Wa380-5 Sebm024710
Wa380-5 Sebm024710
Wa380-5 Sebm024710
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
© 2005
All Rights Reserved 00-1
Printed in Japan 07-05 (03) (10)
00
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
00-2 WA380-5
2
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions must be taken to these pages according to Q Page to be newly added Add
the list below.
q Page to be replaced Replace
WA380-5 00-2-1
(10)
Revision Revision Revision Revision Revision
Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
q 10-171 (10) q 10-231 (10) q 10-279-4 (10) q 20-101-2 (10) q 20-204 (10)
q 10-172 (10) q 10-232 (10) q 10-280 (10) q 20-102 (10) q 20-205 (10)
10-173 q 10-233 (10) 10-281 (8) 20-103 q 20-206 (10)
10-174 q 10-234 (10) q 10-282 (10) q 20-104 (10) q 20-207 (10)
10-175 q 10-235 (10) 10-283 (8) q 20-105 (10) q 20-208 (10)
q 10-176 (10) q 10-236 (10) 10-284 (1) 20-106 q 20-209 (10)
q 10-177 (10) q 10-236-1 (10) q 10-285 (10) 20-107 (5) q 20-210 (10)
10-178 q 10-236-2 (10) q 10-286 (10) 20-108 (5) q 20- 211 (10)
10-179 10-236-3 (8) q 10-287 (10) q 20-109 (10) q 20-212 (10)
10-180 10-236-4 (4) q 10-288 (10) 20- 110 20-214 (9)
10-181 q 10-236-5 (10) q 10-289 (10) q 20- 111 (10) 20-215
q 10-182 (10) q 10-236-6 (10) q 10-290 (10) 20- 112 20-216
10-183 10-236-7 (8) q 10-291 (10) q 20- 113 (10) 20-217 (8)
q 10-184 (10) q 10-236-8 (10) q 10-292 (10) q 20- 114 (10) 20-218 (9)
q 10-185 (10) 10-236-9 (4) q 10-293 (10) 20- 115 q 20-219 (10)
q 10-186 (10) q 10-237 (10) q 10-294 (10) 20- 117 q 20-220 (10)
q 10-187 (10) q 10-240 (10) q 10-295 (10) q 20- 118 (10) q 20-221 (10)
q 10-188 (10) q 10-241 (10) q 10-296 (10) q 20- 119 (10) q 20-222 (10)
q 10-189 (10) q 10-242 (10) q 10-297 (10) 20-120 (9) q 20-223 (10)
q 10-190 (10) q 10-243 (10) q 10-298 (10) 20-121 q 20-224 (10)
10-191 (8) q 10-244 (10) q 10-300 (10) 20-122 20-225 (5)
q 10-192 (10) q 10-245 (10) q 10-301 (10) 20-123 20-226 (5)
q 10-193 (10) q 10-246 (10) q 10-302 (10) 20-124 q 20-227 (10)
10-194 (9) q 10-247 (10) q 10-303 (10) q 20-125 (10) 20-228
10-195 (9) q 10-248 (10) 10-304 20-126 20-229
10-196 (9) q 10-249 (10) 10-305 20-127 20-230
10-197 (9) q 10-250 (10) 10-306 q 20-128 (10) 20-231
10-198 (9) q 10-251 (10) q 10-307 (10) q 20-129 (10) 20-232
q 10-199 (10) q 10-252 (10) q 10-308 (10) 20-130 20-233
q 10-200 (10) q 10-253 (10) q 10-309 (10) 20-131 (9) 20-234
q 10-201 (10) q 10-254 (10) q 10-310 (10) q 20-132 (10) 20-235
q 10-202 (10) q 10-255 (10) q 10- 311 (10) q 20-133 (10) 20-236
q 10-203 (10) q 10-256 (10) 10-312 (8) q 20-134 (10) q 20-237 (10)
q 10-204 (10) q 10-257 (10) 10-313 (8) q 20-135 (10) q 20-238 (10)
q 10-205 (10) q 10-258 (10) 10-314 (8) 20-136 q 20-239 (10)
q 10-206 (10) q 10-259 (10) q 10-315 (10) 20-137 q 20-240 (10)
q 10-207 (10) 10-260 (8) 10-316 (8) q 20-138 (10) q 20-241 (10)
q 10-208 (10) q 10-261 (10) 10-317 (8) q 20-139 (10) q 20-242 (10)
q 10-209 (10) q 10-262 (10) q 10-318 (10) q 20-140 (10) q 20-244 (10)
10-210 (8) q 10-263 (10) 10-319 (8) q 20-141 (10) q 20-245 (10)
q 10- 211 (10) q 10-264 (10) q 10-320 (10) q 20-142 (10) q 20-246 (10)
10-212 (8) q 10-265 (10) q 10-321 (10) q 20-143 (10) q 20-247 (10)
10-213 (9) q 10-266 (10) 10-322 (8) q 20-144 (10) (20-248)
10-214 q 10-267 (10) 10-323 (8) q 20-145 (10) 20-249 (7)
q 10-215 (10) q 10-268 (10) q 10-324 (10) q 20-146 (10) q 20-249-1 (10)
q 10-216 (10) q 10-269 (10) 10-325 (8) 20-147 q 20-249-2 (10)
q 10-217 (10) q 10-270 (10) q 10-326 (10) q 20-148 (10) q 20-249-3 (10)
q 10-218 (10) q 10-271 (10) q 10-327 (10) q 20-149 (10) 20-249-4 (5)
q 10-219 (10) q 10-272 (10) 20-150 (6) q 20-250 (10)
q 10-220 (10) q 10-273 (10) 20- 1 20-151 (7) q 20-251 (10)
q 10-221 (10) q 10-274 (10) q 20- 2 (10) 20-152 (7) 20-252
q 10-222 (10) 10-275 q 20- 3 (10) 20-153 (7) 20-254 (7)
q 10-224 (10) q 10-276 (10) q 20- 4 (10) q 20-154 (10) 20-255
q 10-225 (10) q 10-277 (10) 20- 5 (9) q 20-155 (10) 20-256
q 10-226 (10) 10-278 q 20- 6 (10) q 20-156 (10) 20-257 (7)
q 10-227 (10) q 10-279 (10) q 20- 7 (10) q 20-157 (10) 20-258
q 10-228 (10) 10-279-1 (1) q 20- 8 (10) 20-201 (7) 20-259
q 10-229 (10) 10-279-2 (1) q 20- 9 (10) q 20-202 (10) 20-260
10-230 (4) q 10-279-3 (10) q 20-101 (10) q 20-203 (10) 20-261
00-2-2 WA380-5
(10)
Revision Revision Revision Revision Revision
Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
WA380-5 00-2-3
(10)
Revision Revision Revision Revision Revision
Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
20-714 (5) q 20-775 (10) q 20-910 (10) 20-1019 (9) 30- 56 (9)
20-715 (5) q 20-776 (10) 20-912 q 20-1020 (10) 30- 57 (9)
20-716 (5) 20-777 (5) 20-913 (5) q 20-1021 (10) 30- 58 (9)
20-717 (5) q 20-778 (10) 20-914 (5) 20-1022 (7) 30- 59 (9)
20-718 q 20-779 (10) 20-915 (5) 20-1023 (7) q 30- 60 (10)
20-719 q 20-780 (10) 20-916 (5) q 30- 1 (10) q 30- 61 (10)
20-720 20-781 (5) 20-917 (5) q 30- 2 (10) q 30- 62 (10)
20-721 q 20-782 (10) 20-918 q 30- 3 (10) 30- 63 (9)
q 20-722 (10) q 20-783 (10) q 20-920 (10) q 30- 4 (10) 30- 64 (9)
q 20-723 (10) q 20-784 (10) q 20-921 (10) q 30- 5 (10) 30- 65 (9)
q 20-724 (10) q 20-785 (10) q 20-922 (10) q 30- 7 (10) q 30- 66 (10)
q 20-725 (10) q 20-786 (10) 20-923 (5) q 30- 8 (10) q 30- 67 (10)
q 20-726 (10) q 20-787 (10) q 20-924 (10) q 30- 9 (10) 30- 68 (9)
q 20-727 (10) q 20-788 (10) 20-925 (5) 30- 10 (9) q 30- 69 (10)
q 20-728 (10) q 20-789 (10) q 20-926 (10) 30- 11 (9) q 30- 70 (10)
q 20-729 (10) q 20-790 (10) 20-927 (5) 30- 12 (9) q 30- 71 (10)
q 20-730 (10) q 20-791 (10) q 20-928 (10) 30- 13 (9) q 30- 72 (10)
q 20-731 (10) q 20-792 (10) 20-929 (7) 30- 14 (9) q 30- 73 (10)
q 20-732 (10) q 20-793 (10) q 20-930 (10) 30- 15 (9) q 30- 74 (10)
q 20-733 (10) q 20-794 (10) q 20-931 (10) 30- 16 (9) q 30- 75 (10)
q 20-734 (10) q 20-795 (10) q 20-932 (10) 30- 17 (9) 30- 76 (9)
q 20-735 (10) q 20-796 (10) q 20-933 (10) 30- 18 (9) q 30- 77 (10)
q 20-736 (10) q 20-797 (10) 20-934 (5) q 30- 19 (10) q 30- 78 (10)
q 20-737 (10) q 20-801 (10) q 20-935 (10) 30- 20 (9) q 30- 79 (10)
q 20-738 (10) 20-802 (8) q 20-936 (10) 30- 21 (9) 30- 80 (9)
q 20-739 (10) q 20-803 (10) q 20-937 (10) q 30- 22 (10) 30- 81 (9)
q 20-740 (10) 20-804 (8) q 20-938 (10) 30- 23 (9) 30- 82 (9)
q 20-741 (10) q 20-805 (10) 20-939 (5) 30- 24 (9) q 30- 83 (10)
q 20-742 (10) q 20-806 (10) q 20-940 (10) 30- 25 (9) 30- 84 (9)
q 20-744 (10) q 20-807 (10) q 20-941 (10) 30- 26 (9) 30- 85 (9)
q 20-745 (10) 20-808 (8) 20-942 (5) 30- 27 (9) 30- 86 (9)
q 20-746 (10) q 20-809 (10) q 20-943 (10) q 30- 28 (10) 30- 87 (9)
q 20-747 (10) 20-810 (8) q 20-944 (10) q 30- 29 (10) 30- 88 (9)
q 20-748 (10) q 20- 811 (10) q 20-945 (10) 30- 30 (9) q 30- 89 (10)
(20-749) q 20-812 (10) q 20-946 (10) 30- 31 (9) q 30- 90 (10)
q 20-750 (10) q 20-813 (10) q 20-947 (10) 30- 32 (9) 30- 91 (9)
q 20-751 (10) q 20-814 (10) q 20-948 (10) 30- 33 (9) q 30- 92 (10)
q 20-752 (10) 20-815 (8) 20-949 (5) 30- 34 (9) q 30- 93 (10)
q 20-753 (10) q 20-816 (10) q 20-950 (10) 30- 35 (9) 30- 94 (9)
q 20-754 (10) 20-817 (8) q 20-951 (10) q 30- 36 (10) 30- 95 (9)
q 20-755 (10) 20-818 (8) q 20-952 (10) 30- 37 (9) q 30- 96 (10)
q 20-756 (10) q 20-819 (10) q 20-1001 (10) q 30- 38 (10) 30- 97 (9)
q 20-757 (10) q 20-820 (10) 20-1002 (9) 30- 39 (9) q 30- 98 (10)
q 20-758 (10) q 20-821 (10) 20-1003 (7) 30- 40 (9) q 30- 99 (10)
q 20-759 (10) 20-822 (8) 20-1004 (9) q 30- 41 (10) q 30-100 (10)
q 20-760 (10) 20-823 (8) 20-1005 (9) 30- 42 (9) q 30-101 (10)
q 20-761 (10) 20-824 (8) q 20-1006 (10) 30- 43 (9) q 30-102 (10)
q 20-762 (10) 20-825 (8) 20-1007 (9) 30- 44 (9) 30-103 (9)
q 20-763 (10) 20-826 (8) 20-1008 (9) q 30- 45 (10) 30-104 (9)
q 20-764 (10) 20-827 (8) 20-1009 (9) 30- 46 (9) 30-105 (9)
q 20-765 (10) q 20-828 (10) 20-1010 (7) 30- 47 (9) q 30-106 (10)
q 20-766 (10) 20-901 (5) q 20-1011 (10) 30- 48 (9) 30-107 (9)
q 20-768 (10) 20-903 (5) 20-1012 (9) 30- 49 (9) 30-108 (9)
q 20-769 (10) 20-904 (5) 20-1013 (9) q 30- 50 (10) q 30-109 (10)
q 20-770 (10) q 20-905 (10) 20-1014 (7) 30- 51 (9) 30- 110 (9)
q 20-771 (10) 20-906 (5) q 20-1015 (10) 30- 52 (9) q 30- 111 (10)
q 20-772 (10) q 20-907 (10) 20-1016 (9) 30- 53 (9) q 30- 112 (10)
q 20-773 (10) q 20-908 (10) 20-1017 (7) 30- 54 (9) q 30- 113 (10)
q 20-774 (10) 20-909 (5) q 20-1018 (10) 30- 55 (9) q 30- 114 (10)
00-2-4 WA380-5
(10)
Revision Revision Revision Revision Revision
Mark Pages Mark Pages Mark Pages Mark Pages Mark Pages
number number number number number
WA380-5 00-2-5
(10)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
WA380-5 01-1
GENERAL GENERAL ASSEMBLY DRAWING
01-2 WA380-5
(8)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Tread mm 2,160
Min. ground clearance mm 390
Max. height of bucket hinge pin mm 4,030
Dumping clearance (tip of BOC) mm 2,885 / 2,800
Dumping reach (tip of BOC) mm 1,165 / 1,210
Steering angle deg 40
Bucket tilt angle (travel posture) deg 50
Bucket tilt angle (max. height) deg 65
Bucket dump angle (max. height) deg 49
Digging depth (10° dump) (tip of BOC) mm 310/360
WA380-5 01-3
(8)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Model SAA6D114E-2
4-cycle, water-cooled, serial 6-cylinder,
Type direct injection type with supercharger and air cooling
aftercooler
No. of cylinders - bore x stroke mm 6 - 114 x 135
Piston displacement l {cc} 8.27 {8,270}
N mode P mode
Flywheel horsepower kW {HP}/rpm 136/1,730 140/2,000
Engine
{182/1,730} {187/2,000}
Maximum torque Nm {kgm}/rpm 882/1,400 882/1,400
{90/1,400} {90/1,400}
Min. fuel consumption ratio g/kWh {g/HPh} 219{163} 219{163}
High idle speed rpm 1,900 ± 50 2,210 ± 50
Low idle speed rpm 900 (+50/0) 900 (+50/0)
Starting motor 24 V 7.5 kW
Alternator 24 V 35 A
Battery (*1) 24 V 136 Ah x 2 pcs. (165G51)
3-element, 1-stage, 1-phase
Torque converter 3-element, 1-stage, 2-phase (with lockup clutch)
Multple-shaft power shift, helical gear and spur gear,
Power train
constant-mesh type
Transmission Multiple plate disc type, hydrualically actuated, modula-
tion type
Reduction gear Spiral bevel gear, splash lubrication type
Differential Straight bevel gear type
Final drive Planetary gear 1-stage, splash lubrication type
Drive type Front and rear wheel drive
Axle
01-4 WA380-5
(9)
GENERAL SPECIFICATIONS
• Delivery l /min 94
Hydraulic pump
Hydraulic pump
• Delivery l /min 94
Pilot control pump
• Type Gear type
l /min
Hydraulic system
• Delivery 48
Cooling fan pump
• Type Variable displacement piston type
Type Reciprocating piston type
Steering cylinder
WA380-5 01-5
(10)
GENERAL SPECIFICATIONS
01-6 WA380-5
(8)
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WA380-5
WA380-5 01-7
(10)
GENERAL WEIGHT TABLE
Unit: kg
Machine model WA380-5
Battery (each) 36
Operator’s Cab (If equipped) 700
Operator’s seat 36
Air conditioner unit (If equipped) 12.5
Floor board 313
Oil cooler 3.5
Torque convertor oil cooler 21
Cooling fan drive pump 25
Cooling fan drive motor 13
01-8 WA380-5
(10)
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANT
★ As engine oil for the engine oil pan, SAE10W30 (API CH-4, CI-4) may be used instead of SAE10W30DH,
Unit: l
and SAE15W40 (API CH-4, CI-4) may be used instead of SAE15W40DH.
WA380-5
CAPACITY
Specified Refill
Engine oil pan 37 32
Transmission case 62 54
Hydraulic system 186 129
Axle (each) 38 38
Fuel tank 300 —
Cooling system 36 —
WA380-5 01-9
4
(10)
10 STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD
WA380-5 10-1
(8)
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
Specifications
10-2 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
Unit: mm
WA380-5 10-3
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
• The power from engine (3) is transmitted • The power from the transmission output shaft
through the engine flywheel to torque con- passes through center drive shaft (6), front
verter (2). The turbine in the torque converter is drive shaft (7) and rear drive shaft (5), and is
connected to the input shaft of transmission (1). transmitted to front axle (8) and rear axle (4) to
• The transmission has 6 hydraulically operated drive the wheels.
clutches. These provide 4 FORWARD and
REVERSE speeds.
10-4 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
WA380-5 10-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
10-6 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
Outline
1. Front axle
2. Differential • The power from engine (15) is transmitted
3. Wet-type multiple-disc brake through the flywheel to torque converter (16).
4. Final drive The torque converter uses oil as a medium to
5. Front drive shaft vary the transmission torque according to the
6. Center drive shaft. change in the load. It transmits the power to
7. Parking brake (wet-type multiple-disc) the transmission input shaft.
8. Transmission (multiple-shaft) The power from the engine passes through
9. Rear drive shaft the torque converter pump drive gear and is
10. Rear tire transmitted to steering pump (20), switch pump
11. Final drive (21), cooling fan drive pump (22), transmission
12. Wet-type multiple-disc brake and torque converter charging pump (17), work
13. Differential equipment hydraulic pump (18), and PPC
14. Rear axle pump (19) to drive these pumps.
15. Engine • Transmission (8) operates the directional valves
16. Torque converter and speed valves in the transmission to actuate
17. Torque converter charging pump the 6 hydraulically operated clutches and select
18. Work equipment hydraulic pump one of the 4 FORWARD or REVERSE speeds.
19. Pilot pump
• Parking brake (7) is applied by an electromag-
20. Steering pump
netic valve that is actuated when the parking
21. Switch pump
brake switch is operated. It is a wet-type multi-
22. Cooling fan drive pump
ple-disc brake installed to the front of the out-
23. Flange bearing
put shaft to stop the machine.
24. Front tire
25. Torque converter lock-up clutch • The power from the output shaft of transmis-
sion (8) is transmitted to the front and rear
axles. At the front, the power is transmitted to
front axle (1) through center drive shaft (6),
flange bearing (23), and front drive shaft (5).
At the rear, it is transmitted to rear axle (14)
through rear drive shaft (9).
• The power transmitted to front axle (1) and rear
axle (14) is reduced by the pinion gear in differ-
entials (2) and (13), and is transmitted through
the differential mechanism to the sun gear
shaft.
• The power from the sun gear is further reduced
by planetary-type final drive (11) and is trans-
mitted to the wheels through the axle shaft.
WA380-5 10-7
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DRIVE SHAFT (PROPELLER SHAFT)
10-8 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER, TRANSMISSION PIPING
WA380-5 10-9
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Without lock-up clutch
1. Flywheel 6. Pump
2. Drive case (Number of teeth: 72) 7. PTO drive gear (Number of teeth: 97)
3. Boss 8. Stator shaft
4. Turbine 9. Transmission input shaft
5. Stator
Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 3.27
10-10 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-11
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
• The torque converter is installed between the • The oil passes through the main relief valve and
engine and transmission. its pressure is adjusted by the torque con-
The power from the engine goes from flywheel verter relief valve so that it is less than the set
(1) and enters drive case (2). pressure. It then enters inlet port A, passes
Drive case (2), pump (3), and PTO gear (4) are through the passage in stator shaft (1), and
each fixed by bolts and are rotated directly by flows to pump (2).
the rotation of the engine. The oil is given centrifugal force by pump (2).
The power from pump (3) uses oil as a medium It then enters turbine (3) and transmits the
to rotate turbine (5) and transmit the power to energy of the oil to the turbine.
transmission input shaft (7) through the boss The oil from turbine (3) is sent to stator (4),
(6). and enters the pump (2) again. However, part
The power from drive case (2) passes through of the oil is sent from stator (4) through outlet
PTO gear (4) and is used as the power to drive port B to the cooler.
the gear pump.
10-12 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Specifications
Type 3-element, 1-stage, 2-phase
Stall torque ratio 2.98
WA380-5 10-13
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
10-14 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
No. Check item Criteria Remedy
-0.00
Width 3.95 3.55
Wear of stator shaft -0.1
7 seal ring
Thickness 4.6 ±0.1 4.14
WA380-5 10-15
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
• When the lock-up clutch is disengaged, the con- • When the lock-up clutch is engaged, drive case
nection of drive case (3) and turbine (6) is dis- (3) and turbine (6) are connected and form one
connected, and the torque converter functions unit. Stator (9) is rotated by the rotation of
as normal. pump (4) and turbine (6).
The power generated by the engine is transmit- The power generated by the engine is transmit-
ted from flywheel (1) to clutch housing (2), and ted from flywheel (1) to clutch housing (2), and
rotates drive case (3) and pump (4) as one unit. rotates drive case (3) and pump (4) as one unit.
The power from pump (4) uses oil as a medium In addition, drive case (3) and turbine (6) are
to rotate turbine (6) and transmits the power connected by the lock-up clutch, so the power
from turbine (6) to transmission input shaft (8) is transmitted directly from turbine (6) to
through boss (7). transmission input shaft (8) without using oil
The power from drive case (3) passes through as a medium.
PTO gear (5) and is used as the power to drive The power from drive case (3) passes through
the gear pump. PTO gear (5) and is used as the power to drive
the gear pump.
10-16 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Flow of oil
WA380-5 10-17
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
10-18 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
WA380-5 10-19
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
10-20 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
No. Check item Criteria Remedy
Tolerance Standard Clearance
Standard size
Clearance between PTO driven Shaft Hole clearance limit
1 gear shaft and bearing (F)
+0.030 0. 00 -0.045 -
55 —
+0.011 -0.015 -0.011
Clearance between PTO driven 0. 00 +0.030
2 gear bearing and housing (R) 100 -0.015 +0.035 0 - 0.045 —
WA380-5 10-21
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
Outline
Table of the combination of the clutch and reduc-
• The transmission shall be installed after the tion gear ratio
torque converter and the power from the
Speed step Using clutch Reduction gear ratio
torque converter shall enter into the transmis-
F1 F X 1st 4.095
sion passing through the transmission input
shaft. F2 F X 2nd 2.311
F3 F X 3rd 1.265
• The transmission shall transfer the power of the
transmission input shaft to the output shaft F4 F X 4th 0.706
after changing the speed into forward 1 speed R1 R X 1st 3.834
through 4 speed and into reverse 1 speed R2 R X 2nd 2.163
through 4 speed by combination of the F • R R3 R X 3rd 1.185
clutch and 4 pcs. of the speed clutch. R4 R X 4th 0.661
10-22 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
1. Spacer 6. F clutch
2. Thrust washer 7. F gear (Number of teeth: 40)
3. R gear (Number of teeth: 31) 8. Thrust washer
4. R clutch 9. Spacer
5. F • R cylinder 10. Transmission input shaft
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-23
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
1. Spacer 6. F clutch
2. Thrust washer 7. F gear (Number of teeth: 40)
3. R gear (Number of teeth: 31) 8. Thrust washer
4. R clutch 9. Spacer
5. F • R cylinder 10. Transmission input shaft
Unit: mm
No. Check item Criteria Remedy
10-24 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
1st•4th Clutch
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-25
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
2nd•3rd Clutch
Unit: mm
10-26 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
Operation of clutch
Clutch engaged Clutch disengaged
• The oil sent from the transmission valve passes • The oil sent from the transmission valve is shut
through the passage inside shaft (1), goes to off, so the pressure of the oil acting on the back
the back face of piston (6), and actuates piston face of piston (6) drops.
