.9 ± 0.05 kgm)
« Insert hose (1) until it contacts the turbocharger
flange.
Turbocharger mounting bolt :

37.3 ± 7.8 Nm (3.8 ± 0.8 kgm)
30-17
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1 2
2. Remove intake connector.

« Remove the intake connector only when remov-
ing the No. 4 nozzle holder assembly.
3. Remove fuel injection pipe (1) and lead (2). ❈1
DEW01373
4. Remove holder (3). ❈2
5. Remove spill hose (4), then remove nozzle holder

(5).
4
5
3
DEW01374
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY

moval.
❈1
Fuel injection pipe sleeve nut :
22.6 ± 2.9 Nm (2.3 ± 0.3 kgm)
Lead mounting nut :
1.5 ± 0.5 Nm (0.15 ± 0.05 kgm)
❈2
Holder mounting bolt :
44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
30-18
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1
1. Open engine hood side cover.
2
3. Remove connector (1) from clip and disconnect.

4
4. Remove cover (2).
« Do not disconnect the hose. ❈1
DEW01375
5. Remove thermostat (3).
INSTALLATION OF
THERMOSTAT ASSEMBLY

moval.
DEW01376
❈1
Clamp spill hose (4) securely.

30-19
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER
HEAD ASSEMBLY

3. Remove radiator upper tube (1).
4. Remove water temperature sensor connector (2) 6

from clip and disconnect. 2
5. Disconnect spill hose (3), loosen clamp of hose

(4), then remove thermostat connector (5).
« Thermostat connector (5) is tightened together
with the cylinder head hanger, so after remov-
ing the connector, secure hanger (6) with the
bolts.
5
4
3
DBW00019
6. Remove mounting bracket (7) at top of water pump

assembly.
7. Remove muffler assembly (8) together with bracket.
8. Remove intake hose (9).
9. Disconnect dust indicator connector (10), and re-
move air cleaner assembly (11) together with mount- 7
ing bracket. ❈1
« There are 4 spacers between the mounting
bracket and the exhaust manifold, so be careful
not to lose them.
DBW00020
9
10 11 8
DBW00023 DBW00021 DBW00022
30-20
10. Remove air supply connector (12).

12
DBW00024
11. Disconnect wiring harness clamps , , and ,

and remove turbocharger lubrication inlet tube (13).
13
q
w DBW00025
12. Loosen clamp of turbocharger lubrication tube joint

hose (14), and disconnect lubrication return tube
(15) from turbocharger. 15
16
13. Remove mounting bolts, then remove turbocharger
and exhaust manifold assembly (16).
❈2
« After removing together with the lubrication re-
turn tube, pull out the tube from the turbocharger
and exhaust manifold assembly.
14. Disconnect oil pressure sensor wiring (17) and re- 14

lay wiring (18), then disconnect heater relay con- DBW00026
nector (19) from clip.
19 18
17
DBW00027
30-21
15. Disconnect clamp of wiring harness (20) from in-

take manifold, and remove boost compensation tube 20
(21).
16. Remove mounting bolts of fuel filter assembly (22),

and move it towards frame. 22
21
DBW00028
17. Remove oil filter and tube assembly (23).
23
DBW00029
18. Disconnect heater relay wiring (24).
19. Loosen nut of No. 5 and 6 fuel injection pipes (25),

and remove clamp (26). 26 24
25 DBW00030
20. Remove clamps (28) and (29) of No. 1 – 3 fuel

injection pipes (27).
27 28 29 27
DBW00031
30-22
21. Remove clamp (30) of No. 5 and 6 fuel injection

pipe from intake manifold, then remove intake mani- 30 31
fold (31). ❈3
DBW00032
22. Remove fuel injection pipes (25) and (27). ❈4

25 27
DBW00033
23. Remove 5 leads (28). ❈5
❈6 29 28
24. Remove holder (29).
25. Remove spill hoses (30) and nozzles (31).
« Spill hoses: 25; nozzles: 6
DBW00034
29
30 31
DBW00036 DBW00035
30-23
26. Remove head cover (32). ❈7

32
DBW00037
27. Remove rocker arm assembly (33). ❈8

« Loosen the locknut and turn the adjustment screw
33
back 2 – 3 turns.
DBW00038
28. Remove 12 push rods (34).
34
DBW00039
29. Remove cylinder head assembly (35). ❈9
35
DBW00040
30-24
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
moval.
❈1
Hose clamp : 8.8 ± 0.5 Nm (0.9 ± 0.05
kgm)
« Insert the hose until it contacts the turbocharger
flange.
❈2
« Tighten the bolts in the order – shown in
the diagram on the right.
The length of the bolts marked ✰ is 60 mm; the DEW01398
length of the other bolts is 80 mm.

Tightening torque:
Tightening order Tightening torque

(Nm (kgm))
14.8 ± 4.9
1st step – (1.5 ± 0.5)
2nd step – 63.7 ± 9.8
(6.5 ± 1.0)
– 63.7 ± 9.8
3rd step (6.5 ± 1.0)
❈3
Mounting bolt of after-cooler assembly:
24.5 ± 9.8 Nm (2.5 ± 1.0 kgm)
(Only the bolts marked ✰ in the diagram DEW01399
on the right.)
❈4 Fuel injection pipe
Sleeve nut : 22.6 ± 2.9 Nm (2.3 ± 0.3 kgm)
❈5
Lead mounting nut :
1.5 ± 0.5 Nm (0.15 ± 0.05 kgm)
❈6
Mounting bolt of nozzle holder :
44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
❈7
Mounting bolt of cylinder head cover :
8.8 ± 1.0 Nm (0.9 ± 0.1 kgm)
30-25
❈8
« Tighten the mounting bolts and nuts in turn,
starting from the center and working to the out-
side.
« Check that the ball of the adjustment screw is
fitted securely in the socket of the push rod.
« Adjust the valve clearance. For details, see TEST-
ING AND ADJUSTING, Adjusting valve clear-
ance.
Rocker arm mounting bolt, nut :
24.5 ± 4.9 Nm (2.5 ± 0.5 kgm)
Locknut : 44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
❈9
« If any rust of more than 5 mm square is found
on the shaft or the thread of the bolt, replace the
Order tightening head bolts
head bolt with a new bolt.
« Be careful to check that there is no dirt or dust
on the mounting surface of the cylinder head or Intake side
inside the cylinder. 22 14 3 5 11 19
« When installing the gasket, check that the grom- 25

#1
18
#2
10
#3
1
#4
7
#5
15
#6
23
mets have not come out. Front 26 16 8 2 9 17 24

Rear
« Tighten the cylinder head mounting bolts 2 – 3 20 12 6 4 13 21
turns by hand, then tighten in the order given in Exhaust side

the diagram.
Mounting bolt: DEW01400
Anti-friction compound (LM-P)
Cylinder head mounting bolt:
Torque
Step Tightening torque (Nm (kgm))
1st step 98 ± 9.8 (10 ± 1.0)
2nd step 147 ± 4.9 (15 ± 0.5)

(make a mark on the cylinder head
3rd step 90°
+ 30°
and bolt before tightening.)
– 0°
« After tightening, make one punch mark on the

bolt head to indicate the number of times it has Make marks on bolt
been tightened. and cylinder head
• If any bolt already has five punch marks, do not
reuse it. Replace it with a new bolt. 90ß +30ß
0
Add water through the water filler to the speci-
fied level. Run the engine to circulate the water
through the system. Then check the water level
again.
DEW01401
30-26
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
Stop the machine on level ground and install the

safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
Release the remaining pressure in the piping.
« When operating the levers, raise portion a of the

bucket 30 – 50 mm and lower portion b to the a b DEW00447
ground, then stop the engine.
« After operating the levers, check that the whole
bottom surface of the bucket (both portion a and
portion b) are in contact with the ground. 1
« Loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic tank. Then operate the
control levers several times to release the remaining
pressure in the hydraulic piping.
Disconnect the cable from the negative (–)terminal
of the battery.
1. Cover
1) Remove mounting bolts, then remove inspection
cover (1). DBW01864
2) Loosen plugs (2) at top of hydraulic tank filter

and plugs (3) of pump piping to prevent oil
inside tank from flowing out.
DBW01865
2. Draining water ❈1
Loosen drain valve (4) and drain coolant.
« If the colant contains antifreeze, dispose of it
correctly.
Coolant : 53 l
4 DLW01866
30-27
3. Grill
1) Loosen mounting bolts of grill (5), then fit grill to 7 8
engine hood (6) temporarily, and remove light
wiring from clip portion of engine hood (6).
2) Disconnect wiring connector (7), and remove 5
grill (5).
« Open left and right side panels (8) to make
it possible to fit the lifting tool. 6
DLW01867
4. Engine hood
1) Remove radiator left and right plates (9) and
bottom cover (10).
9
2) Pass nylon rope through left and right hinge
portions of side panel (8), then connect to lifting
chain and lift at 4 points.
« Be careful that the lifting tool does not come
off.
« Fit the lifting tool with the exhaust pipe still
installed.
10
3) Remove the front, rear, left, and right mounting DLW01868
bolts and top front mounting bolts of engine

hood (6). q
Hood assembly : 6 8
200 kg (without rear fender)
Hood assembly :
260 kg (with rear fender)
« Thread size when using eyebolts for re-
moval : 12 mm
DLW01869
5. Wiring
13
1) Disconnect wiring connector (12) for radiator
water level sensor.
2) Disconnect hose (13) between radiator and sub-
tank at radiator end.
« To prevent the water from leaking out of the
sub-tank, bend the tip of the hose and fix it 12
with a band.
« Remove the sub-tank hose and wirings (14) 14
from the radiator clip.
DLW01870
30-28
6. Fan guard, stay ❈2

1) Remove mounting bolts of radiator stay (15) at
radiator end.
2) Remove fan guard (16). 16
« Be careful not to damage the radiator fins 15
when removing.
DLW01871
7. Radiator hoses ❈3
1) Disconnect radiator upper hose (17) at engine
end.
2) Disconnect radiator lower hose (18) at radiator 18
end.
19
« Loosen the hose clamp of the connection
portion at the radiator end.
17
DLW01872 DLW01873
8. Hydraulic piping ❈4
Disconnect oil cooler hoses (19), (20), (21), and
(22) at connection portion of tube at bottom of 21
radiator.
« Mask the openings to prevent water or dust from
entering.
22
20
DLW01874
9. Radiator ❈5
Remove mounting bolts of radiator (23) and lift off. 23
Radiator : 165 kg
« Be careful not to damage the radiator fins when
removing.
DLW01875
30-29
INSTALLATION OF RADIATOR
ASSEMBLY
moval.
❈1
« Run the engine to circulate the water through
❈2
« Temporarily install the radiator stays.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
« Install the fan guard so that the clearance be-
tween the fan and fan guard is uniform.
❈3
Hose clamp : 5.9 ± 0.5 Nm (0.6 ± 0.05
kgm)
❈4
« Fit the O-ring securely into the groove and be
careful that it does not get caught when assem-
bling.
« Install the hoses without twisting or interference.
Joint nut : 196 ± 49 Nm (20.0 ± 5.0 kgm)
(width across flats: 41 mm)
❈5
« Be careful not to damage the radiator fins.
« Install the radiator from the counterweight slowly.
« Install so that the clearance from the fan is
uniform.
Radiator mounting bolt :
176 ± 19.6 Nm (18.0 ± 2.0 kgm)
« Tighten the mounting bolts of the radiator stay
fully.
• Refilling with oil

1) Tighten drain valve and add transmission oil
through oil filler to the specified level.
« Run the engine to circulate the oil through
the system. Then check the oil level again.
Transmission : 35 l
2) Tighten plug at top of hydraulic tank filter and
plug of pump piping, then add hydraulic oil
through oil filler to specified level.
30-30
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY

« When operating the levers, raise portion a of the

bucket 30 – 50 mm and lower portion b to the a b DEW00447
ground, then stop the engine.
« After operating the levers, check that the whole
bottom surface of the bucket (both portion a and
portion b) are in contact with the ground.
« Loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic tank. Then operate the 1
pressure in the hydraulic piping. 2
1
of the battery.
1. Air conditioner compressor assembly ❈1

« Remove air conditioner compressor. 3 DBW01876
For details, see REMOVAL OF AIR CONDI-
TIONER COMPRESSOR.
« Leave air conditioner hoses (1) installed to com-
pressor (2), then remove mounting bolts (3) and 5
put the compressor assembly on top of the fuel
tank.
2. Radiator assembly ❈2
« Remove radiator assembly.
For details, see REMOVAL OF RADIATOR AS-
SEMBLY.
« Loosen connecting hose clamp (5) of radiator
lower tube (4) at engine end, then disconnect.
6 4
DBW01877
3. Heater hoses
1) Leave left heater hose (6) installed to radiator
lower tube (4). 7
2) Disconnect heater hose (8) from right side of

engine assembly (7).
« Fit a blind plug in the heater hose to pre-
vent antifreeze from flowing out.
3) Remove rubber (9) at bottom of bulkhead.

8 9
DBW01878
30-31
4. Electric wiring ❈3
Disconnect the following electric wiring. 11
« When disconnecting the wiring, fit tags to distin-
guish them.
1) Disconnect slow blow fuse wiring (10) from slow
blow fuse (11).
10
Starting motor
10
DBW01879
15
16 DBW01883
13
14
2) Disconnect engine wiring (12) from connectors

(13) and (14).
« Disconnect from the connectors at the bot- 12
tom right side of the bulkhead.
DBW01880
3) Disconnect cable (15) between starting motor

and battery relay from starting motor end.
4) Disconnect ground connection wiring (16).

15
« Remove the bracket for the transmission
valve wiring from the engine housing por-
tion.
16
DBW01881
5. Fuel hoses ❈4
Disconnect fuel hoses (17), (18), and (19) from fuel
tank end.
« When disconnecting the hoses, fit tags to distin-
19
guish them.
17
« Disconnect the hose clamps and bands.
« Disconnect the connectors of the fuel tank level
sensor wiring. 18
DBW01882
30-32
6. Fuel control cable ❈5

Remove locknut of fuel control cable (20), then
remove.
« Before removing the locknut, make match marks
to act as a guide when assembling.
20
DBW01884
8. Oil cooler hose bracket

Remove mounting bolts, then remove oil cooler hose
bracket (26) from engine.
« Loosen the hose lock U-bolt.
26
DBW01886
9. Drive shaft ❈7
Remove rear drive shaft (27). 27
« Make match marks to show the mounting posi-
tion.
DBW01887
30-33
10. Transmission support stand

Set support stand under transmission.
« Use a stand with adjustable height and fix it
securely so that it does not slip.
« Adjust to the correct height.
q DBW00075
11. Air cleaner assembly

1) Disconnect electric wiring of dust indicator (28) 28
from connecting portion.
2) Remove clip (30) from electric wiring (29). 29
30
DBW01888
3) Loosen clamp (32) of air cleaner hose (31), and

disconnect hose from air cleaner. 31
« Disconnect the hose at the turbocharger
end.
32 DBW01889
4) Remove mounting bolts of air cleaner bracket

(33), and lift off air cleaner assembly (34). 34
« Fit a cover to prevent water or dust from 33
entering.
« It is difficult to stand, so be extremely care-
ful when removing the air cleaner assembly.
a
« Remove the hose at the turbocharger end to
make it possible to fit the lifting tool to hook
a.
DBW01890
30-34
12. Muffler assembly

37 37 35
Sling muffler (35), remove left and right mounting
bolts, then lift off muffler together with bracket (36).
« When removing the muffler, be careful not to
damage drain tubes (37). 36
« It is difficult to stand, so be extremely careful 35
when removing the muffler.
Muffler assembly (with bracket) : 30 kg
DBW01891 DBW01892
13. Engine oil drain valve

38
Remove engine oil drain valve assembly (38) from
fuel tank.
« To prevent the drain valve from catching on any
other part when the engine assembly is re-
moved, coil the hose, raise it and tie it in posi-
tion with wire.
DBW01893
14. Engine assembly ❈8

41
1) Sling engine assembly (7), and remove left and
right mounting bolts (39) of engine.
« When slinging the engine, be sure to keep
it horizontal.
« Check the way that the cushion and spacer
are installed and use for reference when
installing.
2) Remove connecting bolt (41) of engine and
torque converter assembly (40).
3) After removing all connecting bolts (41), keep 39
horizontal, move approx. 30 mm to rear, then lift 40
DBW01894 DBW01895
off engine assembly (7).
« The engine flywheel ring gear and torque
converter ring gear and shaft are meshed,
so when raising the engine, be sure to keep
it horizontal.
« When raising the engine assembly, check
that there is no interference.
Engine assembly : 730 kg
7 DBW01896
30-35
INSTALLATION OF ENGINE
ASSEMBLY
moval.
❈1
« Install air conditioner compressor.
For details, see INSTALLATION OF AIR CON-
DITIONER COMPRESSOR.
❈2
« Install radiator assembly.
For details, see INSTALLATION OF RADIATOR
ASSEMBLY.
❈3
« Connect the electric wiring connectors securely.
❈4
« Match the distinguishing tags and connect the
hoses.
❈5
« See TESTING AND ADJUSTING for details of
adjusting the cable length.
❈7
« When connecting the drive shaft, clean the mat-
ing surface of the spider and the coupling,
mesh the pilot securely, and install.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈8
« Check that there is an O-ring at the torque
converter mating surface.
« When connecting the engine to the torque con- Bracket
verter, adjust the height so that the torque con-
verter pilot can enter smoothly. Never use force
to connect them. Washer
Outside circumference of O-ring : Cushion
Soapy water Engine
« Be careful of the direction of assembly of the Cushion
rubber cushion.
Washer
« Fit the rubber cushion securely into the groove
of the bracket. DBW01897
« Position the engine properly.

Mounting bolt :
549 ± 58 Nm (56.0 ± 6.0kgm)
(width across flats: 32 mm)
• Refilling with hydraulic oil
Tighten the plug at top of the hydraulic tank filter
and add hydraulic oil through the oil filler.
Filter top plug :
11.8 ± 1.0 Nm (1.2 ± 0.1 kgm)
333.5mm
667.0mm
DBW01898
30-36
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
REMOVAL OF TORQUE
CONVERTER CHARGING
PUMP ASSEMBLY 3

ground and stop the engine. Then apply the parking 1
« Open the left inspection cover and apply the
lock.
1. Cover
Remove cover (1) at bottom of cab, transmission 2 DBW00084
inspection cover (2), and side inspection cover (3).
2. Air conditioner hose, fuel control cable
Remove clamp of air conditioner hose (4), and raise
air conditioner hose and fuel control cable (5) with
wire. 5
DLW01899
3. Hydraulic piping
Disconnect the following hydraulic piping. (WA350-
3S)
• Tube (6) between transmission strainer and
charging pump
• Hose (7) between charging pump and torque
converter oil filter
• Hose (8) between charging pump and top of
transmission
« Disconnect the tubes and hoses from the
6
pump end.
DLW01900
Disconnect the following hydraulic piping. (WA350-

3H)
• Tube (6) between transmission strainer and 8 7
charging pump 8-1
7-1
• Hose (7-1) between charging pump and flange
at top of flow control valve
• Hose (8-1) between charging pump and flange
at top of flow control valve
« Disconnect the tubes and hoses from the
pump end.
DLW01901
30-41
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
4. Torque converter charging pump ❈1

Remove mounting bolts, and pull out torque con-
verter charging pump (9) from cover removal por-
tion.
« The working space is confined, so be careful
not to crush your hands or fingers.
« Carry out the removal operation with two work- q
ers, and fit lifting tool to prevent the pump
from falling.
Torque converter charging pump : 9

10 kg DLW01902
INSTALLATION OF TORQUE DLW01903
CONVERTER CHARGING
PUMP ASSEMBLY
moval.
❈1
« Check that there is an O-ring at the mating
surface with the housing.
« Fit the O-ring securely in the groove and be
careful not to get it caught when assembling.
30-42
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
REMOVAL OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
• Drain transmission oil.
Loosen the oil filler cap slowly to release the pres-

pressure in the hydraulic piping.

of the battery.
1. Loosen plugs (1) at top of hydraulic tank filter and

plugs (2) of pump piping to prevent oil inside tank 2
from flowing out.
2. Remove cab and floor frame assembly.

For details, see REMOVAL OF CAB, FLOOR FRAME
ASSEMBLY. 1 DBW01904
3. Remove bulkhead assembly as follows. ❈1

1) Disconnect air conditioner connector (3).
2) Disconnect air conditioner hose (4).
3) Disconnect 2 reservoir tank hoses (5).
4) Disconnect breather hose (6).
3
DBW01905
DBW01907
5 4 DBW01906
30-43
5) Sling bulkhead (7), remove mounting bolt, then

7
remove bulkhead.
DBW01908
4. Remove hose clamp (8), then remove pipes (9) and 9

(10) at top of hydraulic and steering pump.
10
8 DBW01909
5. Disconnect hoses (11) and (12) mounted at bottom

of hydraulic and steering pump. ❈2
13
« The hose flange and spacer are tightened to-
gether, so be careful not to lose them when
disconnecting hose (11).
6. Disconnect transmission cooler hose (13).
12
11 DBW01910
7. Sling hydraulic and steering pump assembly (14),

remove mounting bolts, then lift off. 14
DBW01911
30-44
8. Disconnect tube (15) between valve and cooler at

transmission valve end. 15
9. Remove 3 connectors (16) from clip and discon-

nect.
16
DBW01912
10. Remove connector (17) from clip and disconnect.

17
11. Disconnect hoses (18) and (19).
19
18
DBW01913
12. Disconnect front drive shaft (20). ❈3
20
DBW01914
13. Remove rear drive shaft (21). ❈4

« Be careful not to let the coupling fall out. 21
DBW01915
30-45
14. Set block between rear axle (22) and engine

flywheel, and support engine (23). 23
20
21 22
DBW01916
15. Remove oil filler tube (24).

25 26
16. Sling torque converter and transmission assembly,
remove left and right mounting bolts (25), then re-
move spacer (26) and cushion (27).
« Measure the clearances of clearance adjust-
ment bolt (28).
« Make match marks on the mount bracket and
rear frame mount, then measure the protrusion
of the positioning bolt, and use it as a guide
when assembling. ❈5
24 28 27
DBW01917
17. Lift off torque converter and transmission assembly

(29), taking care not to hit rear frame. 29
« When raising, be extremely careful of the mesh-
ing of the engine and torque converter gear.
❈5
Torque converter, transmission assembly:

700 kg
DBW01918
30-46
INSTALLATION OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY

moval.
❈1
Air conditioner hose sleeve nut :
22.1 ± 2.5 Nm (2.25 ± 0.25 kgm)
❈2
« When connecting the 3 hoses at the bottom of
the hydraulic and steering pump, check the
hose and spacer mount O-rings for damage and
deterioration before installing.
❈3 ❈4
Drive shaft mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈5
• Position torque converter and transmission assem-
bly as follows.
1) Replace the O-ring at the mating surface of the
engine and transmission with a new part, fit
securely in the groove, then align the tooth
groove of the ring gear and connect to the
engine.
2) Assemble cushion (27) and spacer (26).
« Assemble the cushion so that the cham-
fered surface is on the spacer side.
« When assembling the cushion, do not use 25 26
oil or soapy water under any circumstances.
3) Tighten mounting bolt (25) temporarily.
4) Adjust clearance of clearance adjustment bolt
(28). (4 places)
« Standard value for clearance a of clearance
adjustment bolt : 1 – 2 mm
Clearance adjustment nut :
549 ± 59 Nm (56.0 ± 6.0 kgm)
❈6
Mounting bolt (25) : 24 28 27
DBW01917
549 ± 59 Nm (56.0 ± 6.0 kgm)

Add transmission oil to the specified level. Run the
engine to circulate the oil through the system. Then
check the oil level again. 28
DBW01919
30-47
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Turbine, case assembly

1) Remove stator shaft and pump assembly (2)
from turbine and case assembly (3). 2
DEW00529
2) Disassemble turbine and case assembly as fol-

lows. 4
i) Remove pilot (4).
ii) Remove snap ring (5), then remove plate
(1). 5 1
DEW00530 DEW00531
iii) Push boss portion of turbine (6) and re-

move from case (7).
7
DEW00532
iv) Remove mounting bolts and disconnect tur-

bine (6) and boss (18).
6
v) Remove bearing (8) from case. 8
18
DEW00533 DEW00534
30-48
2. Stator
1) Remove snap ring (9).
2) Remove stator (10).
3. Stator shaft
Using forcing screws 1, push from stator shaft (11) 11
end and disconnect from pump assembly (12).
12
DEW00536
4. Gear
Remove gear (13) from pump (14). 13
14
DEW00537
5. Bearing
Remove bearing (15) from gear (13). 13
15
DEW00538
30-49
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
13
1. Bearing
Install bearing (15) to gear (13).
15
DEW00539
2. Gear
Install gear (13) to pump (14). 13
Mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
14
DEW00537
3. Stator shaft
1) Install seal ring (16) to stator shaft (11).
Seal ring: Grease (G2-LI)
« Make the protrusion of the seal ring uniform. 11
16
DEW00540
2) Push inner race of bearing and install pump

assembly (12) to shaft (11).
12
11
DEW00541
30-50
4. Stator
1) Install stator (10). 10 9
2) Install snap ring (9).
DEW00535
5. Turbine, case assembly

1) Assemble turbine and case assembly as fol-
lows.
i) Install bearing (8) to case. 8
« Press fit the bearing until it contacts the
case.
DEW00543
ii) Install boss (18) to turbine (6).

Mounting bolt: 6
Thread tightener (LT-2)
Mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
18
DEW00533
iii) Push inner race of bearing and install tur-

bine (6) to case (7).
7
DEW00545
30-51
iv) Fit plate (1) and install snap ring (5).

v) Install pilot (4). 4
Mounting bolt:
Mounting bolt: 5 1
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
DEW00531 DEW00530
2) Install turbine and case assembly (3) to stator

shaft and pump assembly (2).
Mounting bolt:
Mounting bolt: 2
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
3
DEW00529
30-52
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
• Remove the left and right mount brackets from the
transmission assembly first.
1. Oil filler, rear coupling 1
Remove oil filler (1) and rear coupling (2).
« Lower the transmission assembly and install it
to the assembly stand.
DLW00170 DLW00171
2. Hydraulic piping
1) Remove tube hose (3) between strainer and
charging pump.
3
2) Remove tube hose (4) between torque converter 4
filter and transmission valve from transmission
valve.
« Remove the tube clamps.
3. Transmission control valve 5

1) Remove modulation valve (5). DBW00172
2) Remove accumulator valve (6).
3) Lift off transmission control valve (7).
« Leave the upper valve and lower valve as-
sembly set bolts installed.
Transmission control valve assembly: 10

7
45 kg
DBW00173
4. Charging pump
1) Remove hoses and flanges (8) and (9) from
charging pump (10) and housing.
2) Remove charging pump (10).
« For the WA380-3, the charging pump pip-
ing and transmission valve portion are dif-
ferent.
10
9
8
DBW00174
30-53
5. Hydraulic piping 11
1) Remove PTO lubrication tube (11).
« Be careful not to crush the tube during the
operation. 9
« After removing the tube, fit a cover to pro-
tect the thread.
2) Remove clamp of hose (9).
DBW00175
6. Oil filter 11
1) Remove mounting bracket of oil filter (12), then
remove together with bracket, filter, and hose.
12 DBW00176
7. Rear housing
1) Remove torque converter pilot cap (13). A1 13
2) Install tool A1 to rear housing (14) and sling.
« Install tool A1 securely so that it does not
come off.
A1
14
DBW00177
3) Using forcing screws, raise rear housing (14),

then use tool A1 to lift it off. A1 A1
« Remove slowly and be careful not to dam-
age the seal ring.
« When removing, install a guide bolt to front 14
housing (15), then lift off horizontally.
Rear housing, torque converter

assembly : 190 kg 15
DBW00178
30-54
8. Torque converter
14
Lift off torque converter (16) from rear housing (14).
« Before removing, use a felt pen to make match
marks on the mating surface of the housing
and torque converter.
Torque converter assembly : 55 kg
Rear housing : 135 kg
16 DBW00179
9. Pump (torque converter, loader)

1) Remove snap ring (17) at torque converter pump 17
mount.
DBW00180
2) Turn over rear housing (14), remove snap ring

(19) of pump gear (18), then remove ring washer 14
(20) and split spacer (21).
14 19 18
18
21 20
DBW00181
23
22 DLW00183
21
17
20
3) Insert screwdriver between rear housing (14) 18

and shaft (22), then lever shaft and push down 21 19
to remove. DBW00182
30-55
4) Remove bearing (23) from shaft (22).

« Carry out the same procedure at the loader ¿93
pump end.
¿61
23
22
DLW00184
10. Seal ring

Remove seal rings (24) from each clutch shaft.
24 DBW00185
11. 2nd, 4th, and 1st, 3rd clutch

1) Remove 2nd, 4th clutch (25) and 1st, 3rd clutch
(26) together from housing bearing, then move 26
towards 2nd, 4th clutch output shaft.
« Remove 1st, 3rd clutch from bearing, then
move towards FORWARD, REVERSE side.
25 DBW00186
2) Using tool A3, lift off 1st, 3rd clutch (26).

« Remove slowly and take care not to hit any A3
26
other gear.
1st, 3rd clutch : 47 kg
DBW00187
30-56
3) Using tool A3, lift off 2nd, 4th clutch (25).