(6). • Piston (6) is returned to its original position by
• When piston (6) is actuated, separator plate (2) wave spring (7), and shaft (1) and clutch gear (4)
and friction plate (3) are pressed together, so are separated.
shaft (1) and clutch gear (4) form one unit, and • When the clutch is disengaged, the oil at the
transmit the power. back face of the piston is drained through oil
When this happens, the oil is drained from oil drain hole (5) by centrifugal force to prevent the
drain hole (5), but the amount of oil drained is clutch from remaining partially engaged.
less than the amount of oil supplied, so there is
no influence on the operation of the clutch.
WA380-5 10-27
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 1ST
Operation
• In the case of FORWARD 1st, F clutch (3) and 1st • 1st clutch (9) is engaged, so the power trans-
clutch (9) are engaged. The power transmitted mitted to 1st•4th cylinder gear (7) goes through
from the torque converter to input shaft (1) is 1st clutch (9) and is transmitted from 1st gear
transmitted to output shaft (22). (10) to 2nd•3rd cylinder gear (16). From here, it
• The clutch discs of F clutch (3) and 1st clutch (9) passes through lower shaft (20), output gear
are fixed by the hydraulic pressure applied to (19), and output gear (21), and is transmitted to
the clutch piston. output shaft (22).
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted to 1st•4th cylinder gear (7).
10-28 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 2ND
Operation
• In the case of FORWARD 2nd, F clutch (3) and • 2nd clutch (17) is engaged, so the power trans-
2nd clutch (17) are engaged. The power trans- mitted to 2nd gear (18) goes through 2nd clutch
mitted from the torque converter to input shaft (17) and is transmitted to 2nd•3rd cylinder gear
(1) is transmitted to output shaft (22). (16). From here, it passes through lower shaft
• The clutch discs of F clutch (3) and 2nd clutch (20), output gear (19), and output gear (21), and
(17) are fixed by the hydraulic pressure applied is transmitted to output shaft (22).
to the clutch piston.
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted through 1st•4th cylinder gear
(7), upper shaft (12), and idler gear (11) to 2nd
gear (18).
WA380-5 10-29
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 3RD
Operation
• In the case of FORWARD 3rd, F clutch (3) and • 3rd clutch (15) is engaged, so the power trans-
3rd clutch (15) are engaged. The power trans- mitted to 3rd gear (14) goes through 3rd clutch
mitted from the torque converter to input shaft (15) and is transmitted to 2nd•3rd cylinder gear
(1) is transmitted to output shaft (22). (16). From here, it passes through lower shaft
• The clutch discs of F clutch (3) and 3rd clutch (20), output gear (19), and output gear (21), and
(15) are fixed by the hydraulic pressure applied is transmitted to output shaft (22).
to the clutch piston.
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted through 1st•4th cylinder gear
(7) to 3rd gear (14).
10-30 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 4TH
Operation
• In the case of FORWARD 4th, F clutch (3) and • 4th clutch (8) is engaged, so the power trans-
4th clutch (8) are engaged. The power transmit- mitted to 1st•4th cylinder gear (7) goes through
ted from the torque converter to input shaft (1) 4th clutch (8) and is transmitted from 4th gear
is transmitted to output shaft (22). (6) to 4th gear (13). From here, it passes
• The clutch discs of F clutch (3) and 4th clutch (8) through lower shaft (20), output gear (19), and
are fixed by the hydraulic pressure applied to output gear (21), and is transmitted to output
the clutch piston. shaft (22).
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted to 1st•4th cylinder gear (7).
WA380-5 10-31
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
REVERSE 1ST
Operation
• In the case of REVERSE 1st, R clutch (4) and 1st • 1st clutch (9) is engaged, so the power trans-
clutch (9) are engaged. The power transmitted mitted to 1st•4th cylinder gear (7) goes through
from the torque converter to input shaft (1) is 1st clutch (9) and is transmitted from 1st gear
transmitted to output shaft (22). (10) to 2nd•3rd cylinder gear (16). From here, it
• The clutch discs of R clutch (4) and 1st clutch (9) passes through lower shaft (20), output gear
are fixed by the hydraulic pressure applied to (19), and output gear (21), and is transmitted to
the clutch piston. output shaft (22).
• The power from the torque converter goes from
input shaft (1) through R clutch (4) to R gear (5).
The direction of rotation is reversed by idler
gear (23), and is transmitted through idler gear
(11) and upper shaft (12) to 1st•4th cylinder gear
(7).
10-32 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
10-34 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Main relief oil pressure detection port 7. Parking brake solenoid valve
H: Torque converter relief oil pressure detection port 8. Main relief, torque converter
J: Parking brake oil pressure detection port relief valve
9. Last-chance filter
WA380-5 10-34-1
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
ECMV
F R 1st 2nd 3rd 4th
Gear
speed range
F1 c c
F2 c c
F3 c c
F4 c c
R1 c c
R2 c c
R3 c c
R4 c c
Outline
WA380-5 10-35
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Lock-up clutch oil pressure detection port 7. ECMV (for lock-up clutch)
H: Main relief oil pressure detection port 8. Parking brake solenoid valve
J: Torque converter relief oil pressure detection port 9. Main relief, torque converter
K: Parking brake oil pressure detection port relief valve
10. Last-chance filteR
10-36 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Lock-up clutch oil pressure detection port 7. ECMV (for lock-up clutch)
H: Main relief oil pressure detection port 8. Parking brake solenoid valve
J: Torque converter relief oil pressure detection port 9. Main relief, torque converter
K: Parking brake oil pressure detection port relief valve
10. Last-chance filteR
WA380-5 10-36-1
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
ECMV
F R 1st 2nd 3rd 4th Lock
Gear up
speed range
F1 c c
F2 c c
F3 c c c
F4 c c c
R1 c c
R2 c c
R3 c c c
R4 c c c
Outline
WA380-5 10-37
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
10-38 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
WA380-5 10-39
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Actuation of ECMV
• The ECMV is controlled by the command cur- 1. Before shifting gear (when draining) (range A in
rent from the controller to the proportional graph)
solenoid and the fill switch output signal. When no current is flowing to proportional
The relationship between ECMV proportional solenoid (1), pressure control valve spool (3)
solenoid command current and the clutch input drains the oil at clutch port A through drain
pressure and fill switch output signal is as port T.
shown in the diagram below. When this happens, there is no hydraulic force
Range A: Before shifting gear acting on oil pressure detection valve spool (4),
(when draining) so fill switch (6) goes OFF.
Range B: During filling
Range C: Pressure adjustment
Range D: During filling (during trigger)
Range E: Fill started
Range F: Fill completed
10-40 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
WA380-5 10-41
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
10-42 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
WA380-5 10-43
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
10-44 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Operation
WA380-5 10-45
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
FLOW VALVE
1. Valve body
2. Valve spool
Unit: mm
No. Check item Criteria Remedy
Operation
10-46 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE
AXLE
FRONT AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/level plug
8. Drain plug
10-48 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE
REAR AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/level plug
8. Drain plug
WA380-5 10-49
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
10-50 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
REAR DIFFERENTIAL
WA380-5 10-51
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
10-52 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
WA380-5 10-53
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
1. Plate
2. Disc
3. Pinion
4. Washer
5. Side gear
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Case
10-54 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
WA380-5 10-55
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
1 Washer thickness 2
±0.03 1.8
2.1
3
2 Plate thickness ±0.02 2.9
3.1
+0.04
3 Disc thickness 3 2.95
-0.03
Standard Standard Clearance
Shaft Hole
Clearance between spider and size Clearance limit
4 differential pinion gear -0.110 +0.050 0.110 -
30 0.3
-0.160 +0 0.210
Piston assembly portion of dif- -0.110 +0.079 0.110 -
5 ferential housing (housing, pis- 290.5 —
-0.191 +0 0.270
ton)
Piston assembly portion of -0.111 +0.081 0.111 -
6 311 —
bearing carrier (piston, carrier) -0.190 +0 0.271
Replace
-0 -0.045 -0.085 -
Outer race 150 —
Clearance at differ- -0.016 -0.085 -0.029
7 ential side bearing +0.059 -0 -0.079 -
Inner race 100 —
+0.037 -0.020 -0.037
-0 -0.050 -0.075 -
Clearance of bear- Outer race 150 —
-0.020 -0.075 -0.030
8 ing at pinion shaft
gear end +0.039 -0 -0.054 -
Inner race 70 —
+0.020 -0.015 -0.020
-0 -0.048 -0.088 -
Clearance of bear- Outer race 140 —
-0.018 -0.088 -0.030
9 ing at pinion shaft
coupling end +0.039 -0 -0.054 -
Inner race 65 —
+0.020 -0.015 -0.020
Backlash between case and
10 0 - 0.4
plate
Clearance between disc and
11 0.2 - 0.6
plate
Backlash between side gear and
12 0.13 - 0.36
disc
End play (one end) of side gear
13 0.15 - 0.35
in axial direction
10-56 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
WA380-5 10-57
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
2. When there is imbalance between drive Difference in wheel drive force for each type of dif-
force of left and right wheels [Road surface ferential when wheel on one side slips
condition (friction coefficient) and load for left and Wheel drive force
right wheels are not uniform and it is easier for (when one wheel is slipping)
wheel on one side to slip] Slipping Locked Total
Example 1. When digging, and wheel on one side is wheel wheel (ratio)
on soft surface Limited slip differ- 3.64
Example 2. When clearing snow, and wheel on one 1 2.64
ential (1.82)
side is on snow and wheel on other side is on
Normal differential 1 1 2 (1)
asphalt
Example 3. When traveling on slope, and there is
imbalance between load on left and right wheels On road surfaces where the wheel on one side is
The power from the transmission is divided likely to slip, the limited slip differential increases
equally to the left and right by the differential gear. the drive force by 1.82 times more than the nor-
However, when the drive force exceeds the wheel mal differential.
slip limit on the side where the wheel is slipping,
the amount of the force exceeding the wheel slip
limit passes through the brake and case at the rear When turning
face of the side gear and is transmitted to the brake
The differential gears built into a limited slip differ-
on the opposite side (locked side) and is sent to
ential are the same as the gears used in a normal
the wheel on the locked side.
differential, so the difference in rotation between
If this excess portion of the drive force becomes
the inside and outside wheels when turning the
greater than the braking force, the differential
machine can be generated smoothly.
starts to work.
10-58 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
WA380-5 10-59
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between pinion gear size Clearance limit
6 Shaft Hole
bearing and shaft
Replace
+0.013 -0 -0.025 -
40 —
+0.002 -0.012 -0.002
Clearance between axle hous- +0.100 +0.100 -0.100 -
7 358 —
ing and ring gear +0.030 +0 0.070
Clearance between oil seal and
8 Max. 0.2 Adjust
housing
+0.500 -0.072 -0.050 -
Press-fitting por- Housing 215 —
+0.300 -0 -0.372
9 tion of axle shaft
seal -0 -0.300 -0.500 -
Shaft 180 —
-0.063 -0.500 -0.237
10-60 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
Outline
WA380-5 10-61
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
1. Front axle
2. Front frame Outline
3. Rear axle
4. Rear frame • The front frame and rear frame are joined
through a bearing by the center hinge pin. In
addition, the left and right steering cylinders
are connected to the front and rear frames,
and the articulation angle of the frame (the
steering radius) is adjusted by the movement of
the cylinder.
10-62 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-63
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
10-64 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between upper hinge size Clearance limit
1 Shaft Hole
pin and rear frame
-0.030 +0.071 0.066 -
80 —
-0.049 +0.036 0.120
Clearance between upper hinge -0.030 +0.060 0.060 -
2 80 —
pin and spacer (small) -0.049 +0.030 0.109
Clearance between upper hinge -0.030 -0 0.015 -
3 80 —
pin and bearing -0.049 -0.015 0.049
Clearance between upper hinge -0.030 +0.030 0.030 -
4 80 —
pin and spacer (large) -0.049 +0 0.079
Clearance between rear frame -0.036 +0.071 0.072 -
5 95 —
and spacer (large) -0.071 +0.036 0.142
Clearance between front frame -0 -0.048 -0.088 -
6 130 —
and upper hinge bearing -0.025 -0.088 -0.023
Replace
Clearance between lower hinge -0.030 +0.067 0.057 -
7 80 —
pin and rear frame bushing -0.076 +0.027 0.143
Clearance between lower hinge -0.030 -0 0.015 -
8 80 —
pin and bearing -0.076 -0.015 0.076
Clearance between front frame -0 -0.048 -0.088 -
9 130 —
and lower hinge bearing -0.025 -0.088 -0.023
Clearance between rear frame +0.089 +0.054 -0.089 -
10 95 —
and bushing +0.054 +0 0
Clearance at seal press-fitting +0.17 +0.054 -0.17 -
11 105 —
portion of lower hinge pin +0.08 +0 -0.026
Standard size
Shim value for upper hinge and
14 retainer
2.5
WA380-5 10-65
b
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PIPING
STEERING PIPING
10-66 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING COLUMN, ORBIT-ROLL
WA380-5 10-67
b
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
10-68 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
A : To steering cylinder
B : To steering cylinder
Pa : From orbit-roll
Pb : To orbit-roll
P1 : From steering pump
P2 : From switch pump
PB : To work equipment circuit
T : To tank
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-69
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
Function
• The overload relief valve is installed to the
steering valve. If the cylinder is subjected to
impact when the steering valve is at neutral
and abnormal pressure is generated, this valve
functions as a safety valve and relieves the
circuit to prevent the damage to the cylinder
or hydraulic piping. If negative pressure forms
at the cylinder end, it functions as a suction
valve to prevent the formation of any vacuum.
10-70 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When pilot poppet (4) opens, the pressure • If negative pressure forms at port A, check
behind poppet (1) drops, so poppet (1) moves valve poppet (3) opens because of the differ-
and seats pilot poppet (4). ence in area between diameters d3 and d4.
When this happens, the oil flows from port B
to port A to prevent any vacuum from forming.
WA380-5 10-71
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The steering relief valve is inside the steering
valve. It sets the maximum pressure in the
steering circuit when the steering valve is
being operated. In other words, when the
steering valve is operated, if the pressure in
the steering circuit goes above the set pressure
of this valve, it relieves the oil from the valve,
and by relieving the oil, actuates the flow con-
trol spool of the demand valve and drains the
oil going to the steering circuit.
10-72 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When the pressure in the circuit rises and • When flow control spool (6) moves, the oil
reaches the pressure set by adjustment screw from the steering pump is drained and the oil
(1) and spring (2), pilot poppet (4) opens and from the switch pump is relieved to the main
drains the oil. control valve to prevent the pressure in the
• When this happens, the balance between the steering circuit from going above the set pres-
pressures in pressure-receiving chamber (I) and sure.
the pressure-receiving chamber (II) is lost and
flow control spool (6) moves to the left in the
direction of the arrow (").
WA380-5 10-73
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• The oil from the steering pump enters port A; • When the pressure in the pressure-receiving
the oil from the switch pump enters port B. chamber (I) reaches a certain value (set by
• When steering spool (2) is at neutral, pressure- spring (5)), notch f opens and the oil from the
receiving chamber (II) is connected to the drain steering pump is relieved to the drain circuit;
circuit through orifice b; in addition, notch c is in addition, notch g closes, so all the flow of oil
closed. from the switch pump goes to the main control
• Because notch c is closed, the pressure of the valve.
oil at port A and port B rises, and this pres-
sure passes through orifice a, is taken to pres-
sure-receiving chamber (I) and moves flow
control spool (1) to the left in the direction of
the arrow (").
10-74 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When steering spool (2) is pushed (operated), • The merged oil passes through notches c and
pressure-receiving chamber (II) and the drain d, pushes up load check valve (4), and flows to
circuit are shut off, and at the same time, notch the cylinder. The return oil from the cylinder
c opens. passes through notch e and enters the drain cir-
• As a result, the pressure in pressure-receiving cuit.
chamber (II) rises, and flow control spool (1) is • When this happens, the pressure before pass-
moved to the right in the direction of the arrow ing through notch c goes to pressure-receiv-
(!) until notch h closes. ing chamber (I) and the pressure after passing
through notch c goes to pressure-receiving
• The passage from port B to the main control chamber (II). Flow control spool (1) is actuated
valve is shut off, so the oil from the switch so that the difference in pressure on both sides
pump pushes up merge check valve (3) and the of notch c is maintained at a constant value.
oil is merged with the oil from the steering • Therefore, an oil flow matching the degree of
pump at port A. opening of notch c is discharged from the cyl-
inder port. These pressure differences (control
pressure) are set by spring (5).
WA380-5 10-75
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• No extra oil is needed from the switch pump, • The oil from the steering pump passes through
so the pressure of the steering pump rises notches c and d, pushes up load check valve
until notch g closes and shuts off the merge (4), and flows to the cylinder. The return oil
passage at port B. from the cylinder passes through notch e and
• The difference in pressure on both sides of enters the drain circuit.
notch c is controlled only by notch f. The • Notch g is closed, so the oil from the switch
excess oil from the steering pump is drained to pump is sent from port B to the main control
the drain circuit from notch f. (When this hap- valve.
pens, notch g is completely closed.)
10-76 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
FLOW AMP
WA380-5 10-77
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When the oil flows to port PiA, the pressure • Port PiB is connected to the drain circuit
inside the cap at end A rises and moves steer- through the Orbit-roll valve, so the oil flowing
ing spool (1) in the direction of the arrow. to end B is drained.
• The oil entering for port PiA passes through • The pressure generated at port PiA is propor-
the hole in spring seat (3), through orifice (7) in tional to the amount of oil flowing in, so steer-
steering spool (1), and then flows to the oppo- ing spool (1) moves to a position where the
site end (B end). opening of the flow amp notch balances the
pressure generated with the force of return
spring (4).
10-78 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
WA380-5 10-79
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• The steering wheel is not being operated, so • When the pressures at ports A and B rise, flow
steering spool (1) does not move. control spool (4) is moved to the left in the
• The oil from the steering pump enters port A. direction of the arrow (!), and the oil from the
The oil from the switch pump enters port B. steering 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.
10-80 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
Turning right
• When the steering wheel is turned to the right, • The oil at the opposite ends of the left and
the control linkage is actuated and steering right cylinders passes through load check
spool (1) moves to the left in the direction of valve (3) of the steering spool and is drained.
the arrow ("). • The oil from the switch pump enters port B,
• The oil from the steering pump enters port A, goes through flow control spool (2), pushes
goes through flow control spool (2) and flows open check valve (5), and merges with the oil
to steering spool (1). It then pushes open load from the steering pump.
check valve (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.
WA380-5 10-81
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
Turning left
• When the steering wheel is turned to the left, • The oil at the opposite ends of the left and
the control linkage is actuated and steering right cylinders passes through load check
spool (1) moves to the right in the direction of valve (4) of the steering spool and is drained.
the arrow (!). • The oil from the switch pump enters port B,
• The oil from the steering pump enters port A, goes through flow control spool (2), pushes
goes through flow control spool (2) and flows open check valve (5), and merges with the oil
to steering spool (1). It then pushes open load from the steering pump.
check valve (3) of the spool, and flows to the
rod end of the left cylinder and the bottom end
of the right cylinder to turn the machine to the
left.
10-82 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
WA380-5 10-83
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
Outline
10-84 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
WA380-5 10-85
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
10-86 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STOP VALVE
STOP VALVE
WA380-5 10-87
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP
10-88 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP
Unit: mm
No. Check item Criteria Remedy
Repair
Model Standard size Tolerance limit
Standard Discharge
Discharge
Speed discharge amount
Model pressure
(rpm) amount limit
(MPa {kg/cm²} —
Discharge amount (l/min) (l/min)
— Oil: SAE 10WCD
Oil temperature: 45 - 55°C SAL(3)45 101 96
20.6
2,500 {210}
SAL(3)45 101 96
WA380-5 10-89
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EMERGENCY
EMERGENCY STEERING
STEERING PUMP (IF(If
PUMP equipped)
EQUIPPED)
Function
• The emergency steering pump is installed to
the transmission together with the emergency
steering motor. If the engine stops or if the oil
pressure in the steering circuit drops below
the set pressure, it supplies oil to the steering
circuit.
Unit: mm
No. Check item Criteria Remedy
Standard Discharge
Speed Discharge discharge
Discharge amount pressure amount limit —
(rpm) (MPa {kg/cm²} amount
(l/min)
— Oil: SAE 10WCD (l/min)
Oil temperature: 45 - 55°C
3,500 20.6 67.6 62.4
{210}
10-90 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EMERGENCY
EMERGENCY STEERING
STEERING MOTOR(IF(IfEQUIPPED)
MOTOR equipped)
1.Terminal E
2.Terminal M
Function
• If there is an abnormal drop in the oil pressure
in the steering circuit, the emergency steering
motor receives a signal from the transmission
controller and drives the emergency pump.
Specifications
Type Direct current motor
WA380-5 10-91
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between mounting size Clearance limit
1 pin and bushing at connection Shaft Hole
of frame and cylinder rod
-0 +0.142 0.080 -
50 —
-0.025 +0.080 0.167
Clearance between mounting -0 +0.142 0.080 -
2 pin and bushing at connection 50 — Replace
-0.025 +0.080 0.167
of frame and cylinder bottom
Standard clearance
Width of boss Width of hinge
Connection of steering cylinder (a + b)
3 and front frame Max. 0.5
60 66 (after adjusting shim)
Connection of steering cylinder Max. 0.5
4 60 63
and rear frame (after adjusting shim)
10-92 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING CYLINDER
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between piston rod size Clearance limit
1 Shaft Hole
and bushing
5 Tightening torque of cylinder 1.25 ± 0.13 kNm {127 ± 12.7 kgm} (Width across flats: 50 mm) Tighten
piston
WA380-5 10-93
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD JOYSTICK
JOYSTICK STEERING
STEERING LEVER
LEVER (IF(IfEQUIPPED)
equipped)
10-94 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING
STEERING LEVER
LEVER (IF(IfEQUIPPED)
equipped)
1. Body 5. Retainer
2. Piston 6. Lever
3. Lever 7. Potentiometer
4. Disc 8. Connector
Function
WA380-5 10-95
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING
STEERING LEVER
LEVER (IF(If equipped)
EQUIPPED)
Unit: mm
No. Check item Criteria Remedy
10-96 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING
STEERING SWITCH
SWITCH VALVE
VALVE (IF(IfEQUIPPED)
equipped)
Operation
WA380-5 10-97
b
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
10-98 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE PIPING
WA380-5 10-99
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (LEFT)
10-100 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between pedal size clearance limit
5 Shaft Hole
mount hole and pin
-0.025 +0.1 0.025 -
10 0.25
-0.075 0 0.175
Clearance between roller and -0.025 +0.1 0.025 -
6 10 0.25
pin -0.075 0 0.175
WA380-5 10-101
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
10-102 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between pedal size clearance limit
8 Shaft Hole
mount hole and pin
-0.025 +0.1 0.025 -
10 0.25
-0.075 0 0.175
Clearance between roller and -0.025 +0.1 0.025 -
9 10 0.25
pin -0.075 0 0.175
WA380-5 10-103
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Outline
• There are two brake valves installed in parallel When brake is applied (left brake valve)
at the bottom front of the operator's compart-
ment. They are actuated when the pedal is • When pedal (7) is depressed, spool (10) is
depressed. pushed up by rod (8) and spring (9), and closes
drain port c. The oil from the pump and accu-
• When the right pedal is depressed, oil is sent to
mulator flows from port E to port F.
the brake cylinder and the brake is applied.