A3
2nd, 4th clutch : 54 kg
25
DBW00188
12. FORWARD, REVERSE clutch

A2
1) Using tool A2, pull out FORWARD, REVERSE
clutch (27).
Be careful not to get your fingers caught
between gear (32) and the housing.
FORWARD, REVERSE clutch : 44.1 kg
27
32 DBW00189
13. Bearing 32
1) Remove FORWARD, REVERSE outer bearing 31
(28), 1st, 3rd outer bearing (29), and 2nd, 4th
outer bearing (30) from housing.
30
14. Idler gear

1) Remove snap ring (31), then remove idler gear
(33) from housing.
2) Remove snap ring from idler gear (32), then

remove bearings (33). 28
29 DBW00190
32
33 DBW00191
30-57
15. Rear dust seal, oil seal

Remove dust seal (34) and oil seal (35).
34,35
DBW00192
16. Parking brake assembly

37 36
« Turn over the front housing.
1) Remove mounting bolts, then remove front cou- 40
pling (36), holder (37), and O-ring.
39
2) Remove mounting bolts, then remove lock plate
(38) and manual cancel bolt (39).
3) Remove mounting bolts, then remove cover (40)

and gasket (40-1). 38 40 - 1 DBW00193
« There is a dowel pin, so use forcing screws
to remove.
4) Remove dust seal (41) and oil seal (42) from 41

cover (40).
5) Install manual cancel bolt (39) to parking brake

housing (43), and set piston in FREE condition.
40
6) Tighten tool A4 with coupling mounting bolts.
« Bolt length of tool A4: 64 mm 42 DBW00194
7) Remove snap ring (44), remove tool A4, then

A4
remove end plate (45). 39
43
44 45 DBW00195
30-58
8) Remove separate plates (46), wave springs (47), 49 39

47 48 46
and discs (48), then remove hub (49) and spacer
(50).
« Remove the manual cancel bolt.
46
50 DLW00196
47 48 47 48
DLW00200
43 43 - 1
9) Set guide bolts (43-1) to parking brake housing
(43), then remove mounting bolts, and lift off.
« Loosen the mounting bolts uniformly a little
at a time.
« Guide bolt : (12 mm, pitch 1.75 mm, length:
130 mm)
« Install the lifting tool. (12 mm, pitch: 1.75
mm)
Parking brake housing : 21 kg
DBW00197
10) Turn over parking brake housing (43) and re- 53

move O-rings (51) and (52).
43
51
52 DBW00198
11. Remove piston (53) and snap ring (54) from park-
ing brake housing (43). 53 43
54
DLW00199
30-59
12) Remove piston seal rings (55) and (56) from

piston (53). P
53
55
53 56
DLW00201
13) Remove springs (57) and (58) from parking 43 - 1

brake retainer.
« Remove guide bolts (43-1).
57,58 DBW00202
17. Parking brake retainer 60

1) Remove mounting bolts (59) from front hous-
ing, then remove parking brake retainer (60).
« Check the number and thickness of the
shims (61) and use for reference when as-
sembling.
59 60
DBW00203
61
62
DLW00205
2) Remove bearing cup (62) from parking brake 60

DBW00204
retainer (60).
30-60
18. Output shaft gear

1) Support output shaft (63) from outside, and re- 63
move shroud (64).
DLW00206
« Fit a cover to the shaft spline to prevent

damage to the oil seal.
Cover
DBW00207
2) Remove shroud (64).

« Be careful not to cut your hand on the edge
of the shroud.
64
DBW00208
3) Remove snap ring (65) from groove, move to-

wards center, then move gear (66) to same
66
position as snap ring.
65
DBW00209
30-61
4) Push in shaft (63) towards rear, then pass shaft

through front housing and remove. 63
Be careful not to get your fingers caught
between gear and the housing.
« Be careful not to damage the spline groove
of the shaft.
5) Remove bearing cup (67).
67
DLW00210
6) Remove bearing cone (68), snap ring (65), gear

(66), and bearing cone (69) from shaft (63).
68 65 69
63 66
DLW00211
72
19. Covers
1) Remove covers (70) and (71).
« Remove both the O-rings.
2) Remove O-ring (72).

71
70 DBW00212
30-62
ASSEMBLY OF TRANSMISSION
ASSEMBLY
72
1. Covers
Assemble O-rings and assemble covers (70) and
(71) to front housing.
« Be careful not to the O-rings fall out.
« Install O-ring (72) to the mating surface of the 71
parking brake housing.
Outside circumference of O-ring :
Grease (G2-LI)
70 DBW00212
2. Output shaft gear

1) Press fit bearing cone (69) to output shaft (63),
assemble gear (66) and snap ring (65), then 68 65 69
press fit bearing cone (68).
« To prevent defective adjustment of the end
play, press fit the cone as far as the shoul-
der of the shaft.
« Do not insert snap ring (65) into the groove.
Move it to the center, then remove gear
(66) from the spline groove, and put it in the 63 66
same position as the snap ring.
DLW00211
2) Press fit bearing cup (67) to front housing.

« Press fit the bearing cup fully to the stepped 63
portion of the housing, and check that there
is no clearance.
67
DLW00213
3) Assemble shaft (63) to front housing.

« Set the shaft at an angle and insert it. 63
4) Support output shaft (63) from outside.

« Temporarily assemble the bolt and secure
with wire. Or carry out the work with two
workers and support it by hand.
DLW00206
30-63
5) Insert gear (66) in shaft spline portion, and se-

cure with snap ring (65).
66
6) Coat mounting bolts with thread tightener, and
install shroud (64).
« Wash and remove all oil and grease from
the mounting bolt hole and mounting bolt. 65
« Insert the shroud from immediately above
the gear, then turn over and assemble.
« Check that the gear does not interfere with
the shroud.
Mounting bolt : DBW00209
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
Mounting bolt :
64
DBW00208
3. Parking brake retainer

1) Press fit bearing cup (62) to parking brake re-
tainer (60). 60 62
« Press fit the bearing cup fully to the stepped
portion of the retainer, and check that there
is no clearance.
DLW00214
2) Turn over front housing (15).

« When turning over, be careful that the out-
put shaft does not become at an angle.
« Set a stand under the top of the front hous-
ing.
« After turning over, hold the output shaft bear-
ing cone in the bottom bearing cup.
15
DLW00215
30-64
3) Assemble desired shims (61) to parking brake

retainer assembly (60), then tighten 3 mounting
bolts (59) to specified torque. 59 60 Standard
Mounting bolt : shim thickness:
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm) @ @ @0.95mm
« To settle the bearing, rotate the shaft while
tightening. After tightening, tap the end face
of the shaft several times with a plastic ham-
mer to settle the bearing again.
« Coat the bearing well with oil.
« Standard shim thickness: 0.95 mm
Bearing: Transmission oil DBW00216
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
63
4) Tighten coupling mounting bolts to shaft (63)
and measure rotating torque.
« Rotating torque : 0.1 – 1 Nm (0.01 – 0.1
kgm)
« If a small torque wrench is not available, it
is possible to measure as follows.
« Install measurement plate (63-1) and re-
tainer plate to shaft (63), tighten coupling
mounting bolts, then install push-pull scale
to tip of plate (63-1) and measure.
• Plate length l : 100 mm DBW00217
• Reading of push-pull scale : 1.0 – 9.8
Nm (0.1 – 1.0 kgm)
« When measuring the rotating torque, do not
measure at the point where movement be- l
gins. Measure while it is rotating. 63 - 1
« If the rotating torque is not within the stand-
ard value, change the shim thickness to 63
adjust again. Push-pull scale
« If the rotating torque is within the standard
value, check that the end play is "O".
5) Assemble selected shims (61) to parking brake DLW00218

retainer (60), then assemble to front housing.
« Assemble the thinnest shim on the inside
and the thickest shim on the outside.
« Assemble so that the casting holes (3
places) are at the bottom. 59 60
Mounting bolt (59):
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
61
DLW00205
30-65
4. Parking brake assembly

43 - 1
1) Assemble springs (57) and (58) to parking brake
retainer.
« Keep the inner and outer springs in sets.
« Set guide bolts (43-1) in position.
Guide bolt : (12 mm, pitch: 1.75 mm, length:
130 mm)
57,58 DBW00202
2) Install seal rings (55) and (56) to piston (53).

P
« Be sure to assemble the piston seal facing
53
in the correct direction and without twisting.
55
53 56
DLW00201
3) Assemble snap ring (54) to parking brake hous-

ing (43), and install piston (53). 53 43
« Check that the snap ring is fitted securely in
the groove.
« Knock in the piston uniformly a little at a
time with a plastic hammer.
Outside circumference of seal ring,
sliding surface : Transmission oil
54
DLW00199
4) Assemble O-rings (51) and (52) to parking brake 53

housing (43).
43
« Fit the O-rings securely in the grooves.
« Coat the O-rings thinly with grease and stick
them on to prevent them from falling out.
Outside circumference of O-ring :
Grease (G2-LI)
51
52 DBW00198
30-66
5) Turn over parking brake housing (43), align with 43 - 1

guide bolts (43-1), and set in position. 43
« Lifting bolt : 12 mm, pitch: 1.75
DBW00197
6) Tighten parking brake housing (43) with 3 tem-

porary tightening bolts (43-2) uniformly and
screw in approx. 30 mm. Then replace one at a
time with standard bolts (43-3) and tighten uni- 43-2
formly.
« Temporary tightening bolt : 12 mm, pitch:
1.75, length: 60 mm
« Springs (57) and (58) are strong, so be

careful to tighten uniformly.
« Be careful not to let the O-ring fall out or DLW00219
get caught.
Mounting bolt (43-3) :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
43
43 - 3
7) Install manual cancel bolt (39) to parking brake
housing (43), and set piston to FREE position.
58
57
DLW00220
8) Align spacer (50) and hub (49) with output shaft

spline, then assemble. 39
47 48 46 49
9) Assemble separate plates (46), wave springs
(47), and discs (48).
« Align the separate plate with the parking
brake housing spline when assembling.
« Be careful not to let the plate or spring get
caught in the housing ring groove.
« Align the disc with the hub spline, then as-
semble.
« Be careful not to let the spring and plate
rest on top of each other. 50 DLW00196
30-67
10) Assemble end plate (45), then install tool A4,

and tighten with coupling mounting bolts. A4
39
« Bolt length of tool A4 : 64 mm
43
11) Install snap ring (44), and remove tool A4.
« Check that the snap ring is fitted securely in
the groove.
« Check that the shaft turns, then remove
manual cancel bolt (39).
44 45 DBW00195
12) Press fit oil seal (42) and dust seal (41) to
cover (40).
Press-fitting dimension a : 28.5 ± 1 mm
Press-fitting dimension b : 17.5 ± 1 mm 41
Lip of oil seal : Grease (G2-LI)
Coat lip of
oil seal with G2-LI
13) Install gasket (40-1) to parking brake housing
(43), align with dowel pin, then install cover (40). 42 ba
« Knock the cover in uniformly with a plastic 41
hammer.
« Be careful not to let the oil seal contact the
shaft.
Mounting bolt : 42 40 DLW00221
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
14) Tighten manual cancel bolt (39) by hand, lock 39

40
at position of lock plate (38), then tighten lock
plate (38) with mounting bolts.
Mounting bolt : 40 - 1
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
15) Tighten coupling (36), O-ring and holder (37)

with mounting bolts.
« Push the O-ring into the shaft groove.
« Be careful not to damage the oil seal. DLW00222
Outside circumference of coupling :
Transmission oil
Coupling mounting bolt :
37 36
549 ± 59 Nm (56.0 ± 6.0 kgm)
40
39
38 40 - 1 DBW00193
30-68
5. Rear oil seal, dust seal

1) Turn over front housing, and press fit oil seal
(35) and dust seal (34).
« Press fitting dimension a : 28.0 ± 1.0 mm
« Press fitting dimension b : 36.0 ± 1.0 mm 35, 34
DLW00223
b a 34 35
DLW00224
6. Idler gear
1) Press fit bearings (33) to idler gear (32). 32
2) Press fit idler gear (32) to shaft, and install
snap ring (31).
« If the shaft has been removed, cool the
shaft to –70°C, then press fit it to dimen-
sion g.
« Shaft dimension g : 46.5 ± 0.5 mm
32 g
33 DBW00191
32 31
30
DLW00225
7. Bearing
1) Assemble FORWARD, REVERSE outer bear-
ing (28), 1st, 3rd outer bearing (29), and 2nd, 28
4th outer bearing (30) to housing. 29 DBW00190
30-69
8. FORWARD, REVERSE clutch

1) Using tool A2, insert FORWARD, REVERSE 27
clutch (27) in housing, then align REVERSE
A2
gear and idler gear (32) and assemble.
Be careful not to get your fingers caught in
32
the gears.
DBW00226
9. 2nd, 4th, and 1st, 3rd clutch A3

1) Using tool A3, insert 2nd, 4th clutch (25) in
housing, and move it towards output shaft end.
25
DBW00227
2) Using tool A3, assemble 1st, 3rd clutch (26) to

housing. A3
« Do not fit the bearing at the bottom of the
clutch completely.
26
DBW00228
3) When 1st gear (73) passes 2nd, 4th clutch gear

(74), insert bearing of 2nd, 4th clutch into hous-
ing.
73
74
DLW00229
30-70
4) Insert 1st, 3rd clutch (26) into bearing assembly

portion. 26
« Check that each gear is correctly meshed
when inserting into the bearing.
« If the gears are not properly meshed, do
not use force. Rotate slightly to assemble.
25 DLW00230
10. Seal rings

Install seal rings (24) to each clutch shaft.
« Coat the seal rings well with oil, then assemble
and check that the rotation is smooth.
Seal ring : Transmission oil
24 DBW00185
11. Pump (torque converter, loader)

1) Press fit bearing (23) to shaft (22). Press
« Press fit so that there is no clearance at the
rear of the shaft.
22
23
DLW00321
2) Assemble gear (18), ring washer (20), and snap 19

ring (19) to inside of rear housing (14), then 14
insert shaft (22) from pump mount end. 18
20
22 DLW00232
30-71
3) Assemble split spacer (21) to stepped portion

of shaft, then assemble ring washer (20) to split 19
spacer, and install snap ring (19). 14
21 20
22 DLW00233
4) Turn over rear housing, and install snap ring

17
(17) at pump mount.
« Carry out the same procedure at the loader
pump end.
DBW00180
12. Torque converter

Using eyebolts, raise rear housing (14), then set to
mounting position of torque converter, and tighten
mounting bolts (16-1).
« Align the mounting bolt holes properly, be care-
ful of the meshing with the pump accessory
14
gear, and install.
« Blow in air to check if the oil holes are correctly
aligned.
Mounting bolt :
112.8 ±9.8 Nm (11.5 ± 1.0 kgm)
DBW00234
16-1
DLW00235
30-72
13. Rear housing

1) Using tool A1, raise rear housing (14), and as- A1 A1
semble to front housing (15).
« Screw guide pins into the front housing. (12
mm, pitch: 1.75 mm, length: 55 mm) 14
« Make sure that the gasket sealant is not
squeezed out inside the case. Be careful
also not to coat with too much gasket seal-
ant. 15
DBW00178
« See the right for details of the procedure for

coating with gasket sealant.
« Mesh the input shaft spline correctly.
« Be careful not to damage the seal ring of Outside
each shaft.
´1
Mating surface of housing :
Gasket sealant (Three Bond 1207B)
Housing mounting bolt : ´1 ´2
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm) Inside
´2
DBW00236
2) Assemble pilot cap (13).

« Remove all oil and grease from the bolt A1 13
hole before installing the mounting bolt.
Cap mounting bolt :
Cap mounting bolt :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
« Remove tool A1 from rear housing (14).
A1
14
DBW00177
14. Oil filter 11

Assemble oil filter (12) with bracket assembly.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
12 DBW00176
30-73
15. Hydraulic piping

11
1) Install PTO lubrication tube (11).
« Be careful not to crush the tube during the
operation.
9
2) Assemble clamp to hose (9) between torque
converter oil filter and torque converter charg-
ing pump.
16. Charging pump

1) Assemble O-ring to charging pump (10), and
install to transmission.
« Be careful not to get the O-ring caught. DBW00175
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
2) Install hose and flange (8) and (9) to charging
pump (10) and rear housing.
« Be careful not to get the O-ring caught.
Hose, flange (pump end) :
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
Hose, flange (housing end) :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
Hose joint :
10
177 ± 29 Nm (18.0 ± 3.0 kgm)
« For the WA350-3H, the charging pump ˜pip- 9
ing ˜and transmission valve are different, so 8
be careful not to make any mistake when DBW00174
assembling.
17. Transmission control valve

1) Install guide bolt to mount portion of transmis-
sion control valve (7).
« Wash and remove all oil and grease from 7
10
the control valve mounting bolt hole and
mounting bolt thread.
2) Align with guide bolt and assemble gasket, then
fit control valve (7) temporarily.
3) Coat mounting bolts of control valve (7) with
thread tightener and tighten. 6
« Tighten the mounting bolts in turn on dia-
metrically opposite sides and be careful not DBW00173
to tighten too much.
« The length of the mounting bolts is differ-
ent, so be careful when using them.
Mounting bolt : ´140
Mounting bolt :
34.3 ±4.9 Nm (3.5 ± 0.5 kgm) ´90
´85
´115
DBW00237
30-74
4) Assemble O-ring to accumulator valve (6), and

install to transmission.
« Wash and remove all oil and grease from 5
the mounting bolt hole and mounting bolt.
Mounting bolt :
Mounting bolt :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
5) Align gasket with modulation valve (5) and as- 6
semble to transmission valve.
the mounting bolt hole and mounting bolt. DLW00238
Mounting bolt :
Mounting bolt :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
3
1) Install tube and hose (4) between torque con-
verter filter and transmission valve to transmis-
sion valve.
« Install the tube clamps.
the mounting bolt hole and mounting bolt.
Mounting bolt : 5
Thread tightener (LT-2) DBW00172
Mounting bolt :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
2) Install tube hose (3) between strainer and charg-
ing pump.
Mounting bolt (pump end) :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
Mounting bolt (strainer end) :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
Hose clamp :
4.4 ± 0.5 Nm (0.45 ± 0.05 kgm)
19. Oil filler, rear coupling

1) Sling transmission assembly and lift off from
assembly stand.
« When standing the transmission assembly
up, be careful of the center of gravity, and
lift off slowly.
2) Assemble O-ring and install oil filler (1). 1
Mounting bolt :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
DLW00170
30-75
3) Assemble so that rear coupling (2) and front

coupling face in same direction.
DLW00239
20. Adjusting speedometer sensor

Transmission case
1) Screw in sensor (75) until it contacts outermost
surface of gear (76).
« Before installing the sensor, check that the
gear is at the outermost circumference in
relation to the mounting surface.
« When screwing in the sensor with a wrench,
stop before it contacts the gear, and finally
tighten by hand until it is lightly in contact. 1/2 - 1 turn
2) After sensor (75) contacts gear (76), turn it back
1/2 – 1 turn, and secure it in position with locknut 77
(77). 76 75 DLW00240
« When securing with the locknut, hold the
nut with a wrench when tightening.
Sensor thread portion :
Gasket sealant (LG-5)
Sensor locknut :
58.8 ± 9.8 Nm (6.0 ± 1.0 kgm)
« Install the transmission bracket.
30-76
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DISASSEMBLY OF TRANSMISSION
CLUTCH PACK ASSEMBLY
Disassembly of FORWARD, REVERSE clutch pack
The clutch pack is oily, so be careful not to let it slip
when setting the clutch pack on the stand. Be care-
ful also not to get your fingers caught between the
1
stand and the clutch pack.
« Set on tool B1 with the FORWARD clutch side at
the top.
1. Bearing
Using puller, remove bearing (1).
DBW00242
2. Spacer, FORWARD gear

Remove spacer (2), thrust washer (3), needle bear-
ing (4), FORWARD gear (5), thrust washer (6), thrust
7 4 2
bearing (7), and washer (8).
8 6 5 3
DBW00243
3. End plate B5
B3
1) Install tools B3 and B5, then tighten tool B4,
and remove ring (9). B4
« After removing the ring, remove tool B3.
DBW00244
2) Remove end plate (10).
10
DBW00245
30-79
4. Clutch plate
Remove plate (11), disc (12), and spring (13) from 13 12 11
housing.
B1
DBW00246
5. Piston
Blow air in FORWARD oil hole of shaft and remove 14
piston (14).
« If the piston is at an angle and cannot be re-
moved, push the piston in and try to remove it
again.
« Do not use force to remove it. The inside cir-
cumference of the cylinder will be damaged.
DBW00247
6. Return spring, plate

Remove snap ring (14-1), them remove plate (14-
2), return spring (14-3), and plate (14-4).
« Return spring (reference value)
14-2 14-1
• Free length : 100 mm
• Installed length : 45 mm 14-3
• Installed load : 14-4
612 ± 25 Nm (62.4 ± 2.6 kgm)
When removing snap ring (14-1), there is danger
that the snap ring and washer will fly off under the
force of the spring, so use ample force to push the
spring down, then remove the snap ring slowly from
the groove in the shaft. DLW01920
7. Snap ring
« Set on tool B1 with the REVERSE clutch side at
the top. 15
16
Remove snap ring (15). 18
19
8. Bearing, REVERSE gear 20
Using puller, remove spacer (16), gear (17), inner 21
17
bearing (18), spacer (19), thrust washer (20), nee-
dle bearing (21), thrust washer (22), thrust bearing
(23), and washer (24). 22
Use the same procedure as in Steps 3 – 5 for the 23
FORWARD gear to continue disassembly.
24 DBW00248
30-80

Remove snap ring (24-1), then remove plate (24-2),
return spring (24-3), and plate (24-4).
« The free length and other dimensions for the 24-1 24-2
return spring are the same as in Step 6.
24-3
24-4
DLW01921
10. Shaft, cylinder

1) Remove snap ring (26) from shaft and housing 27 28 26
(25), then remove housing (27).
2) Remove snap ring (28), then remove housing
(27).
25
DLW00249
30-81
Disassembly of 1st, 3rd clutch

29
« Set on tool B1 with the 1st clutch side at the top.
1. Idler gear 30
1) Remove snap ring (29), then using puller, re-
31
move spacer (30), inner bearing (31), and idler 33
34
gear (32).
35
32
2. 1st gear
1) Remove snap ring (33), then remove thrust DBW00250 DBW00251
washer (34).
2) Remove 1st gear (35), and needle bearings (36)
and (37).
37 36
35 34
DBW00252
3. End plate
1) Install tool B3 and B5, then tighten tool B4, and
remove ring (38).
B4
« After removing the ring, remove tool B3. B5
B3
38
B1
DBW00253
2) Remove end plate (39).
39
DBW00254
30-82
4. Clutch plate
42
1) Remove plate (40), disc (41), and spring (42) 41 43
from housing.
2) Remove thrust washer (43).
40
DBW00255 DBW00256
5. Piston
Blow air in REVERSE oil hole of shaft, and remove
piston (44). 44
again.
DBW00257
6. Bearing
Set on tool B1 with the 3rd clutch side at the top.
Using puller, remove bearing (45).
45
B1
DBW00258
7. 3rd gear
Remove spacer (46), thrust washer (47), needle
bearing (48), and 3rd gear (49). 48
« Use the same procedure as in Steps 3 – 5 for 46
the 1st gear to continue disassembly.
49 47
DLW00259
30-83
Disassembly of 2nd, 4th clutch pack

« Set on tool B1 with the 4th clutch side at the
top.
1. Idler gear 51
Fit puller to idler gear (50), then remove bearing 50
(51) together with idler gear.
B1
DBW00260
2. 4th gear
1) Remove thrust washer (52), 4th gear (53), nee-
dle bearing (54), and thrust washer (55).
2) Remove snap ring (56), spacer (57), and nee-
dle bearing (58) from 4th gear (53).
55 53 54 52
DBW00261
3. End plate
1) Install tools B3 and B5, then tighten tool B4, 56 57 58 53
and remove ring (59).
« After removing the ring, remove tool B3.
2) Remove end plate (60). DLW02260
60 B4
59
B5
B3
DBW00263 DBW00262
30-84
4. Clutch plate 63
Remove plate (61), disc (62), and spring (63) from
62
housing. 61
B1
DBW00264
5. Piston
Blow air in 4th oil hole of shaft, and remove piston
64
(64).
again.
DBW00265
6. Idler gear
« Set on tool B1 with the 2nd clutch side at the
top.
65
1) Remove snap ring (65).
68 66
2) Using puller, remove spacer (66), inner bearing
(67), and idler gear (68). 67
« When fitting the puller, put the plate in contact
with the center first. 69
70
DLW02267
7. 2nd gear
Remove thrust washer (69), needle bearing (70),
2nd gear (71), and thrust washer (72).
« Use the same procedure as in Steps 3 – 5 for
the 2nd gear to continue disassembly.
72 71 70 69
DBW00266
30-85
ASSEMBLY OF
TRANSMISSION CLUTCH
PACK ASSEMBLY
Assembly of FORWARD, REVERSE clutch pack 25
• Set on the assembly stand with the REVERSE clutch
26
side at the top.
1.Housing 28
Assemble snap ring (28) to one side of housing
27
(27). DLW00267
2. Shaft, housing
1) Put housing (27) and snap ring (27) on tool B1.
2) Assemble shaft and housing to housing (27),
and install snap ring (26).
73
3. Piston seal Piston seal
Assemble piston seal (73-1) to piston (73). 73-1
before using tool B6
« When assembling a new piston seal, use tool
B6 to make the seal fit well (time: approx. 2 – 3 73
minutes), then assemble the seal.
« If the seal is assembled to the cylinder without
making it fit first, the seal will be damaged.
Inside surface of tool B6 : 73-1 B6
Transmission oil (F¥R)
DLW00268
4. REVERSE piston
Install REVERSE piston (73).
« Be careful not to damage the piston seal.
« Check that the spring pin does not extend from 73
the circumference of the shaft.
Sliding surface of piston seal :
Spring side
Transmission oil
24-4
B1
Cylinder side

1) Assemble plate (24-4), return spring (24-3), and DLW01922 DBW02296
plate (24-2) to shaft.
« Check that plate (24-4) is facing in the cor-
rect direction for assembly, then insert it on
the shaft.
2) Assemble snap ring (24-1) to shaft, then use a
ring clamp to push in so that snap ring fits in 24-1 24-2
shaft groove.
« Check that the snap ring is fitted in the 24-3
24-4
shaft groove.
« Be extremely careful that the ring clamp
does not come off.
« Installed load of spring :
612 Nm (62.4 kg)
DLW01921
30-90
6. Clutch plate 74
Insert tool B2 into housing, then assemble plate 75
(74), disc (75), and spring (76) in turn. 76
« Soak disc (75) in clean transmission oil for at
least 2 minutes before assembling. B2
« Be careful to assemble so that disc (75) and
spring (76) are not resting on each other.
« Be careful that the plate or spring are not caught
in the clutch housing ring groove when assem-
bling.
DBW00270
7. End plate
1) Install tools B3 and B5, then tighten tool B4 to B3
B4
push in end plate (77). B5
2) Assemble ring (78), and remove tool B3.
« Check that the disc rotates smoothly by
hand.
78
77
DBW00271
8. Thrust washer
Assemble washer (24), thrust bearing (23), thrust
washer (22).
9. REVERSE gear 21
Align spline groove on inside of plate with a screw- 17
driver to assemble gear (17).
« If the gear spline does not match, turn lightly 22
when assembling. Never use force to push it in.
23
10. Needle bearing 24
Assemble needle bearing (21) and thrust washer DLW02268
(20).
« Check that the end face of the thrust washer is
below the surface of the stepped portion of the
shaft. 15
16
11. Bearing 18
19
1) Assemble spacer (19), then press fit inner bear- 20
ing (18) and spacer (16).
« Press fit completely so that there is no clear-
ance.
Thrust washer : Transmission oil
2) Assemble snap ring (15).
DLW02269
30-91
3) After press fitting bearing, check that clearance

"a" between thrust washer and spacer is within
standard value. a
« a = 0.106 – 0.991 mm
DLW02270
12. FORWARD piston

1) Turn over clutch pack.
14
When turning over the clutch pack, be care-
ful not to get your fingers caught between
the stand and clutch pack.
2) In the same way as with REVERSE piston, make
sure that piston seal fits well before assembling
it to piston (14).
3) Assemble piston (14) in the same way as RE-
VERSE piston.
Transmission oil DBW00272

1) Assemble plate (14-4), return spring (14-3), and
plate (14-2) to shaft.
« Check that plate (14-4) is facing in the cor- 14-1 14-2
rect direction for assembly, then insert it on
14-3
the shaft. 14-4
Spring side
14-4
Cylinder side
DLW01924
DLW02297
2) Assemble snap ring (14-1) to shaft, then use a

ring clamp to push in so that snap ring fits in
shaft groove.
« Check that the snap ring is fitted in the
shaft groove.
« Be extremely careful that the ring clamp
does not come off.
« Installed load of spring :
612 Nm (62.4 kg)
30-92
14. Clutch plate 13

Insert tool B2 in housing, and assemble plate (11), B2
disc (12), and spring (13) in turn. 12
« Assemble in the same way as for the REVERSE
clutch plate.
11
DBW00273
15. End plate

B3 B4
1) Install tools B3 and B5, then tighten tool B4 to
push in end plate (10).
« Assemble in the same way as for the RE-
VERSE end plate.
B5 9
10
DBW00274
16. Thrust washer

Assemble washer (8), thrust bearing (7), and thrust 4
washer (6). 5
Thrust washer : Transmission oil 6
17. FORWARD gear

Assemble FORWARD gear (5). 7
« Assemble in the same way as for the REVERSE
gear.
18. Needle bearing 8

Assemble needle bearing (4). DBW00275 DLW00276
30-93
19. Spacer
Assemble thrust washer (3), then assemble spacer 3
(2). 2
« Check that the end face of the thrust race of
the thrust washer is below the surface of the
stepped portion of the shaft.
DBW00277
20. Bearing
Press fit bearing (1).
« Press fit completely so that the spacer is in tight 1
contact with bearing (1) at the stepped portion
of the shaft.
DBW00278
« After press fitting bearing (1), check that clear-

ance "b" between the thrust washer and the
spacer is within the standard value. 1
b
« b = 0.106 – 0.991 mm
DLW02271
21. Clutch pack operation test

FORWARD, REVERSE clutch assembly
Blow in compressed air through oil hole in shaft and
check that each clutch works properly.
« If the gear where the air is blown in is held in
position, the clutch is working properly.
DBW00279
30-94
Assembly of 1st, 3rd clutch pack

« Set the shaft housing on the assembly stand
with the 3rd clutch side at the top.
1. Piston seal
Assemble piston seal (79-1) to piston (79). 79
« When assembling a new piston seal, use tool
B7 to make the seal fit well (time: approx. 2 – 3 79-1 Piston seal before
using tool B7
« If the seal is assembled to the cylinder without 79
making it fit first, the seal will be damaged.
Inside surface of tool B7 :
Transmission oil
79-1
B7
DLW00280
2. 3rd piston
Install 3rd piston (79).
79
« Check that the spring pin does not extend from
Transmission oil
B1
DBW00281
3. Clutch plate
Assemble plate (80), disc (81), and spring (82) in
82 81 80
turn to housing.
least 2 minutes before assembling.
« Be careful that plate (80) or spring (82) are not
caught in the clutch housing ring groove when
assembling.
DBW00282
30-95
4. End plate
1) Install tools B3 and B5, then tighten tool B4 to B3 B4
« Check that ring (84) is fitted securely in the
groove. 84
hand.
83
B5
DBW00283
3) Assemble thrust washer (85).

49
5. 3rd gear 85 48
Assemble 3rd gear (49), then assemble needle bear-
ing (48).
« If the gear spline does not match, turn lightly
« Assemble the needle bearing at the bottom first.
DBW00284 DBW00285
6. Bearing
Assemble thrust washer (47) and spacer (46), then
press fit bearing (45).
« Check that the end face of the thrust washer is 45
shaft.
46
« Press fit completely so that the spacer is in tight
contact with bearing (45) at the stepped portion
of the shaft. 47
DBW00286
« After press fitting bearing, check that clearance
"d" between thrust washer (47) and spacer (46)
is within standard value.
« d = 0.1 - 0.9 mm
d
46
DLW02272
30-96
7. 1st piston
1) Turn over clutch pack. 44
ful not to get your fingers caught between
2) In the same way as with 3rd piston, make sure
that piston seal fits well before assembling it to
piston (44).
3) Assemble piston (44) in the same way as 3rd
piston.
8. Clutch plate
42 41
turn to housing.
« Assemble in the same way as for the 3rd clutch
plate.
40
DLW00288
9. End plate
push in end plate (39). B3 B4
B5
2) Assemble ring (38), and remove tools B3 and
B4.
« Assemble in the same way as for the 3rd 39
end plate.
38
DBW00289

35
10. 1st gear
1) Assemble 1st gear (35) and needle bearing (37). 43
« Assemble in the same way as for the 3rd
37
gear.
DBW00290 DBW00291
30-97
2) Assemble needle bearing (36) and thrust washer 34

(34).
3) Assemble snap ring (33). 36
« Fit the snap ring securely in the groove of
the shaft.
DBW00292
11. Idler gear

29
1) Assemble idler gear (32).
30
12. Bearing
31
1) Press fit inner bearing (31) and spacer (30). 33
34
2) Assemble snap ring (29).
« Fit the snap ring securely in the shaft groove.
35
32
DBW00251 DBW00250
« After press fitting the bearing, check that

clearance "c" between the thrust washer
and the gear is within the standard value.
« c = 0.02 – 1.58 mm
DBW00293

1st, 3nd clutch assembly
check that each clutch works properly.
DBW00294
30-98
Assembly of 2nd, 4th clutch pack

« Set the shaft housing on tool B1 with the 2nd
clutch side at the top.
1. Piston seal
Assemble piston seal (86-1) to piston (86). 86
« When assembling a new piston seal, use tool Piston seal before
B7 to make the seal fit well (time: approx. 2 – 3 using tool B7
86-1
« If the seal is assembled to the cylinder without
making it fit first, the seal will be damaged. 86
Inside surface of tool B7 :
Transmission oil
86-1
B7
DLW01926
2. 2nd piston
Install 2nd piston (86).
86
« Check that the spring pin does not extend from
Shaft housing
B1
DBW00296
3. Clutch plate
Assemble plate (87), disc (88), and spring (89) in 89
88
turn to housing.
least 2 minutes before assembling.
« Be careful that the plate or spring are not caught
in the clutch housing ring groove when assem-
bling.
87
DBW00297
30-99
4. End plate
B3 B4
B5
hand. 91
90
DBW00298
5. Thrust washer
Assemble thrust washer (72). 71 70
6. 2nd gear 72
Assemble 2nd gear (71), then assemble needle bear-
ing (70).
« If the gear spline does not match, turn lightly
7. Idler gear
Assemble thrust washer (69) and idler gear (68).
« Check that the end face of the thrust washer is
shaft.
Thrust washer : Transmission oil DBW00299 DBW00300
8. Bearing
1) Press fit inner bearing (67) and spacer (66).
2) Assemble snap ring (65). 65
« Fit the snap ring securely in the shaft groove.
68 66
« After press fitting the bearing, check that
clearance "e" between the thrust washer 67
and the idler gear is within the standard
value. 69
« e = 0.34 – 1.66 mm
70
DLW02267
65
66
67
e
68
DLW02273 DBW00301
30-100
9. 4th piston
1) Turn over clutch pack.
ful not to get your fingers caught between 64
2) In the same way as with 1st piston, make sure
that piston seal fits well before assembling it to
piston (64).
3) Assemble piston (64) in the same way as 2nd
piston.
10. Clutch plate 61

62
turn to housing.
« Assemble in the same way as for the 2nd clutch 63
plate.
DBW00303
11. End plate

push in end plate (60). B3
2) Assemble ring (59), and remove tool B3. 59
« Assemble in the same way as for the 2nd 60
end plate.
B5
B4
DBW00304
55
DBW00305
30-101
12. 4th gear

1) Assemble in same way as for 2nd gear. 56 57 58 53
2) Assemble needle bearing (58), spacer (57), and
snap ring (56) to 4th gear (53), then assemble
4th gear (53).
3) Assemble top needle bearing (54).
« Check that the end face of the thrust washer
is below the surface of the stepped portion
of the shaft.
DLW02260
13. Bearing
Assemble idler gear (50), then press fit bearing (51). 52
« Press fit completely so that the idler gear is in 54
tight contact with bearing (51) at the stepped
portion of the shaft.
« After press fitting the bearing, check that clear- 53
ance "f" between the thrust washer and the
idler gear is within the standard value.
« f = 0.17 – 1.43 mm
DBW00306
51 50
f
DLW02274
DBW00307

check that each clutch works properly. 2nd. 4th clutch assembly
DBW00308
30-102
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
3
brake and put blocks under the wheels to prevent 1
1. Remove covers (1), (2), and (3).
2 DBW00084
2. Remove parking brake hose (4), elbow (5), and

nipple (6).
6 5
DBW00309
3. Remove accumulator valve (7).
Accumulator valve : 8.5 kg ❈ 1
4. Torque converter cooler tube

1) Remove mounting bolts, and disconnect torque 7
converter cooler tube (8). ❈ 2
2) Remove lock bracket (9) of torque converter
cooler tube (8) from engine. DBW00310
« Move the tube up.
8 9 8
DBW00312 DBW00311
30-103
5. Electric wiring
1) Disconnect clamp of transmission wiring (10)
from transmission valve. 10
2) Disconnect transmission wiring (11), (12), (13),
(14), and (15) from transmission valve. 11 (T05)
❈3
« Fit tags to distinguish the wiring. 12 (T04)
13 (T03)
14 (T01)
DBW00313
6. Disconnect tube (16) between transmission filters

15 (T02) 16
from transmission valve. ❈4
« Remove the valve mounting bolts, then remove
clamp (17).
17
DBW00314
7. Remove modulating valve (18). ❈5
8. Sling transmission valve assembly (19), then re-

move mounting bolts, and lower assembly under
chassis. ❈6 18 DBW00315
« Leave upper and lower valve mounting bolts
(20) installed.
« Remove together with the wiring bracket. 19 20
The working space is confined, so be extremely
careful when carrying out this operation.
« When fitting the lifting tool, avoid the connec-
tors, fit securely to the valve body, and be care-
ful to maintain the balance.
Transmission valve : 46 kg
« The valve mounting bolts for the WA350-3S
and WA350-3H are different, so record the
mounting position of the mounting bolts.
20 DBW00316
30-104
INSTALLATION OF
TRANSMISSION CONTROL WA350-3S
VALVE ASSEMBLY
´80 ´90
moval.
20
❈4
« Use a new part for the O-ring.

« Wash and remove all oil and grease from the
mounting bolts and bolt holes.
Mounting bolt : Thread tightener (LT-2)
Mounting bolt :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
❈3
´140
Connect the wiring connector securely.
❈5
« Use a new part for the gasket.
mounting bolts and bolt holes.
20
Mounting bolt: Thread tightener (LT-2)
Mounting bolt :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm) ´115 DBW00317
❈6
The working space is confined, so be extremely WA350-3H

« Use a new part for the gasket.
« Use guide bolts to prevent the part from falling
out during installation. ´=40 ´=85
20 ´=90
« Lock with upper and lower valve set bolts (20).
valve mounting bolts and bolt holes.
´=45
Mounting bolt :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
Set bolt : 49 ± 4.9 Nm (5.0 ± 0.5 kgm)
« The mounting bolts on the WA350-3S and
WA350-3H are different, so be careful not to
make any mistake when installing.
20
´=115 ´=40
DLW01928
30-105
DISASSEMBLY OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
35
57 a
49 56
48 b
55
36
37
38
46
58
47
56
55 40
34 39
45
63 59 50 38
33
39 1
40 59
38
41
43 42
44
54
a 53
b 62
61 - 1
52
10
51 20 11 - 1
Lower valve 12 - 1
21
1 3 22
15
16
17
2 18
19
31 - 1
13 - 1
13 - 3 13 - 2
13 - 4
14 -1
14 - 3
8
14 - 2 9
32
7
5
6
24 - 1
23 - 1 4
DBW01930
30-112
1. Disconnection 11) Remove orifice (59) and plugs (61-1) and

Remove mounting bolts, then disconnect upper (63) from lower valve (1).
valve (2) from lower valve (1), and remove gas- « When removing the orifice, check the
ket (3). assembly position and use for reference
when assembling.
2. Disassembly of upper valve
1) Remove mounting bolts, remove lock plate
(4), then remove manual valve (5).
2) Remove O-ring (6) and orifice (7) from
manual valve (5).
3) Remove plug (8) and O-ring (9).
4) Remove mounting bolts, then remove sole-
noid valve (13-1) and O-ring (13-2).
5) Remove mounting bolts, then remove
bracket (10), cover (11-1), gasket (12-1),
modulating valve (13-3), modulating piston
(13-4), and modulating spring (14-1).
6) Remove valve (15), spring (16), valve (17),
main relief valve (18), and mode spring (19).
« Record the shim thickness.
7) Remove dummy spool (20), torque converter
out spring (21), and torque converter out
valve (22).
8) Remove mounting bolts, then remove cover
(23-1), gasket (24-1), pilot valve (14-2), and
spring (14-3).
9) Remove orifice (31-1) and plug (32) from
upper valve (2).
3. Disassembly of lower valve

1) Remove mounting bolts, then remove pilot
filter (33) and O-ring (34).
2) Remove mounting bolts, then remove park-
ing brake solenoid (35), and O-rings (36)
and (37).
3) Remove mounting bolts, then remove sole-
noid valve (38), and O-rings (39) and (40).
(41), gasket (42), F return spring (43), and
sleeve (44).
5) Remove priority valve (45).
6) Remove brake valve (46) and return spring
(47).
(48), gasket (49), and priority spring (50).
8) Remove F return spring (51) and sleeve
(52), then remove F–R valve (53).
9) Remove plug (54) from F–R valve (53).
10) Remove return spring (55) and spring spacer
(56), then remove speed valve (57) and H–
L valve (58).
30-113
35
57 a
49 56
48 b
55
36
37
38
46
58
47
56
55 40
34 39
45
63 59 50 38
33
39 1
40 59
38
41
43 42
44
54
a 53
b 62
61 - 1
52
10
51 20 11 - 1
Lower valve 12 - 1
21
1 3 22
15
16
17
2 18
19
31 - 1
13 - 1
13 - 3 13 - 2
13 - 4
14 -1
14 - 3
8
14 - 2 9
32
7
5
6
24 - 1
23 - 1 4
DBW01930
30-114
1. Assembly of lower valve « Check that there are no scratches,

1) Install plug (63) to lower valve (1). cracks, deformation, or any other dete-
Plug : Sealant (LG-1 or LG-5) rioration in the O-rings.
« Set the mounting angle of reverse sole-
Coat with sealant
noid valve (38) to 45°, then tighten the
nut.
Mounting bolt :
1.62 ± 0.15 Nm (0.165 ± 0.015 kgm)
6-7mm Solenoid nut :
2-3mm
12.5 ± 4.7 Nm (1.275 ± 0.475 kgm)
10) Fit O-rings (37) and (36) to parking brake
solenoid (35), and install parking brake so-
DLW00319
lenoid (35).
2) Install plug (61-1) and orifice (59) (ø1.1) to « Check that there are no scratches,
lower valve (1). cracks, deformation, or any other dete-
3) Install H–L valve (58), speed valve (57), rioration in the O-rings.
spring spacer (56), and return spring (55) Mounting bolt :
(L=48). 1.62 ± 0.15 Nm (0.165 ± 0.015 kgm)
4) Install plug (54) to F–R valve (53), then 11) Assemble O-ring (34) to pilot filter (33), then
assemble F–R valve, and install sleeve (52) install pilot filter (33).
and F return spring (51) (L=42). « Check that there are no scratches,
5) Install priority spring (50) (L=150), set gas- cracks, deformation, or any other dete-
ket (49) in position, then install cover (48). rioration in the O-rings.
Mounting bolt :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
Guide bolts
48
DBW00320
Mounting bolt :
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
« Install guide bolts.
« Replace the gasket with a new part.
6) Install return spring (47) (L=46) and brake
valve (46).
7) Install priority valve (45).
8) Install sleeve (44) and F return spring (43)
(L=42), set gasket (42) in position, then in-
stall cover (41).
Mounting bolt :
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
9) Assemble O-rings (40) and (39) to solenoid
valve (38), then install solenoid valve (38).
30-115
2. Assembly of upper valve 3. Connection

1) Install plug (32) to upper valve (2). Set gasket (3) to lower valve (1), and assemble
Plug : Sealant (LG-1 or LG-5) upper valve (2) with set bolts (2-1).
Coat with sealant « Replace the gasket with a new part.
Set bolt : 49 ± 4.9 Nm (5.0 ± 0.5 kgm)
6-7mm 2-1
2-3mm 2-1
DLW00319
2) Install orifice (31-1) (ø4.0) to upper valve

(2).
3) Assemble spring (14-3) and pilot valve (14-
2), set gasket (24-1) in position, then install
cover (23-1). DBW00321
Mounting bolt :
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
4) Install torque converter out valve (22), torque
converter out spring (21) (L=65), and dummy
spool (20).
5) Install mode spring (19) (L=163.5), main re-
lief valve (18), valve (17), spring (16) (L=26)
and valve (15).
« Install the recorded shim thickness to
the main relief valve, and set with the
mode spring.
6) Assemble modulating spring (14-1), modu-
lating piston (13-4), and modulating valve
(13-3), then install gasket (12-1), cover (11-
1), and bracket (10).
« Coat the modulating piston with oil, then
insert it in the modulating valve, and
assemble the valve assembly.
Outside diameter of modulating
piston : Transmission oil
7) Fit O-ring (13-2) in groove of solenoid valve
(13-1), then set solenoid valve to upper
cover (11-1), and tighten mounting bolts.
8) Fit O-ring (9) to plug (8), then install plug.
9) Install orifice (7) and O-ring (6) to manual
valve (5).
O-ring : Grease (G2-LI)
10) Install manual valve (5) to upper valve (2),
then install lock plate (4).
Mounting bolt :
53.9 ± 19.6 Nm (5.5 ± 2.0 kgm)
30-116
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY OF
TRANSMISSION
ACCUMULATOR VALVE
ASSEMBLY
1. Remove accumulator valve (4) from transmission
assembly (3).
2. Remove O-rings (1) and (2) from accumulator valve
3
(4). 2
3. Using pads, set accumulator valve body (9) in vice. 1 9
4
DBW00322
4. Remove mounting bolts (5) and (6), and assemble

guide bolts.
• M = 10, P = 1.5, L = Approx. 40 mm 7 5
5. Remove bolts (7) and (8), then remove cover (10)

together with guide bolts.
« The internal parts will come off together with
the cover, so be extremely careful not to dam-
age them when removing.
6 8
DBW00323
6. Pull out valve (11), springs (12) and (14), stoppers

(13) and (15), and spacers (16) and (17) from cover
(10).
« Fit tags to each spring, stopper, spacer, and
use for reference when assembling. 9
« Reference
• WA350-3S
Spring Stopper Spacer
8 Guide bolt 7
l = 135.8 l = 10
10 DBW00324
FWD l = 184.8
1ST l = 157.5 l = 110 l = 50
2ND l = 157.5 l = 110 l = 50

11
12 12
• WA350-3H
Spring Stopper Spacer 13 14
FWD l = 184.8 l = 135.8 l = 10
15 13
1ST l = 157.5 l = 110 l = 30
10
2ND l = 157.5 l = 110 l = 30
16 1ST FWD 2ND 16
17 DLW00325
30-117
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
7. Remove plugs (18) and (19) from cover (10).

18 10 19
• Plug : 5 mm (width across flats)
« Do not remove the plugs unless necessary.
« If plugs (18) and (19) have been removed, coat
the thread with thread tightener as shown in the
diagram below, then tighten the plugs.
« Be careful not to let the thread tightener drip on
to the hatched portion when coating with thread
tightener.
Plug : Thread tightener (LG-1)
DBW00326
6 — 7mm 2 — 3mm
DAW00327
ACCUMULATOR VALVE
ASSEMBLY 9
1. Using pads, set accumulator valve cover (10) in 20

vice. 21
20 11
« Be careful not to tighten the vice on the cover
with excessive force. 11
2. Assemble spacers (18), (17), and (16), stoppers
20
(13), (15), and (13), and springs (12), (14), and (12) 12
to accumulator valve cover (10), then insert valve 11 14
(11) from top of each spring.
3. Fit O-rings (20) and (21) in each groove of accumu-
lator valve body (9). 13
« Assemble the O-ring securely in the body 12
15
groove.
4. Assemble accumulator valve body (9) perpendicu- 16
larly from above cover (10), then temporarily install 17
with guide bolts. 13
« Assemble the body carefully and be sure that
the O-ring does not fall out. 10
5. Push in accumulator valve body (9), and remove 18
1st
guide bolts, then secure with standard bolt.
FWD
Mounting bolt : 2nd
54 ± 19.6 Nm (5.5 ± 2.0 kgm) DBW00328
• Mounting bolt : 8 mm (width across flats)
30-118
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE
SHAFT ASSEMBLY
a
1
1) Remove coupling and tube (1).
« Make match marks a to prevent the cou-
pling from being installed in the opposite
direction.
« Cover (2) is caulked at 2 places with a
punch, so do not remove it unless neces-
sary.
• If cover (2) was removed and the oil seal
was replaced. DEW00809
i) Remove cover (2).
« When removing cover (2), be care-
ful not to damage cover (2) or tube
(3). Caulking 5 4
« When removing the caulking, use a
screwdriver to raise the caulked
portion.
ii) Remove washer (4), oil seal (5) and
washer (6).
6
3 2
DBW01931
2) Loosen bolt (7), and remove coupling (8) and

retainer. 8
7
« Make match marks to prevent the coupling
from being installed in the opposite direc-
tion.
DBW01932
3) Using press, pull out flange bearing (9).

9
DLW01933
30-121
4) Remove bearing cap (10) from spider.

« Be careful not to lose the bearing inside
bearing cap (10).
10
DBW01934
5) Remove ring (11) and bearing (12), then re-

move spider (13).
11
13
12
DBW01935
Center drive shaft

2. Center drive shaft, rear drive shaft
1) Carry out the same operation as in Step 1) for
the front drive shaft.
DBW01936
Rear drive shaft
DBW01937
30-122
Center drive shaft

2) Remove bearing cap (14).
« Be careful not to lose the bearing inside 15
seal bearing cap (14).
Front drive shaft
3) Remove ring (15) and bearing (16), then re-
move spider (17). 15 Transmisson
14
15
14
15 DBW01938
Rear drive shaft

Rear axle
14 14
17 14
16 17
14
DBW01940
Transmission
14 17 DBW01939
30-123
ASSEMBLY OF DRIVE SHAFT

1. Spider, bearing
1) Set bearing (12) of spider (13) in mounting po-
sition, and after assembling spider (13), assem- 11
ble ring (11), then install.
« Assemble so that the grease nipples are 13
facing in the same direction.
« Use the same procedure for the front,
center, and rear drive shafts.
12
DBW01935
2) Assemble seal bearing cap (10).

« Check that the bearing and washer are in- 18
side the bearing cap.
Bearing cap: Grease (G2-LI) 10
« If the spider and bearing cap is worn, re-
place the spider and bearing as a set.
« When welding strap (18) of the cap, be
careful not to damage the bearing with the
heat.
« If cover (2) has been removed, do as fol-
lows.
1) Insert seal (5) and washers (4) and (6) DBW01941
in cover (2) and tube (3), then assem-
ble cover (2) and caulk with a punch at
points on diametrically opposite sides.
Caulking 5 4
6
3 2
DBW01931

1) Press fit flange bearing (9).
« Do not knock the flange bearing in directly 9
with a hammer.
DBW01942
30-124
2) Align match marks, and tighten coupling (8) and

retainer (19) with mounting bolt (7).
« Tighten the bolt to the specified tightening 7
torque after installing to the machine.
Spline portion: Grease (G2-LI)
Mounting bolt:
276 ± 29 Nm (28.2 ± 3.0 kgm)
19
8
DBW01943
3) Align match marks, and install coupling and tube

(1).
« Check that the couplings are facing in the
same direction.
1
« If the spline is worn, replace the whole drive
shaft assembly.
Spline portion: Grease (G2-LI)
DEW00819
Center drive shaft

3. Center, rear drive shaft
« Carry out the same operation as in Step 3) for
the front drive shaft.
DBW01936
Rear drive shaft
DBW01937
30-125
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL OF FRONT AXLE

ASSEMBLY

1. Jacking up chassis
Jack up chassis and insert block under front
frame. ❈1
« Jack up the front frame with the bucket, and set q
block in position when the tires are slightly DLW01944
off the ground.
2. Tire, wheel
Put sling around tire (1), then remove mounting
bolts and lift off. ❈2
Tire, wheel : 317 kg
1
DLW01945
3. Drive shaft ❈3
Disconnect front drive shaft (2).
4. Axle
1) Disconnect brake tube (3). ❈4
When removing the front frame inspection cover
and disconnecting the brake tube to carry out
the operation, set support under the lift arm.
2
DLW01946
q DBW01948 DLW01947
30-126
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL OF REAR AXLE

ASSEMBLY
1
1. Fuel tank
Remove fuel tank (1).
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY. DLW01951
2. Jacking up chassis
1) Set blocks between left and right rear axles
and rear frame.
« Set the blocks so that the angle of the tire
angle on the opposite side does not change
when the tire assembly is removed.
DLW01952
2) Jack up chassis and insert block under rear

frame.
« Jack up the rear frame with a garage jack,
and set block in position when the tires
are slightly off the ground.
w
DLW01953
3) Set support under counterweight (2).

« Set the support securely so that it does not
come out when the tire assembly is re-
moved.
e
DLW01954
30-129
3. Tire, wheel
Put sling around tire (3), then remove mounting
bolts and lift off. ❈1
Tire, wheel : 317 kg

3
DLW01955
4. Drive shaft
Remove rear drive shaft (4). ❈2 4
« Make match marks to show the mounting posi-
tion.
DLW01956
5. Brake, grease tubes

1) Disconnect brake hose (5). ❈3
« Disconnect this brake hose from the con-
5
nection with the tube at the left side of the
engine compartment. 5
DLW01957 DLW01958
2) Remove grease tubes (6) and (7). 6

« Remove the clamps of the grease tubes 7
from the inside right of the engine compart-
ment at the rear frame.
DLW01959
30-130
6. Axle
1) Secure rear pivot (8) to axle with chain or r
wire.
« Fix the pivot securely so that it does not
move.
« When removing the axle assembly, fit a
cover to the coupling to prevent damage to
the dust seal and bushing at the front pivot.
8
DLW01960
2) Sling one side of axle (9) and set a garage jack

under axle housing on opposite side, then re-
move mounting bolts. ❈4
« Adjust the height of the garage jack and
remove the axle.
« When removing the axle, the pivot will go
down, so support it with a garage jack.
Rear axle, pivot : 1,100 kg
9 DLW01961
3) Lower rear pivot (8) a little at a time, taking care

not to let it hit engine oil drain tube (10), move 12
to the rear, then remove from front pivot (12).
« Be careful not to lower the rear pivot too
far. It is lowered too far, there is danger that
it will damage the dust seal and bushing at
the front pivot.
10
DLW01962 DLW01963
4) Pull out axle and pivot assembly (13) from un-

der chassis. 13
« Use a hoist and jack for the operation.
« After pulling the assembly out from the chas-
sis, remove chain or the wire used to
hold it.
DBW01964
30-131
7. Rear pivot
1) Remove trunnion cap (14). ❈5 15 14
« Sling the rear pivot.
16
2) Remove mounting bolts, them remove thrust
plate (15) and thrust washer (16). ❈6
3) Remove plate (17).
4) Lift off rear pivot (8), and remove thrust washer

(18).
« Be careful to fit the lifting tool so that it will DBW01965 DLW01966
not come off, then lift off carefully.
Rear pivot : 120 kg
18
17 8
8 8 16
DBW01967 DBW01968
18
DLW01970
19
20
21
5) Remove retainer (19) from rear pivot, then re-
move packing (20) from retainer. ❈7
6) Remove bushing (21) from rear pivot (8).

❈8 8 DBW02298
8. Front pivot
1) Remove retainer from front pivot (22), then re-
move packing (23) from retainer. ❈9
2) Remove bushing (24) from front pivot, then re-

move dust seal (25). ❈10
24
23
25
22
DBW01969
30-132
INSTALLATION OF REAR AXLE

ASSEMBLY

moval.
❈1
Mounting bolt :
927 ± 103 Nm (94.5 ± 10.5 kgm)
(Width across flats: 36 mm)
❈2
« Align the match marks, and take care to as-
semble the coupling facing in the correct direc-
tion.
« Align the pilot portion securely and take care to
assemble with the yoke facing in the correct
direction.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈3
« Be careful not to tighten the tube nut too far.
Tube nut :
80.9 ± 12.3 Nm (8.25 ± 1.25 kgm)
❈4
« Use the bolt as a guide to set to the mounting
position.
« When tightening the mounting bolts, do not
tighten in one step. Divide the torque and tighten
in three steps.
« After installing the axle assembly, remove the
chain or wire.
Mounting bolt :
1,324 ± 147 Nm (135.0 ± 15.0 kgm)
(Width across flats : 41 mm)
❈5
Mounting bolt :
108 ± 14.7 Nm (11.0 ± 1.5 kgm)
❈6
Front of front pivot Rear of front pivot
mounting bolts and bolt hole.
Rear pivot Bushing
« Coat the mounting bolts with thread tightener.
Retainer
❈ 7 ❈ 9 ❈10
« Check the assembly direction of the packing
Dust Grease Grease Dust
and dust seal. seal seal side
side side
Packing, dust seal : Grease (G2-LI) side
DBW01971 DBW01972
30-133
❈8 ❈10
Bushing : Grease (G2-LI)
• Bleeding air from brake system

For details, see TESTING AND ADJUSTING.
• Greasing
Grease each pivot well.
« Wipe off any grease that is squeezed out.
30-134
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY OF
DIFFERENTIAL ASSEMBLY
1. Draining oil
Remove drain plug (1), and drain oil.
Axle oil : 37 l
1 DBW01973
2. Axle assembly 3 3
1) Set axle assembly (2) on pallet. 2
Axle assembly : 1,021 kg (front)
Axle assembly : 971 kg (rear)

2) Remove brake tubes (3).
DBW01974
4
3. Differential cover
Remove bleeder screws (4), then remove differen-
tial cover (5).
4. Axle housing
1) Sling axle housing assembly (6), and remove
housing mounting bolts.
« Make match marks on the housings to pre-
vent mistakes between the left and right
axle housings. 5
« Set blocks to prevent the assembly from DBW01975
tilting when the housing assembly on one
side is removed.
.
2) Lift off axle housing assembly (6).
Axle housing assembly : 280 kg (front)
Axle housing assembly : 270 kg (rear)
6
DBW01976
30-135
5. Cage
1) Screw in forcing screws, and using guide bolts
(7) (16 mm, P=2, L=50mm), remove cage as- 8
sembly (8).
« Check the number of shims and use as
reference when assembling.
« Loosen the mounting bolts of the coupling, 7
9
and fit temporarily.
Cage assembly : 46 kg
2) Remove O-ring (9) from cage.
DBW01977
6. Brake piston
10
Install bleeder screw, blow in compressed air from
portion a, raise housing and piston (10), and re-
move.
« If the D-ring is damaged, blow in air suddenly to
make a gap between the housing and piston, a
then use a screwdriver to lever it out and re-
move it.
« When removing the piston, be careful not to
damage the housing and piston surface.
Air gun
DBW01978
7. Bearing carrier assembly

1) Sling differential carrier assembly (11), and 11
screw in forcing screws, raise evenly, and re-
move bearing carrier (12).
2) Remove square ring and D-ring.
« Check the number of shims and use as
reference when assembling.
« Make marks to distinguish between the left
and right bearing carriers.
« Fit the sling around the flange half, then
raise.
12
« Use a puller to remove the bearing cone DBW01979
from the bearing carrier.
« Use a puller to remove the bearing cone
from the bearing carrier.
11
8. Differential carrier assembly
1) Lift off differential carrier assembly (11) from
differential housing (13).
« Be extremely careful not to let the lifting
tool come off when removing.
Differential carrier assembly : 120 kg
13
DBW01980
30-136
2) Remove plain half (14) from differential carrier

14
assembly (11).
« Check the match marks on the carrier as-
sembly and flange half.
11
DBW01981
3) Remove thrust washer (16) from bevel gear

16
and flange half assembly (15), then remove side
gear (17).
17
15
DBW01982
4) Remove spider shaft, pinion shaft, and spheri-

cal washer (18).
18
DBW01983
5) Remove spherical washers (20) and pinion gears

(21) from spider shaft (19). 21
20
19
DBW01984
30-137
6) Remove side gear (22) and thrust washer (23).