• Port F of the left brake valve and port PP of the
• When the left pedal is depressed, oil is sent to right brake valve are connected by a hose, so
the right pedal and the brake is applied in the the oil flowing into port F flows to pilot port PP
same way as when the right pedal is depressed. of the right brake valve.
• In addition, when the left brake pedal is
• The oil entering pilot port PP passes through
depressed, the transmission cut-off switch actu-
orifice d and enters port G, pushes piston (11)
ates the transmission solenoid valve electrically
and the spring pushes spool (3) down to apply
to set the transmission to neutral.
the brake in the same way as when the right
brake valve is depressed.
Operation
When brake is applied (right brake valve)
Upper portion
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3). 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 to actuate the rear brake cylinder.
Lower portion
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3). When spool (3) goes down,
plunger (6) moves spool (5) down. When this
happens, drain port b is closed and the oil from
the pump and accumulator flows from port B to
port D to actuate the front brake cylinder.
10-104 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
WA380-5 10-105
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Upper portion
• When pedal (1) is let back and the operating
effort on the top of the spool is removed, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up, drain port a is opened, the oil from the
brake cylinder flows to the hydraulic tank return
circuit, and the rear brake is released.
Lower portion
• When the pedal is let back, at the same time as
spool (3) in the upper portion moves up, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (5),
drain port b is opened, the oil from the brake
cylinder flows to the tank return circuit, and the
front brake is released.
10-106 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
CHARGE VALVE
WA380-5 10-107
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC (EPC*) relief valve (R2)
5. Relief valve (H1)
Function
• The charge valve acts to maintain the oil from
the pump at the specified pressure and to
charge the accumulator.
• 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.
10-108 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
Operation
1. When oil is not being supplied to accumu- 2. When oil is being supplied to accumulator
lator (cut-out condition)
1) Cut-in condition
• The pressure at port B is higher than the set
• When the pressure at port B goes below the
pressure of relief valve R1, so piston (2) is
set pressure of relief valve R1, piston (2) is
forcibly pushed up by the oil pressure at
pushed back down by spring (8), valve seat
port B and poppet (1) opens, and port C
(9) and poppet (1) are put in tight contact,
and port T are connected.
and port C and port T are shut off.
• The spring chamber at the right end of • The spring chamber at the right end of
spool (6) is connected to port C of relief spool (6) is also shut off from port T, so the
valve R1, so it is the tank pressure. pressure rises. The pressure at port P also
• The oil from the pump enters port P and a rises in the same way.
low pressure equivalent to the load of • At the moment the pressure at port P goes
spring (5) pushes spool (6) to the right, then above the pressure of port B (accumulator
flows from port A to the PPC valve, orbit- pressure), the supply of oil to the accumula-
roll and fan pump. tor starts. In this case, it is determined by
At the same time, it also passes through the size (area) of orifice (7) and the pres-
orifices (7), (4), and (3), and returns to the sure difference generated on both sides of
tank. the orifice (equivalent to the load of spring
(5)). A fixed amount is supplied, regardless
of the speed of the engine, and the
remaining oil flows to port A.
WA380-5 10-109
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
10-110 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
Specifications
• The accumulator is installed between the Gas used : Nitrogen gas
charge valve and brake valve. Amount of gas : 2,850 cc
The area between cylinder (3) and free piston Charge pressure: 3.43 ± 0.1 MPa {35 ± 1.0 kg/cm²}
(4) is charged with nitrogen gas. The compres- (at 20°C)
sion ability of this gas is used to absorb the
pulse of the hydraulic pump and to ensure
that there is power to carry out braking and
operate the machine if the engine stops.
WA380-5 10-111
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)
1. Top cover
2. Piston
3. Cylinder
4. End cover
5. Core
Function
Specifications
• This is installed between the brake valve and Gas used : Nitrogen gas
the brake cylinder. The area between cylinder Amount of gas : 46 cc
(3) and free piston (2) is charged with nitrogen Charge pressure: 0.29 ± 0.05 MPa {3 ± 0.5 kg/cm²}
gas. The compression ability of this gas is used (at 50°C)
to ensure that there is power to carry out brak-
ing and operate the machine.
10-112 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
BRAKE
FRONT
★ Figure shows brake with limited slip differential.
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x3)
WA380-5 10-113
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
Unit: mm
No. Check item Criteria Remedy
Outline
• The front brake has a wet-type multiple-disc
structure, and consists of piston (3), inner ring
(5), discs (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of axle housing (7).
• Discs (9) have a lining adhered to both sides.
They are assembled between inner ring (5) and
outer ring (8), and are joined by the spline of
sun gear shaft (6).
10-114 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
REAR
★ Figure shows brake with limited slip differential.
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x3)
WA380-5 10-115
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
Unit: mm
No. Check item Criteria Remedy
Outline
• The rear brake has a wet-type single-disc struc-
ture, and consists of piston (3), inner ring (5),
disc (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of axle housing (7).
• Disc (9) has a lining stuck to both sides. It is
assembled between inner ring (5) and outer
ring (8), and is joined by the spline of sun gear
shaft (6).
10-116 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
Outline
When brake is applied When brake is released
• When the brake pedal is depressed, pressure oil • When the oil pressure is released, piston (2) is
P goes from the hydraulic tank through the returned to its original position by the force of
pump and brake charge valve. It acts on the spring (8), a gap is formed between inner ring
piston inside the brake cylinder and the piston (3) and outer ring (5), and discs (4) become free.
slides. Lattice shape grooves are cut into the lining
Therefore, piston (2) stops the rotation of discs stuck to disc (4), and when disc (4) is rotating,
(4) fitted between inner ring (3) and outer ring oil flows in the grooves and carries out cooling
(5), and applies the brake to the machine. of the lining.
WA380-5 10-117
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CONTROL
Outline
• The parking brake is a wet-type multiple disc • While the parking brake is being applied (when
brake built into the transmission. It is installed the solenoid is OFF), the signal from the trans-
to the bearing portion of the output shaft. It is mission controller to the transmission solenoid
applied mechanically by the pushing force of a valve is cut by the neutralizer signal, and the
spring, and is released by hydraulic power. transmission is held at neutral.
• When the parking brake switch (1) in the opera- • Parking brake emergency release valve (2) is
tor's compartment is turned ON, the hydraulic installed to release the parking brake if it is
pressure is shut off by parking brake solenoid necessary to move the machine when trouble
valve (4) installed to transmission control has occurred in the engine or drive system
valve (3), and the parking brake is applied. and the machine remains stopped (the parking
When the parking brake switch is turned OFF, brake remains applied).
the parking brake is released by the hydraulic
pressure of the cylinder.
10-118 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
WA380-5 10-119
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE
Unit: mm
No. Check item Criteria Remedy
10-120 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE
WA380-5 10-121
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE
Operation
Parking brake applied (solenoid OFF) Parking brake released (solenoid ON)
• When the parking brake switch in the operator's • When the parking brake switch is turned OFF,
compartment is turned ON, the solenoid is the solenoid is turned ON and spool (5) moves
turned OFF and spool (5) is pushed to the left by to the right. When this happens, the pressure
spring (4). When this happens, the circuit oil from the pump goes from port P through
between pump port P and parking brake port A the inside of spool (5) and flows from port A to
is closed and the pressure oil from the pump the parking brake. At the same time, port T is
does not flow to the parking brake. closed and the oil is not drained. As a result,
• At the same time, the oil from the parking brake the spring inside the parking brake is pushed
flows from port A to port T, and is drained. back by the hydraulic force and the parking
As a result, the discs inside the parking brake brake is released.
are pushed by the spring and the parking brake
is applied.
10-122 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE EMERGENCY RELEASE VALVE
1. Grip
2. Valve
A : From accumulator
B : To parking brake solenoid
Outline
• The parking brake emergency release valve is
installed between the brake circuit accumula-
tor and the parking brake solenoid. It is possi-
ble to open this valve manually if no pressure
oil can be supplied from the transmission
pump because of engine failure or other fail-
ure. This makes it possible to supply pressure
from the brake circuit accumulator to the park-
ing brake cylinder.
WA380-5 10-123
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING
HYDRAULIC PIPING
10-124 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING
WA380-5 10-125
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING
Outline
1. Work equipment valve
2. Bucket cylinder • The hydraulic system consists of the work
3. Steering valve equipment circuit and steering circuit. The
4. Hydraulic oil tank work equipment circuit controls the operation
5. Breather of the bucket and attachments.
6. PPC valve • The oil from hydraulic tank (4) is sent by work
7. Cooling fan pump equipment pump (11) to work equipment valve
8. Steering switch pump (1). If the bucket and lift arm spools of the work
9. Oil cooler equipment valve are in the HOLD position, the
10. Torque converter oil cooler oil is sent through the drain circuit of the work
11. Torque converter oil pressure • work equipment equipment valve, filtered by the filter in the
oil pressure • pilot control pump hydraulic tank, and returned to the tank.
12. PPC accumulator • If the work equipment control lever is operated,
13. Charge valve the bucket or lift arm spool of the PPC valve (6)
14. E.C.S.S. valve moves to operate each spool of the work equip-
15. Steering cylinder ment valve (1) hydraulically. Then, the oil flows
16. E.C.S.S. accumulator from the work equipment valve to lift cylinder
17. Lift cylinder (17) or bucket cylinder (2) to move the lift arm
18. Emergency steering pump or bucket.
19. Emergency steering motor • The maximum pressure in the hydraulic circuit
20. Cooling fan motor is controlled with the relief valve in the work
equipment valve. The bucket cylinder circuit is
equipped with the safety-suction valve for pro-
Note: If EPC valve is installed, change "PPC valve" tection of the circuit.
to "EPC valve" when reading. • PPC accumulator (12) is installed to the PPC
pilot circuit so that the lift arm can be lowered
to the ground even while the engine is stopped.
• Hydraulic tank is pressurized, enclosed, and
equipped with breather (5) having the relief
valve. Certain pressure is applied to this tank to
prevent generation of negative pressure in the
tank and cavitation in the pump.
• If the vehicle cannot be steered normally
because of a stall of the engine, a trouble in the
steering pump, oil leakage from the piping, etc.,
emergency steering motor (19) drives emer-
gency steering pump (18) so that the vehicle
can be steered.
• Fan motor (20) installed to the radiator is driven
hydraulically and variably with fan motor drive
pump (7).
10-126 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER
WA380-5 10-127
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER
10-128 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
WA380-5 10-129
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC TANK
Breather
1. Nut
2. Filter element
3. Poppet
4. Sleeve
10-130 WA380-5
(8)
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS
WA380-5 10-131
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS
Unit: mm
No. Check item Criteria Remedy
SAL(3)80
4 Side clearance 0.10 - 0.15
SAL(3)90 0.19
SAL(3)80
Clearance between inside 0.069 - 0.149
5 diameter of plain bearing and SAL(3)90 0.20 Replace
outside diameter of gear shaft
SAL(1)20 0.06 - 0.119
Repair
Model Standard size Tolerance limit
SAL(3)80
6 Driving depth of pin 14
-0
SAL(3)90 —
-0.5
SAL(1)20 10
Standard Discharge
Discharge
Speed discharge amount
Model pressure
(rpm) amount limit
(MPa {kg/cm²} (l/min) (l/min)
Discharge amount —
— Oil: SAE10WCD SAL(3)80 20.6 {210} 184 170
Oil temperature: 45 - 55°C
SAL(3)90 2,500 20.6 {210} 208 192
10-132 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC RELIEF VALVE
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Outline
• The PPC relief valve is installed in the charge
valve between the PPC pump and PPC valve.
While the PPC valve is not in operation or when
abnormal pressure is generated in the PPC cir-
cuit, the PPC relief valve relieves the oil sent
from the pump to protect the pumps and cir-
cuits.
WA380-5 10-133
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC RELIEF VALVE
Operation
• The relief valve is installed to the charge valve • If the pressure in port B lowers, a pressure dif-
and ports A and C are connected to the pump ference is made between ports A and B
circuit and drain circuit respectively. because of the orifice of main valve (1). As a
The oil flows through the orifice of main valve result, main valve (1) is opened by the pressure
(1) and fills port B. in port A and the oil in port A is drained and
Pilot poppet (4) is seated at valve seat (3). relieved into port C.
• If the pressure in ports A and B reaches the set
level, pilot poppet (4) opens and the pressure in
port B is released through port D into port C,
and the pressure in port B lowers consequently.
10-134 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD E.C.S.S.
E.C.S.S. (IF(IfEQUIPPED)
VALVE
VALVE equipped)
WA380-5 10-135
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD E.C.S.S.
E.C.S.S. VALVE
VALVE (IF(If equipped)
EQUIPPED)
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
10-136 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
T : Drain port (To the tank) P2 : From the switch pump (steering valve)
A1: To the bucket cylinder head P1A : From the P1 port of the PPC valve
A2: To the lift cylinder head P1B : From the P2 port of the PPC valve
B1: To the bucket cylinder bottom P2A : From the P3 port of the PPC valve
B2: To the lift cylinder bottom P2B : From the P4 port of the PPC valve
P1: From the work equipment pump
1. Solenoid valve
WA380-5 10-137
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
10-138 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-139
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
2. 3-spool valve
T : Drain port (To the tank) P2 : From the switch pump (Steering valve)
A1: To the attachment cylinder P1A : From the attachment PPC valve
A2: To the bucket cylinder head P1B : From the attachment PPC valve
A3: To the lift cylinder head P2A : From the P1 port of the PPC valve
B1: To the attachment cylinder P2B : From the P3 port of the PPC valve
B2: To the bucket cylinder bottom P3A : From the P2 port of the PPC valve
B3: To the lift cylinder bottom P3B : From the P4 port of the PPC valve
P1: From the work equipment pump
1. Solenoid valve
10-140 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
WA380-5 10-141
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
10-142 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
3. Relief valve
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjusting screw
WA380-5 10-143
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
4. Safety-suction valve
Operation
10-144 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
5. Suction valve
(2) Operation as suction valve
• If negative pressure is generated in port A, the
pressure in port D becomes negative since
those ports are connected to each other.
• Since the tank pressure of port B is applied to
port E, the safety valve receives oil pressure e
corresponding to the area difference between
d2 and d1.
• Accordingly, oil pressure is applied in the open-
ing direction of the valve and oil pressure a is
applied in the closing direction of suction valve
(1).
• If the pressure in port A lowers to near 0, it is
lower than oil pressure e.
• When oil pressure e becomes larger than the 1. Main poppet
total of oil pressure a and the force of valve 2. Sleeve
spring (5), suction valve (1) opens and the oil 3. Spring
flows from port B to port A to prevent genera-
tion of negative pressure in port A.
Function
Operation
WA380-5 10-145
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
6. Cut-off valve
Function
Standard Hi c ± ±
specifica-
tion vehi- S c ± c
cle Lo c c c
Operation
10-146 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
2) When work equipment pump pressure is (3) When solenoid valve is turned ON
higher than cut-off pressure • Since port SP is connected to the drain circuit,
• If the work equipment pump pressure reaches the pilot oil flows along the arrows.
the cut-off pressure, cut-off valve (2) is opened • Then, differential pressure is generated in
by the oil pressure in chamber a and then the unload valve (3) and it opens unload valve (3).
oil in chamber b of unload valve (3) is drained • Accordingly, the oil from switching pump (the
through chamber c of cut-off valve (2). oil from the steering valve) is always drained,
• Since the oil in chamber d of unload valve (3) regardless of the level of the work equipment
flows through orifices e and f to chamber b, the port pressure.
oil pressure in chamber d lowers and unload
valve (3) opens.
• Accordingly, the oil from the switching pump is
drained.
WA380-5 10-147
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• The oil goes into the port A from the pump and • Although the oil coming from the PPC pump
the maximum pressure is being stipulated by goes into the port L of the PPC valve, as the lift
the relief valve (1). arm lever and the bucket lever are being set to
• As for the bucket spool (2), a bypass circuit is the holding position, the oil return to the
being opened for holding purpose and the oil hydraulic oil tank through the PPC relief valve.
coming from the port A passes around the
spool to flow into the port B.
• As for the lift arm spool (3) also, a bypass circuit
is being opened to make the neutral state and
the oil coming from the port B passes around
the spool to return to the tank through the drain
circuit.
10-148 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the lift arm lever (4) is pulled, the oil • After that, oil flow to the port D and further to
flows from the port L to the port N of the PPC the cylinder bottom.
valve and, from there, it goes into the port S of • The oil from the PPC valve flows through check
the work equipment control valve. valve (13) into port L of the PPC valve. Since
• Also, oil of the port T flow into the drain circuit the lift arm and bucket control levers are in the
passing through the port M. The pressurized hold position, however, the oil returns through
oil of the port S pushes the lift arm spool (3) to PPC relief valve (12) to the hydraulic tank.
the UP position.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the spool (3).
• Since the bypass circuit is being closed by the
spool (3), the oil pushes open the check valve
(5).
WA380-5 10-149
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the lift arm lever (4) is pushed, the oil • After that, oil flow to the port E and further to
flows from the port L to the port M of the PPC the cylinder head.
valve and, from there, it goes into the port T of • On the other hand, the oil in the cylinder bot-
the work equipment control valve. tom goes into the drain port F through the port
• Also, oil of the port S flow into the drain circuit. D to return to the tank. As the result, the lift
The pressurized oil of the port T pushes the lift arm goes down.
arm spool (3) to the LOWER position.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the spool (3).
• Since the bypass circuit is being closed by the
spool (3), the oil pushes open the check valve
(5).
10-150 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the lift arm lever is pushed to the FLOAT • As the result, while the bucket is contacting the
position, the lift arm spool (3) further moves ground surface, the bucket can move up and
from the LOWER position to the FLOAT posi- down when the ground surface is uneven.
tion.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the lift arm spool (3).
• Because of the spool (3), the oil in the bypass
circuit flows into the drain circuit and the oil
cannot push-open the check valve.
• Also, since both of the lift cylinder RAISE circuit
D and the LOWER circuit E are being connected
to the drain circuit, the lift arm comes down by
its own weight.
WA380-5 10-151
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the bucket lever (6) is pushed, the pres-
surized oil form the port L of the PPC valve • On the other hand, the oil in the bucket cylinder
flows into the port V of the work equipment bottom flow into the drain port F through the
control valve through the port Q. port G to return to the tank. As the result, the
bucket dumps.
• Also, the oil from the port R flows to the drain
circuit.
The pressurized oil from the port V moves the
bucket spool (2) to the DUMP position.
• Since the oil coming from the pump is being
closed by the spool (2), the oil from the port A
pushes the check valve (7) to let it open.
• The oil coming from the check valve (7) flows
into the bucket cylinder head through the port
H.
10-152 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the bucket lever (6) is pulled, the pressur- • The oil coming from the check valve (7) flows
ized oil form the port L of the PPC valve flows into the bucket cylinder bottom through the
into the port R of the work equipment control port G.
valve through the port P. • On the other hand, the oil in the bucket cylinder
• Also, the oil from the port V flows to the drain head flow into the drain port F through the port
circuit. H to return to the tank. As the result, the
The pressurized oil from the port R moves the bucket tilts.
bucket spool (2) to the TILT position.
• Since the oil coming from the pump is being
closed by the spool (2), the oil from the port A
pushes the check valve (7) to let it open.
WA380-5 10-153
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
10-154 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
1. Spool 9. Ring
2. Metering spring 10. Plate
3. Centering spring 11. Retainer
4. Spring 12. Piston
5. Retainer 13. Body
6. Solenoid 14. Ball
7. Rod 15. Detent spring
8. Lever 16. Retainer
WA380-5 10-155
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
Operation
1. When in NEUTRAL
(1) PPC valve for bucket (2) PPC valve for lift arm
• Ports PA and PB of the bucket control valve • Ports PA and PB of the lift arm control valve
and ports P1 and P2 of the PPC valve are con- and ports P3 and P4 of the PPC valve are con-
nected through fine control hole f of spool (1) nected through fine control hole f of spool (1)
to the drain chamber D. to the drain chamber D.
10-156 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
WA380-5 10-157
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
• If lever (8) begins to return, the force of center- • If lever (8) and rod (7) push down piston (12)
ing spring (3) and the pressure in port P1 push and retainer (11) pushes down spool (1), fine
up spool (1). control hole f is disconnected from drain cham-
• As a result, fine control hole f is connected to ber D and connected to pump pressure cham-
drain chamber D and the oil in port P1 is ber PP.
released. • Accordingly, the pilot oil from the main pump
• If the pressure in port P1 lowers too much, flows through fine control hole f and port P1
spool (1) is pushed down by metering spring (2) into chamber PB and pushes the control valve
and fine control hole f is disconnected from spool.
drain chamber D and connected to pump pres- • The oil returning from chamber PA flows
sure chamber PP almost simultaneously. Then, through port P2 and fine control f' into drain
the pump pressure is applied until the pressure chamber D.
in port P1 is restored to the level corresponding
to the position of the lever.
• When the control valve spool returns, the oil in
drain chamber D flows in through fine control
hole f of the valve which is not in operation and
then flows through port P2 into chamber PA.
10-158 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
5. When lift arm is FLOATED 6. When FLOAT state of lift arm is reset
• If rod (7) and piston (12) on the LOWER side of • Lever (8) is returned from the FLOAT position
port P3 are pushed down by lever (8), ball (14) by pushing it down with a force greater than
touches projection a of rod (7) in the middle of the attractive force of solenoid (6) and retainer
the stroke (The detent starts to operate). (5).
• If rod (7) is pushed in further, ball (14) pushes • The FLOAT state also can be reset and the lever
up retainer (16) supported on detent spring (15) can be returned to the neutral position by turn-
and escapes out to go over projection a of the ing off the current in solenoid (6) (demagnetiz-
piston. ing the solenoid).
• At this time, rod (7) on the opposite side is • The lift arm RAISE and bucket TILT operations
pushed up by spring (4) through retainer (11). are carried out similarly to the above.
• If rod (7') is pushed up and the current is flow-
ing in solenoid (6), retainer (5) is attracted by
solenoid (6).
• Accordingly, rod (7') is kept pushed up and the
FLOAT state is kept even if the lever is released.
• At the same time, the control valve is also
moved to the FLOAT position and kept at that
position.
WA380-5 10-159
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
10-159-1 WA380-5
1
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
1. Spool 9. Plate
2. Metering spring 10. Retainer
3. Centering spring 11. Piston
4. Spring 12. Body
5. Retainer 13. Ball
6. Solenoid 14. Detent spring
7. Rod 15. Retainer
8. Disc
WA380-5 10-159-2
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
OPERATION
1. At NEUTRAL
(1) PPC Valve for Bucket (2) PPC Valve for Lift arm
• PA and PB ports of the control valve for bucket • PA and PB ports of the control valve for lift arm
and P1 and P2 ports of the PPC valve lead to and P3 and P4 ports of the PPC valve lead to
the drain chamber D through the fine control the drain chamber D through the fine control
hole f of the spool (1). hole f of the spool (1).
10-159-3 WA380-5
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
2. At Fine Control
(Neutral Fine Control)
• When the rod (7) and the piston (11) are pressed
with the disc (8), the retainer (10) is also
pressed, and the spool (1) is pressed with the
metering spring (2) and moves downward.
• When the fine control hole f is interrupted from
the drain chamber D as a result of the down-
ward movement, it leads to the pump pressure
chamber PP almost at the same time. Then,
pilot pressure oil of the main pump is sent from
the P4 port to the PB port through the fine con-
trol hole f.
• When the pressure is increased at the port P4,
the spool (1) is pushed back, and when the fine
control hole f is interrupted from the pump
pressure chamber PP, it leads to the drain
chamber D almost at the same time, and the
pressure is released from the P4 port.
• Therefore, the spool (1) rises and falls so that
pressure at the P4 port balances with force of
the metering spring.
The positional relations between the retainer
(10) and the body (12) (the fine control hole f is
at the intermediate position between the drain
chamber D and the pump pressure chamber
PP) do not change until the retainer (10) gets to
the spool (1).
• Since the metering spring (2) is tightened in
proportion to control lever stroke, pressure at
the P4 port rises in proportion to the control
lever stroke.
• Therefore, the control valve spool moves to the
position where pressure of the PB chamber (the
same as pressure at the P4 port) balances with
force of the return spring of the control valve
spool.
WA380-5 10-159-4
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
10-159-5 WA380-5
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
WA380-5 10-159-6
b
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC
EPC SOLENOID
SOLENOID VALVE (IF(If
VALVE equipped)
EQUIPPED)
WA380-5
10-160 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC
EPC SOLENOID
SOLENOID VALVE (IF(If
VALVE equipped)
EQUIPPED)
Function Operation
• The EPC valve consists of the proportional sole- 1. When the signal current is 0 (Coil is de-
noid section and the hydraulic valve section. magnetized)
• On the receiving signal current from the pump • While the signal current from the controller is
controller, the EPC valve generates an EPC out- not flowing in coil (10), coil (10) is demagne-
put pressure in proportion to the signal current tized.
and applies it to the control valve. • Accordingly, spool (7) is pressed by spring (8)
to the right.
• Port P is closed and the hydraulic oil from the
control pump does not flow in the control valve.
• The oil from the work equipment control valve
is drained through parts C and T.
WA380-5 10-161
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC
EPC SOLENOID
SOLENOID VALVE (IF(If
VALVE equipped)
EQUIPPED)
2. When signal current is small (Coil is mag- 3. When signal current is maximum (Coil is
netized in fine control mode) magnetized in full operation.
• If a small signal current flows in coil (10), coil • If the signal current flows in coil (10), coil (10) is
(10) is magnetized and a thrust to the left is gen- magnetized.
erated in plunger (11). Since the signal current is at maximum, the
• Push pin (9) pushes spool (7) to the left and the thrust in plunger (11) becomes maximum.
hydraulic oil from port P flows in port C. • Accordingly, push pin (9) presses spool (7) to
• The pressure in port C rises. If the total of the the left.
force applied to face a of spool (7) and the load • As a result, the maximum hydraulic oil flows
of spring (8) exceeds the thrust of plunger (11), from port P to port C and the pressure in the
spool (7) is pushed to the right. circuit between the EPC valve and control valve
• Ports P and C are disconnected from each other becomes highest.
and port C and port T are connected to each • At this time, port T is closed and the oil does
other simultaneously. not flow in the tank.
• As a result, spool (7) moves to the right or left
until the thrust of plunger (11) is balanced with
the total of the pressure in port c and the load
of spring (8).
• Accordingly, the pressure in the circuit between
the EPC valve and control valve is controlled in
proportion to the signal current.
a Control valve
10-162 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SHUT
SHUT OFF
OFF VALVE (IF(If
VALVE equipped)
EQUIPPED)
Function
A : To EPC valve • If the signal from the controller is turned on, the
P : From pilot circuit pump (Pump from EPC) shut-off valve is turned on to connect the oil
T : To hydraulic tank path from the pilot circuit pump to the EPC
valve.
WA380-5 10-163
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(If equipped)
EQUIPPED)
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
10-164 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(IfEQUIPPED)
equipped)
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-165
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(IfEQUIPPED)
equipped)
Operation
10-166 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(IfEQUIPPED)
equipped)
WA380-5 10-167
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
Specifications
Model : LMF28
Capacity : 28.0 cc/rev
Rated speed : 1,400 rpm
Rated flow : 40 l/min
Cracking pressure of check valve : 0.044 MPa {0.45 kg/cm²}
10-168 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-169
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
1. HYDRAULIC MOTOR
Function
• This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of
the hydraulic oil sent from the hydraulic pump
into revolution.
Principle of operation
10-170 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
2. SUCTION VALVE
(2) When pump is stopped
Function
• If the engine is stopped and the input revolution
• If the fan pump stops, the hydraulic oil does not of the fan pump lowers to 0 rpm, the hydraulic
flow into the motor. Since the motor continues oil from the pump is not supplied to port P any
revolution because of the force of inertia, how- more. As the hydraulic oil is not supplied to the
ever, the pressure on the outlet side of the MA side of the motor, the motor speed lowers
motor rises. gradually to stop.
• When the oil stops flowing in from inlet port P, • If the motor shaft is revolved by the force of
the suction valve sucks in the oil on the outlet inertia while the oil flow in the port P is reduc-
side and supplies it to the port MA where there ing, the oil in port T on the outlet side is sent by
is not sufficient oil to prevent cavitation. the suction valve to the MA side to prevent cav-
itation.
Operation
WA380-5 10-171
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
3. OPERATION OF REVOLUTION
DIRECTION CHANGEOVER
VALVE
(1) When ON-OFF solenoid for changeover (2) When ON-OFF solenoid for changeover
valve is turned OFF valve is turned ON
• If ON-OFF solenoid (1) for changeover valve is • If ON-OFF solenoid (1) for changeover valve is
turned "OFF", the hydraulic oil from the pump is turned "ON", ON-OFF changeover valve (2)
blocked by ON-OFF changeover valve (2) and changes to let the hydraulic oil from the pump
port C is connected to the tank circuit. flow through port C into spool chamber D.
• Accordingly, changeover spool (3) is pushed by • The hydraulic oil in chamber D pushes
changeover spool spring (4) to the right to open changeover spool (3) against changeover spool
motor port MA and then the hydraulic oil flows spring (4). As a result, motor port MB opens
in to revolve the motor forward (clockwise). and the hydraulic oil flows in to revolve the
motor in reverse (counterclockwise).
10-172 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
1. Bleeder
WA380-5 10-173
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
10-174 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
Function
• This pump converts the revolution and torque • The oil in each cylinder of cylinder block (7) can
of the engine transmitted from its shaft into be drawn and discharged through valve plate
hydraulic energy and discharges hydraulic oil (8).
according to the load.
• The discharge amount can be changed by
changing the swash plate angle.
Structure
WA380-5 10-175
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
Operation
1. Operation of pump
• Shaft (1) and cylinder block (7) revolve together • If center line X of rocker cam (4) is in the direc-
and shoe (5) slides on plane A. As rocker cam tion of the axis of cylinder block (7) (Swash
(4) slants around ball (11) at this time, angle α plate angle = 0), the difference between vol-
between the center line X of rocker cam (4) and umes E and F in cylinder block (7) is 0 and oil is
axis of cylinder block (7) changes. Angle α is not sucked or discharged (The swash plate
called the swash plate angle. angle is not reduced to 0 actually, however).
• If the angle between the center line X of rocker • In short, swash plate angle α is in proportion to
cam (4) and the axis of cylinder block (7) is α, the discharge of the pump.
plane A works as a cam for shoe (5).
• Accordingly, each piston (6) slides inside cylin-
der block (7) and makes difference between vol-
umes E and F in cylinder block (7) and the oil is
drawn and discharged by the difference.
• In short, if cylinder block (7) revolves and vol-
ume of chamber E is reduced, the oil is dis-
charged. On the other hand, the volume of
chamber F is increased and the oil is sucked.
(The figure shows the end of suction process of
chamber F and the end of discharge process of
chamber E.)
10-176 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
2. Control of discharge
WA380-5 10-177
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
SERVO VALVE
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
10-178 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
WA380-5 10-179
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
SAFETY VALVE
Function
10-180 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WA380-5 10-181
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between bushing size clearance limit
7 and pin at each end of bucket Shaft Hole
link
-0.036 +0.207 0.156 -
85 1.0
-0.090 +0.120 0.297
Clearance between bushing -0.036 +0.207 0.156 -
8 and pin of joint of lift arm and 85 1.0
-0.090 +0.120 0.297
bucket
Clearance between bushing -0.036 +0.207 0.156 -
9 and pin of joint of lift arm and 95 1.0
-0.090 +0.120 0.297
frame
Clearance between bushing Replace
-0.036 +0.207 0.156 - (Replace if pin
10 and pin of joint of bucket cylin- 110 1.0
-0.090 +0.120 0.297 has scuff mark)
der bottom and frame
Clearance between bushing -0.036 +0.207 0.156 -
11 and pin of joint of bucket cylin- 110 1.0
-0.090 +0.120 0.297
der rod and lever
Clearance between bushing -0.036 +0.245 0.181 -
12 and pin of joint of bell crank 120 1.0
-0.090 +0.145 0.335
and lift arm
Clearance between bushing -0.036 +0.207 0.156 -
13 and pin of joint of lift cylinder 95 1.0
-0.090 +0.120 0.297
rod and lift arm
Clearance between bushing -0.036 +0.207 0.156 -
14 and pin of joint of lift cylinder 95 1.0
-0.090 +0.120 0.297
bottom and frame
10-182 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET
BUCKET
1. Bucket
2. Bolt-on cutting edge
3. Bucket tooth
Unit: mm
No. Check item Criteria Remedy
WA380-5 10-183
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
1. Proximity switch
2. Bucket cylinder rod
3. Lever
4. Plate
Unit: mm
No. Check item Criteria Remedy
10-184 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
WA380-5 10-185
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
• When lift arm (3) is lower than the set position • If lift arm control lever (7) is moved to the raise
of the boom kick-out, plate (2) is not on the position, lift arm spool (8) is moved to the posi-
detection plane of proximity switch (1). Boom tion of the arrow and held at that position by
kick-out relay (4) is turned off and the current the coil turned on by detent solenoid (6). As a
flows in detent solenoid (6) of PPC valve (5) and result, lift arm control lever (7) is held at the
the coil is turned on. RAISE position and lift arm (3) is raised.
10-186 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
WA380-5 10-187
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
• When the bucket is tilted more than the set • If bucket control lever (7) is moved to the TILT
position of the bucket leveler, lever (2) is on the position, DUMP spool (8) is moved to the posi-
detection plane of proximity switch (1) and tion of the arrow and held at that position by
proximity switch (1) lights up. At this time, the coil turned on by detent solenoid (6). As a
bucket positioner relay (4) is turned on and the result, bucket control lever (7) is held at the TILT
current flows in detent solenoid (6) of PPC valve position and the bucket is tilted.
(5) and the coil is turned on.
10-188 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
WA380-5 10-189
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
BUCKET CYLINDER
Unit: mm
No. Check item Criteria Remedy
Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Clearance between Shaft Hole
Replace
1 piston rod and
-0.036 +0.257 0.084 - bushing
bushing Lift 90 0.647
-0.090 +0.048 0.347
-0.036 +0.257 0.084 -
Bucket 90 0.647
-0.090 +0.048 0.347
-0.036 +0.35 0.236 -
Clearance between Lift 95 1.0
-0.090 +0.20 0.440
2 piston rod support
shaft and bushing -0.036 +0.207 0.156 -
Bucket 110 1.0
-0.090 +0.120 0.297 Replace pin
-0.036 +0.207 0.156 - and bushing
Clearance between Lift 95 1.0
cylinder bottom -0.090 +0.120 0.297
3 support shaft and -0.036 +0.207 0.156 -
bushing Bucket 110 1.0
-0.090 +0.120 0.297
10-190 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CAB
CAB
1. Front glass
2. Front windshield wiper
3. Rear windshield wiper
4. Door
5. Air conditioner filter (If equipped)
6. Antenna (If equipped)
WA380-5 10-191
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AIR
AIR CONDITIONER
CONDITIONER (IF(If equipped)
EQUIPPED)
10-192 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
WA380-5 10-193
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
• This machine monitoring system is equipped • The machine monitoring system consists of the
with the service mode function to facilitate the machine monitor proper, buzzer, and switches
troubleshooting work for respective controllers that are used for inputting data to the machine
(including the machine monitor itself) on the monitor proper, sensors, respective controller
network. The description below applies to the on the network, and relevant switches and sen-
contents of the main functions. sors.
4. Tuning
This function is to be used for compensation
and adjustment of the installation errors and
dispersions in the manufacturing processes of
individual parts of sensors, proportional elec-
tromagnetic valves.
10-194 WA380-5
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
Load meter
WA380-5 10-195
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
Sensing functions
10-196 WA380-5
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
WA380-5 10-197
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
10-198 WA380-5
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
WA380-5 10-199
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
MACHINE MONITOR
SPEEDMETER SPECIFICATIONS
10-200 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Torque converter oil temperature gauge 23. Battery electrolyte level caution lamp
2. Torque converter oil temperature caution lamp 24. Battery charge circuit caution lamp
3. Engine coolant temperature gauge 25. Steering oil pressure caution lamp
4. Engine coolant temperature caution lamp 26. Emergency steering pilot lamp
5. Speedometer or engine tachometer 27. Character display
6. Turn signal pilot lamp (left) 28. Output mode pilot lamp
7. Headlamp high beam pilot lamp 29. Semi auto digging pilot lamp
8. Turn signal pilot lamp (right) 30. Preheating pilot lamp
9. Hydraulic oil temperature caution lamp 31. Auto greasing pilot lamp
10. Hydraulic oil temperature gauge 32. Joystick pilot lamp
11. Fuel level caution lamp 33. Directional selector pilot lamp
12. Fuel gauge 34. Shift indicator
13. Central warning lamp 35. Auto-shift pilot lamp
14. Brake oil pressure caution lamp 36. Lockup pilot lamp
15. Engine oil pressure caution lamp 37. Shift hold pilot lamp
16. Engine oil level caution lamp 38. Shift lever position pilot lamp
17. Radiator coolant level caution lamp 39. Brake oil level caution lamp
18. Air cleaner clogging caution lamp 40. Transmission oil filter clogging caution lamp
19. Parking brake pilot lamp 41. Bucket load indication
20. Axle oil temperature caution lamp 42. Work indication
21. Cooling fan reverse rotation pilot lamp 43. Addition mode: Gross load indication
22. Maintenance caution lamp Subtraction mode: Residual amount indica-
tion
WA380-5 10-201
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
c: Occurs.
—: Does
not occur.
To be turned on by
Concen- respective controllers
trated Concentrated
When an error occurs U U U U U U U U Red and message will be
warning
13 warning lamp LED c indicated simulta-
neously.
lamp
Other cases than above — — — — — — —
10-202 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
c: Occurs.
—: Does
not occur.
Upper digits: F, N, R
Lower digits: Speed
stages Speed stage indication
Actual gear shift 9 segment Indication will be main-
34 stage LCD — tained until the starting — — — — — — — will not be made while
at the "N" stage.
key is turned OFF when a
combination error has
occurred.
Normal voltage — — — — — — —
When the abnormality
was detected while the
Other 24 Battery charge LED c Charging trouble c c AB00AMA Red engine is stopped, the
symbols alarm will continue after
starting the engine also.
When an abnormality is
detected c c AB00L6 — — — Red
WA380-5 10-203
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
c: Occurs.
—: Does
not occur.
Normal (CLOSE) — — — — — — —
When the abnormality
When sensor 1 is being was detected while the
18 Air cleaner LED c blinded (OPEN) — — — — c — AA1ANX Red engine is stopped, the
clogging alarm will continue after
When an abnormality is starting the engine also.
detected with sensor 1 — — — DHA4KA — — — —
Normal — — — — — — —
2V or less — c — — c — D61AZK Red
Battery electro-
23 lyte level LED c When this option is not
(Optional) installed — — — — — — —
When an abnormality is
detected — — — DJBAKX — — — DJBAKX —
10-204 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
c: Occurs.
—: Does
not occur.
Not in operation/Not
installed — — — — — — —
In operation — c — — c — Green
Auto greasing
31 (Optional) LED c
The tank is empty — — — — Green
1Hz 1Hz
Abnormal — — — — Green
2Hz 2Hz
Normal — — — — — — —
22 Maintenance LED c
Less than 30 hours after
maintenance — — U — — U — Simultaneously, the
message display will
monitor indicate the content.
Less than 30 hours before The indicator will light
maintenance for 30 sec. only after the
or maintenance time has — c — U — c — U Red starting key is turned
come ON.
WA380-5 10-205
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
c: Occurs.
—: Does
not occur.
As indi- As indi-
Cooling fan Cooling fan reverse rota- Orange Will indicate the state
21 reverse LED c tion — c — cated at — c — cated at where the fan is in for-
right right
rotation ward/reverse rotation.
As indi- As indi-
Fan switch and solenoid
are not in conformity — — cated at — — cated at Orange
Other right right
symbols When the load meter indi-
5 Load meter cation is being made U U U U U U U U —
41 (Load meter Calculation results will
42 specification) LCD c be shown in figures.
When the load meter indi-
cation is not being made — — — — — — —
43 (Optional)
When an abnormality is
detected (Rear) — — — DGR2KA — — — DGR2KA —
Priority degrees of the buzzer sound: Repetitive () > Intermittent (✩) > Cancellation of operation > Confirmation of receiving the operation
10-206 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Check the settings or change the settings of the rotary switches, dip switches and check or change the
option setting in the following cases:
In case it becomes necessary to remove the machine monitor once and when reinstalling it
In case the machine monitor has been replaced with a new monitor
In case the tire size has been changed (speed compensation settings)
In case the optional equipment is being installed or being removed
Setting statuses of respective switches can be checked on the real time monitor under the service mode.
Refer to the "Real time monitoring function".
WA380-5 10-207
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
When making settings, turn off the power supply and remove the machine monitor in advance. Refer to
the Chapter "Disassembly and Assembly" when removing the machine monitor.
Make settings of respective switches (SW1, 2, 3, 5 and 6) according to the instructions.
When turning the rotary switches, turn them gently using a precision plus head type screwdriver, etc.
With the rotary switches, the triangular projection is the arrow mark for setting.
When changing the settings of the dip switches, move them gently using a precision minus head type
screwdriver, etc.
When inserting a tool inside the grommeted hole, be careful not to touch any other parts than the targeted
switch.
As for the option setting, the settings can be changed or checked using the "Optional Select" under the ser-
vice mode. (Refer to the Section "Initial Setting/Adjustment". page10-241 and above)
Depending on the type of the option, it becomes necessary to make the initial state setting. (Refer to the
Section "Initial Setting/Adjustment".)
As for the initial stage adjustment, the adjustment can be made by the "Tuning" under the service mode.
(Refer to the Section "Initial Setting/Adjustment".)
1. Precautions
When making settings, observe the instructions.
When moving the switches, move them gently using a precision screwdriver, etc.
When inserting a tool inside the grommeted hole, be careful not to touch any other parts than the tar-
geted switch.
Be careful not to let dust and any other foreign substance enter into the equipment.
After finishing the setting work, be sure to insert the grommets back to their original positions securely.
2. When making the machine model selection settings (Setting of the rotary switch [SW1])
Since a single type of machine monitor is being applied to many machine models, it is necessary make
the setting for the machine model to which the machine monitor has been installed.
When the machine monitor has been replaced, it becomes necessary to make machine model selection
setting by the rotary switch [SW1] to let the system make proper controls for the machine model to
which the machine monitor has been installed.
Adjustment procedures
Make the setting indicated in the following Table to fit to the machine model to which the machine
monitor has been installed.
10-208 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
4. When making the speedometer/tachometer indication changeover setting and tire size selection setting
(Setting of the rotary switch [SW3])
Since the machine monitor is being set to the tire size of standard tires for speed calculations, when the
tire size has been changed, it becomes necessary to adjust to the new tire size by the rotary switch
[SW3] for compensation of the speed indications.
Adjustment procedures
Make the setting according to the following Table to fit to the tire size.
Meter indication SW3 Tire size Remarks
changeover
km/h indication 0 Small diameter tire
Making the speedometer/tachometer indication changeover setting means to change the indication content
of the speedmeter located in the central section of the monitor.
Changeover from the speedometer to (engine) tachometer can also be made using the "Optional Select".
After the above setting is made, the indication unit of the travel distance integrating meter (odometer) will
become according to the setting made as above.
Since the MPH indication is only for the countries employing the non-SI-unit only, do not make the MPH
indication setting for machines being used in countries employing the SI-unit.
In case other tires than the above or when the speed indications deviate from the actual speed by wears of
the tires, it is possible to make tire compensations using the "Optional Select".
5. When making necessary setting when the engine controller is installed (Setting of the dip switch [SW5-
1])
Make the setting as follows and do not change it.
Setting position of the SW5-1 in case of machines not equipped with the KOMATSU Common Rail
engine (WA380-5 ): "OFF"
6. When making necessary setting for the work equipment/joystick controller (Setting of the dip switch
[SW5-2])
When the work equipment/joystick controller is newly installed or removed, make the setting as fol-
lows.
Setting position of the SW5-2 in case the controller has been removed: "OFF"
Setting position of the SW5-2 in case the controller has been newly installed: "ON"
WA380-5 10-209
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Setting position of the SW5-4 in the case the use of the 3rd gear speed lockup, 4th gear speed, and 4th
gear speed lockup is prohibited: "OFF"
Setting position of the SW5-4 in the case the use of the 3rd gear speed lockup, 4th gear speed, and 4th
gear speed lockup is permitted: "ON"
10-210 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
***: Indicates which sequence number of fault history counting from the top.
######: Indicates the failure code.
$$$: Indicates the number of times of occurrence of the subject failure code
%%%%%: Indicates the elapsed time from the initial occurrence of the same electric fault (the value
deducting the service meter value when the electric fault initially occurred from the current service
meter value).
@@@@@: Indicates the elapsed time from last occurrence of the same electric fault (the value
deducting the service meter value when the electric fault last occurred from the current service
meter value).
When the indication is showing the currently occurring electric fault, the failure code flashes. Up to
max. 20 failure codes can be memorized.
2) Machine fault history
Use this function to check the machine fault history of respective controllers being memorized by
the machine monitor. Regarding the failure code being used in the machine fault history, refer to
the Chapter "Troubleshooting".
The machine fault history indications on the character display are as follows.
***: Indicates which sequence number of fault history counting from the top.
######: Indicates the failure code.
$$$: Indicates the number of times of occurrence of the subject failure code.