22
23
DBW01985
7) Turn over bevel gear and flange half assembly

(15), then remove mounting bolts (24), and re-
move flange half (25).
25
Bevel gear, flange half assembly : 50 kg
Bevel gear : 24 kg
Flange half : 25 kg
8) Use a puller to pull out bearing cups (26) and

(27) from plain half (14) and flange half (25). 24
15 DBW01986
9. Coupling
1) Remove mounting bolts (28), then remove holder
(29), coupling (30), and O-ring (31). 26
« Do not remove the protector press fitted to
the coupling unless necessary.
2) Remove oil seal (32).
25 14
27 DBW01987
31 28 29
30
30
28
32
DLW00379 DBW01988
30-138
10. Pinion gear

1) Using press, pull out pinion gear (33) from cage
assembly (8), then remove bearing cone (34). 8
Press
34
33
33
DBW01989
Press stand 36 33
DLW00383
« Be careful not to let the bearing catch on

the press stand when removing.
2) Remove spacer (35) and bearing cone (36) from
pinion gear (33).
35
DBW01990
11. Cage
Remove bearing cups (38) and (39) from cage (37). 37
38 39
DBW01991
30-139
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
1. Cage 37
Press fit bearing cups (39) and (38) to cage (37).
« After press fitting the cup, check that there is 38
no clearance at portion a.
« Coat the cup press-fitting portion with oil.
Cup press-fitting portion : Oil (axle oil) a
39
DLW00384
2. Pinion gear
1) Press fit bearing cone (36) to pinion gear (33),
and assemble spacer (35).
36
« Check that there is no clearance at the
mating surface of each part. 35
2) Assemble pinion gear (33) to cage (37), and
press fit bearing cone (34). 33
« Use a press to apply pressure at the speci-
fied load to the bearing, and rotate the case
to settle the bearing.
« Press load : 145 KN (14.8 ton)
Bearing : Oil (axle oil) DBW01992
« Reference
• Starting turning force : Max. 62 N (6.3
kg)
• End play : 0 – 0.187 mm
« When the case has been rotated at the A
specified load, check that it can be rotated 37
smoothly by hand.
« If the rotation is heavy, replace the bearing
and spacer, then check again.
3) Coat seal press-fitting portion of cage (37) with
gasket sealant, then press fit oil seal (32).
« Press fit so that the oil seal is level with the
surface of portion b.
Oil press-fitting portion : DBW01993
Gasket sealant (Seal end 242)

145 KN (14.8 ton)
32 33
b
37 34
35
A
37
PCD
275mm
DBW01994
DLW00388
30-140
3. Coupling
Install coupling (30), O-ring (31), and holder (29) to 31 29
30
pinion gear (33), and tighten mounting bolts.
« Tighten the mounting bolts temporarily, and
tighten fully after assembling.
« When inserting the coupling, be extremely care-
ful not to damage the seal 33
(When tightening fully)
Mounting bolt :
549 ± 59 Nm (56.0 ± 6.0 kgm)
DLW00389
4. Differential carrier assembly

25 26
1) Press fit bearing cups (27) and (26) to plain half
(14) and flange half (25). 27
« After press fitting the cups, check that there
is no clearance at portions c and d.
Bearing cup press-fitting portion :
Oil (axle oil)
14 27
14 DBW01995
c c
DLW00393 25
26 q q
25
d DLW00394
w
2) Set bevel gear (40) on block with gear side 40 DBW01996
at bottom, then install guide bolts (Thread
dia. = 14mm, Pitch = 2mm, Length =
55mm).
« Check that there is no clearance at mating 25
e
portion e of flange half (25) and bevel gear
(40).
the threaded hole of the bevel gear.
« Tighten the mounting bolts on diametrically
opposite sides.
Mounting bolt :
Mounting bolt : e e
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm) 40 DBW01997
30-141
3) Turn over bevel gear and flange half assembly

15
(15), align with dowel pin (41), install thrust 22
washer (23), coat with thrust washer oil, then
assemble side gear (22).
« When assembling the thrust washer, be
careful not to assemble it upside down. 23
41
41
DBW01998
DLW00398
19
Thrust washer sliding surface :
Oil (axle oil) 21
4) Coat spider shaft (19) with oil, assemble pinion

gear (21), then assemble spherical washer (20).
Spider shaft : Oil (axle oil)
Spherical washer : Oil (axle oil)
5) Assemble spider shaft, pinion gear, and spheri- 15
cal washer (18), then assemble to bevel gear 20
DBW01999
and flange half assembly (15).
18
18
15
DLW00373
DLW00399
6) Assemble side gear (17) to bevel gear and

flange half assembly (15).
15 16
7) Coat thrust washer (16) with grease, align with
dowel pin of plain half (14), then stick thrust
washer (16) in position, and be careful that it
does not fall out when assembling.
« When assembling the thrust washer, be 17
careful not to assemble it upside down.
Thrust washer : Grease (G2-LI)
« Be careful not to coat with too much grease.
14
DBW02000
30-142
8) Align match mark on plain half (14) with bevel

gear and flange half assemble (15), and install.
« Align the match marks securely.
« Tighten the mounting bolts on diagonally
opposite sides.
Mounting bolt :
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)
14
15
DBW02001
5. Adjusting shim of cage

1) Assemble guide bolt (16 mm, P = 2, L =
55mm), then assemble cage assembly (8) to
8
differential housing (13) without shims.
Mounting bolt :
277 ± 32 Nm (28.25 ± 3.25 kgm)
2) Insert measurement tool C1 to differential hous-
ing (13), then measure distance L between bevel 13
pinion gear end face and tool C1 with inside
micrometer or cylinder gauge. e
« When inserting tool C1 in the differential
housing, coat with oil thinly, and insert uni-
formly so that it is not twisted. DBW02002
3) Selection of shims
t = C – (L + D/2)
t : Shim thickness
C : (A + a) – (B + b)
L : Actual measured value
A
D : Diameter of tool C1
A : 212 ± 0.3
B : 64 ± 0.3
a : Deviation from dimension A
b : Deviation from dimension B
« Use the actual measured value for dimen-
sion D.
« Adjust so that shim thickness "t" is within a
range of 0.91 – 1.61 mm. DBW02003
« Mark the end face of the pinion gear with
an electric pen as follows.
MD + 0.10 (– 0.01)
t
Dimension b
(unit: mm)
B C1
Dimension a
A L
(unit: mm) C
« Always use the bevel pinion gear and bevel
gear in pairs with the same number. D
DBW02004
30-143
6. Bearing carrier
Press fit bearing cones (42) and (43) to bearing 42
carrier assemblies (12) and (12-1). 43
Oil (axle oil)
« After press fitting the bear-
ing, check that there is no 42,43
clearance at portion f.
f 12
DBW02009 f
7. Adjusting shim of bearing carrier 12-1
DBW02005
1) Raise differential carrier assembly (11), then
set to mounting position on differential housing.
2) Using guide bolt (14 mm, P=2, L=55mm), 11

assemble a shim to bearing carrier assembly
(12-1) at plain half end and a shim to bearing
carrier assembly (12) at bevel gear end, and
assembly the diifferential carrier assembly to
defferential housing.
« Reference value
• Shim thickness (plain half side):
0.75 mm r
• Shim thickness (bevel gear side): 12-1
0.95 mm 12
DBW02006
« Assemble the differential carrier assembly
so that the bevel gear is on the right side as
seen from the cage mount end.
« Assemble the bearing carrier assembly with-
out the square ring and D-ring, and adjust.
« Rotate the bevel gear and coat the bearing
with oil.
Bearing oil : Oil (axle oil)
« To settle all the parts, rotate the bevel gear
when tightening.
3) Tighten mounting bolts of bearing carrier as-

semblies (12) and (12-1). 12
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)
4) Measure preload of bevel gear with a spring

balance and check that it is within standard
range.
« Starting turning force:
13 – 36 N (1.3 – 3.7 kg)
« If the starting turning force is not within
the standard value, adjust the shim
thickness.
« Reference value
• Standard shim thickness on one side:
0.3 – 1.25 mm
Spring balance
DBW02008
30-144
8. Cage
8
1) Fit O-ring (9) in groove of cage assembly (8).
O-ring : Oil (axle oil)
« Coat thinly with oil.
9
DBW02010
2) Install guide bolts to differential carrier as-

sembly (11), assemble shim (44) selected in
Step 5, then install cage assembly (8). t
11 8
« Assemble the shims with the thinner shim
on the inside and the thicker shim on the
outside.
44
Mounting bolt :
277 ± 31.9 Nm (28.25 ± 3.25 kgm)
DBW02011 DBW02012
9. Adjusting backlash
1) Measure backlash of bevel gear with dial gauge.
« Backlash standard value: 0.30 – 0.46 mm
« Measure the backlash at three places
around the circumference of the bevel
gear, and check that the variation be-
tween each measurement is less than
0.1 mm.
DBW02013
2) To get backlash within standard value, move

part of shim on bevel gear side to opposite
side.
« When moving the shim, do not change the
total for the left and right shim thickness.
« If the backlash is too large: b
a
Move part of shim b to shim a.
« If the backlash is too small:
Move part of shim a to shim b.
DBW02014
30-145
10. Adjusting tooth contact

Coat face of 7 or 8 teeth of bevel gear lightly with red lead (minimum). Hold the bevel gear by hand to act
as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
Tooth contact Cause Procedure for adjustment

The tooth contact pattern Adjust the pinion gear by adjusting the shims at
should start from about the cage. Adjust the bevel gear in the same way as
5 mm from the toe of when adjusting backlash.
the bevel gear and cover
about 50% of the length
of the tooth. It should
be in the center of
DEW00910
the tooth height.
Bevel pinion gear is too 1. Reduce shims at pinion

far from bevel gear. gear to bring closer
to bevel gear.
2
2. Move bevel gear further
away from pinion
gear and adjust
backlash correctly.
1 DEW00908
DEW00904
Bevel pinion gear is too 1. Increase shims at pinion

close to bevel gear. gear to move away
from bevel gear.
2
2. Move bevel gear closer
to pinion gear and adjust
backlash correctly.
1
DEW00905 DEW00909
Bevel gear is too close to 1. Reduce shims at pinion gear

pinion gear. to bring closer to bevel gear.
2. Move bevel gear further
2
away from pinion
gear and adjust
backlash correctly.
1 DEW00908
DEW00906
Bevel gear is too far from 1. Increase shims at pinion

pinion gear. gear to move away
from bevel gear. 2
2. Move bevel gear closer
to pinion gear and
adjust backlash correctly.
1
DEW00907 DEW00909
« When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left
and right. Always keep the same total thickness of shims.
30-146
11. Bearing carrier assembly 12-1

Remove bearing carrier assembly (12-1), assemble 45
square ring (45) and D-ring (46), then assemble
again using adjusted shims.
« Coat the square ring with grease and be careful
not to let it drop out when assembling.
« When assembling bearing carrier assembly (12- 46
1), there is danger that the square ring may fall
out, so do not hit with a hammer when assem-
bling.
Square ring, D-ring : Grease (G2-LI)
176.5 ± 19.6 kgm (18.0 ± 2.0 kgm)
12. Brake piston
1) Assemble D-ring (46-1) in groove of brake pis-
10
ton (10).
« Coat the brake piston and piston mount
thinly with grease to prevent the O-ring from
being twisted or cut.
Piston and piston mounting surface :
Grease (G2-LI)
2) Install piston press-fitting tool C2 to differential 46-1
housing, and tighten tool C3 uniformly to press
fit.
« Press fit completely until the piston con-
tacts the housing. DBW02016
« Do not hit with a plastic hammer to insert. If
a hammer is used, the D-ring and piston
will be damaged.
10
« Put a pad under tool C3 to prevent damage
to the piston surface.
« When pushing the piston with the end face
of tool C3, install tool C2 to make sure that
the center of the piston is pushed.
DBW02017
C4 C3 C3
C2
C4
Pad
10
Adjustment
washer
C2
Differential housing
DBW02019
DBW02018
30-147
13. Checking for brake oil leakage

1) Install bleeder screw. 47
2) After screwing in tool C3 of each piston press-
fitting tool C2 fully, turn back one turn.
3) Install tools C5 and C6 to brake tube mount
(47), then bleed air inside cylinder.
4) Operate tool C7, and raise pressure to 1.4 MPa
(14 kg/cm2).
« After raising pressure to 1.4 MPa (14 kg/
cm2), leave for 5 minutes and check that C5
C6
the drop in pressure is less than 0.35 MPa
Differential housing
(3.5 kg/cm2). DLW02020
5) If the result of the inspection shows that there is
no oil leakage, raise the pressure further to 4.9
MPa (50 kg/cm2).
« After raising pressure to 4.9 MPa (50 kg/
cm2), leave for 5 minutes and check that
the drop in pressure is less than 0.1 MPa 47
(1.0 kg/cm2).
« If there is oil leakage, remove the brake
piston, check the O-ring and other parts for C6
damage, then assemble again.
C5
« After checking for brake oil leakage, insert oil
the piston fully.
C7
DBW02021
14. Coupling
Tighten mounting bolts of coupling (30) fully.
Mounting bolt : Thread tightener (LT-2) 13
Mounting bolt :
549 ± 59 Nm (56.0 ± 6.0 kgm)
15. Differential cover

1) Wash and remove all oil and grease from mount-
ing surface of differential cover (5) and differen-
30
tial housing (13), then coat with gasket sealant.
« Guide bolt : 14 mm, P = 2, L = 40 mm
« When installing the differential cover, screw DBW02022
the mounting bolts into the forcing screw
holes, and raise.
« Temporarily assemble the bleeder screw so
that gasket sealant does not get into the
mounting hole of the bleeder screw.
« See the diagram on the right for details of
coating.
• Coat continuously with a bead diameter
of 2 – 3 mm.
• The shape of the differential cover at
portion « is different, so coat and take
care that the bead does not come off.
Bead diameter : 2 - 3mm 5
DLW01587
30-148
2) Install differential cover (5) to differential hous-

5
ing.
« Coat carefully with gasket sealant so that
there is no break in the gasket sealant.
Cover mating surface :
Gasket sealant (Loctite 515)
Cover mating surface :
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)
DLW01588
3) Check that there is no gasket sealant stuck to

the bolt hole, then tighten bleeder screw (4)
fully.
DBW02023
16. Axle housing assembly
17. Refilling with oil

« For details, see Step 13 in ASSEMBLY OF
AXLE HOUSING ASSEMBLY.
30-149
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DISASSEMBLY OF AXLE
HOUSING ASSEMBLY
1. Draining oil
Remove drain plug (1) and drain oil.
Axle oil : 37 l
1 DBW01973
« Set axle assembly (2) on pallet. 2
Axle assembly : 1,021 kg (front)
Axle assembly : 971 kg (rear)
DBW02024
2. Differential cover 3
Using forcing screws, remove differential cover (3).
« Do not remove the differential cover unless nec-
essary.
« When removing the differential cover, be care-
ful not to damage the bleeder screw.
« When moving the differential assembly, remove
the 4 cover mounting bolts, and use eyebolts to
lift at 4 points and move.
(F) Differential assembly : 300 kg

DBW02025
(R) Differential assembly : 320 kg
3. Axle housing
1) Sling axle housing assembly (4), and remove
housing mounting bolts.
« Make match marks on the housings to pre-
vent mistakes between the left and right
axle housings.
« Set blocks to prevent the assembly from
tilting when the housing assembly on one
side is removed.
4
DLW02026
30-150
2) Lift off axle housing assembly (4).
Axle housing assembly :

280 kg (front)
Axle housing assembly : 270 kg (rear)
« Change the place for the axle housing lift-
ing tool, and stand the axle housing assem-
bly upright.
4
DBW02027
4. Brake disc, plate
1) Remove lock bolts (7) of plate (6) and brake
disc (5).
7
7 6
5 6
DBW02028
DLW01598
2) Remove plate (6) and brake disc (5).

6 5
« Be careful not to damage the front face of
the disc.
3) Remove wave spring (8).
5. Sun gear shaft, outer ring

1) Remove shaft (9). DBW02029
2) Remove outer ring (10).
« Be careful not to damage face in contact
with the brake disc.
9
8
10
10
DBW02030
DBW02031
30-151
6. Brake housing
Remove mounting bolts (11), then remove brake
housing (12).
« Remove the O-ring.
11
O-ring
12
Detail P DBW02032
DLW01604
t 13
Brake housing : 25 kg
7. Planetary carrier assembly

1) Remove axle shaft mounting bolts, then lift off
planetary carrier assembly (13) with
lifting tool
« The planetary carrier assembly is heavy, so
be extremely careful when removing it.
DBW02033
Planetary carrier assembly : 48 kg
« Lifting tool
t 14
40mm
235mm
DBW02035
DLW01602
2) Remove shims (14).

« Record the shim thickness and use for ref-
erence when assembling.
8. Ring gear q
Use puller and pull up uniformly to remove ring
gear (15) from axle housing (16).
w
« Assemble spacer to the end face of the puller
bolt to adjust the height. 15
« When pulling up with the puller, be extremely
careful that the teeth of the puller do not come 16
off the ring gear.
Ring gear : 15 kg DBW02034
30-152
9. Axle shaft
1) Stand housing and shaft assembly, then raise
housing (16).
2) Put a copper hammer in contact with end face
of axle shaft (17), then knock in shaft and ro-
tate housing (16) to remove shaft.
Copper hammer
16
DBW02036
16
Pad
(copper
hammer)
17
DLW01609 17
16
Axle shaft assembly : 90 kg
Axle housing : 85 kg
DBW02037
3) Pull out bearing (18) from axle shaft (17).

« Do not use a gas cutter or heat to remove
the bearing under any circumstances.
• If the shaft is heated, the hardening of the 17
shaft will be reduced and the strength will
drop. 18
DBW02038
« Remove the bearing as follows.
4) When removing bearing (18) of axle shaft (17),

be careful not to let adjustment bolt of puller
contact outside circumference a of oil seal and 18
sleeve (19).
b
« Install the puller so that the teeth grip the
whole circumference of portion b of bearing a
(18).
19
DBW02039
30-153
5) Install bolt (21) in portion d of tool D1.

« Screw the bolt fully into the thread. 21
• Bolt (21) : 1-14UNF D2
D2
d
D1
D3 D3
DLW01611
6) Insert tool D1 under bearing (18), and assem-

ble tools D2 and D3.
« When installing tool D1, be careful not to 18
deform portion e of oil seal sleeve (19).
« When doing this, fix the bearing puller se-
curely in place so that there is no play.
e
19
DBW02041
7) Insert washer between bolt (21) and flange sur-

face, turn bolt (21) to loosen it, and remove
bearing (18).
« The puller has little grip on the bearing, so
be extremely careful that the puller does
18
not come off from the bearing.
« If the thread of bolt (21) is too short, add a A1
washer to the flange surface to adjust the
height of bolt (21) when removing bearing 21
(18). Washer Flange
« Replace the oil seal and sleeve assembly surface
with a new part.
DBW02042
30-154
10. Axle housing

1) Remove oil seal (22) from axle housing (16).
23
16
22
DBW02043
2) Remove bearing cups (23) and (24) from axle

housing (16).
16
24
11. Planetary carrier DBW02044

1) Knock in spring pin (26) of planetary carrier
(25).
« Be careful not to knock the spring pin in too
far.
26
27
26
25
DLW01614
DLW02300
2) Using press, remove shaft (27).

« When removing the shaft, use a block at
the end face of the shaft.
25
27
DBW02299
30-155
3) Remove spring pin (26) from shaft (27).
26
27
DBW02045
4) Remove pinion gear (28) from planetary carrier

(25), then remove bearing cone (29) and spacer
25
(30).
Planetary carrier : 30 kg
28
28
29 29
30
DBW02046
DLW01619
30-156
ASSEMBLY OF AXLE HOUSING

ASSEMBLY
1. Axle housing
Press fit bearing cups (24) and (23) to axle housing
(16).
« Coat the bearing cup press-fitting portion of the
axle housing with oil.
« After press fitting the cup, check that there is
no clearance at portion a. 16
24
a
DBW02047
16
DBW02051
23
Oil (axle oil)
DBW02048
2. Axle shaft
1) Press fit axle shaft (17) and oil seal sleeve (19).
« Be careful not to deform the parts when
hitting with a hammer. c
« Coat the sleeve contact surface portion b of b
the oil seal thinly with axle oil.
Sleeve contact surface of shaft :
Oil (axle oil)
« After press fitting the oil seal sleeve, check
that surface c is level with the surrounding
surface.
DBW02049
2) Press fit bearing (18) to axle shaft (17).

« Be careful not to fit the bearing at an angle.
Bearing press-fitting portion :
Oil (axle oil) 18
« After press fitting the bearing, check that 17
there is no clearance at portion d.
18
d
DBW02301 DBW02050
30-157
3. Housing, shaft
1) Stand shaft (17) upright and install tool D4.
« Adjust the height of the seal support with 17
the adjustment bolts, put the top surface of
tool D4 in light contact with seal (22), then
D4
set so that the clearance is uniform. D4
« Set tool D4 securely so that it does not
come off.
2) Assemble oil seal (22) to oil seal sleeve (19).
« When assembling the oil seal, be extremely
careful not to damage the lip surface. 22 19
Lip of oil seal : Grease (G2-LI) DBW02052
D4 22 19
17
Flange surface
DBW02053
16
« When raising axle housing (16), coat the oil

seal press-fitting portion of the housing with
oil.
Oil seal press-fitting portion : DBW02054
Oil (axle oil)
3) Raise axle housing (16) to a horizontal position,
then insert to shaft carefully.
« Stop axle housing (16) before press fitting
the oil seal.
4) Align axle housing (16) with oil seal press-fitting
portion, then lower housing slowly.
« Use the weight of the axle housing to insert 16
it.
DBW02055
30-158
5) Press fit bearing (30) to shaft (17), then rotate

axle housing by hand, and press fit until end 17
play is 0.1 mm.
« Do not press fit so that there is no end play.
Bearing cone press-fitting portion :
Oil (axle oil)
« Press-fitting force :
Approx. 19.6 KN (2 ton)
30
DBW02056
6) Pull out tool D4 horizontally.
D4 17
Flange surface DBW02057
« After press fitting the bearing to the shaft,

check that there is no stepped portion be-
tween the seal and the sleeve and that sur-
face e is level with the surrounding surface.
« Reference
Clearance (f) : 10.5 ± 0.2 mm
« Be careful not to install the seal at an an-
gle.
f
e Flange surface DBW02058

4. Adjusting end play
1) Stand axle shaft and housing assembly (4) up-
right.
« Secure flange g so that the axle shaft and
housing assembly does not fall over. 4
DBW02059
30-159
2) Install planetary carrier (25) to spline of axle

shaft (17), then assemble shim adjustment tool
D5 to portion j of planetary carrier, and install 25 31
mounting bolts.
« Install planetary carrier (25) without the
gears.
« Remove all adhesive from the mounting
bolts and mounting bolt holes of the axle
shaft before using.
3) Rotate axle housing (16) and tighten retainer j
mounting bolts (31). D5
Bolt : 43 Nm (4.4 kgm) 30
4) Make sure that bearings (18) and (30) are fully
settled, then measure starting turning force "X"
at drill hole h of axle housing (16).
• Starting turning force X : 16
44.1 – 70.6 N (4.5 – 2.5 kg)
17
18
DLW01629
« If the starting turning force is not within the

standard value, adjust again as follows. 4 31
• If the starting turning force is less than
44.1 N (4.5 kg), press fit the bearing
again and repeat the operation from
Step 3).
• If the starting turning force is more than
70.6 N (7.2 kg), loosen mounting bolt
(31) of the shim adjustment tool 1 – 2
turns. h
• At the same time as assembling axle
shaft and housing assembly (4) to the
axle housing, sling at two points and
raise 20 – 30 mm.
• Rotate axle shaft (17) and hit the flange
portion with a copper hammer several 17
times in the direction of the arrow to
remove axle shaft (17).
• Repeat Steps 3) and 4) to bring the
starting turning force within the stand-
ard value. Lifting height
20 — 30mm
DLW01630
30-160
5) Using depth micrometer, measure distance H

from tool D5 to axle shaft end face. 25 D5
t H
Subtract thickness t of the jig from H to give the
value (H – t).
• Shim thickness = (H – t) ++ 0.05 0
6) After deciding shim, loosen bolt and remove plan-
etary carrier (25).
DLW01631
5. Planetary carrier
1) Assemble spacer (32) inside planetary carrier
(25). 25
« Assemble the spacer from the brake hous-
ing side.
2) Assemble bearing cone (29) to gear (28), lift up
spacer (32), and set gear (28) in position.
32
29
32
28
DBW02060
28
29
29 DLW01636
32
3) Align shaft (27) and spring pin hole (33), and
press fit shaft.
Shaft : Oil (axle oil)
Make surface level
27 28
28 DBW02070
26
27
27
DLW01637
« Align the holes of shaft (27) and spring pin

(26), and knock in the spring pin so that it is
33
level with the surface of the carrier. DBW01634 DBW02071
30-161
4) Tap differential side of gear (28) and end face

of shaft (27), and push back bearing (29) so
that the gear can rotate smoothly.
« Check that the gear rotates smoothly.
29
27 28
DBW02072
6. Ring gear
Press fit ring gear (15) to axle housing (16), then 15
insert pin (34).
« Align the pin holes of the ring gear and the

housing, then assemble.
« Press fit horizontally and make sure that the
ring gear is not at an angle.
16
34
DBW02073
7. Planetary carrier assembly

1) Assemble shim (14) selected in Step 5) to end 13
face of axle shaft, then install planetary carrier
assembly (13) and install mounting bolts.
14
mounting bolts and mounting bolt holes of
axle shaft.
DBW02074
Mounting bolt :
Mounting bolt : 14
927 ± 98 Nm (94.5 ± 10.0 kgm)
« Clean the end face of the shaft and the
planetary carrier spline before assembling.
When assembling the planetary carrier, be
extremely careful not to get your fingers
caught in the gear.
13
DBW02075
30-162
2) Make sure that bearing is fully settled, then

check turning force "X" at axle housing assem- h
bly (4) and drill hole (h).
« Reference value
• Starting turning force X:
44 – 71 N (4.5 – 7.2 kg)
3) Install stand of dial gauge to axle housing (4),
and measure end play of planetary carrier at
end face of planetary carrier.
« Reference value
• End play of planetary carrier : 4
0 – 0.1 mm DBW02076
8. Brake housing
1) Assemble O-ring (35) in groove of axle housing 35
(4).
« Coat the O-ring thinly with grease.
O-ring : Grease (G2-LI)
4
DBW02077
2) Align axle housing (4) and portion i, and install

brake housing (12).
« Be careful that the O-ring is not twisted or
caught when installing.
12
i
Front (right) Front (left)
12 DBW02032
Plug for measuring the brake disc wear DBW02079

Mounting bolt
« Assemble the axle housing so that the plug 12

for measuring the brake disc wear is facing
the rear.
« Axle housing
4
• Front (left)
• Rear (right)
• Front (left)
• Rear (right)
DBW02078
30-163
9. Sun gear shaft, outer ring

1) Align match mark of outer ring (10) with spline 10
portion at bottom of brake housing (12), then
assemble.
12
« Always align the match mark with the spline
portion when assembling. Match marks
« Be careful not to damage the surface in
Spline
contact with the brake disc.
10
DBW02080
DBW02082 9
8
2) Assemble shaft (9).