%%%%%: Indicates the service meter value at the time of initial occurrence of the same machine
fault.
@@@@@: Indicates the service meter value at the time of last occurrence of the same machine
fault.
When the indication is showing the currently occurring machine fault, the failure code flashes. As for
the failure codes of the machine fault, up to several failure codes can be memorized.
WA380-5 10-211
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-212 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-213
(9)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
2. Operation methods
10-214 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-215
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
3) Selection of displaying the fault history of electric system and clearing the entire fault history of
electric system (second layer)
A current fault is displayed prior to the restored ones.
Pressing the > switch displays the next older fault.
Pressing the < switch displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the switch changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the switch changes the screen to the [Clear individually the fault history of electric sys-
tem] or [Clear the fault history of electric system] screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-
out clearing (but change the screen to that for individual clearing).
4) Clearing individually the fault history of electric system, and clearing the entire fault history of elec-
tric system (the third layer)
Select YES or NO with the < or > switch.
Cursor (_) blinks on the selected item. Pressing the switch changes the display as follows, with
the history reset if YES was selected, or not if NO was selected:
1 If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
2 If YES (clear ) was selected, the display returns to the [Display the fault history of electric
system] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the
screen returns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
If a fault was cleared, peeps sound (on for 0.1 sec. - off for 0.1 sec. - on for0.1 sec.) to notify that the
operation has been accepted.
If the entire history was cleared, it is considered to have been cleared even if it consisted of only
one fault .
10-216 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-217
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-218 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-219
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-220 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-221
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
The maintenance interval time is set when the machine is shipped as in the following table:
Interval for
Items replacement (h) Items shown ID numbers
10-222 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation
1. Press the switch and < switch for more than five seconds to go to the [ID Entry] screen.
2. Enter ID with the < and > switch, and press the switch to go to the screen for service persons.
3. Press the < and > switch to display the [Select the real-time monitor] screen, then press the switch to
fix the screen.
10-224 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
4. Press the switch, and the [Select the information displayed on monitor panel] screen appears. Press-
ing the < or > switch display the screens [Select the information of the transmission controller], [Select
the information of the engine controller], [Select the information of the working machine controller],
and [Select the 2-item display] in order.
5. Pressing the switch, while each selection screen is shown, displays the [One-item display] screen or
the [Select information on 2-item display] screen.
In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying the
information each controller has.
WA380-5 10-225
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
How to Enter an ID
After the screen was changed from another, “00000” is shown.
Enter a number 0-9 in the cursor position.
The cursor is at the highest digit first. Each time the < or > switch was pressed, the number changes by 1
within a range 0-9.
If the desired number was entered, press the switch.
The cursor moves to the second highest digit. Repeat the procedures mentioned above until the last num-
ber is filled in the lowest digit.
If the lowest digit was entered, press the switch, and the screen changes to that for displaying/selecting
the second item. Alternately, pressing the switch returns the screen to that for displaying/selecting two
items.
In the case of 2-item display, enter the IDs of the information to be displayed, and the two items are shown
simultaneously. The IDs shown are the same as those on the 1-item display screen.
6. In the case of 1-item display, pressing the < and > switch changes the items shown in turn, displaying
the information each controller has.
10-226 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-227
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
A value out
SI unit sys- of the range
All the items are shown even Abridged due to tem so long displayed is
if some of them are not
equipped depending on mod- limitation of num- as the val- shown as the
ber of letters. ues have lowest (high-
els and options. units est) value in
the range.
Transmission controller
41100 Pressure of left-hand brake L.H. BRAKE 0.1MPa 0.00-50.00 Transmission L61-19
Calculated
41200 Transmission cut-off pressure CUT OFF 0.01MPa 0.00-50.00 Transmission
value
Calculated
41300 Number of times of kick-down K/D TIMES — — Transmission
value
Calculated
41400 Average cycle time CYCLE TIME 1 SEC — Transmission
value
41400 Fan pump EPC current FAN EPC 1mA 0-1000 Transmission L63-36
41500 Transmission oil temperature ECMV OIL TEMP 1°C 24-131 Transmission L61-9
Calculated
41700 Selection of shift mode SHIFT MODE — H/M/L Transmission
value
41802 1st-clutch fill time FILL TIME 1 10msec 0-2550 Transmission Calculated
value
41803 2nd-clutch fill time FILL TIME 2 10msec 0-2550 Transmission Calculated
value
Calculated
41804 3rd-clutch fill time FILL TIME 3 10msec 0-2550 Transmission value
Calculated
41805 4th-clutch fill time FILL TIME 4 10msec 0-2550 Transmission value
Transmission Seesheet
separate
40907 Input signal D_IN_16-23 D-IN-16-----23 — 10101010
10-228 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
A value out
SI unit sys- of the range
All the items are shown even Abridged due to tem so long displayed is
if some of them are not
equipped depending on mod- limitation of num- as the val- shown as the
ber of letters. ues have lowest (high-
els and options. units est) value in
the range.
Work equipment controller
Part No. of work equipment con- Work Shows part No. of
20202 troller’s ROM BOOM ROM — — equipment — ROM
Work
41900 Lift arm-raising EPC current RAISE EPC 1mA 0-1000 L73-6
equipment
Work
41901 Lift arm-lowering EPC current LOWER EPC 1mA 0-1000 L73-16
equipment
Work
41902 Bucket tilt EPC current TILT EPC 1mA 0-1000 L73-5
equipment
Work
41903 Bucket dump EPC current DUMP EPC 1mA 0-1000 L73-15
equipment
Work
41904 R.H. Joystick EPC current R.H. J/S EPC 1mA 0-1000 L73-26
equipment
Work
41905 L.H. Joystick EPC current L.H. J/S EPC 1mA 0-1000 L73-36
equipment
Work
41906 3rd valve 1 EPC current 3RD EPC1 1mA 0-1000 L73-25
equipment
Work
41907 3rd valve 2 EPC current 3RD EPC2 1mA 0-1000 L73-35
equipment
42000 Lever potentiometer-voltage lift BOOM POT1 0.01V 0.00-5.00 Work L71-19
arm 1 equipment
Lever potentiometer-voltage lift Work
42001 BOOM POT2 0.01V 0.00-5.00 L71-13
arm 2 equipment
Lever potentiometer-voltage Work
42002 bucket 1 BUCKET POT1 0.01V 0.00-5.00 equipment L71-7
WA380-5 10-229
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
How to read input signals (D-IN--0------7) How to read output signals (D-OUT-0------7)
The signal input into controller by ON/OFF switch is The signal output from controller by ON/OFF switch
shown as [D-IN-*] (* represents input No.). is shown as [D-OUT-*] (* represents output No.).
The display shows it as follows: The display shows it as follows:
10-230 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-231
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-232 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-233
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-234 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
After checking those conditions on the real-time monitor, check the engine speed
Conditions Real-time monitor item Component ID
Engine speed ENG SPEED Machine monitor 01001
Check the Transmission controller first to see if any abnormality was found and to see if an error was
issued.
If no error was detected, check the status of input signals on the real-time monitor.
1. Check the cut-off selection switch
Item Real-time monitor item Pin position ID
D-IN-2 D-IN--0------7 L61-11 40905
40905:**0****
The third digit is [0] if the Transmission cut-off selection switch has recognized itself as not ON.
Item Real-time monitor item Pin position ID
D-IN-2 D-IN--0------7 L61-11 40905
40905:**1****
On the contrary, the digit is [1] if the switch has recognized itself as ON.
If [0] continues after you operated the switch, you can consider that the cut-off selection switch system
is abnormal.
WA380-5 10-235
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
40905:***0***
The fourth digit is [0] if the Transmission cut-off set switch has recognized itself as not ON.
Item Real-time monitor item Pin position ID
D-IN-3 D-IN--0------7 L61-11 40905
40905:***1***
On the contrary, the digit is [1] if the switch has recognized itself as ON.
If [0] continues after you operated the switch, you can consider that the cut-off set switch is abnormal.
41100:*.**MPa
If the pressure does not change after you stepped on/released the cut-off brake, you can consider that
the sensor system is abnormal.
If you stepped on the left-hand brake fully, about 5.00Mpa {51kg/cm²} of pressure should be shown.
If you released the brake, a value less than 0.5Mpa {5kg/cm²} should be shown.
The pressure may change when you stepped on the brake even when the engine is stopped if some
pressure remains in accumulator; if no pressure remains in it, a value less than 0.5Mpa {5kg/cm²}
should be shown.
41200: 1.50MPa
The result is accepted if the value is substantially the same with the value previously set.
Although, if the cut-off pressure has been set to less than 0.49Mpa{5kg/cm²}, 0.49Mpa{5kg/cm²}
shall be adopted as the set value; if the cut-off pressure has been set to more than 4.5Mpa{45kg/
cm²}, 4.5Mpa{45kg/cm²} shall be adopted as the set value.
10-236 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Outline
For the load meter, there are addition mode, subtraction mode, data display mode, calibration mode
and calculation stop mode, and each mode can be selected with the monitor panel mode selector
switch. If a printer (If equipped) is connected to the load meter, it is possible to print out measurement
data.
2. Operating Method
WA380-5 10-236-1
10-236
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
3. Weight Calculation However, the real measured value (D) of lift arm
Since the pressure sensor (A) mounted on the pressure has characteristics shown in the figure
bottom side of the lift cylinder and the pressure below because operations of the tires and the
sensor (B) mounted on the head side detect work equipment cause spring effect to the
operating pressures (P) of the lift arm, and also machine.
the lift arm angle sensor (C) calculates positions
of the center of gravity, the load meter calcu-
lates weight (W) of load.
10-236-2
10-237 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
The lift arm angle ranges from -10° to -30°. (The range between below horizontal and above touching
Condition 1 the ground)
The lift arm angle increases more than 0.1° in 0.1 second. (The lift arm started moving upward at a
Condition 2 fixed speed.)
The lift arm angle incseases less than 0.5° in 0.5 seconds. (The lift arm lifting speed reduced below
Condition 1 fixed value.)
Condition 2 The lift arm moves downward. (When lift arm lowering operation is done, the calculation is finished.)
Condition 3 The lift arm angle became up to +20° (The calculation stops at high position.)
The lift arm lifting speed changed suddenly. (The speed reduced below 70% in comparison with the
Condition 4 previous angular velocity.)
Calculation count Calculating time (sec.) Weight calculating and displaying methods
Weight is displayed by only one calculation. In this case, the weight
1 time only 1.5 - 2.5 display flashes to inform the operator that the calculating time is
short and the calculation accuracy is not enough.
2 times 2.5 - 3.5 Averaged weight of the two calculations is displayed.
3 times or more 3.5 - The averaged weight of the latest three calculations is displayed.
WA380-5 10-236-3
10-238
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
• When the addition mode is selected, • When the subtraction mode is selected,
"TOTAL LOADED" (1) is displayed, and each "REMAINING TARGET"(1) is displayed, and
calculated bucket load (3) is added to the the calculated bucket load (3) is reduced
total load display (2). from the residual quantity display (2).
• Weights of any five kinds of object materi- • Weights of any five kinds of object materials
als can be independently accumulated and can be independently accumulated and dis-
displayed. For selection of object materi- played. For selection of object materials, the
als, the five kinds from A to E can be five kinds from A to E are selected and set
selected and set in the display of work in the display of work object materials (4).
object materials (4).
• Values up to 9999t are displayed in the total ★ For the detail of display and calculation
load display (2) unless data are cleared with methods of bucket load display (3) larger
the load meter sub-total switch. Values up than the residual quantity (2), see the para-
to 999.9t are displayed in units of 0.1t, and graph of "Operation of Load Meter" in the
when the value is over 1000t, the decimal Operation and Maintenance Manual.
point disappears and values are displayed
★ For the detail of residual quantity display,
in units of 1t.
see the paragraph of "Total Load Display
and Residual Quantity Display."
★ For the detail of total load display, see the
paragraph of "Total Load Display and Resid-
ual Quantity Display."
10-236-4
10-239 WA380-5
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-236-5
10-241
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-236-6
10-242 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-236-7
10-243
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Material: D Maintenance
1: 1.43t 2: 2.27t Engine oil 250h
3: 2.05t 4: 3.38t Transmission oil 1000h
Total: 4 times 9.04t Hydraulic oil 2000h
Axle oil 2000h
Material: E Engine oil filter 250h
1: 3.48t 2: 2.94t Transmission oil filter 500h
3: 3.64t 4: 1.97t Hydraulic oil filter 1000h
5: 2.79t Axle pivot pin 500h
Total: 5 times 14.82t Bobm pin 100h
Steering cylinder pin 250h
Center hinge pin 1000h
10-236-8
10-245 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-236-9
10-244
4
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Machine setting
Setting of machine serial number
1. Hold down the switch and < switch for 5 sec- 4. Enter the machine serial number.
onds or more, and change to the [ID entry
screen].
Entering ID
At transition to the screen, “50000” or “set
numeric value” is displayed on the screen.
2. Use the < and > switch to enter ID, and press Enter a numeric value 0 to 9 at the cursor posi-
the switch to enter the service person screen. tion.
The cursor appears on the highest-order posi-
tion, and 0 to 9 is displayed one by one each
time the > or < switch is pressed.
When a target numeric value is displayed, press
the switch.
The cursor moves to the second digit. Follow
the same procedure to enter up to the lowest-
order digit, and press the switch.
If a numeric value is changed, the operation
acceptance completion sound is output.
If an incorrect numeric value is entered, use the
switch to return to the [Select Setting] screen
once, and repeat the procedure from the begin-
ning.
3. Use the < and > switch to display the [machine
serial No. entry] screen, and press the switch
to decide the machine serial number.
WA380-5 10-237
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-240 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-241
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation method
1. Operate the monitor mode switch to select a 4. After a target controller is selected, press and
service mode optional select. release the monitor mode switch ( ). The set-
Pressing the monitor mode switch changes the ting state for each option appears as follows.
option setting as follows.
10-242 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
(1) Hold down the switch and < switch for 5 seconds or more at the same time, and change to
the ID entry screen. (Figure 1)
(2) Use the < and > switch to enter ID, and press the switch to enter the service person screen.
(3) Use the < and > switch to display the sensor initialization selection screen (Figure 2), and
press the switch to decide the value.
(4) Use the < and > switch to display the Transmission initial learning screen (Figure 3) of set
item 1.
(5) Depress the switch, and the transmission initial learning setting screen (Fig. 4-1 or Fig. 4-
2) appears.
(6)-1 If the initial learning has not been carried out, the initial learning incompletion (reset) screen
(Fig. 4-1) appears.
(6)-2 If the initial learning has been carried out, the initial learning completion screen (Fig. 4-2)
appears.
(7) To reset the initial learning, depress the switch to display the initial learning reset screen
(Fig. 5).
(8)-1 To reset the initial learning, select YEW with the < switch and depress the switch.
After the switch is depressed, if the initial learning incompletion (reset) screen (Fig. 4-1)
appears, the initial learning is reset.
(8)-2 If you do not need to reset the initial learning, select NO and depress the switch.
After the switch is depressed, the screen before the ž switch was depressed (Fig. 4-1 or
Fig. 4-2) appears and resetting is cancelled.
If the initial learning is necessary, carry out (1) - (5), and then carry out the resetting operation (up to (8)-1)
once while either the screen in (6)-1 or the screen in (6)-2 is displayed.
WA380-5 10-243
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Carry out initial learning operation at the state of the machine mentioned above. (Do not stop the engine.)
2. Check that the oil temperature of transmission is in the range of 55 - 70°C on the real-time monitor.
If it is outside of the specified range, be sure to carry it out within the specified temperature range.
★ If the initial learning is carried out at the temperature outside of the specified range, it may cause
time lag and gear shift shock.
3. Shift the transmission by operating the gear shift lever and directional lever.
Gear range N2 F2 F1 F2 F3 F4 F3 F2 N2 R2 N2
Holding time 5 sec 5 sec 5 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec
After holding each gear speed for the time specified or more, shift gears to the next range.
Operate the engine at low idling, place the shift mode switch in the MANUAL position, and the transmission cut-off switch in the
OFF position (the lockup switch in the OFF position).
Carry out shifting operation while driving the machine actually or while depressing the brake pedal.
★ When setting to N2 initially, operate the directional lever by placing it in the N position following the
F2 or R2 position.
Even if the shift lever is changed to 2 after placing the directional lever in N, the gear will not
change. Therefore, operate the directional lever by placing it in the N position after setting the gear
shift lever to 2.
When the directional lever is placed in the N position at the shift lever in other than 2, place the
directional lever in the F or R position and then operate the directional lever in the N position fol-
lowing F2 or R2.
★ Hold the shift lever for the specified holding time or more for each speed of gear range.
If the gear shift lever is operated for the holding time or less, completion of initial learning (display
of TUNED) will not appear.
4. Check that completion of initial learning (display of TUNED) appears on the initial learning of transmis-
sion setting screen on the real-time monitor.
5. When the initial learning is not carried out (display of INITIAL STATUS), repeat operations mentioned in
3 and 4 until completion of initial learning (display of TUNED) appears.
10-244 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Hold down the switch < switch for 5 seconds 4. Press the < and > switch to display the [Work
or more at the same time, and change to the [ID Equipment Lift Arm Angle Adjustment] screen
Entry] screen. of set item 2.
2. After the ID is entered using the < and > switch, 5. Press the switch here; the [Work Equipment
press the switch to enter the service person Lift Arm Angle Set] screen appears.
screen.
3. Press the < and > switch to display the [Sensor 6. Adjust the lift arm to the highest position with-
Initial Setting Selection] screen, and press the out load.
switch to decide the value.
7. Press the switch here: the lift arm angle sen-
sor value is read, and a difference between the
read result and reference value is stored as an
offset value.
WA380-5 10-245
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Item setting
1. Hold down the < and > switch for 5 seconds or more at he same time, and change to the [ID Entry] screen.
2. Use the < and > switch to enter ID, and press the switch to enter the service person screen.
3. Use the < and > switch to display the [Sensor Initial Setting Selection] screen, and press the switch to
decide the value.
4. Use the < and > switch to display the [Work Equipment EPC Adjustment] screen on set items 4 to 7.
Lift arm up: No.4
Lift arm down: No.5
Bucket tilt: No.6
Bucket dump: No.7
3-valve extension: No.8
3-valve reduction: No.9
Set the value individually.
5. Press the switch here; the [Work Equipment EPC Setting] screen appears.
10-246 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-247
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Bucket tilt
1. Dump the bucket to lower the lift arm, and lift the front tires. Tilt the bucket by degrees in the engine
high idling state. (Lower the machine.)
2. Return the lever by fine operation to stop the bucket (tire floating), then hold the lever at that position.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the dump direction, the buzzer sounds for 1 sec-
ond, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
7. When the switch is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.
Bucket dump
1. Adjust the bucket to the horizontal level without load, and lower the bucket by degrees in the engine
high idling state.
2. Return the lever by fine operation to stop the lift arm, then hold the lever at that position.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the tilt direction, the buzzer sounds for 1 second,
and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
3-valve extension
1. Extend three valves by degrees in the engine high idling state.
2. Return the lever by fine operation. After the cylinder of three valves stops, hold the lever at that posi-
tion.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the fastening direction, the buzzer sounds for 1
second, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains dis-
played.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
7. When the switch is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.
3-valve reduction
1. Reduce three valves by degrees in the engine high idling state.
2. Return the lever by fine operation. After the cylinder of three valves stops, hold the lever at that posi-
tion.
3. Press the switch here; the EPC command value is read, and a difference between the read value and
reference value is stored as an offset value.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the switch is pressed as the lever stroke is in the extension direction, the buzzer sounds for 1
second, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains dis-
played.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared,
and the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC
Adjustment] screen.
7. When the switch is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.
10-248 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Push and hold the switch and > switch simul- 4. Display the screen for adjusting items No. 4 — 6
taneously for 5 seconds to go to the "Input ID" of the work equipment EPC with the < switch
screen. and > switch.
WA380-5 10-249
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
< Adjustment of each EPC lever > [Adjustment of position of lift arm RAISE
[Adjustment of position of lift arm LOWER detent]
(FLOAT) detent] Perform the following procedure with the
1) -1. Lower the lift arm to the ground. engine stopped.
2) -1. Stop and hold the lift arm lever before the 1) -2. Lower the lift arm to the ground.
FLOAT detent position. 2) -2. Stop and hold the lift arm lever before the
3) -1. Push the switch at this time. The lever volt- RAISE detent position.
age is read and the standard value is changed 3) -2. Push the switch at this time. The lever volt-
and saved. age is read and the standard value is changed
4) -1. The buzzer sounds twice. The screen for and saved.
adjusting the work equipment EPC appears and 4) -2. The buzzer sounds twice. The screen for
the adjustment is completed. adjusting the work equipment EPC appears and
the adjustment is completed.
Screen for adjusting work equipment EPC 5) -2. At this time, if the switch is pushed while
the lever output voltage is below the standard
value (out of design range), the buzzer sounds for
1 second and the screen for setting work equip-
ment EPC does not change. The adjustment is
cancelled in this case.
10-250 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA380-5 10-251
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
2. Use the < and > switch to enter ID, and press
the switch to enter the service person screen.
2. Use the < and > switch to enter ID, and press 5. Press the switch here; the [Work Equipment
the switch to enter the service person screen. Lift Arm Angle Setting] screen appears.
3. Use the < and > switch to display the [Sensor 6. Adjust the lift arm to the highest position with-
Initialization Setting] screen, and press the out load.
switch to decide the value. 7. Press the switch here; the lift arm angle sen-
sor value is read, and a difference between the
read result and reference value is stored as an
offset value.
8. The buzzer sounds twice (two short tones), and
the menu returns to the [Lift Arm Angle Adjust-
ment] screen. The setting is then completed.
9. Press the switch; the lift arm angle correction
is ended even if it is in progress of processing.
WA380-5 10-253
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Hold down the switch < switch for 5 seconds 4. Use the < and > switch to display the [Work
or more at the same time, and change to the [ID Equipment Lift Arm Angle Adjustment] screen
Entry] screen. of set item 17.
2. Use the < and > switch to enter ID, and press 5. Press the switch here; the [Work Equipment
the switch to enter the service person screen. Lift Arm Angle Setting] screen appears.
3. Use the < and > switch to display the [Sensor 6. Adjust the lift arm to the lowest position with-
Initialization Setting] screen, and press the out load. (Lift cylinder stroke end)
switch to decide the value. 7. Press the switch here; the lift arm angle sen-
sor value is read, and a difference between the
read result and reference value is stored as an
offset value.
8. The buzzer sounds twice (two short tones), and
the menu returns to the [Lift Arm Angle Adjust-
ment] screen. The setting is then completed.
9. Press the switch; the lift arm angle correction
is ended even if it is in progress of processing.
10-254 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-20P [CN-L51]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
1 — — — — —
4 NSW power (+24V) I — Power +24V NSW power (+24V) NSW power (+24V)
5 NSW power (+24V) I — Power +24V NSW power (+24V) NSW power (+24V)
8 — — — — —
Sensor power output Lift arm pressure Lift arm pressure For load meter
15 O — Sensor power (Spare for
(+24V) sensor power sensor power standard)
Sensor power output Lift arm angle sen- Lift arm angle sen- For load meter
16 O — Sensor power (Spare for
(+5V) sor power sor power standard)
WA380-5 10-255
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-18P(1) [CN-L52]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
10-256 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-18P(2) [CN-L54]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
18 (NC) — — (NC) —
AMP070-12P(2) [CN-L55]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
WA380-5 10-257
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-12P(3) [CN-L56]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
Machine monitor-
Transmission, and
1 S_NET(+) I/O N S-NET S_NET+
work equipment
controller
Machine monitor-
2 S_NET(+) I/O N S-NET Transmission, and S_NET+
work equipment
controller
Machine monitor-
Transmission, and
3 CAN+ I/O P CAN work equipment CAN+
controller
4 S_NET(-) O N S-NET S_NET GND S_NET-
10 (NC)
11 (NC)
12 (NC)
AMP070-14P(2) [CN-L57]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
1 (NC) — — —
RS232_C serial
2 RS232C_1_RTS I/O Q communication —
5 RS232C_2_RTS I/O R NC —
Load meter printer
6 — — Printer BUSY For load meter
busy input
7 (NC) — — —
11 RS232C_2_SG O R NC —
12 RS232C_2_TX O R TX NC —
13 RS232C_2_CTS I/O R NC —
14 (NC) — —
10-258 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP040-8P [CN-L58]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
WA380-5 10-259
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
10-260 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
Control Function
When the engine speed is 1000 rpm or above, switching between the auto-shift up and down in the
auto-shift mode is implemented according to a travel speed mode selected from the “Table - Auto
Shift Point List” stored in the transmission controller’s memory. Here, selection of a shift mode is
done by referencing the signals from the forward-reverse lever, shift lever and travel speed sensor.
1] Shift lever at 1st to 4th speeds
This function limits the maximum gear speed (range of speed change) available for the auto-
matic gear speed change.
Start at the 2nd speed is usually employed in the auto-shift mode. Thus, when the shift lever is
at the 4th speed, the shift up/down is performed in the range of the 2nd and 4th speeds. It is,
however, done at the 1st speed when the kick down function is used.
WA380-5 10-261
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
10-262 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA380-5 10-263
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
3
3T/C3L/U(L) 11.0 16.0 0
3T/C4T/C(H) 18.0 18.0 1
3T/C4T/C(M) 16.5 16.5 1
3T/C4T/C(L) 15.0 15.0 1
4
4T/C4L/U(H) 23.7 25.2 0
4T/C4L/U(M) 22.2 23.6 0
4T/C4L/U(L) 20.7 22.0 0
4L/U4T/C(L&M&H) 40.0 40.0 5
4L/U4T/C(L&M&H) 19.1 20.3 1
4 4T/C3T/C(H) 16.0 16.0 1
4T/C3T/C(M) 14.5 14.5 1
4T/C3T/C(L) 13.0 13.0 1
3T/C2T/C(H) 10.7 10.7 2
3 or 4 3T/C2T/C(M) 9.5 9.5 2
3T/C2T/C(L) 6.5 6.5 2
1,000 rpm)
(less than
1.
10-264 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
4L/U4T/C(H) Zone III & 18.0 and up Zone III & 18.0 and up 2
When direction switch is shifted (1) (F) NR
4L/U4T/C(M) Zone III & 16.5 and up Zone III & 16.5 and up 2
4L/U4T/C(L) Zone III & 15.0 and up Zone III & 15.0 and up 2
4L/U3T/C(H) Zone III & 13.0-18.0 Zone III & 13.0-18.0 2
4L/U3T/C(M) Zone III & 13.0-16.5 Zone III & 13.0-16.5 2
4L/U3T/C(L) Zone III & 13.0-15.0 Zone III & 13.0-15.0 2
4T/C3T/C(H) Zone III & 13.0-18.0 Zone III & 13.0-18.0 2
4
4T/C3T/C(M) Zone III & 13.0-16.5 Zone III & 13.0-16.5 2
4T/C3T/C(L) Zone III & 13.0-15.0 Zone III & 13.0-15.0 2
3T/C3T/C(H)No gear Zone III & 13.0-18.0 Zone III & 13.0-18.0 2
speed change
3T/C3T/C(M) No Zone III & 13.0-16.5 Zone III & 13.0-16.5 2
gear speed change
3T/C3T/C(L) No gear Zone III & 13.0-15.0 Zone III & 13.0-15.0 2
speed change
3L/U3T/C(L&M&H) Zone III Zone III 2
3 3T/C3T/C(L&M&H) No
gear speed change Zone III Zone III 2
WA380-5 10-265
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
10-266 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
4) Output conditions for the buzzer, indicator (main monitor) and indicator built in the Transmission
cutoff switch
Indicator built in the Trans-
Output condition Buzzer sound Cutoff point
mission cutoff switch
Control is done based on
When Transmission cutoff Comes on Not available the value stored in previous
switch is ON operation
Setup complete buzzer is
While Transmission cutoff Pressure at your releasing
Flashes sounded as the set switch is
point is being set the set switch is stored
released
When Transmission cutoff No control is provided.
switch is ON but error is Goes off Not available Stored value is not changed.
present on sensor
Control is done based on
When Transmission cutoff the value stored in previous
switch is ON but error is Goes off Not available operation.
present on set switch Stored value is not changed.
A separation of 0.20MPa (2kg/cm²) is provided between the cutoff IN pressure (causing Transmis-
sion to neutral) and OUT (reset) pressure.
Example: When 0.98MPa (10kg/cm²) is set on the pressure sensor
Cutoff IN pressure = 0.98MPa (10kg/cm²)
Cutoff OUT pressure = 0.78MPa (8kg/cm²)
WA380-5 10-267
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
System Diagram
10-268 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA380-5 10-269
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
5. Gear Speed Change Function available from Joystick Steering (If equipped)
Forward-reverse travel of the travel system as well as gear speed change operation is available from
the transmission controller-controlled joystick function.
As long as the joystick function is turned on, travel at the 4th speed is prohibited in order to ensure
driver safety.
Steering on both sides is done from the joystick work equipment controller.
System Diagram
10-270 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA380-5 10-271
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
When it is fixed at N,
switching becomes When the lever is
Switching available from the joy- positioned at the
between for-
ward and stick. maximum gear speed
Manual shift Shift up Shift down At any other positions, (limiter), selection is
reverse is avail- precedence is given to available only in the
able from the
switch the lever, though accom- range of 1st to 3rd
panied by an error warn- speeds.
When joy- ing.
stick is
selected When it is fixed at N,
switching becomes When the lever is
Switching available from the joy- positioned at the
between for-
Auto-shift ward and stick. maximum gear speed
Disabled Disabled At any other positions, (limiter), selection is
(L,M,H) reverse is avail- precedence is given to available only in the
able from the
switch the lever, though accom- range of 1st to 3rd
panied by an error warn- speeds.
ing.
Normal opera-
tion is available
when fixed to Switching between for- Switching between
forward and reverse
Manual shift N. An error will Disabled Disabled ward and reverse is is available from the
be warned at available from the lever.
any position lever.
When steer- other than N.
ing column is
selected Normal opera-
tion is available
when fixed to Switching between for-
Auto-shift N. An error will ward and reverse is Maximum gear speed
(L,M,H) Disabled Disabled (limiter)
be warned at available from the lever.
any position
other than N.
10-272 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA380-5 10-273
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
10-274 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
The emergency steering ON signal at the self-check is output for 3 seconds maximum. If the moni-
tor detects presence of the emergency steering operating pressure within 3 seconds, the monitor
sends the emergency steering operation detection signal to the network. Upon output of this sig-
nal, the transmission controller ends the self-check of the emergency steering.
If the above signal is not sent within 3 seconds, the controller warns an error.
WA380-5 10-275
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
Engine coolant temperature, operating oil temperature and oil temperature of the torque converter
detected by the machine monitor are sent to the transmission controller via the network. Upon
receiving above information, the transmission controller turns on a fan revolution suitable to the
temperature and engine speed by controlling the swash plate of the hydraulic pump by use of elec-
tric current.
10-276 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
ON ONOFF ON * ONBlinking
*: Output from the fan pump EPC while the fan is in reverse rotation
Engine speed Less than 1,500 rpm 1,500 rpm or above
EPC control MIN rotation MAX rotation
WA380-5 10-277
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
The switch pump cutoff signal is output when digging operation is turned on from the kick down
switch.
10-278 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
3) Protect alarm cancel condition: In any of the following cases, output of the protect alarm is stopped
and normal control is restored.
1 When matching is established between the input instruction and output instruction from the
gearshift lever (shift switch).
2 When a shift above the one specified with the output instruction is selected from the gearshift
lever (shift switch).
4) Operations restricted while the shift down protect is turned on: As long as the protect is turned on,
hold and kick down operations are disabled.
Transmission output shaft speed and travel speed Protection travel speed (km/h)
WA380-5 (small diameter tire) WA380-5 (large diameter tire)
2,658 30.3 33.2
Transmission output
shaft speed converted 1,846 21.1 23.0
to travel speed (rpm)
1,107 12.6 13.8
11. Troubleshooting
The transmission controller self diagnoses the system by monitoring the input/output signals con-
stantly.
If any errors are found in the self-diagnosis, the controller sends the error information to the machine
monitor via the network. The machine monitor allows you to check the errors.
WA380-5 10-279
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA380-5
10-279-1 WA380-5
1
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA380-5 10-279-2
1
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
5) Kickdown function
1] Kickdown during manual shift
The kickdown switch can be operated only at the forward 2nd-speed (F2). Operation of the kick-
down switch is ignored at other than forward 2nd-speed.
When the directional lever (or FNR switch) is shifted to other than F or the directional lever (or FNR
switch) is shifted to R, the gear speed is changed to 2nd-speed.
When the gear shift lever is changed to other than 2nd-speed, the speed is changed to the range
corresponding to the lever position.
2] Kickdown during auto-shift
The kickdown switch functions regardless of the directional and gear shift lever positions.
The gear speed shifted by the kickdown switch operation changes according to the travel speed as
shown in the following table.
After shifting by kickdown, shift the speed according to the list of normal auto-shift points after the
expiration of the time that the speed cannot be shifted or when the directional lever is operated.
Speed range after shift- Time that speed cannot
Speed range Travel speed ing be shifted
2nd-speed Whole range 1st-speed 5 seconds
Less than 12.5 km/h 1st-speed 5 seconds
3rd-speed Less than 12.5 - 25 km/h 2nd-speed 4 seconds
25 km/h or higher No shifting (3-speed) —
Less than 12.5 km/h 1st-speed 5 seconds
4th-speed Less than 12.5 - 35 km/h 3rd-speed 4 seconds
35 km/h or higher No shifting (4-speed) —
Less than 12.5 km/h 1st-speed 5 seconds
3rd-speed (at lockup)
12.5 km/h or higher 3rd-speed (lockup released) *1
Less than 12.5 km/h 1st-speed 5 seconds
4th-speed (at lockup)
12.5 km/h or higher 4th-speed (lockup released) *1
*1: When the lockup is released by kickdown switch operation, lockup must not be applied again until the following conditions
occur:
● Change the torque converter lockup switch from OFF to ON temporarily.
● The travel speed less than that with the lockup ON in the list of the auto shift points changes to the speed exceeding it.
10-279-3 WA380-5
1
(10)
STRUCTURE AND FUNCTION TRANSMISSION CONTROL SYSTEM
At a low temperature, the oil viscosity is high and the pump load torque increases against the engine
starting torque and the engine start ability becomes poor. As for the corrective action, when starting
the engine at a low temperature, bypass oil inside the pump to reduce load to the pump, so that the
engine start ability will improve.
The bypass solenoid operation signal outputting conditions are shown in the table below. When Con-
ditions 1 to 4 are all satisfied, the bypass solenoid operation signal is output.
Condition 1 Starting Signal C is switched on or 10 seconds after the signal is switched on to off.
Condition 2 Engine coolant temperature: Less than -15°C.
Condition 3 Engine speed condition A (for prevention of hunting)).
Solenoid energizing time: Less than 30 seconds (total operating time after the starting switch is set to
Condition 4 "ON")
WA380-5 10-279-4
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
TRANSMISSION CONTROLSYSTEM
Electric Circuit Diagram (Standard)
WA380-5
10-280 WA380-5
(10)
1
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
WA380-5 10-281
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
10-282 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
WA380-5 10-283
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
10-284 WA380-5
1
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLLER
DEUTSCH-40P(1) [CN-L62]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 NC Output 21 S_NET Input/Output
2 ECMV fill switch lock-up Input 22 CAN0_L Input/Output
3 ECMV fill switch 4th Input 23 CAN1_L Input/Output
4 232C_RxD Input 24 Write-to-flash-memory enable signal Input
5 Right FNR (Joystick) forward-reverse R Input 25 Right FNR (Joystick) forward-reverse F Input
6 Neutralizer (Parking brake) signal Input 26 Forward-reverse lever N Input
7 ECMV fill switch 2nd Input 27 ECMV fill switch R Input
8 NC Output 28 NC Input
9 Engine speed pulse unlatched output Output 29 Pulse GND —
10 Engine speed signal (+) Input 30 NC Input
11 NC Output 31 S_NET GND —
12 CAN shield — 32 CAN0_H Input/Output
13 ECMV fill switch 3rd Input 33 CAN1_H Input/Output
14 232_TxD Output 34 RS232C GND —
15 Right FNR (Joystick) forward-reverse N Input 35 Right FNR (Joystick) switch Input
16 Forward-reverse lever R Input 36 Forward-reverse lever F Input
17 ECMV fill switch 1st Input 37 ECMV fill switch F Input
18 NC Output 38 Shift hold switch Input
19 Travel speed pulse unlatched output Output 39 Pulse GND —
20 Travel speed signal (+) Input 40 NC Input
DEUTSCH-40P(2) [CN-L63]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 VB (controller power) Input 21 GND (controller ground) Input
2 VIS (solenoid power) Input 22 VIS (solenoid power) Input
3 SOL_COM (common solenoid ground) Input 23 SOL_COM (common solenoid ground) Input
4 Back lamp relay Output 24 Key switch signal Input
5 ECMV F Output 25 ECMV 1st Output
6 ECMV 2nd Output 26 ECMV 4th Output
7 Electric emergency steering relay Output 27 Switch pump cutoff relay Output
8 Indicator built in Transmission cutoff Output 28 Reverse fan pump rotation solenoid Output
9 Joystick shift up switch Input 29 Electric emergency steering operation switch Input
10 Gearshift lever 1st speed Input 30 Gearshift lever 3rd speed Input
11 VB (controller power) Input 31 GND (controller ground) Input
12 VIS (solenoid power) Input 32 GND (controller ground) Input
13 SOL_COM (common solenoid ground) Input 33 GND (controller ground) Input
14 Key switch signal Input 34 NC —
15 ECMV R Output 35 ECMV lock-up Output
16 ECMV 3rd Output 36 Fan pump EPC Output
17 E.C.S.S. Output 37 Neutral output Output
18 Low temperature bypass relay Output 38 Fan pump neutral solenoid Output
19 Joystick shift down switch Input 39 Starter switch C-terminal Input
20 Gearshift lever 2nd speed Input 40 Gearshift lever 4th speed Input
WA380-5 10-285
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
10-286 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
WA380-5 10-287
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
Function table
Operator’s Controller Controller Movement at
action input output machine
Work equip-
Work equip- Work equipment
ment lever Hydraulic power
ment lever Neutral lock valve
switch
Raise ON OFF Active
(FREE) (CLOSE) (OPEN)
Lower OFF ON Inactive
(LOCK) (OPEN) (24V)
10-288 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
2) Detent control
Boom kick-out control
• Operating the lift arm lever to reach the RAISE detent range allows a detent-on signal to be output
from the work equipment controller.
This enables the lift arm lever to be maintained in the RAISE state even when the lever is released.
When the lift arm is raised and an input signal of the lift arm angle sensor approaches the top angle,
detent is cancelled and the lift arm stops rising. At this same time, the work equipment controller
gradually slows down the lift arm RAISE EPC (referred to as modulation control) to prevent exces-
sive impact from arising upon stoppage of the lift arm motion.
Detent can be cancelled (manually) by operating the work equipment lever toward the neutral posi-
tion side, in which case, EPC performs ordinary control according to how much the lever was
moved.
WA380-5 10-289
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
10-290 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
Functions
The remote positioner stops after slowing down at the lift arm RAISE/LOWER position.
The work equipment controller constantly detects the lift arm angle (position) based upon the direction
in which the lever is operated and data from the arm angle potentiometer.
• To stop the lift arm RAISE operation (when the RAISE selection switch is turned on)
Operating the lift arm lever to enter RAISE detent and allowing the lift arm to be raised before the
set position cancels lift arm RAISE detent, which starts modulation control for stopping the lift arm.
The lift arm can be manually raised in all cases except for the RAISE detent position.
If RAISE is not selected (when the selection switch is turned off), only kick-out is enabled.
• To stop lift arm LOWER operation (when the LOWER selection switch is turned on)
Place the lift arm lever at the "FLOAT detent" position. The lift arm starts slowing down at 10
degrees before the set position, and FLOAT detent is canceled 4 degrees before the set position to
perform modulation control for stopping the lift arm.
Retain the lift arm lever at that position to restart lowering it.
If LOWER is not selected (when the LOWER selection switch is turned off), only FLOAT detent is
enabled.
If the lift arm angle is above the horizontal position when the lever is placed in the detent position,
only FLOAT detent is enabled.
Selection mode
RAISE and
RAISE stop LOWER stop LOWER stop
Selection switch
RAISE selection switch ON(●) OFF({) ON(●)
LOWER selection switch OFF({) ON(●) ON(●)
Indicator output
Lamp on (Switch ON) : ●
Lamp off (Switch OFF) : {
Stop position
For RAISE For LOWER
Model
WA380 0° - +45.8° 0° - -40.8°
0°: Horizontal lift arm position
WA380-5 10-291
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
Control items
RAISE position setting
1 Remote positioner RAISE stop control RAISE lift arm stop (selection switch = on)
RAISE selection switch = On (remote positioner RAISE stop enabled)
Enabled if: Work equipment lever (lift arm) stroke = Neutral (within ±10%)
1)Raise the lift arm to the position to be set.
2)Press the remote positioner RAISE position setting switch and
release it.
3) If the setting position where the switch was released is within the
applicable range, the angle attained when the switch was released
Setting procedure is tentatively saved, and the setting completion buzzer beeps twice.
Otherwise, the setting cancellation buzzer beeps.
Setting of remote 4)The RAISE indicator blinks (for 2.5 seconds).
2 positioner RAISE
stop angle point 5)The setting is saved after the indicator blinks for 2.5 seconds (the
setting mode completed). (The set status is maintained even after
the equipment is keyed off.)
1)During the 2.5-second interval in setting step 4 above (while the
RAISE indicator is blinking), press the remote positioner RAISE
position setting switch again, and release it.
Resetting procedure 2)As the indicator stops blinking, set the RAISE stop position point to
"0°" (horizontal). The setting cancellation buzzer beeps.
3)The set value is saved (as the default value). (The set status is main-
tained even after the equipment is keyed off.)
10-292 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
1 Remote positioner LOWER stop control LOWER lift arm stop (selection switch = ON)
LOWER selection switch = ON
Enabled if: (remote positioner LOWER stop enabled)
Work equipment lever (lift arm) stroke = Neutral (within ±10%)
1. Lower the lift arm to the position to be set.
2. Press the remote positioner LOWER position setting switch and
release it.
3. If the setting position where the switch was released is within the
Setting procedure applicable range, the angle attained when the switch was released
Setting of remote is tentatively saved, and the setting completion buzzer beeps twice.
2 positioner LOWER Otherwise, the setting cancellation buzzer beeps.
stop angle point 4. The LOWER indicator blinks (for 2.5 seconds).
5. The setting is saved after the indicator blink
1. During the 2.5-second interval in setting step 4 above (while the
LOWER indicator is blinking), press the remote positioner LOWER
position setting switch again, and release it.
Resetting procedure 2. As the indicator stops blinking, set the LOWER stop position point
to "0°" (horizontal). The setting cancellation buzzer beeps.
3. The set value is saved (as the default value). (The set status is
maintained even after the equipment is keyed off.)
Indicator
Output condition Buzzer output Stop position
lamp
Controlled with the
Remote positioner selection switch = On Comes on None value saved previously
Controlled with the
Remote positioner selection switch = On; Blinks Setting completion value saved previously.
Position setting switch = On. (for 2.5 sec- buzzer beeps upon Value attained when set-
Output for 2.5 seconds or until reset onds or until releasing setting switch ting switch was released
(When the sensor is operating normally) reset) is saved.
Controlled with the
Remote positioner selection switch = On; Setting cancellation value saved previously.
Position setting switch = ON; Comes on. buzzer beeps upon The value stored is not
Lift arm angle = Outside the setting range. releasing setting switch. altered.
Not controlled.
Remote positioner selection switch = On; Goes off. None The value stored is not
When the sensor is not operating normally. altered.
Controlled with the
Remote positioner selection switch = On; value saved previously.
Comes on. None
When the sensor is not operating normally. The value stored is not
altered.
Remote positioner selection switch = On; Controlled with the
Setting cancellation
Position setting switch = On. value saved previously.
Comes on. buzzer beeps upon
Reset during 2.5-second blinking The default value is
releasing setting switch.
(Position setting switch = On again) saved.
Not controlled.
Remote positioner selection switch = Off Goes off. None RAISE/FLOAT détente is
controlled.
WA380-5 10-293
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
10-294 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
2] When the lift arm lever was placed in the detent position after semi-auto digging had started:
• AUTO-TILT does not start if the lift arm RAISE speed does not drop due to failure of loading
into the bucket (after the lift arm continued to be raised at 1 deg/sec for 0.5 seconds).
• AUTO-TILT starts when the bucket stops being raised (after being raised at 1 deg/sec for 0.5
seconds).
WA380-5 10-295
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
10-296 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
1) Steering control
Steering control with the joystick provides an articulation speed according to how the joystick lever
is moved.
A more fine steering range is provided for the "Lo" mode then the "Hi" mode for the joystick.
2) Modulation control
Steering with the joystick applies modulation control in order to reduce impact that may be experi-
enced when operation is started or finished.
A greater degree of modulation control is provided for the "Lo" for more impact reduction.
This modulation control enables steering of the machine even during traveling at a high speed, as it
improves response of the machine toward lever operation according to the travel speed.
WA380-5 10-297
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
5. Calibration function
1) EPC calibration
This is an adjusting function to reduce variances of the starting points of the lift arm, bucket and
joystick due to cumulative errors with the electric lever, EPC valve and main valve.
2) Sensor adjustment
This function provides offset adjustment for errors due to installation of the lift arm angle potenti-
ometer to enable the position data of the work equipment to be correctly detected.
3) Calibrating method
Calibration is performed in the service mode on the monitor panel. See the "Equipment Monitoring"
section for details.
6. Troubleshooting
The work equipment controller constantly monitors the I/O signal status and provides a self-diagnosis
function for the system. If any abnormalities are detected through self-diagnosis, it outputs fault infor-
mation via the equipment-monitoring network. In case of faulty occurrences, you can check the status
with the equipment-monitoring function.