« Always install the shaft before assembling
the brake disc, wave spring, and plate. 10
DBW02030
10. Brake disc, plate

1) Align end gap of wave spring (8), then assem-
ble both to range (h).
« Assemble so that the end gap of the wave
spring is on the O-ring boss hole side for 10
measuring the disc wear, and is also within h Assembly range
of spring
range (h). 8
« Always use 2 wave springs together. Target position for
assembly of spring end gap
O-ring boss hole for measuring brake disc wear DBW02081
2) Assemble brake disc (5), plate (6), wave spring

(8), brake disc (5), and plate (6) in order.
« Be careful not to damage the front face of
6 5
the brake disc.
« Check that there is no damage to the front
face of the plate when assembling.
DBW02029
30-164
3) Assemble brake disc (5) and plate (6), then

install lock bolt (7).
7
7 6
6
DBW02028
DBW02084
11. Axle housing assembly

1) Wash and remove all oil and grease from mount- Bead
ing surface of axle housing (4) and differential diameter
: 2-3mm
housing (36), then coat with gasket sealant.
« See the diagram on the right for the coating
procedure.
• Coat with a continuous bead diameter
of 2 – 3 mm.
• The shape at portion « is different at
the differential housing end. Coat so 4
that the bead does not come off.
« Wash and remove all oil and grease from DBW02302
the axle housing and differential housing
mounting surface, then coat with a con-
tinuous line of gasket sealant so that there
is no break. e 36
Mating surface of housing :
Gasket sealant (Loctite 515)
2) Raise axle housing (4) horizontally, then align
spline groove and guide bolts (20 mm, P=2.5,
L=230mm), and assemble carefully.
« When assembling the axle housing, be care-
ful not to cut the gasket bead.
« When assembling, be careful not to dam-
age the plate surface. 4 e
DBW02083
3) Install mounting bolts (37) on diagonally oppo-

site sides, and tighten.
Housing mounting bolt :
549 ± 59 Nm (56.0 ± 6.0 kgm)
4
37 DLW01654
30-165
12. Differential cover 3

If differential cover (3) was removed, see DISAS-
SEMBLY AND ASSEMBLY OF DIFFERENTIAL
ASSEMBLY.
DBW02025
13. Refilling with oil

Tighten drain plug (1) and add oil through oil filler
(38) to specified level.
« Set the axle horizontal and add a small amount
of oil. (Before installing to chassis)
« After installing to the chassis, add oil and check
the oil level again.
38 (When checking oil level)
Oil level
1 DBW01973
HIGH
LOW
38
DBW01656
« Set to a horizontal position when checking the

oil level. DBW02243
30-166
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN


control levers several times to release the remain-
ing pressure in the hydraulic piping.

of the battery.
1. Loosen plug (1) at top of hydraulic tank filter and

plug (2) of pump piping to prevent oil inside tank
from flowing out.
2
2. Remove cab and floor frame assembly.
For details, see REMOVAL OF CAB AND FLOOR
FRAME ASSEMBLY. ❈1
1 DBW01904
3. Remove lock bolt at rod end of steering cylinder,

3
then remove pin (3). ❈2
• Do the same for both left and right steering
cylinders.
« If there are shims, check the number and thick-
ness of the shims, and keep in a safe place.
DBW02085
4. Disconnect center drive shaft (4).

4
DBW02086
30-167
5. Disconnect hoses (5) and (6), and cable (7).

« Disconnect hose (5) at the connecting portion 5
at the rear frame end, then disconnect hose (6)
7
at the valve end.
DBW02087
6. Remove steering rod (8) together with mounting

bracket (9). 9
8
DBW02088
7. Disconnect frame as follows. ❈1

1) Adjust height of rear frame (10) and set block
in position.
« Set block under the frame on the left and
right sides.
2) Adjust height of front frame (11), then set block
in position, and assemble rollers between
frame (11) and block . 11
« Set block and rollers under the frame
on the left and right sides.
« Adjust the height of the frame carefully. 10
e w q
DBW02089
3) Set support under counterweight (12).

« Block the left and right rear tires securely to
prevent them from moving.
« Choose a support with adjustable height for
support .
4) Remove safety bar.
12
DBW02090
30-168
5) Remove lower hinge pin mounting bolts, and

remove pin (13) from top.
« Adjust the height of the front frame and 14
rear frame carefully and set so that the pin
can be removed without using force.
6) Remove upper hinge pin mounting bolts, and

remove pin (14) from bottom.
« Be careful not to let the pin fall.
13
DBW02091 DLW02092
7) Remove mounting bolts, then remove retainer

(15) at rear frame end.
« There are shims, so check the number and 15
thickness of the shims, and keep in a safe
place.
16
15
DBW02093
16
DLW02096
8) Pull out spacer (16).

DBW02094
9) Jack up front differential, and pull out front frame Front frame
towards front.
« Be careful not to get the spacer at the bot- Rear frame
tom of the upper hinge caught in the rear
frame. After disconnecting, remove the
spacer.
« Be extremely careful to maintain the bal-
ance during the operation. A
A
A A
DBW02095
30-169
8. Lower hinge bearing ❈4

1) Remove both top and bottom dust seals (17). 20
17
2) Remove snap rings (18) and (19), and pull out
bearing (20).
18
20
DBW02095
19
DLW02101 22
9. Upper hinge bearing ❈5

1) Remove mounting bolts, remove retainer (21),
then remove dust seal (22) from retainer.
« There are shims between the retainer and
the front frame, so check the number and
thickness of the shims and keep in a safe
place.
21
DBW02098
2) Remove bottom spacer (23) and seal (24) from

front frame.
25
23
21
24 23 DBW02099
DAW02102
3) Remove bearing (25).
25
DLW02100
30-170
INSTALLATION OF CENTER
HINGE PIN
moval.
❈1
Install cab and floor assembly.
For details, see INSTALLATION OF CAB, FLOOR
FRAME ASSEMBLY.
❈2
« Be careful not to forget to assemble the shim.
« Adjust the shims so that the clearance between
the cylinder and frame is 0 – 0.5 mm.
❈3
Connect the frame as follows.
1) Jack up front differential, then move front frame
towards rear frame end, and align pin holes.
« Be careful that the spacer at the bottom of
the upper hinge does not interfere with the
rear frame.
« Align the pin holes securely.
When aligning the position of the pin hole,
always use a bar. Never insert your fingers
in the pin hole. 16
2) Assemble spacer (16) to upper hinge.
DBW02103
« Assemble spacer (16) from the top so that
the large chamfered side is on the bearing
side.
« Be careful not to damage the dust seal lip. 14
Outside circumference of hinge : 16
Grease (G2-LI) 15
Inside circumference of spacer :
Grease (G2-LI)
3) Assemble upper hinge pin (14) from bottom.
4) Tighten retainer (15) to upper hinge pin with 3
mounting bolts (27), then select shims so that
clearance b between hinge and retainer is be-
low 0.2 mm, and assemble.
Pin mounting bolt :
DLW02104
19.6 ± 2 Nm (2.0 ± 0.2 kgm)
(When adjusting shims)
« Temporarily tighten mounting bolts (28),
leaving a clearance of approx. 5 mm from
the surface of retainer (15).
27
28
DBW02105
30-171
5) After adjusting shims, tighten retainer mounting

15 28 27
bolt (28) to specified torque, then tighten pin
mounting bolt (27) fully.
Retainer mounting bolt :
Clearance b
Retainer mounting bolt :
206 ± 19.6 Nm (21.0 ± 19.6 kgm)
Pin mounting bolt :
Pin mounting bolt :
206 ± 9.8 Nm (21.0 ± 1.0 kgm)
Retainer mounting bolt : DLW02106
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
6) Insert lower hinge pin (13) and secure with lock

bolt.
Outside circumference of hinge pin :
Grease (G2-LI)
7) Remove support from counterweight, and front
and rear frames.
8) Install safety bar.
13
DBW02107
❈4
1. Lower hinge bearing
17 18
1) Assemble snap ring (19) to front frame lower
hinge, then use tools E1 and E2 to press fit
bearing (20), and secure with snap ring (18).
« Press fit so that the bearing is level with the 20
surface of snap ring (19).
19
17 DLW02303
2) After assembling snap ring (18), press fit dust

seals (17) to top and bottom of pin portion.
« Replace the dust seal with a new part, and E1
press fit so that the lip surface is facing the
outside.
Lip of dust seal : Grease (G2-LI) E2
DLW02108
30-172
❈5
2. Upper hinge bearing
1) Assemble tools E3, E4, E5, E7, E8, and E9 to
top of front frame upper hinge, set bearing (25) E9
in tool E6, then set to press-fitting portion from
above and press fit.
« When press fitting, use tool E8 as a guide.
« Be careful that the bearing is not at an an- E6
gle.
« Fill the inside of bearing (25) with an ample
amount of grease. E8
« When assembling the bearing, do not for- E7
DBW02109
get to assemble spacer (26).
« The clearance of bearing (25) is adjusted,
so do not change the combination with
spacer (26). E5
When replacing, always replace the parts
as a set. E4 22
2) Press fit dust seal (22) to retainer (21). E9
« Replace the dust seal with a new part, and
E6
To E3
outside. E8
Lip of seal : Grease (G2-LI) 25 26 21
3) Tighten retainer (21) with 3 mounting bolts, and 25 Front
select shims so that maximum clearance a be- frame
tween retainer and hinge is below 0.1 mm, then E7 Block
DBW02110 DBW02111
assemble.
Clearance a
DLW02114
Mounting bolt : 21 DBW02112

19.6 ± 2.0 Nm (2.0 ± 0.2 kgm)
(When adjusting shims)
Mounting bolt :
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
4) Install dust seal (24) and spacer (23) from un-
der front frame.
Lip of dust seal : Grease (G2-LI)
Inside circumference of spacer :
Grease (G2-LI)
« Replace the dust seal with a new part, and
outside.
« Assemble spacer (23) from the bottom so 24 23
that the large chamfered side is on the bear- DLW02113
ing side.
30-173
DISASSEMBLY AND ASSEMBLY STEERING GEAR
REMOVAL OF STEERING GEAR

ASSEMBLY
Stop the machine on level ground and install the 1

« After stopping the engine, operate the steering wheel

to the left and right 2 or 3 times to set the steering
valve to the neutral position.
1. Cover DBW02304
Remove cover (1) at bottom of cab.
❈1
3. Column cover
1) Remove steering post cover (4).
2) Remove plug and pull up boot (5).
4 5
DBW02117 DLW02118
4. Steering gear ❈2
1) Remove lock bolt (6).
« Remove the lock bolt at column joint (6–1)
end.
« Make match marks on the joint and the
steering gear shaft.
6-1 6
DLW02119
30-174
30-175
DISASSEMBLY AND ASSEMBLY STEERING GEAR
INSTALLATION OF ORBIT-ROLL
ASSEMBLY
moval.
Lock bolt :
55.9 ± 6.9 Nm (5.7 ± 0.7 kgm)
Orbit-Roll mounting bolt :

112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
30-176
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DISASSEMBLY OF STEERING
ASSEMBLY
« Use a wire brush to remove all the dirt and dust
stuck to the joint around the outside circumference
of the unit.
« Carry out the operation in a clean place to prevent

dirt or dust from sticking to the valve.
« As far as possible, hold the valve in a vice when

disassembling.
DISASSEMBLY OF ROTOR
1. Set rotor side facing up, and hold mounting flange

lightly in vice .
« Put acopper plate in contact with the vice and be

careful not to tighten the vice too hard.
2. Remove screw (1), then remove end cap (2).
3. Remove O-ring (3) from end cap (2).
4. Pull out rotor set (4), then remove O-ring (5).

« Be careful not to drop the star inside the
rotor set.
5. Remove spacer (6).
30-177
6. Remove drive shaft (7).

10
7. Remove spacer plate (8).
8. Remove O-ring (9) from housing (10).
8
7
9
DLW01703
DISASSEMBLY OF CONTROL SIDE
9. Remove housing (10) from vice, and place on a

11
clean cloth. Be careful not to damage the finished
surface.
10
10. Raise tip of snap ring (11) with screwdriver, and
DLW01704
remove from housing.

11. Turn spool and sleeve to place pin in a horizontal
position, then push in spool and sleeve with your
thumb, and remove bushing (12) from housing. 12
DLW01705
13
12. Remove X-ring seal (13) from bushing (12).
13. Remove dust seal (14) from bushing (12) with screw-
driver. 12
« Be careful not to damage the bushing.
14
DLW01706
30-177-1
14. Remove 2 bearing races (15) and thrust needle

(16) from spool and sleeve.
15
16
15
DLW01707
15. Pull out spool and sleeve assembly (17) from hous-
ing (10) in the direction of the arrow.
« To prevent the spool and sleeve assembly from 10
catching in the housing, rotate the spool and
sleeve assembly slowly to the left and right when
pulling out from the housing.
17
16. Pull out pin (18) from spool and sleeve assembly
(17). 18
DLW01708
17. Push spool (20) inside sleeve (19) slightly to front,

and remove 6 centering springs (21) from spool 19
21
(20) carefully by hand.
20
18. Turn spool (20) slowly and pull out from rear of
sleeve (19) (in the direction of the arrow).
19 20
DLW01709
19. Remove O-ring (22) from housing.
20. Remove set screw (23) from housing. 22
21. Screw a threaded bar into check sheet (24), and

pull out check sheet (24).
25
22. Remove O-rings (25) and (26) from check sheet
(24).
28
23 24 27
23. Tap housing, and remove ball (27) and retainer (28). 26
DLW01710
30-177-2
ASSEMBLY OF STEERING
VALVE
« Check all parts for damage or burrs.
« Wash all metal parts in clean solvent and blow dry
with air.
« Do not use a file or polish any part with rough
sandpaper.
« Coat the O-rings with clean grease. (No need to put
grease on new X-ring seals)
« Coat the O-ring for the rotor set with a small amount
of grease.
ASSEMBLY OF CONTROL SIDE
1. Insert retainer (28) in housing with tweezers.

« Check that the retainer is not inserted at an
angle.
2. Insert ball (27).
3. Fit O-rings (26) and (25) in check sheet (24), and

push check sheet (24) into housing.
« Be careful to set the top and bottom of the
check sheet facing in the correct direction.
4. Install set screw (23).

« Check that the set screw is set in slightly from
the end face of the housing.
Set screw : 11.8 Nm (1.2 kgm)
Set screw : adhesive (LT-2)
5. Assemble spool (20) and sleeve (19) so that spring

groove is on same side.
« Rotate the spool and slide it in.
« Grip the splined portion of the spool lightly and
check that the spool rotates smoothly inside the
sleeve.
« If there are match marks, check that the match
marks are aligned.
30-178
6. Align spring groove positions of spool (20) and sleeve

(19), and set on flat plate, then insert spring (21) in
20
spring groove.
« Set so that the notches at both ends are at the 21
bottom.
19
DLW01713
7. Insert pin (18) in spool and sleeve assembly (17).
17
18
DLW01714
8. Insert spool and sleeve assembly (17) in housing

(10) in the direction of the arrow.
1) Keep pin horizontal and rotate to left and right a
little at a time to insert.
« Be extremely careful not to get it caught.
2) Make the spool and sleeve assembly flush with 17
the rear end face of the housing.
« If it is inserted beyond the end face, the pin will
fall out.
3) Check that spool and sleeve rotate smoothly
inside housing. 10
DLW01715
9. Install O-ring (22) to housing (10).
16 15
10. Fit 2 bearing races (15) and thrust needle (16) in 15
case (10).
22
10
DLW01716
30-179
11. Insert dust seal (14) in bushing (12).

11
12. Insert X-ring seal (13) in bushing (12).
12 14
13. Insert bushing (12) in spool, and rotate to install.
• Tap with a plastic hammer to assemble to the
specified position. 10
• It must be in contact horizontally with the bear-
ing race.
DLW01717
14. Fit snap ring (11) in housing.
Screw-
14 driver
11
12
13
22
DLW01718
ASSEMBLY OF ROTOR
15. Hold flange of housing lightly in vice.

« Be careful not to tighten the vice too hard.
« Check that the spool and sleeve are set in
slightly from the housing surface with fourteen
holes.
DLW01719
16. Insert O-ring (9) in housing.
8
17. Put on spacer plate (8), and align positions of bolt
hole and tap hole of housing.
DLW01720
30-180
18. Turn spool and sleeve assembly to make pin (18)

and port surface of housing parallel, then mesh pin
and yoke of drive shaft (7). Port surface
« To position accurately, draw a line on the end 7
face of the drive shaft spline. Make pin and
port surface parallel
18
DLW01721
19. Insert O-ring (5) in rotor set (4).
5
DLW01722
20. Make O-ring (5) end of rotor set to spacer plate

end, then align insert portion of star of rotor (4) with Inset portion of star of rotor set A
drive.
B
1) Check that lines A,B,C, and D are all parallel.
2) Without removing joint of drive (7), position bolt C
D
holes of rotor set. 7 (Make line)
« This procedure is very important for determin-
ing the valve timing of unit.
Pin Port surface

DLW01723
21. Insert spacer (6) inside rotor set.

1
2
22. Set end cap (2) on rotor set, and align bolt hole. 3
6
DLW01724
30-180-1
23. Coat thread of screw with grease, and tighten end

cap.
« Install the handle to the spool, and check that 6 4
the spool rotates.
End cap mounting screw
1 2
First step : 14.7 Nm (1.5 kgm)
Second step :
27.0 ± 1.5 Nm (2.75 ± 0.15 kgm)
3 7
5
DLW01725
30-180-2
REMOVAL OF STEERING
VALVE ASSEMBLY

« Release the remaining pressure in the piping. For

details, see REMOVAL OF RADIATOR ASSEM-
BLY.
• Remove plugs (1) and (2) at the top of the hydraulic

tanc filter, and prevent the oil inside the tank from
floating out.
1. Covers
Remove covers (3) under cab.
2. Steering pipes
Remove the orbit-roll servo pipes (4).
.
30-181
Disconnect following hydraulic piping from steering
valve.
• Tube (8) between switch pump and steering
valve
• Tube (9) between steering pump and steering
valve
• Tube (10) between steering valve and main con-
trol valve
• Tubes (11) and (12) between steering valve
and steering cylinder
• Tube (13) between steering valve and hydraulic
tank
4. Steering valve ❈2
Sling steering valve (6), and remove mounting bolts
(14), then lift off steering valve.
Steering valve : 24 kg
« Carry out the removal operation with two work-
ers.
The steering valve is oily, so be careful not to
let it slip.
30-182
INSTALLATION OF STEERING
VALVE ASSEMBLY

moval.
❈1
« Check that the steering valve is at neutral.

❈2
« Replace the O-ring with a new part.

« Remove the clamp to avoid applying force when
installing the tube.

Tighten the plug at the top of the hydraulic tank
filter and add hydraulic oil through oil filler to the
specified level.
Plug at top of filter :
11.8 ± 1.0 Nm (1.2 ± 0.1 kgm)
30-183
DISASSEMBLY OF STEERING
VALVE ASSEMBLY
1. Relief valves 33
1) Remove overload relief valve (33) from valve
housing (1).
2) Remove main relief valve (33) from plug (4) in
same way.
« Remove the O-ring at the mount, but do not
disassemble the relief valve any further. 4
1 32
DEW01028 DEW01029
2. Flow control
1) Remove plug (4).
2) Remove spring (9).
9
4
DEW01030 DEW01031
3) Remove flow control spool (2).
DEW01032
30-184
4) Merge check valve

Remove plug (25), then remove spring (for merge
check valve) (35) and poppet (34) from inside.
5) Steering spool (disassembly)

1) Use an industrial drier to heat plug (18) fully
before removing it.
« The thread of plug (18) and cap screw (12)
at both ends of the spool is coated with
adhesive, so heat them fully before carrying
out the removal operation.
When assembling, replace spring (14), O-
rings (17) and (19), backup ring (20), seal
(23), and wiper (24) with new parts.
6) Remove spring (for load check) (11) and poppet

(10) from inside of spool.
30-185
30-186
ASSEMBLY OF STEERING
VALVE ASSEMBLY
1. Spool assembly
1) Install poppet (10) and spring (11) to head end
of steering spool (3).
2) Install O-ring and backup ring to plug (18), then

coat thread of spool with thread tightener and
tighten.
« Be careful not to get thread tightener on the
front part of the spool (chassis ring mount).
Be careful also not to coat with too much
thread tightener and let the thread tightener
drip inside the spool.
Thread tightener: Loctite #271
Plug: 8.8 ± 1 Nm (0.9 ± 0.1 kgm)
3) Merge check valve

1) Assemble poppet (34) and spring (35) to valve
housing.
2) Install O-ring, then tighten plug (25).
Plug: 63.7 ± 4.9 Nm (6.5 ± 0.5 kgm)
3) Install O-ring, then tighten plug (28).

Plug: 93.2 ± 4.9 Nm (9.5 ± 0.5 kgm)
30-187
3. Flow control
1) Fit O-ring to plug (5) and install to valve hous-
ing.
Plug: 142 ± 2.5 Nm (14.05 ± 0.25
kgm)
2) Assemble flow control spool (2) slowly.

« If any shims were removed during assem-
bly, assemble the same number of shims.
3) Assemble spring (for flow control) (9).

4) Fit O-ring and backup ring to plug (4) and tighten.
« When installing the plug, be careful not to
bend the spring.
Plug: 142 ± 2.5 Nm (14.05 ± 0.25
kgm)
4. Relief valve
1) Install overload relif valve (33)
Valve: 73.6 ± 4.9 Nm (7.5 ± 0.5kgm)
2) Install main relief valve assembly (32) to plug

(4)
Plug: 73.6 ± 4.9 Nm (7.5 ± 0.5kgm)
30-188
30-189
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER ASSEMBLY

For details, see REMOVAL OF RADIATOR ASSEM-
BLY.
1. Hydraulic piping
Disconnect steering cylinder rod and bottom hoses
(1) and (2) at cylinder end.
« After removing the hoses, fit plugs to prevent
the entry of dirt or dust.
2
DEW01081
2. Steering cylinder ❈1
1) Remove rod bolt, then remove pin (3).
3
DEW00965
2) Disconnect bottom grease tube (4).

3) Remove bottom bolt, then remove pin (5). 4
« Check the shim thickness and use as a
guide when assembling.
4) Remove steering cylinder (6).
« Carry out the removal operation with two 6
people.
« Be careful not to scratch the cylinder rod. 5
Steering cylinder: 25 kg
DEW01083
30-190
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
INSTALLATION OF STEERING
CYLINDER ASSEMBLY

moval.
❈1 a
Always use a bar when aligning the pin holes. Never

insert your fingers. a
« Adjust the shims so that clearance a is the standard

value. DEW01084
Clearance a = Max. 0.5 mm
« Remove all grease and oil from the cylinder pin,
and wipe off the grease that is pushed out.
30-191
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY


steering wheel and control levers several times to
release the remaining pressure in the hydraulic pip- DBW02304
ing.
Release the pressure inside the accumulator by

depressing the brake pedal slowly and repeatedly 3 5 4
2
(at least 17 times) until there is no more reaction
when the brake pedal is depressed. 9
1. Covers 6
Remove covers (1) under cab.
2. Piping (right brake valve)

1) Disconnect hoses (2) and (3) between ac-
cumulator and brake valve, and adapters
(4) and (5) at valve end. ❈1 13
7 8 19 DEW01086
2) Disconnect brake valve drain hose and tube
(6) at valve end.
3) Disconnect hose (7) going to left brake valve
at valve end. 19 12
4) Disconnect tube (8) which goes to front 13
brake and tube (9) going to rear brake at
valve end. ❈2 11
3. Piping (left brake valve)

1) Disconnect tube (10) and hose from accumula-
tor to left brake valve at brake valve end. ❈ 3
2) Disconnect left and right brake valve hoses and

elbow (11) at brake valve end. ❈4 10 DEW01087
3) Remove brake valve drain tube (12) and hose
at valve end.
« After disconnecting the piping, make marks
and fit plugs to prevent the entry of dirt or
dust.
4. Wiring
Disconnect connector of brake valve switch sensor
(13).
30-192
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
5. Pedal
Pull out cotter pin (16) of pin (15) of brake pedal 18 19
(14), then pull out pin, and remove pedal.
« Carry out the same procedure for both the left
and right brake pedals.
6. Brake valve ❈5 14
1) Remove brake valve mounting bolts (17), and
disconnect mount flange (18) and body (19),
then pull out cap (20). 15
2) Remove mount flange mounting bolts (21), then
remove mount flange from floor portion. 20 17
16
DEW01088 DEW01089
INSTALLATION OF BRAKE
VALVE ASSEMBLY
moval.
❈1 ❈2 ❈3 ❈4
❈5
Mounting bolt :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
Mounting bolt :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
« After completion of assembly, bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air from brake system.
30-193
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE
DISASSEMBLY OF RIGHT
BRAKE VALVE ASSEMBLY
(TANDEM) 1 104 4-11ø
52
2
25.75
1. Bracket assembly
1) Remove seat (1), pedal stopper (2), and boot 3
104
(3) from brake valve. 5
51.5
52
2) Remove mounting bolts (5) of bracket assem- 4
bly (4), then remove bracket assembly. 51ø
3) Remove oil seal (6) from upper portion of brake 25.75
51.5
10
valve. 6
6 6
2. Valve DEW01090 Jig q DEW01091
1) Install valve to jig 1 with bolts (5), and secure jig
in vice.
« Make match marks before disassembling
the valve. Match marks 7
2) Remove valve mounting bolts (10), then remove
S cylinder assembly (7). 8
3) Remove plug (13) of S cylinder assembly, then
remove spring (14) and O-ring.
4) Remove spring (11) and O-ring (12), then re- Jig
move P cylinder assembly (8).
« Remove spring (15) inside the plunger of 9
the P cylinder assembly. Vice
5) Remove holder (16), springs (17), (18), and (19)
and O-ring (20) from T flange assembly (9). DEW01092
« The cylinders, plungers, and spools inside
the T flange assembly and the S and P
cylinders form sets, so be careful not to mix
14 13
the parts for any set.
« Fit seals to prevent dirt or dust from enter-
ing, and be careful not to damage the cylin- 7
13
ders or flange assembly. 10
10 11
7 12
8
8 15
DEW01093 DDW01094
16
17 20
17
18
9
20 19
DEW01095 DDW01096
30-194
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE
ASSEMBLY OF RIGHT BRAKE

VALVE ASSEMBLY (TANDEM)
16
17 20 17
1. Valve
Install T flange assembly (9) to jig with bolts (5), 18
9
and hold jig in vice. 20 19
1) Install springs (19), (18), and (17) to T flange
assembly (9) in order, then install holder (16)
on top of spring.
2) Install O-ring (20) to T flange assembly (9). 9
O-ring: Lithium grease
3) Set P cylinder assembly (8) to T flange assem- DEW01095 DDW01096
bly (9).
« When setting in position, align the match
marks. 13
14
4) Install spring (11) and spring (15) inside plunger
of P cylinder assembly to P cylinder assembly 7
(8). 13
5) Install O-ring (12) to P cylinder assembly (8). 10
« Use a new part for the O-ring. 10 11
O-ring: Lithium grease 7 12
6) Set S cylinder assembly (7) to P cylinder as- 8
sembly (8), and tighten with mounting bolts (10).
8 15
« When setting the S cylinder assembly in
position, align the match marks.
Mounting bolt: DEW01093 DDW01094
58.8 – 73.6 Nm (6.0 – 7.5 kgm)

7) Install spring (14) and O-ring to S cylinder as-
sembly (7), and tighten with plug (13).
Thread of plug: Thread tightener
(Thread lock 1303B)
Plug:
152.0 ± 24.5 Nm (15.5 ± 2.5 kgm)
2. Bracket assembly
Remove valve from jig .
1) Set T flange assembly facing up, and install oil
seal (6).
« Use a new part for the oil seal.
Lip of oil seal: Lithium grease
2) Install bracket assembly (4), and tighten with
mounting bolts (5).
Mounting bolt:
58.8 – 73.6 Nm (6.0 – 7.5 kgm)
3) Install seat (1), pedal stopper (2), and boot (3)
to valve.
30-195
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE
DISASSEMBLY OF LEFT BRAKE

VALVE ASSEMBLY (SINGLE)
1 104 4-11ø
52
1. Bracket assembly 2
25.75
1) Remove seat (1), pedal stopper (2), and boot
(3) from brake valve. 3
104
5
51.5
52
2) Remove mounting bolts (5) of bracket assem- 4
bly (4), then remove bracket assembly. 51ø
25.75
51.5
10
3) Remove oil seal (6) from upper portion of brake 6
valve.
6 6
DEW01090 Jig q DEW01091
2. Valve
1) Install valve to jig with bolts (5), and secure 7
jig in vice. Match mark
« Make match marks before disassembling
the valve. 8
Jig
Vice
DEW01103
2) Remove valve mounting bolts (10), then remove

S cylinder assembly (7). 12 10
3) Remove plug (10) of S cylinder assembly, then 11

7
remove spring (11) and O-ring (12).
9
10
DEW01104 DDW01105
4) Remove holder (13), springs (14) and (15), and

O-ring (16) from S flange assembly (8). 13
14
« The cylinders, plungers, and spools inside 16
14
the S flange and the S cylinder form sets,
so be careful not to mix the parts for any 16 8
15
set.
« Fit seals to prevent dirt or dust from enter- 8

ing, and be careful not to damage the cylin-
ders or flange assembly.
DEW01106 DDW01107
30-196
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE
ASSEMBLY OF LEFT BRAKE

VALVE ASSEMBLY (SINGLE)
1
1. Valve 2
Install S flange assembly (8) to jig with bolts (5),
and hold jig in vice. 3
1) Install springs (14) and (15) to S flange assem- 5
4
bly (8), then install holder (13) on top of spring.
2) Install O-ring (16) to S flange assembly (8).
O-ring: Lithium grease 6
3) Set S cylinder assembly (7) to S flange assem- DEW01090

bly (8), and tighten with mounting bolts (9).
« When setting the S cylinder assembly in
position, align the match marks.
Mounting bolt: 13
58.8 – 73.6 Nm (6.0 – 7.5 kgm) 14
4) Install spring (11) and O-ring (12) to S cylinder 16
14
assembly (7), and tighten with plug (10).
« Use a new part for the O-ring. 16 8
15
O-ring: Lithium grease
Thread of plug: Thread tightener
(Thread lock 1303B) 8
Plug:
152.0 ± 24.5 Nm (15.5 ± 2.5 kgm)
DEW01106 DDW01107
2. Bracket assembly
Remove valve from jig .
1) Set S flange assembly facing up, and install oil
seal (6). 12 10
« Use a new part for the oil seal.
Lip of oil seal: Lithium grease 11
7
2) Install bracket assembly (4), and tighten with
mounting bolts (5). 9
10
Mounting bolt:
58.8 – 73.6 Nm (6.0 – 7.5 kgm) 7
3) Install seat (1), pedal stopper (2), and boot (3)
to valve. 9
DEW01104 DDW01105
30-197
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
REMOVAL OF PARKING BRAKE

DISC
Stop the machine on level ground, lower the work

equipment to the ground, apply the parking brake,
and put blocks under the wheels to prevent the
machine from moving.
« Release the parking brake.
1. Loosen drain plug (1) and drain transmission oil.
Transmission oil : 40 l 1
DBW01729
2. Drive shaft
Remove protector (2-1) of drive shaft, and discon-
nect center drive shaft (2) at transmission end.
❈1
« After disconnecting the drive shaft, move it to
the right end.
2-1
2
DBW02132
3. Remove mounting bolt (4) and washer (5) of cou-

3
pling (3) at front end of transmission from coupling.
❈2
« Remove together with the O-ring.
5
4 DBW01731
4. Remove lock plate (7) and 3 mounting bolts (8) of

parking brake manual cancel bolt (6).
8
DBW01732
30-198
5. Remove cover mounting bolts, then using guide bolt

(9) and forcing screws (10), remove cover (11).
❈3 10
« Be careful not to damage or get dirt on the oil
seal lip surface.
Cover assembly : 6.2 kg

9
11
DBW01733
6. Install 3 parking brake manual cancel bolts (6), then

tighten, and release parking brake.
4
7. Tighten tool A4 with coupling mounting bolt (4).
« Bolt length of tool : 56 mm
6
12
A4
DBW01734
8. Remove snap ring (12), then remove tool A4.