10-298 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
10-300 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
WA380-5 10-301
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROLLER (IF EQUIPPED)
10-302 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROLLER (IF EQUIPPED)
DEUTSCH-40P(1) [CN-L72]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 NC Output 21 S_NET Input/Output
2 Remote positioner lifting select switch Input 22 CAN0_L Input/Output
3 Remote positioner lowering select switch Input 23 CAN1_L Input/Output
4 232C_RxD Input 24 Flash memory write enable signal Input
5 NC Input 25 NC Input
6 NC Input 26 NC Input
7 NC Input 27 NC Input
8 NC Output 28 NC Input
9 NC Output 29 Pulse GND —
10 Engine rev. signal Input 30 NC Input
11 NC Output 31 S_NET GND —
12 CAN shield — 32 CAN0_H Input/Output
13 Remote positioner lifting set switch Input 33 CAN1_H Input/Output
14 232_TxD Output 34 RS232C GND —
15 NC Input 35 NC Input
16 NC Input 36 NC Input
17 NC Input 37 NC Input
18 NC Output 38 Remote positioner lowering select switch Input
19 NC Output 39 Pulse GND —
20 Vehicle speed signal Input 40 NC Input
DEUTSCH-40P(2) [CN-L73]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 Controller power Input 21 GND (controller ground) Input
2 Solenoid power Input 22 Solenoid power Input
3 SOL_COM (common solenoid ground) Input 23 SOL_COM (common solenoid ground) Input
4 NC Output 24 KEY_SIG Input
5 Bucket tilting EPC Output 25 Third EXT EPC Output
6 Lift arm lifting EPC Output 26 Joystick right EPC Output
7 Joystick EPC cut-off relay Output 27 Lift arm lever manual detention of float Output
8 Remote positioner lifting indicator Output 28 Bucket and lift arm neutral lock solenoid Output
9 Semiautomatic loading hard mode switch Input 29 NC Input
10 Joystick speed select switch Input 30 Bucket cylinder tilt switch Input
11 VB (controller power) Input 31 GND (controller ground) Input
12 VIS (solenoid power) Input 32 GND (controller ground) Input
13 SOL_COM (common solenoid ground) Input 33 GND (controller ground) Input
14 KEY_SIG Input 34 Reserve —
15 Bucket dumping EPC Output 35 Third RET EPC Output
16 Lift arm lowering EPC Output 36 Joystick left EPC Output
17 Lift arm lever automatic detection of lifting Output 37 Magnetic detention of bucket lever tilt pos Output
18 Remote positioner lowering indicator Output 38 NC Output
19 Semiautomatic loading soft mode switch Input 39 NC Input
20 Bucket cylinder horizontal switch Input 40 NC Input
WA380-5 10-303
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
10-304 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
Functions
1 Selection of forward, reverse or N (neutral) It is performed from the forward-reverse lever
2 Selection of gear speed It is done from the gearshift lever
Shift down is available from this switch, too, without resorting to
the gearshift lever. In the manual shift mode, forward move at
3 Kick down switch the 2nd speed alone can be shifted down to the 1st speed. When
the auto-shift mode is selected, shift down is carried out accord-
ing to the gear speed and travel speed being selected prior to
operation of this is operated.
When the auto-shift is selected, this switch maintains the gear
4 Hold switch speed of the time when the switch is depressed without allowing
shift up accompanying increased travel speed.
5 Transmission cutoff function You can cause the transmission to neutral by turning on the
transmission cutoff switch and depressing the left brake pedal.
6 Transmission cutoff position adjusting You can specify any pedal depression depth for turning on the
function transmission cutoff function.
It allows you to enable or disable the transmission cutoff func-
7 Transmission cutoff switching function tion. When the function is disabled, the left brake pedal offers
the same braking function as that of the right brake pedal.
It shifts the transmission to neutral as long as the parking brake
8 Neutralizer is in operation. It prevents seizure of the parking brake that can
result from travelling while the parking brake is in operation.
This function disables startup of the engine from the starter
9 Neutral safety function switch when the forward-reverse lever is not at N (neutral). This
function is provided to prevent accidents due to unexpected
starting of the machine.
10 Alarm function As the reverse travel is started, this function turns on the back
lamp and back horn buzzer to alert nearby people.
WA380-5 10-305
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
COMBINATION SWITCH
Overview
• The forward-reverse lever and the gearshift lever switch have 3 positions and 4 positions, respectively.
Independent switches do not have the detent mechanism. This mechanism is provided on the combi-
nation switch body. Each switch is positioned with two pins and then fixed to the combination switch
with three screws. Moving a lever to a desired position turns on the corresponding switch connected
via the shaft to conduct current to the designated circuit.
Functions
1 Forward-reverse lever switch Used for switching between for forward, reverse and neutral.
2 Gearshift lever switch Used for switching gear speed.
3 Gearshift lever stopper Used for preventing the gearshift lever get into the 3rd or 4th
speed.
4 Turn signal It is a signal to be turned ON at right or left turn.
5 Self-cancel This function returns the turn signal lever to neutral position
after right or left turn is complete.
6 Lamp switch Used to turn ON the tail lamp, front lamp or parking lamp.
7 Dimmer switch Used to turn ON the travel or low beam.
8 Hazard switch Used to turn ON blinking of the right and left turn signals at the
same time.
9 Emergency blinking pilot lamp It starts blinking with emergency blinking lamp.
10 Parking brake switch Used to turn ON (activation) or OFF (deactivation) the parking
brake.
10-306 WA380-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
Operation
• The forward-reverse lever (1) and the gearshift
lever shaft (2) on the combination switch are
united with the magnet (3). Thus, as the lever
(1) is moved, the magnet (3) is moved, too.
• The control switch (5) with the built-in hall IC (4)
is attached under the magnet (3). A hall IC (4) is
provided on the board for respective positions.
• If you set the forward-reverse lever (1) at F posi-
tion, the magnet comes right above the hall IC
(4) of the control switch at F position. Thus,
magnetism of the magnet (3) is irradiated to the
hall IC (4) through the clearance and case (6).
• Since the hall IC (4) is inside the magnetism
detection circuit, the circuit detects magnetism
from the magnet (3) and then sends the F posi-
tion signal to the current amplifier circuit.
Receiving this signal, the current amplifier cir-
cuit outputs the signal to operate the transmis-
sion.
WA380-5 10-307
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD KICK DOWN, HOLD SWITCH
Functions
• Being installed on the lift arm-operating lever,
switch A (1) and switch B (4) function as the kick
down switch and hold switch, respectively.
• When the load meter (optional) is provided,
switch A and switch B are installed on the
bucket-operating lever. In this case, switch A
and B function as the cancel switch and sub-
total switch, respectively.
• Contact of both switches A and B resets auto-
matically, namely it is closed only when the
switches are depressed.
10-308 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
Function
Adoption of the neutral safety circuit assured safety
when starting the engine.
• The engine cannot start except when the
forward-reverse lever is in the N (neutral)
position.
• When the right FNR selector switch (If
equipped) is in the ON position, the engine
cannot start except when the right FNR
switch (If equipped) is in the N (neutral)
position.
• When the joystick steering (If equipped) is
in the ON position, the engine cannot start
except when the FNR switch of Joystick
lever is in the N (neutral) position and also
the Joystick lever is in the N (neutral) posi-
tion.
WA380-5 10-309
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
Operation
1. When the starting switch is in the [ON] position • When the Joystick steering (If equipped) is
• If you place the starting switch in the [ON] used, lower the Joystick arm rest and place
position, the terminals B and BR of starting the Joystick selector switch in the ON posi-
switch close. Current flows from the bat- tion. Then, current flows from the Joystick
tery, and goes through the starting switch selector switch to the exchange relay coil to
and battery relay coil to grounding, closing operate the relay. If the FNR switch of the
the battery relay contacts. By this opera- Joystick lever is in the N (neutral) position
tion, every circuit of the machine is pow- and the Joystick lever is in the N (neutral)
ered. position, the Transmission controller out-
At this time, the current from ACC terminal puts current to the exchange relay. It goes
of starting switch flows to timer relay, then through the exchanger relay to the neutral
contacts close for 3 seconds, then current safety relay coil, consequently making the
flows to the pull side coil of fuel cut sole- current flow between the terminals 3 and 5
noid. The current from ACC terminal of of the neutral safety relay.
starting switch also flows to hold side coil (When the Joystick steering is mounted, the
of fuel cut solenoid. So, by hold side coil Joystick flip switch and Joystick selector
after pull side coil is magnetized, fuel can switch are mounted instead of the right FNR
be supplied to engine. Provision of starting selector switch in the figure above, and the
engine is completed. Joystick lever FNR switch is mounted
instead of right FNR switch.)
2. Neutral safety circuit
• If you place the forward-reverse lever at the 3. When the starting switch is in the [Start] posi-
N (neutral) position, and then, current flows tion
from the N contact of forward-reverse lever • If you place the starting switch in the [Start]
and goes through the exchange relay to the position, and then, current goes from the
neutral safety relay coil. As a result, the terminal B of starting switch, terminal C,
current is carried between the terminals 3 terminal 3 of neutral safety relay, and termi-
and 5 of neutral safety relay. nal 5 to the starter, starting the engine.
• When the right FNR switch (If equipped) is • Except when the forward-reverse lever is in
used (when the right FNR selector switch is the N (neutral) position, the right FNR
in the ON position), current flows from the switch is the N (neutral) position (when the
right FNR selector switch to the exchange right FNR switch is used), or the Joystick
relay coil to operate the relay. If the right lever FNR switch is in the N (neutral) posi-
FNR switch is in the N (neutral) position at tion and also the Joystick lever is in the N
that time, the Transmission controller out- (neutral) position, the neutral safety relay,
puts current to the exchange relay. It flows not allowing the engine to start.
from the Transmission controller to the
exchange relay and finally it reaches the
neutral safety relay coil. As a result, the
current is carried between the terminals 3
and 5 of neutral safety relay.
10-310 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE STOP CIRCUIT
Operation
• The current from ACC terminal of starting
switch to hold side coil of fuel cut solenoid is
cutoff when starting is turned (OFF). Fuel sup-
ply to engine is shut off.
When the fuel supply is stopped, the engine
reduces its speed and stops. Then, the power
generation of the alternator stops to shut off
voltage supply from the terminal R of the alter-
nator. In addition, the current from the terminal
BR of starting switch is shut off. Consequently,
the battery relay contact opens to shut down
the power supplied to every circuit of the
machine.
WA380-5 10-311
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PREHEATING CIRCUIT
PREHEATING CIRCUIT
Outline Operation
• The automatic preheating system and manual • When the starting switch is turned to the ON
preheating system are installed so that the position, the machine monitor starts. If the
engine will start easily in a cold district. coolant temperature is 0 - 7 °C or below 0 °C at
• The automatic preheating system shortens the this time, the machine monitor connects the
preheating time and sets the preheating time preheater relay coil to the ground 6 seconds or
automatically according to the engine coolant immediately after the starting switch is turned
temperature when the starting switch is turned to the ON position. Then, the preheater relay
to the ON position. operates to operate the heater relay, thus the
• If the starting switch is turned to the ON posi- ribbon heater preheats the engine.
tion, the preheater pilot lamp of the machine • The preheating time is shown below.
monitor lights up and the ribbon heater pre-
heats the intake air.
The controller built in the machine monitor sets
the preheating time according to the coolant
temperature measured by the coolant tempera-
ture sensor.
• While the engine is preheated, the preheating
pilot lamp of the main monitor keeps lighting
up. Keep the starting switch in the ON position
during this period. If the starting switch is
turned to the START position, preheating is
reset.
• With the manual preheating system, the opera-
tor can adjust the preheating time manually,
regardless of the coolant temperature, by turn-
ing the starting switch to the HEAT position.
• If the starting switch is turned to the HEAT posi-
tion, the preheater pilot lamp of the machine
monitor lights up and the ribbon heater pre-
heats the intake air. The operator can set the
preheating time manually, regardless of the
coolant temperature.
10-312 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE POWER MODE SELECTOR CIRCUIT
Function
• When the power mode selector switch is set to The accelerator pedal hi-idle stopper motor
"POWER", the stroke restriction of the accelera- cable extends completely under the state, and
tor pedal will be released and the engine power the stopper limiting the stroke of the accelera-
will be controlled. Also, when the switch is set tor pedal is released. Then, the power mode is
to "NORMAL", the stroke of the accelerator selected.
pedal will be limited and the work fuel con-
• When the power mode selector switch is set to
sumption will be reduced.
"NORMAL", the relay coil will be demagnetized.
• Switching signals are input into the transmis-
• The current from the fuse flows to the accelera-
sion controller, and gear speed and travel
tor pedal hi-idle stopper motor terminals A-C,
speed suitable for the power mode are selected
to the engine power mode relay terminals 6-3
at the time of automatic shifting.
and to the motor to rotate the motor. (The cable
will contract.)
Operation • When the motor rotates, the Terminal D will
• When the power mode selector switch is set to rotate at the same time. When the non-continue
"POWER", current will flow from the fuse to the portion of the Terminal D comes to the Terminal
engine power mode relay, to the power mode C, the circuit from the Terminal A to Terminal C
selector switch and to the ground and will ener- will open and the current from the fuse to the
gize the relay coil. motor will be interrupted. Though the motor
• The current from the fuse flows to the accelera- tries to continue rotating by inertia, both poles
tor pedal hi-idle stopper motor terminals A-B, of the motor will be short-circuited with the
to the engine power mode relay terminals 5-3 ground and the motor will stop rotating when
and to the motor to rotate the motor. (The cable the continue portion of the Terminal D touches
will expand.) the Terminal C.
The accelerator pedal hi-idle stopper motor
• When the motor rotates, the terminal D will
cable contracts completely under the state, and
rotate at the same time. When the non-continue
the stopper limits the stroke of the accelerator
portion of the Terminal D comes to the Terminal
pedal.
B, the circuit from the Terminal A to Terminal B
will open and the current from the fuse to the
motor will be interrupted. Though the motor
tries to continue rotating by inertia, both poles
of the motor will be short-circuited with the
ground and the motor will stop rotating when
the continue portion of the Terminal D touches
the Terminal B
WA380-5 10-313
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
Operation
10-314 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
WA380-5 10-315
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
2) When the parking brake is in the OFF (release) position before placing the starting switch in the ON
position
10-316 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
3. When the main brake oil pressure lowers (emergency brake operates)
WA380-5 10-317
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
SENSORS
ENGINE SPEED SENSOR
SPEED SENSOR
1. Coil 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
10-318 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
• This sensor is mounted to the engine block.
The diaphragm detects oil pressure, and when
it reaches below the specified value, the switch
is turned ON.
1. Connector 3. Float
2. Bracket 4. Switch
Function
• This sensor is mounted to the side surface of
the oil pan. The float lowers when the oil level
reaches below the specified level, turning OFF
the switch.
WA380-5 10-319
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
10-320 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Sensor
2. Lead
3. Connector
Function
WA380-5 10-321
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
10-322 WA380-5
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
WA380-5 10-323
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Shaft 4. Rotor
2. Housing 5. Connector
3. Bearing
Function
10-324 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
WA380-5 10-325
(8)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Sensor 3. Connector
2. Lead
Function
10-326 WA380-5
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
WA380-5 10-327
(10)
20 TESTING AND ADJUSTING
★ Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the
machine from the factory and is given for reference. It is used as a guideline for judging the progress
of wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground, insert the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not
let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the radia-
tor cap is removed when the water is still hot, the water will spurt out and cause
burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
WA380-5 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
20-2 WA380-5
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Category Item Measurement Condi- Unit Standard Value For New Service Limit Value
tions Machine
N - FOR-
Operating effort WARD, • Engine Stopped N {kg} 5.9 +4.9
-3.0 {0.6 +0.5
-0.3 } Max. 16.7 {1.7}
Direc- REVERSE
• Measure at center
tional lever N - FOR- of lever knob
Travel WARD, mm 35 ± 10 35 ± 20
REVERSE
1st - 2nd • Engine stopped 5.9 +4.9
-3.0 {0.6 +0.5
-0.3 } Max. 16.7 {1.7}
Operating effort 2nd - 3rd • Measure at center N {kg} 5.9 +4.9
{0.6 +0.5 } Max. 16.7 {1.7}
-3.0 -0.3
of lever knob
Speed 3rd - 4th 5.9 +4.9
-3.0 {0.6 +0.5
-0.3 } Max. 16.7 {1.7}
lever 1st - 2nd 35 ± 10 35 ± 20
Travel 2nd - 3rd mm 35 ± 10 35 ± 20
3rd - 4th 35 ± 10 35 ± 20
HOLD → RAISE • Engine speed: Low Max. 12.8 {1.3} * Max. 19.6 {2.0} *
idle
RAISE → HOLD • Hydraulic oil tem- Max. 14.7 {1.5} Max. 22.6 {2.3}
perature:
HOLD → LOWER 45 - 55 °C Max. 12.8 {1.3} * Max. 19.6 {2.0} *
Lift arm
LOWER → HOLD — —
Operating
effort LOWER → FLOAT N {kg} Max. 15.7 {1.6} Max. 23.5 {2.4}
• Flat, horizontal,
straight, dry paved
road surface 6.9 - 12.6
Operating effort • Engine speed: Low N {kg} {0.7 - 1.3} Max. 19.6 {2.0}
idling (Bucket
Steering empty)
wheel
• Engine speed: High
Turning speed (Not including idling Turns 4.0 ± 0.4 4.0 ± 0.4
play)
• Left lock - right lock
WA380-5 20-3
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Brake
pedal
BWW10090
Play mm 5 ± 0.5 —
Tire mm
Clearance of wheel TEW00003
lock ring C 2 - 10 —
20-4 WA380-5
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Low idle • Torque converter oil tempera- 2.74 ± 0.2 2.74 ± 0.2
Main relief ture: 60 - 80 °C {27.9 ± 2} {27.9 ± 2}
valve Rated • Engine: Rated speed 2.86 ± 0.20 2.86 ± 0.20
speed {29.2 ± 2.0} {29.2 ± 2.0}
Torque converter relief Max. 0.88 Max. 0.88
(Inlet port) pressure {Max. 9.0} {Max. 9.0}
Transmis-
sion, torque Torque converter outlet MPa 0.44 ± 0.05 0.44 ± 0.05
port oil pressure {kg/cm2} {4.5 ± 0.5} {4.5 ± 0.5}
converter
1st, 2nd, • Torque converter oil tempera- 2.11 ± 0.15 2.11 ± 0.15
3rd, 4th ture: 60 - 80 °C {21.5 ± 1.5} {21.5 ± 1.5}
ECMV out- Engine: Rated speed
• 1.91 ± 0.15 1.91 ± 0.15
put (Clutch) F - R {19.5 ± 1.5} {19.5 ± 1.5}
oil pressure • Manual switch ON
WA380-5 20-5
(9)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
• Engine stopped
MPa
• Keep brake pedal depressed at {kg/cm2}
Drop in
brake pres- 4.9 MPa {50 kg/cm2} and mea- Max. 98 {1.0} Max. 98 {1.0}
sure sure drop in oil pressure after 5
min.
20-6 WA380-5
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Parking
brake
Performance — Holds in position Holds in position
TEW01360
WA380-5 20-7
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Work equipment relief • Hydraulic oil temperature: 45 - 55 °C MPa 20.6 ± 0.49 +0.49 +5
20.6 -1.27 {210 -13 }
pressure • Run engine at high idling. {kg/cm2} {210 ± 5}
Lowering time
N mode 2.8 ± 0.5 Max. 4.0
Bucket full
stroke To stroke end
N mode 2.2 ± 0.3 Max. 3.0
Backward
From level position P mode 1.9 ± 0.3 Max. 2.6
mm
Retraction of bucket
Max. 36 Max. 43
cylinder rod
20-8 WA380-5
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
WA380-5 20-9
(10)
TESTING AND ADJUSTING
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unautho-
rized 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.
WA380-5 20-101
(10)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Water temperature,
oil temperature, B 799-101-1502 Digital thermometer 1 –99.9 - 1,299 °C
exhaust temperature
WA380-5 20-101-2
(10)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
WARNING! Put blocks under the tires. 2. Measuring torque converter stall speed.
1) Switch to the monitoring function of Ser-
vice Mode 1 and use the 2-item simulta-
WARNING! Before starting measure- neous monitoring function to display the
ment, check that there is no one in the following 2 items. For details, see SPE-
surrounding area. CIAL FUNCTIONS OF MACHINE MONI-
TOR in the TROUBLESHOOTING section.
★ Monitoring items
★ Measure the engine speed under the follow- 1 Code No. 01001: Engine speed
2 Code No. 40100: Torque converter oil
ing conditions.
temperature
• Coolant temperature: Within operating
range
• Hydraulic temperature: 45 - 55 °C
• Torque converter oil temperature:
60 - 80 °C
BWW100101
20-102 WA380-5
(10)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
3. Measuring hydraulic stall speed: 6) Run the engine at high idling, stall the
1) Switch to the monitoring function of Ser- torque converter, extend the boom cylin-
vice Mode 1 and use the 2-item simulta- der or bucket cylinder at the same time to
neous monitoring function to display the relieve the circuit, and measure the
following 2 items. For details, see SPE- engine speed.
CIAL FUNCTIONS OF MACHINE MONI- ★ Do not keep the stall condition for more
TOR in the TROUBLESHOOTING section. than 20 seconds. Make sure that the
★ Monitoring items torque converter oil temperature does not
1 Code No. 01001: Engine speed exceed 120 °C.
2 Code No. 04401: Hydraulic oil temperature
BWW10012
WA380-5 20-103
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
Sym- Part
Part No. Qty Remarks
bol Name
BPW10341
Handy
1 799-201-9001 Smoke 1
G Checker Bosch index: 0 - 9
Commercially Smoke
2 available meter 1
BPW10022
20-104 WA380-5
(10)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
Sym Part
Part No. Qty Remarks
bol Name
Digital
tempera-
B 799-101-1502 1 -99.9 - 1,299 °C
ture
gauge
BPW10024
1. Remove the adiabatic cover, then remove 3. When measuring the exhaust temperature at
exhaust temperature measurement plug (1) torque converter stall, do as follows.
(R 1/8). • To prevent overheating of the torque con-
verter, stabilize the exhaust temperature
at full stall (torque converter stall +
hydraulic stall), then stall the torque con-
verter only and measure the temperature.
1) Start the engine and raise the coolant
BPW10343 temperature to the operating range.
2) Turn the transmission cut-off selector
switch OFF and depress the left brake
securely.
3) Place the directional lever at F4 or R4.
• Turn the transmission manual switch
ON and place the speed lever at F4
and R4.
2. Install sensor (2) and connect to digital tem- 4) Release the parking brake.
perature gauge B. 5) Depress the accelerator pedal gradually
★ Be careful not to let the wiring harness of to raise the engine speed to full throttle,
the temperature gauge touch the high- stall the torque converter, and extend
temperature portion. boom cylinder or bucket cylinder at the
same time to relieve the circuit.
★ Continue until the exhaust tempera-
ture is around the standard value of
650 °C
WA380-5 20-105
(10)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
20-106 WA380-5
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
Cylinder No.
Exhaust
valve
★ Pushing depth of timing pin (8): 8 mm
Air intake
valve
WA380-5 20-107
5
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
20-108 WA380-5
5
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
WA380-5 20-109
(10)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
20-110 WA380-5
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
WA380-5 20-111
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
1. Testing.
1) Apply bar 1 to the bolt at the crank pulley
end and revolve it forward to bring yellow
paint a of the damper to the top. Push in
timing pin (1) and set the No. 1 cylinder
piston to the compression top dead cen-
ter (Insert the timing pin in the gear hole).
2. Adjusting
• When the timing pin is not meshed
1) Remove the injection pump. For details,
see DISASSEMBLY AND ASSEMBLY,
Removal of fuel injection pump assembly.