❈4 12
A4
DBW01735
9. Remove end plate (13), then remove separator plate

16
(14), wave spring (15), and disc (16) in turn.
« Be careful not to damage or get dirt on the
discs and plates.
15
14
13
DBW01736
30-199
INSTALLATION OF PARKING
BRAKE DISC

moval.
❈1
« Be careful to connect the coupling facing in the
correct direction.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈2
« Be careful to assemble the coupling facing in
the correct direction.
« Fit the O-ring securely in the groove.
Mounting bolt :
549 ± 59 Nm (56.0 ± 6.0 kgm)
❈3
« Be careful not to damage or get dirt on the oil
seal lip surface.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈4
« Assemble the ring securely in the ring groove of
the housing.

Tighten the drain plug and add transmission oil
through oil filler to the specified level.
Transmission oil : 40 l
30-200
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY

Operate the steering wheel and control levers sev-

eral times to release the remaining pressure in the
hydraulic piping. Then loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
1. Cover
Remove covers (1) on right side of floor.
1
DBW02133
2. Ladder
Sling ladder (2), then remove mounting bolts, and
lift off.
« Use the lifting tool to lift at two places.
DBW02134
1) Loosen plugs (3) at top of hydraulic tank filter
and plugs (4) of pump piping to prevent oil in-
side tank from flowing out.
3
DLW02135
30-201
2) Disconnect following hoses and remove each

tube. 9
7
• Brake oil return tube (5)
8
• Oil cooler tube (6)
• Disconnect PPC valve (7) and hose (8) from
6
valve end.
• Tube (9) between main control valves
• Tubes (10) and (11) between hydraulic
pump.
« After removing the tubes, tie them with wire 11
and move them to the side. 10
5
DBW02136
4. Hydraulic tank
1) Sling hydraulic tank (12), and remove front, rear,
and bottom mounting bolts (13).
12
13
DBW02137
2) Lift off hydraulic tank (12).
Hydraulic tank :
365 kg (including oil 190 l)
12
DBW02138
30-202
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY

moval.
❈1

Tighten the plugs at the top of the hydraulic tank
filter and the plugs of the pump piping, and add 14
hydraulic oil through oil filler (14) to the specified
level.
« Run the engine to circulate the oil through the
system. Then check the oil level again.
« After installing the piping, bleed the air. For de-
tails, see the precautions given for the installa-
tion procedure.
DBW02139
30-203
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
REMOVAL OF HYDRAULIC
FILTER ASSEMBLY
1
sure inside the hydraulic tank.
1. Cover
Remove mounting bolts, then remove covers (1)
and (1-1). ❈1
The tension of the spring is applied to cover (1-
1), so be careful when removing.
« Be careful not to damage the O-ring at the mat-
ing surface of cover (1-1) and the tank.
DBW02140
2. Filter
Remove spring (2) and bypass valve (3), then re-
move filter (4). 1-1
DBW02141
INSTALLATION OF HYDRAULIC
FILTER ASSEMBLY
2
moval.
❈1
DBW02142
3 4
DBW02143
30-204
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING, SWITCH, PPC PUMP
REMOVAL OF HYDRAULIC,
STEERING, SWITCH, PPC
PUMP ASSEMBLY
Operate the control levers several times to release

the remaining pressure in the hydraulic piping. Then
loosen the oil filler cap slowly to release the pres-
1. Cover
Remove covers (1) on right side of floor.
1
DBW02133
2. Ladder
Sling ladder (2), then remove mounting bolts, and
lift off.
« Use the lifting tool to lift at two places.
DBW02134
3. Loosen plugs (3) at top of hydraulic tank filter and

plugs (4) of pump piping to prevent oil inside tank
from flowing out. ❈1
3
DLW02135
30-205
4. Floor support ❈2
1) Remove inspection covers (5) and (6) on right 5
side.
6
DBW02144 DBW02145
2) Sling right floor support (7) with nylon lifting tool

, then remove mounting bolts and lift off.
Support : 19 kg
q
DBW02146
5. Hydraulic piping
1) Remove clamps of air conditioner hose (8) and
hydraulic hose (9), then move to rear.
9
8
DBW02147
2) Remove hydraulic hoses (11), (12), (13), and

(14) at bottom of hydraulic pump (10). ❈3 14
« After disconnecting the hoses, fit plugs to
prevent dirt or dust from entering.
« After disconnecting the hoses, mark them
with tags to distinguish them.
10 12 13
11
DBW02148
30-206
3) Remove hydraulic tubes (15) and (16) from hy-

draulic pump (10).
4) Sling hydraulic pump with nylon lifting tool . 15
« After disconnecting the tubes, fit plugs to
prevent dirt or dust from entering.
« After disconnecting the tubes, mark them
with tags to distinguish them. 10
16
q
DBW02149
6. Hydraulic pump
Remove mounting bolts, and take care to maintain
balance when lifting off hydraulic pump (10).
❈4
« The working space is confined, so be extremely
« Carry out the removal operation with two work-
ers.
Hydraulic pump : 46 kg
10
q
DBW02150
30-207
INSTALLATION OF HYDRAULIC,
STEERING, SWITCH, PPC
PUMP ASSEMBLY
moval.
❈1
plug thread and piping thread.
Thread of plug : Gasket sealant (LG-4)
❈2
« Tighten the floor support mounting bolts fully
after installing the floor.
Mounting bolt :
277 ± 31.9 Nm (28.25 ± 3.25 kgm)
❈3
❈4

filter and the plugs of the pump piping, and add
hydraulic oil through the oil filler to the specified
level.
« After installing the piping, bleed the air. For de-

tails, see the precautions given for the installa-
tion procedure.
30-208
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
1
brake and put blocks under the wheels to prevent 2
• Raise the boom, and set support under boom
(1), then remove front cover (2).
Set the support securely.
q
DBW02151

« Remove the cover at the front of the hydraulic tank.
• Loosen plugs (3) at top of hydraulic tank filter and
plugs (4) of pump piping to prevent oil inside tank
from flowing out.
3 4
DBW02152
1. PPC hoses ❈1
Disconnect following hoses from main control valve.
• Hose (5) for bucket spool between PPC valve
(P4) and main control valve (J)
• Hose (6) for boom spool between PPC valve
(P2) and main control valve (K)
• Hose (7) for bucket spool between PPC valve
(P1) and main control valve (H)
• Hose (8) for boom spool between PPC valve
(P3) and main control valve (I)
« After disconnecting the hoses, move them to-
wards the rear of the machine.
« After disconnecting the hoses, mark them with 5 6 DBW02153
tags to distinguish them.
2. Hydraulic hoses ❈2
Disconnect following hydraulic piping. 9
« After removing each hose and tube, move them
to the side.
• Hose (9) between steering valve and main con- 8 7
trol valve
DBW02154
30-209
• Hose (10) between hydraulic pump and hydrau-

lic tank
• Tube (11) between hydraulic pump and main
control valve
11
10
DBW02155
• Tubes (12) and (13) between main control valve

and bucket cylinder
12
• Tubes (14) and (15) between main control valve
and boom cylinder 13
« Remove the tube clamps.

« After disconnecting the tubes, move them to-
wards the rear of the machine.
DBW02156
3. Main control valve ❈3

Sling main control valve (16), then remove mount-
ing bolts and lift off main control valve.
14
15
Main control valve : 75 kg
« When raising the main control valve, be careful
to fit the lifting equipment securely.
« When lifting off the main control valve, be care-
ful not to let it hit the horn.
16
DBW02157
30-210
INSTALLATION OF MAIN
moval.
❈1
« Check the tags on the hoses, then connect the
hoses.
❈2
❈3
« Tighten the mounting bolts on diametrically op-
posite sides, and be careful not to deform the
valve when tightening.
« Be careful of the angle of the tube when tight-
ening the clamp.
« Be careful that the tube does not interfere with
any other part.

filter and the plugs of the pump piping, and add
hydraulic oil through the oil filler to the specified
level.
11.8 ± 1.0 Nm (1.2 ± 0.1 kgm)
Hydraulic oil : 138 l
(Replacement amount)
30-211
DISASSEMBLY OF MAIN
14
15
16
27 17
18 13
44
28
29
25
30
31
26
a
2
32
1
b
41
45 25
42
24 40
39
38
43 37
36
35
34
33
a
19
12
11
10
9 b
8
7
6
5
4
23
22
21
3 20
DDW01547
30-212
1. Remove cut-off valve (2) from valve body (1).

6 8
7
2. Spool assembly (boom)
1) Remove case (3), then remove retainer (4) and 9
spring (5). 11
10
2) Hold spool (19) in position with a wrench (width 19
across flats: 14 mm) at position a shown in
diagram on right and loosen bolt (6). 12
« Loosen bolt (6) with spool (19) assembled
to body (1). (To prevent damage to the
spool)
3) Remove bolt (6), then remove washer (7), re- DEW01548
tainer (8), spring (9), retainer (10), collar (11),
and retainer (12).
4) Remove case (13), then remove retainer (14),
spring (15), retainer (16), spring (17), and re-
tainer (18).
5) Remove spool (19) from body (1).
« Check the correct direction for assembling
spool (19) to the body.
3. Spool assembly (bucket)

1) Remove case (20), then remove spring (21) and
retainer (22).
2) Remove case (13), then remove retainer (14),
spring (15), retainer (16), spring (17), and re-
tainer (18).
3) Remove spool (23) from body (1).
4. Main relief valve assembly

Remove main relief valve assembly (24).
5. Safety valve assembly with suction

Remove safety valve (25).
« The safety valve cannot be adjusted when it is
installed to the machine, so do not disassemble
it.
6. Suction valve assembly

Remove suction valve assembly (26).
7. Check valve assembly, flange, plugs

1) Remove plug (27), then remove spring (28) and
valve (29).
2) Remove flange (30).
3) Remove plugs (44) and (45).

1) Remove pilot valve (31).
2) Remove screen (32).
3) Remove flange (33), then remove piston (34),
spring (35), and valve (36).
4) Remove bar (37), then remove seat (38), spring
(39), and valve (40).
5) Remove plugs (41), (42), and (43).
30-213
ASSEMBLY OF MAIN CONTROL

VALVE ASSEMBLY
14
15
16
27 17
18 13
44
28
29
25
30
31
26
a
2
32
1
b
41
45 25
42
24 40
39
38
43 37
36
35
34
33
a
19
12
11
10
9 b
8
7
6
5
4
23
22
21
3 20
DDW01547
30-214

1) Fit O-rings to plugs (43), (42), and (41) and
install.
Plug (41) :
275 ± 29.4 Nm (28.0 ± 3.0 kgm)
2) Assemble valve (40), spring (39), and seat (38)
to valve body (2), then install O-ring to bar (37)
and install.
Mounting bolt :
66.7 ± 7.8 Nm (6.8 ± 0.8 kgm)
3) Assemble valve (36), spring (35), and piston
(34) to valve body (2), then fit O-ring to flange
(33) and install.
Mounting bolt :
66.7 ± 7.8 Nm (6.8 ± 0.8 kgm)
4) Install screen (32) and pilot valve (31).
Screen :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
Pilot valve :
147 ± 9.8 Nm (15.0 ± 1.0 kgm)
2. Check valve assembly, flange, plugs

1) Install plugs (45) and (44) and install to body
(1).
Plug (44) :
152 ± 24.5 Nm (15.5 ± 2.5 kgm)
2) Install flange (30).
Mounting bolt :
66.7 ± 7.8 Nm (6.8 ± 0.8 kgm)
3) Assemble valve (29) and spring (28) to body
(1), then fit O-ring to plug (27) and install.
Plug : 466 ± 24.5 Nm (47.5 ± 2.5
kgm)
3. Suction valve assembly

Install suction valve (26).
Suction valve assembly :
226 ± 9.8 Nm (23.0 ± 1.0 kgm)
4. Safety valve assembly with suction

Install safety valve assembly (25).
Safety valve assembly :
226 ± 9.8 Nm (23.0 ± 1.0 kgm)
5. Main relief valve assembly

Install main relief valve assembly (24).
Main relief valve assembly :
152 ± 24.5 m (15.5 ± 2.5 kgm)
30-215
6. Spool assembly (bucket)

1) Assemble spool (23) to body (1).
2) Assemble retainer (18), spring (17), retainer (16),
spring (15), and retainer (14), then fit O-ring to
case (13) and install.
3) Assemble retainer (22) and spring (21) to spool
(23), then fit O-ring to case (20) and install.
7. Spool assembly (boom)

1) Assemble spool (19) to body (1).
« Check that spool (19) is facing the correct
direction when assembling it to the body.
2) Assemble retainer (12) to spool (19).
3) Assemble washer (7), retainer (8), spring (9),
retainer (10), and collar (11) to bolt (6), then
6 8
hold spool in position with a wrench (width
7
across flats: 14 mm) at position a shown in
diagram on right, and tighten bolt (6). 9
11
Bolt (6) :
10
13.7 ± 1.5 Nm (1.4 ± 0.15 kgm) 19
4) Assemble spring (5) and retainer (4), then fit O-
ring to case (3) and install. 12
5) Assemble retainer (18), spring (17), retainer (16),
spring (15), and retainer (14), then fit O-ring to
case (13) and install.
DEW01548
8. Install cut-off valve (2) to valve body (1).
Mounting bolt :
108 ± 9.8 Nm (11.0 ± 1.0 kgm)
« Tighten the bolts in the order shown in the dia-
gram on the right.
DEW01551
30-216
DISASSEMBLY AND ASSEMBLY PPC VALVE
REMOVAL OF PPC VALVE

ASSEMBLY

sure inside the hydraulic tank. 1
DBW02133
• Remove cover (1).
• Loosen plugs (2) and (3) at top of hydraulic tank 4

filter to prevent oil inside tank from flowing out.
1. Cover
1) Remove floor inspection cover (4).
2
3 DBW02158
6
Disconnect following hydraulic piping from PPC
valve.
• Hose (6) between PPC valve and PPC valve
• Hose (7) between PPC valve and hydraulic tank
• Hoses P2 (8) and P3 (9) for boom spool
• Hoses P4 (10) and P1 (11) for bucket spool
« When removing the 4 hoses at the bottom of 11

the PPC valve, remove the hoses from the out-
side, then remove the nipple and disconnect 10
the hoses. 9 8 DBW02159
« After disconnecting the hoses, mark them with

tags to distinguish them. 6 7
9
8
Front of
machine
11 10
DBW02160
30-217
3. Linkage ❈1
1) Remove console box side face cover (11).
2) Loosen locknut (12), and disconnect linkage (13)

from PPC valve.
11
DBW02161
12
13
DBW02164
14
DBW02162
4. PPC valve
Remove mounting bolts, then remove PPC valve
(14) from under floor.
« The working space is confined, so be extremely
14
DBW02163
30-218
INSTALLATION OF PPC VALVE

ASSEMBLY
moval.
❈1
« Adjust the linkage.

filter, and add hydraulic oil through oil filler to the
specified level.
11.8 ± 1.0 Nm (1.2 ± 0.1 kgm)
30-219
DISASSEMBLY OF PPC VALVE

ASSEMBLY
1. Remove bolt (1).

1
2. Remove plate (2).
3. Remove seal (3), then remove spool (4).

« Of the 4 spools (4), make a distinguishing mark 4
on the boom LOWER spool and check the
mounting position.
4. Remove collar (5) from spool (4). 2

3
5. Remove valve assembly (6) from body (7).
5
6. Remove collar (8), then remove retainer (9), spring
(10), and shim (11) from valve (12). 9
« Check the number and thickness of the shims, 10
and keep in a safe place.
13
7. Remove spring (13) from body (7).
« The number of coils of spring (13) differs for 12
each hydraulic port, so check the mounting po-
sition of each spring and make distinguishing 7
marks. DEW01221
8 8
9 9
10 10
6 11 6
11
12 12
13
13
DEW01222
30-220
ASSEMBLY OF PPC VALVE

ASSEMBLY
1. Assemble spring (13) to body (7).

« The number of coils of spring (13) differs for
each hydraulic port as shown in the chart be-
1
low, so check each spring and be sure to install
in the correct position.
Port position No. of coils of spring

4
P1 Bucket TILT
11
P2 Boom RAISE
P3 Boom LOWER 2
14
P4 Bucket DUMP 3
5
« The position of each port is stamped on the
valve body. 9
10
2. Assemble shim (11), spring (10), and retainer (9) to
valve (12), and install collar (8). 13
3. Assemble valve assembly (6) to body (7).

12
4. Fit O-ring to collar (5), and assemble to spool (4),
then install spool (4). 7
DEW01221
« For spools (4), check the mounting position of
the boom LOWER spool which was marked
with a distinguishing mark, then install the
spools.
5. Fit seal (3) and install plate (2).

8 8
6. Install bolt (1). 9 9
Bolt: 44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
10 10
6 11 6
11
12 12
13
13
DEW01222
30-221
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
ground and stop the engine. Then apply the park- 1
ing brake and put blocks under the wheels to pre-
vent the machine from moving.

DBW02165
1. Bucket positioner ❈1
1) Disconnect connector (1).
2) Remove wiring clamp (1-1) for bucket positioner.
1-1
DBW02166
2. Rod pin ❈2
Sling cylinder, and remove lock bolt, then remove 2
pin (2).
« Be careful of the center of gravity when sling-
ing, and lift at two places.
« Check the number and thickness of the shims,
and keep in a safe place.
DBW02167
1) Disconnect hose (3) at rod end from cylinder.
3
DBW02168
30-222
3) Disconnect tube (4) and hose (5) at bottom end

from connecting portion.
4
5
DBW02169
4. Bucket cylinder ❈4
1) Remove lock bolt, then remove bottom pin (6). 6 7
« If there are shims, check the number and
place.
2) Lift off bucket cylinder (7).
« Be careful not to damage the cylinder rod
portion.
Bucket cylinder : 170 kg (with tube)
DBW02170
30-223
INSTALLATION OF BUCKET
CYLINDER
moval.
When aligning the position of the pin hole, use a a a

bar. Never insert your fingers in the pin hole.
❈1
« Adjust the bucket positioner.
❈2
« Clearance a : Max. 1.5 mm
DBW02171
❈3
❈4
b b
« Clearance b : Max. 1.5 mm
« Coat each pin with grease.
DBW02172
30-224
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

ground and stop the engine. Then apply the park- 1
vent the machine from moving. 2

« Set the pin at a higher position than the top
face of the tire. DBW02173
« Set a support under the boom.
1. Rod pin ❈1
1) Sling boom cylinder (1), and remove lock bolt,
then remove pin (2).
6
place. 4
2) Start engine, and operate control lever to re- 5
tract cylinder rod of cylinder which has been
removed.
3
1) Disconnect tube (3) and hose (4) at rod end DBW02174
from disconnection.
2) Disconnect tube (5) and hose (6) at bottom end
from connection.
DBW02175
3. Boom cylinder ❈3
1) Remove lock bolt, then remove bottom pin (7).
thickness of the shims, and keep in a safe 1
place.
2) Remove boom cylinder (1).
« Be careful of the center of gravity, and re-
move slowly.
« Be careful not to damage the cylinder rod
portion.
Boom cylinder assembly : DBW02176

170 kg (with tube)
30-225
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
a a
moval.
When aligning the position of the pin hole, use a
❈1
« Clearance (a) : Max. 1.5 mm
DBW02177
❈2
❈3
« Clearance (e) : Max. 2.0 mm
« Remove the support.
« Coat each pin with grease.
e
DBW02178
30-226
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS- Steering cylinder
SEMBLY) G 2 1
1. Set cylinder assembly (1) to tool F. F
2. Cylinder head, piston rod assembly

• Steering cylinder assembly
1) Using tool G, remove cylinder head (2) from
cylinder.
DBW01794
2) Pull out cylinder head and piston rod assembly

Steering cylinder
(3) from cylinder (4), and lift off. 4 3
« Oil will flow out when the piston rod assem-
bly is removed from the cylinder, so place a
container under the cylinder to catch the oil.
DEW01246
• Boom, bucket cylinder assembly

Boom, Bucket cylinder
1) Remove mounting bolts of cylinder head (2). 2
1
Cylinder Width across flats of F

bolt (mm)
Boom cylinder 41
Bucket cylinder 27
DBW01795
2) Pull out cylinder head and piston rod assembly (6)

from cylinder (7), and lift off. 7
« Oil will flow out when the piston rod assem-
bly is removed from the cylinder, so place a
container under the cylinder to catch the oil. 6
DEW01248
30-227
3. Cylinder head
• Steering cylinder assembly H 9 3 2
1) Set cylinder head and piston rod assembly (3)
to tool F.
2) Using tool H, remove nut (8).
« Width across flats of nut: 46 mm F
3) Remove piston (9), then remove cylinder head 8
(2).
DBW01796

12 6 5
1) Set cylinder head and piston rod assembly (6)
to tool F. 10
2) Remove piston mounting bolt (10), then remove
spacer (11), piston (12), and cylinder head (5).
11 F
DBW01797
4. Remove O-ring and backup ring (14) from piston

rod (13). 13
« Rod of boom, bucket cylinder only. 14
DEW01251
5. Disassembly of piston assembly

Remove wear ring (15) and piston ring (16) from
pistons (9) and (12).
9, 12
16
15
DEW01252
30-228
6. Disassembly of cylinder head assembly

• Steering cylinder assembly 17
1) Remove snap ring (17), then remove dust seal
18
(18).
2) Remove rod packing (19), then remove bushing
(20) from cylinder head (2). 2 20
3) Remove O-ring and backup ring (21).
21 19
DEW01253

1) Remove snap ring (22), then remove dust seal
(23). 22 23
2) Remove rod packing (24), then remove bushing 25
(25) from cylinder head (2).
2
3) Remove O-ring and backup ring (26).
26
24
DEW01254
30-229
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS-
SEMBLY)
I
« Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of all parts with engine oil be-
fore installing. Be careful not to damage the rod
25
packing, dust seals or O-rings when assembling.
1. Assembly of cylinder head assembly 2

1) Using tool I, press fit bushing (25) to cylinder DBW01798
head (2).
2) Install rod packing (24).
3) Using tool K, fit dust seal (23), then install snap
ring (22). K
23
22
24
26 DBW01799
DEW01257
I
4) Install O-ring and backup ring (26).
« Do not try to force the backup ring into
position. Warm it in warm water (50 – 60°C)
before fitting it.
20
• Steering assembly
1) Using tool I, press fit bushing (20) to cylinder
head (2).
2
DBW01800
2) Install rod packing (19).

3) Using tool K, install dust seal (18) to cylinder K
head.
18
19
DBW01801
30-230
4) Install snap ring (17).

5) Install O-ring and backup ring (21).
17
« Do not try to force the backup ring into
position. Warm it in warm water (50 – 60°C)
before fitting it.
21
DEW01260
2. Assembly of piston assembly

1) Using tool J1, expand piston ring (16).
« Set the piston ring on the expander and 16 J2 9,12
turn the handle 8 – 10 times to expand the
J1
ring. 16
2) Remove piston ring (16) from tool J1, then as-
semble to pistons (12) and (9).
3) Using tool J2, compress piston ring (16).
4) Assemble wear ring (15).
DBW01802 DBW01803
3. Assemble O-ring and backup ring (14) to piston

rod (13).
« Do not try to force the backup ring into posi-
tion. Warm it in warm water (50 – 60°C) be- 9, 12
14 13
fore fitting it.
16
15
DEW01252 DEW01251
4. Cylinder head, piston rod assembly

• Boom, bucket cylinder assembly 12 6 2
1) Set piston rod assembly (6) to tool F. 10
2) Assemble cylinder head (2), piston (12), and
spacer (11) to piston rod, then tighten mounting
bolt (10).
Mounting bolt: 11 F
Mounting bolt:
Cylinder Nm(kgm)
Boom cylinder
110.8 ± 12.8(11.3 ±1.3) DBW01797
Bucket cylinder
30-231
• Steering cylinder assembly

1) Set piston rod assembly (3) to tool F. H 9 3 2
2) Assemble cylinder head (2) and piston (9) to
piston rod.
3) Assemble nut (8), and using tool H, tighten nut
(8). F
Thread of piston rod: 8
Nut:
Width across flats Nm(kgm)

56 785 ± 78 (80 ± 8) DBW01796
5. Cylinder head
• Boom, bucket cylinder 7 2 6
1) Set cylinder (7) to tool F.
2) Raise cylinder head and piston rod assembly
(6) and assemble to cylinder (7). F
3) Install cylinder head (2) to cylinder (7).
Mounting bolt:
Cylinder Nm(kgm)
Boom cylinder 1,324 ± 147 (135 ± 15)
Bucket cylinder 343 ± 34 (35 ± 3.5)
4) Remove cylinder assembly (1) from tool F. DBW01858
• Steering cylinder assembly Steering cylinder

1) Set cylinder (4) to tool F. 4 3
2) Raise cylinder head and piston rod assembly
(3) and assemble to cylinder (4).
3) Using tool G, install cylinder head (2) to cylinder
(4).
Cylinder head:
588 ± 59 Nm (60 ± 6 kgm)
4) Bend lock of cylinder head (2) into notch at
cylinder end.
5) Remove cylinder assembly (1) from tool F.
DEW01246
Steering cylinder
G 2 1
DBW01794
30-232
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
Wire
ground and stop the engine. Then apply the park-
vent the machine from moving.
1. Bucket link
1) Remove bucket link mounting pin (1). ❈1
« Secure the bucket link to the bellcrank with
wire. 1 2
DBW02179 DBW02180
2) Remove left and right bucket hinge mounting

pins (2). ❈2
When aligning the position of the pin hole,
never insert your fingers in the pin hole.
3) Bucket
Move machine towards rear, then disconnect
bucket (2-1).
Bucket : 1,583 kg (with edge)
2-1
DBW02181
2. Bucket cylinder mounting pin ❈3

3
Sling bucket cylinder (3) and pull out pin (4), then 4
disconnect cylinder rod and bellcrank.
« Set block between the cylinder bottom and
the frame.
Bucket cylinder : 166 kg
q
DBW02182 DBW02183
3. Boom cylinder pin ❈4 6

Sling boom cylinder (5), and remove mounting pin
(6).
« Set a support under the end of the boom.
« Set blocks on the top of the axle and lower
the cylinder. 5
Boom cylinder : 164 kg (each)
w DBW02184
30-233
4. Boom, bellcrank, bucket link

Sling boom, bellcrank, and bucket link assembly
(7), then pull out boom mounting pin (8), and lift off
boom. ❈5 7
Boom, bellcrank, bucket link assembly :

1,380 kg
DBW02185
5. Bellcrank, bucket link

1) Remove pin (10) from bellcrank and bucket link
8
assembly (9), and disconnect bellcrank (11) and
bucket link (12). 9
10
11
12
DBW02186 DBW02187
2) Sling bellcrank (11), then pull out mounting pin

(13), and lift off.
Bellcrank : 310 kg
6. Dust seal, bushing ❈6

1) Pull out dust seal (15) and bushing (16) from 11
boom (14).
13
DBW02265
14
15
15
15
16
14
DLW02190 14
DBW02188 DBW02189
30-234
2) Pull out dust seal (17) and bushing (18) from

11
bellcrank (11).
17
DBW02191
18
17
18 P
P
DBW02192
3) Pull out dust seal (19) and bushing (20) from

bucket link (12).
19 12
DBW02193
12
19
20
DLW02194
30-235
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
moval.
When aligning the position of the pin hole, use a
❈1
« Operate the control levers, align the mounting
pin holes for the bucket and bucket link, install
cord ring (21), insert shims so that clearances a
21
and b on the left and right are uniform, then
assemble the mounting pin and lock with the
bolt. DBW02195
« Be careful not to get the cord ring caught.

« Clearance a : Max. 1.5 mm (bucket link portion)
❈2
« Clearance b : Max. 1.5 mm (bucket hinge por-
tion)
a a b b
DBW02196 DBW02197
❈3
« After assembling the mounting pin, remove block
. c c
« Clearance c : Max. 1.5 mm
DBW02306
❈4
« Clearance d : Max. 2.0 mm
DBW02264
30-236
❈5
« After installing the boom, install boom kickout
switch.
« Clearance e : Max. 1.5 mm
« After assembling the pin, set the support to the
tip of the boom.
e e
DBW02198
❈6
« Press fit bushing (16) to each of bucket link,
bellcrank, and boom with press, then assemble
dust seal (15).
Bushing : Grease (G2-LI)
16
16 15
DBW02199
DLW02201
« Greasing
Coat each pin with grease.
DBW02200
30-237
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT
1
DBW02202
1. Grill
1) Sling grill (1), and remove from engine hood 1
(2), then make a clearance.
2) Disconnect wiring connector (3), then lift off grill
(1).
2. Counterweight ❈1
Sling counterweight (5), then remove mounting bolts
and lift off. 3
« Be careful to maintain the balance when lifting
off.
DBW02203
Counterweight: 1,170 kg
INSTALLATION OF 4
COUNTERWEIGHT
moval.
❈1
DBW02204
Mounting bolt :
927 ± 103 Nm (94.5 ± 10.5 kgm)
(Width across flats: 36 mm)
DBW02205
30-238
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
Open the inspection cover and apply the lock. 1
1. Grill
1) Loosen mounting bolts of grill (1), then fit grill to 2
engine hood (2) temporarily, and remove light
wiring from engine hood (3-1) clip portion. DBW02206
2) Disconnect wiring connector (3), and remove

grill (1).
3
3-1
DBW02207
2. Draining fuel
Loosen drain valve (4) and drain fuel.
DBW02208
3. Drain valve
Remove engine oil drain valve (5) from fuel tank.
« Remove the drain valve, then tie with wire and
move to the side.
DBW02209
30-239
4. Fuel tubes, wiring

1) Disconnect fuel hoses (6) and (7) from fuel tank.
7 6
2) Disconnect spill hose (8) from fuel tank.
DBW02210
3) Disconnect wiring connector (9) for fuel unit.
5. Fuel tank ❈1
1) Sling fuel tank (10), then remove mounting bolts
and lift off. DBW02211
« Use two nylon ropes of a length of approx.
5 m to sling the tank.
« Set a pallet under the tank, then slowly lower
the fuel tank on to the pallet, taking care to
maintain the balance.
Fuel tank : 179 kg (empty)

2) Pull out fuel tank (10) from under machine.
❈2
« Tilt breather tube (11) to the side to prevent
it from hitting the chassis.
« When pulling the fuel tank out from under
10
the chassis, remove it from the right side.
DBW02212
11
11
10
DBW02214 DBW02213
30-240
INSTALLATION OF FUEL TANK

ASSEMBLY
• Carry out installation in the reverse order to re- Bolt
moval. (R.H)
❈1 Bolt
(L.H)
« When tightening the bolts, tighten in the follow-
ing order: left, rear, right
Mounting bolt :
927 ± 103 Nm (94.5 ± 10.5 kgm)
Bolt
(Width across flats: 36 mm) (rear)
« When raising the tank, keep it horizontal and
set it in the mounting position.
« Raise the palleter fully, then lift the fuel tank.
❈2
« Pull the breather tube under the chassis before
connecting.
DBW02215
• Refilling with oil 12

Tighten drain valve and add fuel through oil filler
(12).
DBW02216
30-241
DISASSEMBLY AND ASSEMBLY CAB, FLOOR FRAME
REMOVAL OF CAB, FLOOR

FRAME ASSEMBLY
of the battery.
1. Lift off left and right ladders (1).
Ladder : 60 kg
1
DBW02217
2. Remove 8 connectors (2) from clip and disconnect.

« To distinguish the connectors, mark them with
tags. 3
« After disconnecting, fit the connectors at the
cab end to the clip, and take steps to prevent oil
or mud from getting on the connectors at the
chassis end.
2
3. Disconnect ground connection (3) between cab and
chassis.
DBW02218
4. Disconnect hoses (4), (5), and orbit-roll hoses.
« Disconnect the intermediate hose clamp of hose

6
(6).
« After disconnecting the hoses and rod, tie them 4
securely with wire to the bottom of the cab.
« To distinguish the hoses, mark them with tags.
5
DBW02219
5. Disconnect brake hoses (8), (9), (10), and (11).

« To distinguish the hoses, mark them with tags. 10
11 9
DBW02220
30-242
6. Disconnect work equipment PPC valve hoses (12),

(13), (14), and (15). 12
« When removing the 4 hoses at the bottom of
the PPC valve, remove the hoses from the out-
side, then remove the nipple and disconnect
the hoses.
15
« To distinguish the hoses, mark them with tags.
14
13 DBW02221
7. Disconnect accelerator cable (16) at fuel injection

pump end. ❈1
16
DBW02222
8. Disconnect 2 window washer tubes (17) at washer

tank end. 19 18
« Fit blind plugs to prevent the water inside the
washer tank from leaking out.
« After disconnecting the tubes, check the posi-
tion for inserting them into the tank, then coil
the tubes and secure them to the cab. 20
17
DBW02223
9. Disconnect air conditioner hoses (18) and (19), and

heater hoses (20) and (21). ❈2
« Loosen the sleeve nut of the air conditioner
hose and gradually drain the refrigerant (R-
134a).
« To prevent coolant from leaking out from the
heater hose, bend the tip of the hose and tie it
with wire.
« Put the air conditioner hoses in a vinyl bag to
prevent oil, mud, or dirt from entering.
21
DBW02224
30-243
10. Sling cab and floor frame assembly (22), then re-
move mount bolts, and lift off cab and floor frame 22
assembly (22). ❈3
INSTALLATION OF CAB, FLOOR

FRAME ASSEMBLY
DBW02225
moval.
❈1
• Adjust the accelerator cable.
For details, see TESTING AND ADJUSTING,
25
Measuring accelerator pedal.
❈2
« Check that there is no damage to the air condi-
tioner hose, sleeve nut, or O-ring, then connect.
Sleeve nut:
Thread size Tightening torque

Nm (kgm)
M16 x 1.5 11.8 – 14.7 (1.2 – 1.5)
24 23
M22 x 1.5 19.6 – 24.5 (2.0 – 2.5)
M24 x 1.5 29.4 – 34.3 (3.0 – 3.5)

M6 bolt at receiver
portion 3.9 – 6.9 (0.4 – 0.7)
Other M6 bolts 7.8 – 11.8 (0.8 – 1.2)
DBW02226
❈3
Cab, floor frame assembly : 700 kg

« Align the hole of plate (25) with dowel pin (24)
of viscous mount (23) and assemble.
Align the position of the flange of plate (25) so
that it is easy to prevent rotation during the
tightening operation.
« Charge with refrigerant (R-134a). 25
23 DBW02227
30-244
DISASSEMBLY AND ASSEMBLY CAB
REMOVAL OF CAB ASSEMBLY

1. Cover
1) Remove covers (1), (2), and (3) from under
floor. 1
2
3
DBW01832
2) Remove cover mounting bolts, then remove cov-

ers (4) and (5). 5
4
« Remove the ashtray from cover (5).
3) Remove cover (6).
6 DBW01833
2. Electric wiring
1) Disconnect cab wiring connectors (7). ❈1
« Fit tags to distinguish the connectors.
(Connectors CL1, CL2, CL3)
8
3. Hoses
1) Disconnect 2 window washer hoses (8).
« Make marks to distinguish the hoses.
« Drain the washer fluid. 7
DBW01834
4. Cab
1) Remove steering post and cab mounting bolts
(9).
« Pull the steering post to tip it down.
9
DBW01835
30-245
DISASSEMBLY AND ASSEMBLY CAB
2) Remove floor and cab mounting bolts (10), (11),

and (12) on left and right.
10
11
DBW01836 DBW01837
3) Lift off cab (14).

« Remove 4 plugs (13) from the cab roof, 12
then install eyebolts.
« Raise horizontally and lift off slowly.
Cab : 295 kg
13
DBW01838 DBW01839
14
DBW01840
INSTALLATION OF CAB
ASSEMBLY
moval.
❈1
« Connect the wiring connectors securely.
30-246
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
REMOVAL OF MAIN MONITOR

ASSEMBLY
3
4
of the battery. 1
1. Remove dashboards (1) and (2). DEW01304
2. Remove steering post cover mounting bolts (3) and

(4).
6
3. Remove steering post cover (5).
5
4. Remove mounting bolt caps (7) of steering post
cover (6), then remove bolts.
7
DLW01841
5. Remove mounting bolt caps from steering post cover

(8), then remove mounting bolts (9). 8
« Tip the steering post cover to the front.
DEW01306
6. Remove bracket (10) at back of main monitor.
10
DEW01307
30-247
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
7. Remove 8 mounting bolts (12) of main monitor (11).

« When removing the main monitor, be careful
not to subject it to any strong shock. 11
12
DEW01308
8. Disconnect wiring connectors (13), (14), (15), and

(16) from main monitor, and remove main monitor 13 14
(11). ❈1
15
16
DEW01309
INSTALLATION OF MAIN
MONITOR ASSEMBLY 15 14 13
11

moval.
❈1
« Fit the connector lock securely.
16
DEW01310
30-248
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
REMOVAL OF MAINTENANCE
MONITOR ASSEMBLY
1
Disconnect the cable from the negative – terminal
of the battery.
1. Cover
2
1) Remove cover (1) from cab. DBW01842
« Remove the cover and leave the bolts loos-

ened.
2) Remove cover (2). 3 5
« Open the fuse box cover and leave the bolts
loosened.
4
3) Remove monitor cover (3).
« Remove pad assembly (4) and mounting
bolt cap (5).
« Remove the boot.
« Turn the cover to the outside.
DBW01843
2. Maintenance monitor
1) Remove mounting bolts, then remove mainte-
nance monitor (6).
« Move the maintenance monitor to the side.
6
DBW01844
3. Disconnect electrical wiring (7) from connector.

❈1
« Electrical wiring (7): L18, L19, L22, L20
« Fit tags to distinguish the wiring.
INSTALLATION OF 7
MAINTENANCE MONITOR
ASSEMBLY
moval.
❈1
6
« Connect the connectors securely.
DBW01845
30-249
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT ASSEMBLY
ground and stop the engine. Then apply the parking 1
Disconnect the cable from the negative – terminal

of the battery.
• Remove the cover under the cab.
• Carry out the oil return operation for the com-
pressor, then use a gauge manifold and re- DBW02228
lease the refrigerant slowly from the core of the

compressor high-pressure and low-pressure
valves.
• When carrying out the oil return operation, set
the fan switch to the maximum position, run the
engine at low idling, and operate the air condi-
tioner for 5 minutes.
If the refrigerant gets in your eyes, there is danger

of losing your sight, so always wear protective gog- 1-1
gles.
1-2
1. Remove inspection cover (1) under floor.
DBW02229 DBW02230
2. Remove clamps of heater hoses (1-1) and (1-2).
3. Remove covers (2) and (3) at rear of cab.

« Slide the operator's seat to the front, then tip it
over.
« Remove blind cap (3-1).
« Remove 2 bolts and loosen 6 bolts.
4. Remove 5 mounting bolts of cover (4), remove cover, 2 3-1 3

then remove seat support cover (5).
DEW01316
5
DEW01318 DEW01317
30-250
5. Remove cool and hot box assembly (6) and mount-

ing bolts (7), then remove cool and hot box assem-
bly.
6 DEW01319
6. Remove fuse box assembly bracket (8) from right

console box.
8
DEW01320
7. Remove connectors (9), (10), (11), (12), (13), and

(14) from fuse box assembly bracket, and put fuse 9 10 11 12 13 14
box assembly on right console box temporarily.
« Mark the connectors with a tag to distin-
guish when installing.
DEW01321
8. Disconnect floor wiring connectors (15), (16), and

(17) from air conditioner unit wiring, then disconnect
air conditioner relay wiring connector (18). 15
18
16 17 DEW01322
30-251
9. Remove left console box cover (19).
19
DEW01323
10. Remove left console box mounting bolts (20) and

(21), then remove left console box (22).
21
22
20
DEW01324 DEW01325
11. Remove mounting bolts (24) of air conditioner unit

(23).
24
23
DEW01326
12. Remove mounting bolts (26) of air conditioner unit

(23) and air conditioner damper (25).
« Loosen mounting bolt (27).
« Loosen the 4 mounting bolts at the cab end. 27
25
23
26 DEW01327
30-252
13. Disconnect air conditioner tubes (28) and (29) from

air conditioner unit. ❈1
« Check that the pressure has been reduced. 28
« Remove the clamp.
29
DBW01848
14. Remove cover (30) at rear right of cab.

30
DEW01329
15. Remove air conditioner filter (31), then remove duct

mounting bolts (32). 32
31
DEW01330 DEW01331
16. Remove connecting bolts (33) of air conditioner unit

(23) and air conditioner damper (25). 25
33
23
DEW01332
30-253
17. Remove clamp bolt (34) of air conditioner wiring

connector (16).
34
16
DEW01333
18. Disconnect heater hoses (35) and (36) from air con-
ditioner unit, then remove air conditioner unit (23).
❈2
Air conditioner unit assembly: 38 kg
36
23
35 DEW01334
19. Disconnect air conditioner damper wiring connector

(37) from floor wiring, then remove air conditioner
damper (25).
« After disconnecting, take steps to prevent the

entry of dust or water.
25
37
DEW01335
DEW01336
30-254
INSTALLATION OF AIR
CONDITIONER UNIT ASSEMBLY
moval.
❈1
Tube mounting bolt:
9.8 ± 2 Nm (1.0 ± 0.2 kgm)
« Coat the O-ring with compressor oil ND-OIL8.
❈2
« Pass the air conditioner drain hose through the
floor support grommet.
• Fill the air conditioner with new refrigerant.

« Precautions when filling air conditioner line with
new refrigerant
1) Keep the temperature inside the room at above
3°C.
(If the temperature is below 3°C, the system will
not work.)
2) Use R134a as the refrigerant.
3) When filling with refrigerant, always use the re-
peat vacuum method to completely evacuate.
(Attainment of vacuum: Min. 750 mmHg.)
4) Charge with 1.5 – 1.6 kg of refrigerant.
5) Do not use the can of refrigerant upside-down
or use any other mistaken method. Be careful
not to let liquid freon get into the refrigerating
system.
6) Do not operate the compressor before charging
with refrigerant.
« Check the oil level in the compressor.
(Specified oil level: 150 +140 cc ND-OIL8)
30-255
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
1. Remove left and right covers (1) under bulkhead, 1

and open left and right engine hood inspection cov- 2
ers (2), then apply lock.
DBW02231
« Open inspection cover (3) on top of the bulk-

head. 3
« Carry out the air return operation for the com-
pressor, then use a gauge manifold and re-
lease the refrigerant slowly from the compres-
sor high-pressure valve.
DBW02232
2. Disconnect hoses (4) and (5). ❈1

« After disconnecting the hoses and tubes, fit cov-
ers to prevent dirt, dust, or water from entering
4
the joint.
3. Disconnect electric wiring connectors (6), (7), (8),

and (9).
4. Sling condenser and bracket assembly (10), and
remove mounting bolts of condenser and bracket
assembly.
« Leave 1 mounting bolt each installed temporar-
ily on the left and right sides at the top. DBW02233
9
8
DBW02235
6 10 DBW02236 DBW02234
30-256
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
5. Remove mounting bolts of condenser and bracket

assembly, then remove condenser (12) together with 11
bracket assembly from inside of bulkhead (11).
« Leave dry receiver (13) installed to the bracket
when removing.
Condenser, bracket assembly : 20 kg
(including dry receiver) 12
6. Remove condenser piping, then remove condenser
(12) from brackets (14) and (15). ❈2
« After disconnecting the hoses and tubes, fit cov-
ers to prevent dirt, dust, or water from entering
the joint. DBW02237
Condenser (each) : 5.4 kg
INSTALLATION OF AIR
ASSEMBLY
moval.
❈1 ❈2
« Do not remove the covers from the hoses until
immediately before installing.
« To prevent the hoses from twisting, use two 13
12
wrenches to hold the hoses securely in position 15
when tightening. 14 DBW02238
Hose joint, thread : Compressor oil
« The tightening torques for the air conditioner
piping are as follows.
a Compressor
Thread size Tightening torque
Nm (kgm) d d b b b
Air conditioner a e
a M16 x 1.5 11.8 – 14.7 (1.2 – 1.5) unit
b M22 x 1.5 19.6 – 24.5 (2.0 – 2.5)
c M24 x 1.5 29.4 – 34.3 (3.0 – 3.5)

M6 bolt at receiver
d portion 3.9 – 6.9 (0.4 – 0.7) e e a e
c a Dry receiver Condenser units
e Other M6 bolts 7.8 – 11.8 (0.8 – 1.2)
DBW02239
• Filling with gas
« Fill the air conditioner with gas. (R134a)
« Before filling with refrigerant, always use the
« Checks after assembly
repeat vacuum method to completely evacuate.
Amount of bubbles in
« Do not use the can of refrigerant upside-down receiver sight glass Remedy
or use any other mistaken method. Be careful Almost completely trans-
not to let liquid freon get into the refrigerating parent; even if there are
system. Correct bubbles, becomes trans-
parent when engine speed
« Do not operate the compressor before charging is raised or lowered
with refrigerant.
« Check that the refrigerant level is correct. Connect charging
Continuous stream hose to compres-
« Check the oil level in the compressor. Low of bubbles passes sor, then add
refrigerant until
condition becomes
normal
30-257
DISASSEMBLY AND ASSEMBLY DRY RECEIVER
REMOVAL OF DRY RECEIVER

ASSEMBLY
Stop the machine on level ground and install the 1 -1
« Open inspection cover (1-1) on top of the bulkhead.
1. Carry out oil return operation for compressor, then
use a gauge manifold and release refrigerant slowly
from compressor high-pressure and low-pressure
valves.
• Procedure for oil return operation DBW02232
Set fan switch to maximum position, run engine at

low idling, and operate air conditioner for 5 minutes.
2. Disconnect hoses (1) and (2). ❈1
« After disconnecting the hoses, fit covers to the
1
joint. ❈2
3. Remove mounting U-bolts (3), then remove dry re- 2
ceiver (4) from bracket.
INSTALLATION OF DRY
RECEIVER ASSEMBLY
• Carry out installation in the reverse order to re- 3
4
moval. DBW02240
❈1
Hose mounting bolt :
5.4 ± 1.5 Nm (0.55 ± 0.15 kgm)
« To prevent dirt, dust, or water from entering, do
not remove the covers from the air conditioner
hoses until immediately before installing.
Hose joint : Compressor oil
❈2
U-bolt : 18.6 ± 7.8 Nm (1.9 ± 0.8 kgm)
« Be careful not to tighten the U-bolts too far.

« Fill the air conditioner with gas. (R134a)
« Do not use the can of refrigerant upside-down
not to let liquid freon get into the refrigerating Amount of bubbles in
system. receiver sight glass Remedy
« Do not operate the compressor before charging Almost completely trans-
with refrigerant. parent; even if there are
Correct bubbles, becomes trans-
« Check that the refrigerant level is correct. parent when engine speed
« Check the oil level in the compressor. is raised or lowered
Connect charging
Continuous stream hose to compres-
Low of bubbles passes sor, then add
refrigerant until
condition becomes
normal
30-258
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER COMPRESSOR
REMOVAL OF AIR
COMPRESSOR ASSEMBLY
Open the hood and apply the lock.

of the battery.
1. Carry out oil return operation for compressor, then

use a gauge manifold and release refrigerant slowly
from compressor high-pressure valve.
2. Disconnect electric wiring from connector (1).
3. Remove hose mounting bolts (2), and disconnect

hoses (3) and (4). ❈1 2 1
« After disconnecting the hoses, fit covers to pre-
vent dirt, dust, or water from entering the joint. 3
4. Remove bolt (5), remove V-belt, then remove com- 6
pressor (6). ❈2 4
INSTALLATION OF AIR
CONDITIONER CONDENSER 5 DBW02241
COMPRESSOR ASSEMBLY
V-belt adjustment procedure
moval.
❈1 Adjust belt
with adjustment
Hose mounting bolt : 10kg bolt
7.8 – 11.8 Nm (0.8 – 1.2 kgm)
❈2
« Adjust the V-belt as follows.
10 — 15mm
« V-belt deflection at approx. 98 N (10 kg): (deflection)
10 – 15 mm

« Fill the air conditioner with gas. (R134a) DBW02242
« Do not use the can of refrigerant upside-down
not to let liquid freon get into the refrigerating
system.
« Do not operate the compressor before charging
with refrigerant.
« Check that the refrigerant level is correct.
« Check the oil level in the compressor.
30-259
30-260
40 MAINTENANCE STANDARD
Engine mount, transmission mount .............. 40- 2

Torque converter charging pump ................. 40- 3
Torque converter .......................................... 40- 4
Transmission ................................................. 40- 5
Transmission control valve ............................ 40-13
Flow control valve ......................................... 40-17
Accumulator valve ......................................... 40-18
Drive shaft .................................................... 40-19
Differential .................................................... 40-20
Final drive ..................................................... 40-23
Axle mount .................................................... 40-25
Center hinge pin .......................................... 40-26
Steering column ........................................... 40-28
Steering valve ............................................... 40-29
Steering cylinder mount ............................... 40-30
Brake ............................................................ 40-31
Brake valve ................................................... 40-32
Parking brake ............................................... 40-35
Hydraulic pump ............................................ 40-36
Main control valve ......................................... 40-37
PPC valve ..................................................... 40-41
Hydraulic cylinder ........................................ 40-42
Work equipment linkage ............................... 40-43
Bucket .......................................................... 40-45
Bucket positioner and
boom kick-out ............................................... 40-46
40-1
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
ENGINE MOUNT, TRANSMISSION MOUNT
Unit: mm
No. Check item Criteria Remedy
Crearance between transmis-

1 sion bracket and adjustment 1–2 Adjust
bolt
40-2
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP

(SAL(2)45+20)
Unit: mm
Model Standard clearance Clearance limit

1 Side clearance SAL(2)45
0.10 – 0.15 0.19
SAL(2)20
Clearance between inside
diameter of plain bearing and SAL(2)45
2 outside of diameter 0.060 – 0.125 0.20
of gear shaft SAL(2)20 Replace
Model Standard size Tolerance

3 Depth for knocking in pin SAL(2)45 0
12
SAL(2)20 – 0.5
4 Rotating torque of
spline shaft 5.9 – 13.7Nm (0.6 – 1.4kgm)
Standard Delivery
Rotating Delivery delivery amount limit
Model speed pressure amount
Discharge amount 2.9MPa
— Oil: EO10-CD SAL(2)45 3,000rpm 2
(30kg/cm ) 126 l/min 115 l/min —
Oil temperature: 45 – 55°C
2.9MPa
SAL(2)20 3,000rpm 59 l/min 53 l/min
(30kg/cm2)
40-3
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Unit: mm
Standard size Tolerance Repair limit

1 Outside diameter of pilot 52 – 0.010 51.75 Repair
– 0.040 chrome
plating or
Inside diameter of retainer + 0.035 replace
2 seal ring contact surface 110 0 110.5
– 0.01
Width 3 – 0.03 2.7
3 Wear of stator
shaft seal ring
Thickness 4.3 ± 0.1 3.9 Replace
Backlash between PTO

4 drive gear and drive gear 0.18 – 0.49
40-4
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
40-5
40-6
40-7
Unit: mm
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance between pump
1 drive shaft and bearing
+0.030 0 –0.011 –
60 +0.011 –0.015 –0.045 —

2 drive shaft bearing and 110 0 +0.022 –0.013 – —
housing –0.015 –0.013 0.037
Clearance between pump +0.025 0 –0.009 –
3 drive shaft and bearing 45 —
+0.009 –0.012 –0.037
housing –0.015 –0.013 0.037
Clearance between pump +0.025 0 –0.009 –
+0.009 –0.012 –0.037
housing –0.015 –0.013 0.037
Clearance between pump –0.009 +0.041 –0.034 –
–0.025 +0.025 0.066
housing –0.011 –0.011 0.025
Clearance between idler +0.023 0 –0.011 –
9 shaft and bearing 60 —
+0.011 –0.015 –0.038
Replace
Clearance between idler gear 0 –0.020 –0.005 –
10 and bearing 110 —
–0.015 –0.042 –0.042
Clearance between forward/
11 reverse clutch bearing and 100 0 +0.030 0– —
housing (R) –0.015 0 0.045
Clearance between forward/
12 reverse clutch bearing and 90 0 +0.030 0– —
housing (F) –0.015 0 0.045
Clearance between 1st and
13 3rd clutch bearing and 110 0 +0.030 0– —
housing (R) –0.015 0 0.045
Clearance between 1st and
14 3rd clutch bearing and 130 0 +0.030 0– —
housing (F) –0.018 0 0.048
Clearance between 2nd and
15 4th clutch bearing and 110 0 +0.030 0– —
housing (R) –0.015 0 0.045
Clearance between 2nd and
16 4th clutch bearing and 140 0 +0.030 0– —
housing (F) –0.018 0 0.048
Clearance between output +0.030 0 –0.011 –
17 shaft and bearing (R) 65 —
+0.011 –0.015 –0.045
Clearance between output
18 shaft bearing and housing 100 0 –0.015 0– —
(R) –0.015 –0.040 0.040
Clearance between output +0.030 0 –0.011 –

19 shaft and bearing (F) 65 —
+0.011 –0.015 –0.045
20 shaft bearing and housing (F) 120 0 –0.015 0– —
Clearance between output –0.015 –0.040 0.040
shaft oil seal and housing (R)
21 100 +0.35 +0.054 –0.096 – —
+0.15 0 –0.35
40-8
Unit: mm

22 shaft oil seal and housing (F)
+0.35 +0.054 –0.096 –
100 +0.15 0 –0.35 —

shaft dust seal and housing +0.35 +0.054 –0.046 –
23 100 +0.10 0 –0.35 —
(R)
shaft dust seal and housing +0.35 +0.054 –0.046 –
24 100 +0.10 0 –0.35 —
(F)
Clearance between check –0.016 +0.515 0.516 –
25 valve and case 13 –0.027 +0.500 –0.542 —
Standard size Repair limit

Free length Installed length Installed load Free length Installed load
26 Check valve spring
23.5 16.2 0.39±0.02N 22.6 0.35N
(0.04±0.002kg) (0.036kg)
Inner diameter of housing
seal ring contact surface +0.05
50 0 0.05(wear)
Width of shaft seal ring +0.076

groove 3.2 0 3.5
27 Replace
0
Width of seal ring 3.0 –0.13 2.6
0
Thickness of seal ring 2.29 –0.1 2.1
Outer diameter of coupling oil 0

28 seal slide part (R) 80 –0.074 0.05(wear)
Outer diameter of coupling oil 0

29 seal slide part (F) 80 –0.074 0.05(wear)
Standard size Standard clearance Clearance limit

30 retainer and case
0.95 0.25 – 1.65 —
Inner diameter of housing +0.05

seal ring contact surface 55 0 0.05(wear)
Width of shaft seal ring +0.076

groove 3.2 0 3.5
31
0
Width of seal ring 3.0 –0.13 2.6
Thickness of seal ring 0

2.29 –0.1 2.1
32 Free rotation torque of output 0.1 – 1.0Nm(0.01 – 0.10kgm) Adjust shim.

shaft
40-9
Unit: mm
7 End play of forward gear 0.106 – 0.991
8 End play of reverse gear 0.106 – 0.991

Clearance at forward/reverse size Shaft Hole clearance limit
9 clutch shaft spacer press-
fitted section (R) +0.030 0 –0.011 –
56 +0.011 –0.030 –0.060 —
Clearance at forward/reverse
10 clutch shaft spacer press- +0.025 0 –0.009 –
50.5 +0.009 –0.030 –0.055 —
fitted section (F)
Clearance at forward/reverse
11 clutch shaft bearing end +0.034 –0.020 –0.041 – Replace
50 +0.021 –0.040 –0.074 —
spacer press-fitted section
Forward/reverse clutch Free length Installed length Installed load Free length Installed load
12 piston return spring
100 45 612±25N 96 551N
(62.4±2.6kg) (56.2kg)
Thickness of forward/reverse
13 clutch thrust washer 3.0 ±0.1 2.7
Thickness of forward clutch

14 spacer 5.0 ±0.05 —
Thickness of reverse clutch

15 spacer 5.5 ±0.05 —
40-10
1st and 3rd Clutch
Unit: mm

Clearance between –0.27 +0.06 0.20 –

1 (inner) 110 –0.32 –0.07 0.38 0.43
piston and cylinder
(outer) –0.27 +0.06 0.20 –

165 –0.32 –0.07 0.38 0.43
Clearance at 1st and 3rd

clutch shaft bearing press- +0.054 0 –0.044 –
2 60 +0.044 –0.015 –0.069 —
fitted section (F)
clutch shaft bearing press- +0.030 0 –0.011 –
3 60 +0.011 –0.015 –0.045 —
fitted section (R)
clutch shaft spacer press- +0.054 –0.02 –0.064 –
4 60 +0.044 –0.04 –0.094 — Replace
fitted section (F)
clutch shaft spacer press- +0.030 0 –0.011 –
5 61 +0.011 –0.03 –0.06 —
fitted section (R)
6 Thickness of gear end thrust
washer 3.0 ±0.1 2.7
Thickness of 3rd clutch side

7 spacer 5.0 ±0.05 —
8 End play of 1st gear 0.02 – 1.58
9 End play of 3rd gear 0.1 – 0.9
40-11
2nd and 4th Clutch
Unit: mm

Clearance between –0.27 +0.06 0.20 –

1 (inner) 110 –0.32 –0.07 0.38 0.43
piston and cylinder
(outer) –0.27 +0.06 0.20 –

165 –0.32 –0.07 0.38 0.43
Clearance at 2nd and 4th clutch

shaft bearing press-fitted +0.033 0 –0.017 –
2 60 +0.017 –0.015 –0.048 —
section outer diameter (R)
Clearance at 2nd and 4th clutch
shaft bearing press-fitted +0.059 0 –0.049 –
3 65 +0.049 –0.015 –0.074 — Replace
section outer diameter (F)
Clearance at 2nd and 4th
clutch shaft spacer press- +0.059 –0.021 –0.070 –
4 65 +0.049 –0.041 –0.100 —
fitted section (F)
5 End play of 2nd gear 0.34 – 1.66
6 End play of 4th gear 0.17 – 1.43

7 Thickness of thrust washer
3.0 ±0.1 2.7
40-12
MAINTENANCE STANDARD TRASMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
UPPER VALVE
40-13
Unit: mm

Clearance between emer- size Shaft Hole clearance limit
1 gency manual valve spool
and body –0.02 +0.011 +0.020 –
14 –0.03 0 +0.044 0.050
Clearance between modula- –0.035 +0.013 +0.035 –

2 tion valve spool and body 19 –0.045 0 +0.058 0.065
Clearance at modulation –0.035 +0.012 +0.035 –

3 valve load piston 7 –0.045 0 +0.057 0.065
Clearance between pilot –0.035 +0.013 +0.035 –

4 valve spool and body 19 –0.045 0 +0.058 0.065
Clearance between main relief –0.035 +0.013 +0.035 –

Clearance at main relief valve –0.02 +0.018 +0.020 –

6 load piston 15 –0.03 0 +0.048 0.055
Replace
Clearance between torque
converter regulator valve –0.035 +0.013 +0.035 –
7 25 –0.045 0 +0.058 0.065
spool and body
Clearance between dummy –0.02 +0.013 +0.020 –
8 spool and body 25 –0.03 0 +0.048 0.055

9 Modulation valve spring
8.9±0.5N 8.0N
23.8 13 (0.91±0.05kg) 22.8 (0.82kg)
266.7±13.7N 240N
10 Pilot valve spring 59.8 37 (27.2±1.4kg) 57.4 (24.5kg)
Main relief valve load piston 5.7±0.3N 5.1N

11 spring 26 19 (0.58±0.03kg) 25.0 (0.52kg)
411.9±20.6N 370.7N
12 Main relief valve spring 170.5 132 (42±2.1kg) 163.7 (37.8kg)
Torque converter regulator 93.7±4.7N 84.3N

13 valve spring 65 61 (9.55±0.48kg) 62.4 (8.6kg)
40-14
LOWER VALVE
40-15
Unit: mm

Clearance between size Shaft Hole clearance limit
1 directional selector spool
and body –0.02 +0.013 +0.02 –
19 –0.03 0 +0.043 0.050
Clearance between H-L –0.02 +0.013 +0.02 –

2 selector spool and body 19 –0.03 0 +0.043 0.050
Clearance between range –0.02 +0.013 +0.02 –

3 selector spool and body 19 –0.03 0 +0.043 0.050
Clearance between priority –0.035 +0.013 +0.035 –

Clearance between parking –0.02 +0.013 +0.02 –

5 brake valve spool and body 19 –0.03 0 +0.043 0.050 Replace

6 Directional selector spool
spring 78.9±3.9N 70.6 N
42 32 (8.05±0.4kg) 40.3 (7.2 kg)
H-L selector spool 69.8±3.5N 62.8 N

7 return spring 48 36.7 (7.12±0.36kg) 46.1 (6.4 kg)
841.4±42.2N 757N
8 Priority valve spring 150 111 (85.8±4.3kg) 144 (77.2kg)
81.4±3.9N 73.5N
9 Parking brake valve spring 46 37 (8.3±0.4kg) 44.2 (7.5kg)
40-16
MAINTENANCE STANDARD FLOW CONTROL VALVE
FLOW CONTROL VALVE
Unit: mm

Clearance between flow size Shaft Hole clearance limit
1 control valve spool and body
Flow control valve spring –0.020 +0.013 0.020 –
25 –0.030 0 0.043 0.050

2 Replace
79.5±3.9N 71.6N
63.8 47.0 (8.11±0.4kg) 61.2 (7.3kg)
40-17
MAINTENANCE STANDARD ACCUMULATOR VALVE
Unit: mm

1 Clearance between piston
and body
–0.035 +0.025 0.035 –
32 –0.045 0 0.070 0.08

Forward clutch accumulator Free length Installed length Installed load Free length Installed load Replace
2 spring
319N
184.8 165 (32.5kg) 177.4 —
1st clutch accumulator spring 158N

3 2nd clutch accumulator 157.7 145 (16.1kg) 151.4 —
spring 158N
4 157.7 145 (16.1kg) 151.4 —
40-18
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
40-19
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (1/2)
Unit: mm
Bevel gear starting rotational

1 force 12.7 – 36.3 N (1.3 – 3.7 kg) (outer diameter of bevel gear)
Differential side bearing

2 carrier shim thickness 0.4 – 1.0 Adjust
(one side)
Differential housing and
3 gauge assembly shim 0.66 – 1.86
thickness
40-20
DIFFERENTIAL (2/2)
40-21
Unit: mm

Clearance at 0 –0.045 –0.085 –
1 differential side Outer lace 150 –0.018 –0.085 –0.027 —
bearing
+0.059 0 –0.079 –
Inner lace 100 +0.037 –0.020 –0.037 —
+0.025 –0.028 –0.093 –

Clearance at Outer lace 171.45 0 –0.068 –0.028 —
2 pinion shaft gear
side bearing +0.062 +0.013 –0.062 –
Inner lace 76.2 +0.043 0 –0.030 —
0 –0.048 –0.088 –
Clearance at Outer lace 140 –0.018 –0.088 –0.030 —
pinion shaft
3 coupling side
bearing +0.039 0 –0.054 –
Inner lace 65 +0.020 –0.015 –0.020 — Replace
4
Clearance between pinion –0.06 +0.10 0.11 –
gear and spider 34.93 –0.11 +0.05 0.21 0.3
5
Differential housing piston –0.125 +0.089 0.125 –
mount (housing piston) 326.5 –0.214 0 0.303 —
6
Bearing carrier piston mount –0.110 +0.081 0.110 –
(piston carrier) 304 –0.191 0 0.272 —
7
Thickness of side gear
8 washer 4 ±0.05 3.8
Thickness of pinion gear +0.09

9 washer 1.5 –0.01 1.35
Height of spacer between

10 pinion shaft bearings 66.61 ±0.025 —
11 Bevel gear backlash 0.30 – 0.46
12 Differential gear backlash 0.10 – 0.25 Adjust
End play of pinion gear less than 0.18
40-22
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-23
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

Clearance between axle
1 housing and ring gear
+0.10 +0.10 –0.10 –
374 +0.03 0 0.07 —
+0.025 +0.207 0.120 –

2 Clearance at guide pin 12 +0.007 +0.145 0.200 —
0 –0.045 –0.085 –
Clearance at axle Outer lace 160 –0.025 –0.085 –0.020 —
housing bearing
3 press-fitted
section +0.035 0 –0.055 –
Inner lace 105 +0.013 –0.020 –0.013 —
Replace
0 –0.045 –0.085 –
Clearance at axle Outer lace 180 –0.025 –0.085 –0.020 —
housing bearing
4 press-fitted
section Inner lace +0.045 0 –0.065 –
120 +0.023 –0.020 –0.023 —
+0.072
Axle shaft seal Housing 215 — 0 — —
5 press-fitted
section 0
Shaft 180 — — —
–0.063
Clearance between pinion +0.013 0 –0.025 –

6 gear bearing and shaft 40 +0.002 –0.012 –0.002 —
7 End play of axle shaft 0 – 0.1

Adjust
Clearance between oil seal
8 and housing 0.1 – 1.9
40-24
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
Unit: mm

1 Thickness of thrust plate ±0.5
22 —
2 Thickness of wear plate 5 +0.3 —

–0.1
Standard Tolerance Standard Clearance Replace

Clearance between hole size Shaft Hole clearance limit
3 and shaft at front support
end –0.050 +0.472 0.050 –
190 –0.122 0 0.594 —
Clearance between hole –0.005 +0.522 0.055 –

4 and shaft at rear support 170 –0.124 +0.050 0.646 —
end
40-25
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
40-26
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm

Clearance between upper
1 hinge pin and rear frame
80 –0.030 +0.071 0.066 – —
–0.049 +0.036 0.130
2 Clearance between upper 80 –0.030 +0.060 0.060 – —

hinge pin and spacer (small) –0.049 +0.030 0.109
3 Clearance between upper 80 –0.030 0 0.015 – —

hinge pin and bearing –0.049 –0.015 0.049
4 Clearance between upper 80 –0.030 +0.030 0.030 – —

hinge pin and spacer (large) –0.049 0 0.079
5 Clearance between rear 95 –0.036 +0.071 0.072 – —

frame and spacer (large) –0.071 +0.036 0.142 Replace
Clearance between
6 frame and 130 0 –0.048 –0.088 – —
bearing –0.025 –0.088 –0.023
7 Clearance between lower 80 –0.030 +0.054 0.030 – —

hinge pin and rear frame –0.076 0 0.130
8 Clearance between lower 80 –0.030 0 0.015 – —

hinge pin and bearing –0.076 –0.015 0.076

9 Height of upper hinge
spacer (small) 25.5 ±0.1 —
10 Height of upper hinge 56 ±0.1 —

spacer (large)
Standard size Standard clearance Clearance limit
11 Value for shim between
upper hinge and retainer 2.5 0.05 0.1
Adjust
12 Value for shim between 2.5 0.1 0.2

upper hinge and retainer
40-27
MAINTENANCE STANDARD STEERRING COLUMN
STEERING COLUMN
Unit: mm

1 steering shaft and column Replace
bearing 0 +0.15
19 –0.08 –0.05 0.05 – 0.23 0.4
40-28
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
Unit: mm

58N 48N
1 Steering spool return spring 37,2 32.0 (5.8kg) — (4.8kg)
9.3 ± 4.9 N 7.8N

2 Load check valve springj 20.9 23.2 (0.95±0.5kg) — (0.8kg)
Replace
Flow control 136N 115N
3 return spring 75.1 68.5 (13.88kg) — (11.7kg)
182N 145N
4 Relief valve spring 24.0 22.19 (18.6kg) — (14.8kg)
2.3N 1.8N
5 Check valve return spring 21.6 17.0 (0.23kg) — (0.18kg)
40-29
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
Unit: mm

1 mounting pin and bushing
at connection of steering 0 +0.20 0.10
cylinder rod and frame 50 –0.025 +0.10 – 0.225 —
Clearance between
mounting pin and bushing 0 +0.150 0.050 –
2 at connection of steering 50 –0.025 +0.050 0.175 —
cylinder bottom and frame Replace
Width of boss Width of hinge Standard clearance

Connection between (clearance a + b)
3 steering cylinder and
front frame +0.8
60 0 63±1 —
Connection between Max. 0.5

4 steering cylinder and 60+0.8 66±1 (after adjusting
rear frame 0 with shim)
40-30
MAINTENANCE STANDARD BRAKE
BRAKE
Unit: mm

1 Inner ring thickness
6 ±0.1 5.5
Brake disc thickness 8 ±0.15 7.2
2 Depth of lining grooves 0.9 0.8(min.) 0.4

Replace
Lining thickness 1.0 0.9(min.) —
Wear of brake outer ring disc

3 contact surface 25 ±0.1 0.3

Installed length Installed load Installed load
4 Spring load
682N 549N
7.8 (69.5kg) (56kg)
40-31
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (LEFT)
Unit: mm

1 Control spring
93.2N
34 21.8 (9.5kg) 33 —
459N
2 Control spring 46.3 34.3 (46.8kg) 45.3 —
Return spring 60.8N

3 86.2 58 (6.2kg) 78 —
16.7N
4 Return spring 31.5 19.5 (1.7kg) 28 — Replace

Clearance between pedal size Shaft Hole clearance limit
5 mount hole and bracket hole
Clearance between roller and –0.025 +0.1 0.175 –
10 –0.075 0 0.025 0.25
pin –0.025 +0.1 0.175 –

6 Outside diameter of roller 10 –0.075 0 0.025 29.2

7 0
30 29.2
–0.5
40-32
BRAKE VALVE (RIGHT)
40-33
Unit: mm

1 Control spring
93.2N
34 21.8 (9.5kg) 33 —
459N
2 Control spring 46.3 34.3 (46.8kg) 45.3 —
Return spring 60.8N

3 86.2 58 (6.2kg) 78 —
69.6N
4 Spring 17 15 (7.1kg) 16.2 — Replace
Return spring 16.7N

5 31.5 19.5 (1.7kg) 28 —

Clearance between pedal size Shaft Hole clearance limit
6 mount hole and bracket hole
Clearance between roller and –0.025 +0.1 0.175 –
10 –0.075 0 0.025 0.25
pin –0.025 +0.1 0.175 –

7 Outside diameter of roller 10 –0.075 0 0.025 29.2

8 0
30 29.2
–0.5
40-34
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
Unit: mm

Clearance be-
tween piston and Inner side 0 +0.13 0–
1 215 –0.05 0 0.18 0.23
cylinder
Outer side –0.10 +0.13 0.10 –

250 –0.15 0 0.28 0.33

2 Parking brake
spring 438±21.6N 944N
68.7 53.7 (44.7±2.2kg) 66.0 (96.3kg)
1,049±52.9N 394N
3 Parking brake spring 76.5 53.7 (107±5.4kg) 68.9 (40.2kg)
Thickness 4.0 ±0.05 1.9

4 Separator plate
Distortion — 0.05 0.6
Thickness 3.2 ±0.08 2.97
Depth of
lining +0.175
5 Brake disc 0.45 0 0.375
groove
Lining
thickness 0.7 ±0.075 —
Wave spring load 1,106N(112.8kg) ±56.9N(±5.8kg) 892N(91kg)

6 (Height: 3.2 mm) (Height: 3.2 mm)
40-35
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP (Hydraulic, steering, switch, PPC pump)

(SAL(3)100+50+36+(1)25)
Unit: mm
Model Standard clearance Clearance limit

SAL(3)100 0.13 – 0.18 0.22
1 Side clearance SAL(3)50
SAL(3)36 0.10 – 0.15 0.19
SAL(1)25
SAL(3)100
Clearance between inside di-
ameter of plain bearing and SAL(3)50 0.060 – 0.149
2 outside of diameter of gear 0.20
SAL(3)36
shaft
SAL(1)25 0.060 – 0.119 Replace
Model Standard size Tolerance

SAL(3)100
3 Depth for knocking in pin SAL(3)50 14 0
SAL(3)36 –0.5
SAL(1)25 10
Rotating torque of spline

4 shaft 22.6 – 40.2Nm (2.3 – 4.1kgm)
Rotating Delivery Standard deli- Delivery

Model speed pressure very amount amount limit
Discharge amount SAL(3)100 231 l/min 214 l/min
— Oil: EO10-CD 20.6Mpa
Oil temperature: 45 – 55°C SAL(3)50 (210kg/cm2) 112 l/min 102 l/min —
SAL(3)36 2,500rpm 84 l/min 77 l/min
2.9Mpa
SAL(1)25 (30kg/cm2) 60 l/min 52 l/min
40-36
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

2-SPOOL VALVE
40-37
Unit: mm

1 Spool return spring
(for bucket) 125N
54.8 53.5 (12.7kg) — —
Spool return spring 235N

2 (for bucket and boom) 54.8 52.2 (24kg) — —


4 (for boom) 55.3 40 (23.8kg) — —
Replace
5 (for boom) 86.8 83.5 (21.2kg) — —
Main relief valve main valve 33.3N

6 spring 39.5 23.2 (3.4kg) — —
259N 208N
7 Relief valve poppet spring 49.3 41.9 (26.4kg) 47.8 (21.2kg)
44.1N
8 Check valve spring 32.6 24.5 (4.5kg) — —
6.9N
9 Suction valve spring 27.9 19 (0.7kg) — —
40-38
3-SPOOL VALVE
40-39
Unit: mm

1 Spool return spring
(for bucket and attachment) 125N
54.8 53.5 (12.7kg) — —



4 (for boom) 55.3 40 (23.8kg) — —
Replace
5 (for boom) 86.8 83.5 (21.2kg) — —
Main relief valve main valve 33.3N

6 spring 39.5 23.2 (3.4kg) — —
259N 208N
7 Relief valve poppet spring 49.3 41.9 (26.4kg) 47.8 (21.2kg)
44.1N
8 Check valve spring 32.6 24.5 (4.5kg) — —
6.9N
9 Suction valve spring 27.9 19 (0.7kg) — —
40-40
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
Unit: mm

Free length Installed Installed Free Installed
Centering spring x O.D. length load length load
1 (bucket DUMP,
boom LOWER) 29.4 N 23.5 N
52.78 x 1.3 36.0 (3.0 kg) — (2.4 kg) Replace spring
if damaged
or deformed
2 Centering spring 52.78 x 1.3 36.0 39.2 N — 31.4 N
(bucket TILT, boom RAISE) (4.0 kg) (3.2 kg)
3 Metering spring 31.4 x 7.4 29.4 16.7 N — 13.7 N

(1.7 kg) (1.4 kg)
40-41
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Unit: mm

–0.036 +0.270 0.097 –

Boom 90 –0.123 +0.061 0.393 0.693
Clearance between
1 piston rod and Replace
bushing –0.036 +0.270 0.097 –
Bucket 90 –0.123 +0.061 0.393 0.693
–0.025 +0.152 0.032 –

Steering 45 –0.087 +0.007 0.239 0.539
40-42
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
40-43
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
1 bushing at both ends of
bucket link –0.036 +0.207 0.156 –
85 –0.090 +0.120 0.297 1.0
Clearance between pin and

bushing at connection of –0.036 +0.207 0.156 –
2 85 –0.090 +0.120 0.297 1.0
boom and bucket
3 95 –0.090 +0.120 0.297 1.0
boom and frame
bushing at connection of –0.036 +0.207 0.156 – Replace
4 bucket cylinder bottom and 110 1.0
–0.090 +0.120 0.297 replace if there
frame (is scuffing on
pin)
5 bucket cylinder rod and 110 –0.090 +0.120 0.297 1.0
bellcrank
6 120 –0.090 +0.145 0.335 1.0
bellcrank and boom
bushing at connection of –0.036 +0.207 0.156 – 1.0
7 boom cylinder bottom and 95 –0.090 +0.120 0.297
frame

8 bushing at connection of –0.036 +0.207 0.156 –
boom cylinder rod and boom 95 –0.090 +0.120 0.297 1.0
Connection of bucket cylinder
Standard clearance
Width of boss Width of hinge (Clearance a + b)
and frame
9 Connection of boom and +0.8
110 0 114±1.5 1.7 – 5.5
10 frame 122±1.5 129 +3 5.5 – 11.5 insert shims on

Connection of boom and 0 both sides so
that clearance is
bucket +1.5 less than 1.5 mm
11 Connection of bucket link and 106±1.5 108 0 0.5 – 5 on both left and
right
bucket
12 Connection of boom cylinder 112.5+2.8 116+1.5 0.7 – 5
–0.5 0
and frame
13 Connection of bellcrank and 90+0.8 93.5 +3 2.7 – 6.5
0 0
bucket link +2.8

14 Connection of bellcrank and 112.5– 0.5 117±1.5 0.2 – 6.5
Replace
boom
15 Connection of bucket cylinder 220 +2 223±0.5 0.5 – 5.5
0
insert shims on
both sides so
and bellcrank that clearance is
16 Connection of boom and 110+0.8 117±1.5 4.7 – 8.5 less than 1.5 mm
0
on both left and
right
Adjust with shims
boom cylinder so that clearance
17 103±1.5 106±1.5 0–6 is less than 2.0
Replace
mm on both left and
right
40-44
MAINTENANCE STANDARD BUCKET
BUCKET
Unit: mm
1
Bucket tooth wear 50 18.5 Replace
2 Clearance of bucket Adjust or

tooth mounting base Max. 0.5 — replace
Reverse or
3 Cutting edge wear 93 — replace
40-45
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
Unit: mm
Clearance at bucket
1 positioner switch 3–5
Adjust
Clearance at boom
2 kickout switch 3–5
40-46
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
A
A
B B
Condenser blower
Blower stage 1
Blower stage 4
Blower stage 3
Blower stage 2
C C
Clutch
Box 2 Pos.4
FU M2
20 A
D Box2 Pos.3 FU M1 D
L/R
L/R
B/Y
20 A
L/R
L/R
L/R
L/R
L/R
L/R
RL C RL BM RL EC
RL BM RL BH RL BM2 RL BM1 RL C RL EC
E E
Box 1
Pos.13
R/G
W/L
G/R
20 A
G/B
G
24V VE MAX0,1A
SW K FU B MB
F OFF Nightdesign F
CM B Vaporiser
gr
C ADC
D SP M motor
Kl.30
blower
Kl.15
2-24 bar closed

BR R1 Pressure Switch P 225W
< 2 bar open
M CD1 M CD2
R2
BR/R
Lg/R
L/R
M M R B1 EC
G/R
> 24 bar open
G G
G/Y
G/Y
G/B
Y/B
Lg
Potentiometer position Potentiometer position 110W 110W

BAT 1 9 18 15 17 29 21 19 14 40W
R B
Clutch
D1 D3
4 3 2 1 4 3 2 1
GA Motor Motor
D+
E 27 28 10 11 4 5 35 3 2 22 33 13 30 7 6 31 20 32 34 16 8
H Condenser R B2 H
motors
BR/R
wt/G
L/R
Br/W
R/W
R/Y
Y/R
Y/R
W/L
CM B
G/W
G/W
Y/W
Y/W
Y/G
Y/G
W/B
W/B
Y/B
Br
L
G
Y
CM
D2
0,4-9V R B3
I I
0V
GND
L/W
or
L/B
Y
24V
R
+ E
E +
TH F 3 5 RL BM1 RL BM2 RL BH
4 1
B C D F B C D F
M AM
K M VR M VL M RF K
841019 841016
(Greenball)
2 A E G A E G 2 5
- - - -
Br
W/B
W/B
W/B
L L
B
M M
Sensor Valve(Water) Ventilation flap right Ventilation flap left Fresh/ circulating air
N N
Switch ON temp.+3°C = 29,7kΩ

Switch OFF temp.+6°C = 23,7kΩ
Cold= Terminal5 = 0V
Warm= Terminal5 = 9V
Fresh air = Terminal4 = 0V
Circulating air = Terminal4 = 24V
* WA320-3 WA380-3
Analogcontrolled Digitalcontrolled
WA420-3 WA470-3
O O
Controller
P
* Up to SN WA320H20560 Air-conditioner P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
10-485
Fuse
Fuse
Fuse
Ground
Battery 24V
Generator D+
Ground air-conditioner
Compressor air-conditioner
Blower air-conditioner
10-486
To platform wiring harness
(Heater opt.)
Switch air-conditioner
L.H. blower
Servomotor
Fresh/circulating air
Ventilation flap L.H. + -
Ventilation flap L.H. + -
Valve (water)
Valve (water)
Ventilation flap R.H. + -
Ventilation flap R.H. + -
Memory
Fresh/circulating air
Blower stage 4
Sidelight
Ventilation flap R.H. potentiom. pos. 2
not used
Sensor digital GND
Sensor
Power supply
Option
Wiring harness air-conditioner

Digital (-) only used in controller
not used
not used
Condenser blower
Ventilation flap
Controller air-conditioner
Compressor clutch
Blower stage 1
Blower stage 3
Digital (-) only used in controller
Alternator
Ventilation flap L.H. potentiom. pos. 1
Blower stage 2
Supply (-)
Supply (-)
Servomotor
R.H. blower
fresh air
Thermistor
Servomotor
Circulating /
& resistor
Vaporiser blower
warm-/ cold air

Air-servomotor
Pressure switch
Air-conditioner
Wiring diagram
Wiring harness relays air-conditioner
* Up to SN WA320H20560
Relay
Relay
Relay
Relay
Relay
Relay
blower
blower
blower
blower
(Stage 2)
(Stage 3)
(Stage 4)
(Stage 1)
condenser
compressor
WA420-3 WA470-3
* WA320-3 WA380-3
Ground
From SN WA380H20501
Page 1 / 5
10-281/3
1
Ground
From SN WA380H20501
Page 2 / 5
10-281/4
1
Ground
From SN WA380H20501
Page 3 / 5
10-281/7
1
Ground
From SN WA380H20501
Page 4 / 5
10-281/8
1
Ground
From SN WA380H20501
Page 5 / 5
10-281/11
1
10-281/12
1
Ground
From SN WA380H20837
Page 1 / 5
10-282/3
2
Ground
From SN WA380H20837
Page 2 / 5
10-282/4
2
Ground
From SN WA380H20837
Page 3 / 5
10-282/7
2
Ground
From SN WA380H20837
Page 4 / 5
10-282/8
2
Ground
From SN WA380H20837
Page 5 / 5
10-282/11
2
10-282/12
2
Ground
Page 1 / 5
10-283/3
1
Ground
Page 2 / 5
10-283/4
1
Ground
Page 3 / 5
10-283/7
1
Ground
Page 4 / 5
10-283/8
1
Ground
Page 5 / 5
10-283/11
1
10-283/12
1

VEBM460104 WA380-3 With-Diagrams 09-06 PDF

Uploaded by

Copyright:

Available Formats

VEBM460104 WA380-3 With-Diagrams 09-06 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

VEBM460104 WA380-3 With-Diagrams 09-06 PDF

Uploaded by

Copyright:

Available Formats

What safety precautions should be followed when servicing equipment?

What safety precautions should be followed when servicing equipment?

What are the general preparations required before starting work on equipment?

What are the general preparations required before starting work on equipment?

VEBM460104

10 STRUCTURE AND FUNCTION ....................................... 10-1

20 TESTING AND ADJUSTING ............................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ................................... 30-1

40 MAINTENANCE STANDARD........................................... 40-1

IMPORTANT SAFETY NOTICE

PRECAUTIONS DURING WORK

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

DISTRIBUTION AND UPDATING Weight of parts of systems.

FILING METHOD Tightening Places that require special at-

Item number (10. Structure Places where oil or water must

Example 2 (Engine volume):

3. Additional pages: Additional pages are indicated

• If a part cannot be smoothly removed from the

Wire ropes 4) Do not sling a heavy load with ropes forming

2) Sling wire ropes from the middle portion of

DIMENSIONS, WEIGHTS AND OPERATING DATA

Bucket capacity as per ISO 7546 m3 3.0 3.3

Specific density t/m3 1.8 1.6

a Reach at full lift 45° mm 1.001 1.001

A Overall length mm 7.640 7.640

Measurements, operating data

Material density t/m³ 1.7 1.55

Bucket weight without teeth kg 1,545 1,625

Static tipping load, straight kg 11,800 11,700

Static tipping load, 40° angle kg 10,300 10,210

Breakout force, hydraulic kN 157 149

Lifting capacity, hydraulic, on ground kN 156 152

Operating weight kg 18,755 18,835

a Reach at 45° discharge mm 1,180 1,220

b Dumping height at 45° discharge mm 3,610 3,570

c Lift height, hinge pin mm 4,621 4,621

Turning circle to bucket corners mm 6,666 6,690

A Overall length, bucket on ground mm 8,540 8,600

B Wheel base mm 3,200 3,200

C Bucket width mm 2,926 2,926

F Ground clearance mm 455 455

• The actual volumes Material Bucket filling % Density t/m³

table shows the ideal Sand 100 to 110 1.4 to 1.8

Machine model WA380-3

Serial No. H20001- H20500

Operating weight (kg) 17,420

Distribution (front) (kg)

Distribution (rear) (kg)

Bucket capacity (piled) (m 3) 3.0

Rated load (kg) 5,400

Travel speed FORWARD 1st (km/h) 7.2

FORWARD 2nd (km/h) 11.5

FORWARD 3rd (km/h) 21.6

FORWARD 4th (km/h) 37.0

REVERSE 1st (km/h) 7.7

REVERSE 2nd (km/h) 12.3