2) Revolve the camshaft of the injection
pump and mesh timing pin (3) with timing
pointer (4).
★ Pushing depth of timing pin (1): 8 mm 3) Install the injection pump. For details, see
DISASSEMBLY AND ASSEMBLY,
Removal of fuel injection pump assembly.
20-112 WA380-5
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
WA380-5 20-113
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
20-114 WA380-5
(10)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
1. Install solenoid (1) to bracket (2). 6. Check that stop lever (4) touches the stopper
on the RUN side.
2. Install ball joint (3) to stop lever (4).
7. Install the solenoid so that its rod will be
3. Install bracket (2) to the cylinder block. pulled to the stroke end without fail.
• Stroke of solenoid: 25.4 mm
4. Turn the starting switch to the ON position to
turn on (hold) the solenoid. 8. Check that the engine "starts" and "stops"
normally and the solenoid is not heated
5. Pull (Retract) rod (5) of solenoid (1) with the abnormally.
hand to the stroke end.
WA380-5 20-115
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
1. Adjust the installed length of accelerator 2. Press the accelerator pedal to the end in the
cable (3) so that inclination X of pedal (2) will power mode and insert a steel sheet 0.2 mm
be 48 ° when lever (1) is pressed against the thick to W between stopper (4) on the engine
low idling stopper of the engine. side and lever (1).
• Installed length of cable
Pedal side y: 150 mm 3. Under the above condition, adjust the bolt
Lever side z: 277 mm length so that pedal (2) will touch stopper bolt
★ Screw in the cable and joint more (5) when a force of 29.4 - 49 N {3 - 5 kg} is
than 6 mm. applied to the end of pedal (2).
• Height of stopper bolt (Standard) h: 60 mm
WA380-5 20-117
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
1. Operate the mode selector switch to select 4. Start the engine and adjust stopper bold (4)
the normal mode. [Motor cable (1) is short- so that the high idling speed in the normal
ened.] mode will be 1,900 ± 50 rpm, then tighten
• Installed length X: 140 mm locknut (5).
• Check the clearance between stopper (2)
and lever (3).
Clearance b: 1.0 mm
20-118 WA380-5
(10)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
WA380-5 20-119
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
BWW10037
WARNING! Wait for the temperature
of the oil to go down before installing
or removing the measuring equip-
ment.
Gauge
No. Measuring Oil Pressure MPa {kg/cm2}
1 Main relief pressure 5.9 {60}
2 Torque converter relief pressure 5.9 {60}
3 Torque converter outlet pressure 0.98 {10}
BPW10038
4 Transmission F clutch pressure 5.9 {60}
5 Transmission R clutch pressure 5.9 {60}
Torque converter lock-up clutch
6 5.9 {60}
pressure
Transmission 4th clutch pres-
7 sure 5.9 {60}
20-120 WA380-5
(9)
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
BWW10097
BPW10040
WA380-5 20-121
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
3. Measuring torque converter relief pressure 4. Measuring torque converter outlet pressure
(inlet) 1) Remove oil pressure measurement plug (3)
1) Install hose 1 to oil pressure measure- 1
and install tee C4, nipple and hose .2
ment nipple (2).
BPW10040
20-122 WA380-5
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
WA380-5 20-123
TESTING AND ADJUSTING DRAWING OF SPECIAL TOOL
Tool C4
20-124 WA380-5
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
5 Transmission case: 54 l
WA380-5 20-125
(10)
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE
TESTING AND ADJUSTING FAILS
20-126 WA380-5
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE
TESTING AND ADJUSTING FAILS
3. Depending on the direction for moving the 4. Depress the brake pedal securely.
machine (forward or reverse), remove 2 5. Start the engine, release the parking brake,
ECMV solenoids (3) and install plug K. then release the brake pedal gradually to
• FORWARD: F solenoid and 2nd solenoid allow the machine to start, and move the
• REVERSE: R solenoid and 2nd solenoid machine.
★ If there is any mistake in the selection of ★ If a failure in the electrical system makes
the solenoid to remove, there is danger it impossible to release the parking brake,
that the transmission may be damaged. release the parking brake manually. For
details, see MANUAL RELEASE METHOD
★ Install plus K with the protruding surface
FOR PARKING BRAKE.
facing the ECMV. Check also that there is
an O-ring installed to the mating surface.
★ Be careful not to let any dirt or mud get
WARNING! Remove the blocks from
inside the removed solenoid or valve.
under the tires.
BWG10005
WA380-5 20-127
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CONTROL
Testing
1. Start the engine, operate the steering wheel,
and set the front and rear frames straight.
2. Check the looseness of locknut (2), or stopper
bolt (1).
3. Start the engine and measure clearance
between the front frame and rear frame stop- TKW00897
per when the steering wheel is turned fully to
the left and right.
★ When measureing the clearance, check
that the end face of the spool of stop
valve (3) is in contact with the head of the 3
2
stopper bolt. 1 TKW00897
Adjusting
1. Adjust the stopper bolt.
1) Screw in stopper bolt (1) to make it the
minimum length.
2) Run the engine at low idling and operate
the steering slowly to contact the frame
stopper.
3) Turn the stopper bolt until the head of
stopper bolt (1) contacts the end face of
the spool of the stop valve (3).
4) Set the machine facing straight, and stop
the engine.
5) Loosen stopper bolt (1) 8.5 turns, then
lock it in position with locknut (2).
6) Carry out steps 1) thru 5) for both the left
and right sides.
2. Start the engine and measure clearance a
between the front frame and rear frame stop-
per when the steering wheel is turned fully to
the left and right.
★ When measuring the clearance, check
that the end face of the spool of stop
valve (3) is in contact with the head of the
stopper bolt.
20-128 WA380-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Measuring
BPW10040
WA380-5 20-129
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Adjusting
BWW10066
20-130 WA380-5
TESTING AND ADJUSTING TESTING HYDRAULIC FAN
Sym-
Part No. Part Name Qty Remarks
bol
Measurement
J 799-205-1100 Multi- 1 range:
tachometer
6 - 99999.9rpm
WA380-5 20-131
(9)
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
BEW00563
20-132 WA380-5
(10)
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
WA380-5 20-133
(10)
TESTING AND ADJUSTING TESTING WEAR OF WHEEL BRAKE DISC
BWW10076
20-134 WA380-5
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
• Raise the lift arm and put blocks under the lift
arm, and then remove front frame cover (1).
WA380-5 20-135
(10)
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
Transmission case: . . . . . . . . . . . . 54 l
BPW10045
20-136 WA380-5
TESTING AND ADJUSTING MANUAL RELEASE METHOD FOR PARKING BRAKE
1. Remove 2 plugs (1). (left and right) • Refilling with oil (transmission case)
★ Approx. 20 l of oil will come out from the After carrying out the manual release method
plug mount, so prepare a container to for the parking brake, add oil through the oil
catch it. filler to the specified level. Run the engine to
★ After releasing the parking brake, coat the circulate the oil through the system, then
plug with gasket sealant (LG-5) and check the oil again.
tighten it.
BPW10078
WA380-5 20-137
TESTING AND ADJUSTING TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
Measuring
• Hydraulic oil temperature: 45 - 55 °C
WARNING! Put blocks under the tires. 4. Measure the accumulator charge cut-in pres-
sure.
Start the engine, run at low idling, and mea-
sure the oil pressure when the brake oil pres-
WARNING! Stop the engine, then
sure warning pilot lamp on the maintenance
depress the brake pedal at least 100
monitor goes out.
times to release the pressure inside
5. Measure the accumulator charge cut-out
the accumulator circuit.
pressure.
After the accumulator charge cut-in, the pres-
1. Disconnect accumulator inlet hose (1) on the sure rises. Measure the oil pressure at the
left side of the rear frame. point where the oil pressure gauge indicator
2. Install tool C3 to nipple (2) at charge valve suddenly drops after rising.
end, then assemble hose (1) again.
20-138 WA380-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
Adjusting
★ When the accumulator charge cut-out pres-
sure is adjusted, the cut-in pressure also
changes because of the valve area ratio.
1. Loosen locknut (4) of accumulator charge cut-
out valve (3), then turn adjustment screw (5)
to adjust.
★ Turn the adjustment screw to adjust as
follows.
• To INCREASE the pressure, turn
CLOCKWISE.
• To DECREASE the pressure, turn
COUNTERCLOCKWISE.
★ Amount of adjustment for one turn of
adjustment screw: 5.59 MPa {57 kg/cm2}
WA380-5 20-139
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
Measuring
1. PPC pump basic pressure
1) Remove oil pressure measuring plug (1)
(M10 x 1.25) which is installed to left side
rear frame of the machine.
20-140 WA380-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
2) Remove oil pressure measurement plug ★ After completion of the adjustment, check
(R 1/8) of the circuit to be measured, then the accumulator charge cut-in pressure
fit nipple 1 and hose 2 and install oil and cut-out pressure again. For details,
pressure gauge C1 (5.9 MPa {60 kg/cm2}). see TESTING AND ADJUSTING ACCU-
MULATOR CHARGE PRESSURE.
★ Plug A: Lift arm RAISE
Plug B: Lift arm LOWER, FLOAT
Plug C: Bucket TILT
Plug D: Bucket DUMP
BWW01192
WA380-5 20-141
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
BWW01193
20-142 WA380-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
WA380-5 20-143
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER
Mounting nut: . . . . . . . . . . . . . . . . . . . .
14.7 - 19.6 Nm {1.5 - 2.0 kgm}
BWW01209
20-144 WA380-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT
2. After stopping the engine, measure dimen- ★ After adjusting, operate the lift arm lever
sion a between the center of proximity switch and check that the proximity switch is
(1) and the top of plate (2). actuated normally.
★ Standard dimension a: 0 - 5 mm
BDW00235
BEW00236
WA380-5 20-145
(10)
TESTING AND ADJUSTING CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP
Proximity
Switch
Lights Up Goes Out
Actuation
Pilot Lamp
Detector When detector is positioned at detection surface of When detector has moved away from detection surface
Position proximity switch of proximity switch
Bucket
Positioner TEW00167 TEW00168
Boom Kick-
out
20-146 WA380-5
(10)
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
BWW10306
WA380-5 20-147
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
20-148 WA380-5
(10)
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
WA380-5 20-149
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
20-150 WA380-5
6
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
2) Press ( ) on monitor panel mode selector Performing Calibration for Load (Zero Point
switch 1 to display LOAD METER. Adjustment)
(Supplementary Explanations)
WA380-5 20-151
(7)
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
4) Press ( ) on monitor panel mode selector 8) When the lift arm is lowered, the display
switch 1. EMPTY BUCKET appears on the changes to STEP 2 RAISE TO TOP. It is
lower line. ready to perform calibration for load.
9) Raise the lift arm to its uppermost posi-
tion by following the prompts. When rais-
ing the lift arm, perform operation as
close as to that of actual work.
20-152 WA380-5
(7)
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
13) Input the weight value on the screen for 17) Press ( ) on monitor panel mode selector
entering targets. switch 1. When the monitor accepts the
The weight calculated from the last data entry, two short beeps are sounded and
appears on the screen. The cursor is now calibration for load setting is completed.
on 10 tons. When chaging the last target The display is restored to a normal view
weight 7.1t to7.5t (loaded weight at step of a service meter and clock.
7) of this time, input procedure is as
folows.
WA380-5 20-153
(7)
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
1. Bleeding air from fan motor circuit 3. Bleeding air from cylinders
1) Open the radiator grill, then remove cov- 1) Start the engine and run at idling for
ers (1) and (2). approx. 5 minutes.
2) Run the engine at low idling, then raise
and lower the lift arm 4 - 5 times in suc-
cession.
★ Operate the piston rod to a point
approx. 100 mm before the end of its
stroke. Do not relieve the circuit under
any circumstances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the
end of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air
from the bucket and steering cylinders.
★ When the cylinder has been replaced,
2) Connect air bleed hose 1 to nipple (3) at bleed the air before connecting the
the inlet port of the motor. piston rod.
20-154 WA380-5
(10)
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
WA380-5 20-155
(10)
TESTING AND ADJUSTING Pm
PM CLINIC INSPECTION TABLE
What is maximum level of coolant temperature? What is maximum level of torque converter and
(During operation) transmission oil temperature? (During operation)
White Green Green Green Green Red Red Green Green Green Green Green Red Red
1 2 3 4 5 6 7 1 2 3 4 5 6 7
★ If machine is cold, warm it up. Working mode: P-mode
Standard value Service limit Measure-
Item Condition Unit for new machine value ment result Good Bad
Blow-by pressure Engine at high idle and torque kPa Max. 0.98 Max. 1.96
converter stalled {Max. 1.00} {Max. 200}
Engine
★ When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
Engine at 2.66 – 3.06 2.66 – 3.06
high idle {27.2 – 31.2} {27.2 – 31.2}
Main relief pressure
Engine at 2.54 – 2.94 2.54 – 2.94
low idle • Torque converter oil {25.9 – 29.9} {25.9 – 29.9}
temperature: 60 - 80°C
Transmission valve
20-156 WA380-5
(10)
TESTING AND ADJUSTING Pm
PM CLINIC INSPECTION TABLE
Steering relief Engine at high idling MPa 15.2 – 16.2 14.7 – 16.2
pressure {kg/cm2} {155 – 165} {150 – 165 }
• Torque converter oil temperature:
Parking brake inlet MPa Min. 2.27 Min.2.27
pressure 60 - 80°C {kg/cm2} {Min. 23.1} {Min. 23.1}
• Engine speed: Low idling
• Tire inflation pressure: Specified
pressure Machine must Machine must
Performance • Test on flat and dry paved slope of —
1/5 (11°20'). not move. not move.
• Set machine in operating state.
Disc thickness mm 3.12 – 3.28 2.97
Measure
when brake
Charge cut-in oil pressure 5.9 – 6.4 5.4 – 6.9
pressure {60 – 65} {55 – 70}
• Engine speed: Low warning lamp
idling goes off.
• Hydraulic oil temper- Measure MPa
ature: 45 - 55°C when brake oil {kg/cm2}
Parking brake
Visual check of differential drain Front axle There must not be excessive
Axle
—
plug Rear axle metal powder.
Memo
WA380-5 20-157
(10)
TROUBLESHOOTING
WA380-5 20-201
(7)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER
WHEN TROUBLESHOOTING
Stop the machine in a level place, and check that the safety pin, chocks, 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 coolant 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, coolant or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect 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, an important point is to understand the structure and function of the machine.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of pos-
sible causes of the failure that would produce the reported symptoms.
1) Check the oil level.
1. When carrying out troubleshooting, do not hurry 2) Check for any external leakage of oil from
to disassemble the components. If components the piping or hydraulic equipment.
are disassembled immediately after a failure 3) Check the travel of the control levers.
occurs: 4) Check the stroke of the control valve spool.
• Parts that have no connection with the failure 5) Other maintenance items can be checked
or other unnecessary parts will be disassem- externally, so check any item that is consid-
bled. ered to be necessary.
• It will become impossible to find the cause of 4. Confirming the failure.
the failure. Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as a
It will also cause a waste of man hours, parts, or
problem with the method of operation, etc.
oil and grease. At the same time, it will also lose
the confidence of the user or operator. For this ★ When operating the machine to re-enact the
reason, when carrying out troubleshooting, it is troubleshooting symptoms, do not carry out
necessary to carry out thorough prior investiga- any investigation or measurement that may
tion and to carry out troubleshooting in accor- make the problem worse.
dance with the fixed procedure. 5. Troubleshooting
2. Points to ask the user or operator. Use the results of the investigation and inspec-
1) Have any other problems occurred apart tion in Steps 2 - 4 to narrow down the causes of
from the problem that has been reported? the failure, then use the troubleshooting flow-
2) Was there anything strange about the chart to locate the position of the failure exactly.
machine before the failure occurred? ★ The basic procedure for troubleshooting is
3) Did the failure occur suddenly, or were there as follows.
problems with the machine condition before 1) Start from the simple points.
this? 2) Start from the most likely points.
4) Under what conditions did the failure occur? 3) Investigate other related parts or infor-
5) Had any repairs been carried out before the mation.
failure? When were these repairs carried 6. Measures to remove root cause of failure.
out? Even if the failure is repaired, if the root cause of
6) Has the same kind of failure occurred the failure is not repaired, the same failure will
before? occur again.
To prevent this, always investigate why the prob-
3. Check before troubleshooting. lem occurred. Then, remove the root cause.
20-202 WA380-5
(10)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN
TROUBLESHOOTING
WA380-5 20-203
(10)
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 equipment' and 'Handling hydraulic
equipment' (particularly hydraulic oil).
20-204 WA380-5
(10)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
WA380-5 20-205
(10)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
20-206 WA380-5
(10)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or coolant
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, faulty
contact, corrosion, or damage to the con-
nector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ If there is any oil, coolant, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any coolant has gotten inside the con-
nector, 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.
WA380-5 20-207
(10)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
20-208 WA380-5
(10)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
WA380-5 20-209
(10)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tape, or
vinyl bags to prevent any dirt or dust from enter-
ing. Never leave any openings opened or blocked
with a rag, this could cause particles or dirt to get
into the system.
Drain all oil into a container and not unto the
ground and be sure to follow the proper environ-
mental regulation for any disposal of oil.
20-210 WA380-5
(10)
TROUBLESHOOTING
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 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.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or con-
taminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultra fine (about 3µ) particles that the filter built
into the hydraulic equipment cannot remove, so it
is an extremely effective device.
WA380-5 20-211
(10)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
10. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
12. Check operation of instruments — Repair or replace
13. Check for abnormal noise, smell — Repair
mechanical
— Repair
Hydraulic,
20-212 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-214 WA380-5
(9)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10513
WA380-5 20-215
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10326
20-216 WA380-5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BJW11332
WA380-5 20-217
(8)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Operator Mode
★ No. 2 - No. 8 give an endless display accord-
ing to the operation of the switch.
★ When a failure occurs, the screen changes
automatically to No. 9, regardless of the dis-
play screen.
★ Regardless of the display screen, if no switch
is operated for more than 30 seconds, the
screen automatically changes as follows.
• Goes to No. 1: If there is no failure
• Goes to No. 9: If there is no failure
★ From No. 10 the screen changes to No. 1 with
the switch operation, and if no switch is oper-
ated for more than 10 seconds, the screen
automatically changes to No. 9.
Service Mode 1
★ No. 11 - No. 19 give an endless display
according to the operation of the switch.
★ Once the ID is input and confirmed, it remains
effective until the starting switch is turned
OFF.
Control switches
Control of the machine monitor display is all car-
ried out with machine monitor mode selector
switches (1) and (2).
The following functions are provided for the but-
tons of each switch.
1. ◊: Select, Run
2. ■: Cancel, Release, Select (YES/NO screen
only)
3. >: Right, Next, Continue
4. <: Left, Previous, Return
20-218 WA380-5
(9)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10311
★ For details, see the "OPERATION AND MAINTENANCE MANUAL, Handling Load Meter".
WA380-5 20-219
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
3. Travel distance aggregate display function ★ The replacement interval can be set using
From the normal service meter display, press Service Mode 1.
the [◊] switch to display the odometer. 5. Telephone number input function
• On machines without a load meter, this The telephone number set inside the machine
display is shown first. monitor can be input, corrected, or cancelled
★ For details, see the "OPERATION AND by operating the switches.
MAINTENANCE MANUAL, Machine Mon- ★ When action code [E03] is displayed, the
itor and Other Functions". telephone number is displayed at the
same time as [CALL].
★ For details, see the "OPERATION AND
MAINTENANCE MANUAL, Machine Mon-
itor and Other Functions".
BWW10312
BWW10314
BWW10313
BWW10315
20-220 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
E03 Displayed • Stop engine and machine immediately and contact serviceman.
WA380-5 20-221
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
10. Failure code display function ★ With the service code display function,
While the action code is being displayed on the following data are displayed.
the machine monitor, press the [>] button A. Failure code (location code + problem
once to display the failure codes for the exist- code)
ing failures. B. Controller codes
★ The failure codes detected in the past are MON : Machine monitor
divided into failures of the electrical sys- TM : Transmission controller
tem and the mechanical system and are WRK : Work equipment controller
recorded as trouble data. (For details, see C. System with problem
Service Mode 1.)
★ If more than one failure is occurring,
press the [>] button once more to display
the other failure codes.
★ After pressing the [>] button to display all
the existing failures, press the [>] button
once more to return to the service meter
display screen. BJH10102
If the [>] button is pressed once more, the
failure codes will be displayed again from
the beginning.
If the switch is not operated for 3 seconds,
the display will switch automatically to
the action code screen.
20-222 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Failure Location of Failure (Location, component Nature of Failure (Problem, nature of failure) Con- Action
Code with failure) troller Code
1500L0 Transmission clutch * See separate table (L0) TM E03
15B0NX Transmission filter Clogged (NX) MON E01
15SAL1 Fill switch for F clutch * See separate table (L1) TM E03
15SALH Fill switch for F clutch * See separate table (L.H.) TM E01
15SBL1 Fill switch for R clutch * See separate table (L1) TM E03
15SBLH Fill switch for R clutch * See separate table (L.H.) TM E01
15SEL1 Fill switch for 1st clutch * See separate table (L1) TM E03
15SELH Fill switch for 1st clutch * See separate table (L.H.) TM E01
15SFL1 Fill switch for 2nd clutch * See separate table (L1) TM E03
15SFLH Fill switch for 2nd clutch * See separate table (L.H.) TM E01
15SGL1 Fill switch for 3rd clutch * See separate table (L1) TM E03
15SGLH Fill switch for 3rd clutch * See separate table (L.H.) TM E01
15SHL1 Fill switch for 4th clutch * See separate table (L1) TM E03
15SHLH Fill switch for 4th clutch * See separate table (L.H.) TM E01
15SJL1 Fill switch for lock-up clutch * See separate table (L1) TM E03
15SJLH Fill switch for lock-up clutch * See separate table (L.H.) TM E01
2F00MA Parking Brake Function impossible (MA) MON E00
2G42ZG Accumulator (Front) Drop in oil pressure (ZG) MON E03
2G43ZG Accumulator (Rear) Drop in oil pressure (ZG) MON E03
Transmission overrun prevention command
(989F00) signal Actuated (00) TM E00
WA380-5 20-223
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
DGE3L6 Coolant temperature sensor (Low tempera- * See separate table (L6) MON E01
ture)
DGF1KX Transmission oil temperature sensor Input signal outside range (KX) TM —
DGH2KX Hydraulic tank Input signal outside range (KX) MON E01
DGR2KA Rear brake oil temperature sensor Disconnection (KA) TM E01
20-224 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-225
5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-226 WA380-5
5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-227
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
3) Inputting, confirming ID
Operate the buttons to input the ID.
★ ID: 6491
• [>] button: Number at cursor goes up.
• [<] button: Number at cursor goes down.
• [◊] button: Number at cursor is con-
firmed. BJH10104
• [■] button: Returns to initial screen (see
Note).
Note: When the cursor is at the left edge, the
screen returns to the normal screen
(operator mode).
If the cursor is not at the left edge, the
cursor returns to the left edge.
★ If more than 60 seconds passes before the
switch on the ID input screen is operated,
the screen returns automatically to the
normal screen.
20-228 WA380-5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-229
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
1) Menu selection
Select the display function for ELECTRIC
FAULT trouble data on the menu screen
of Service Mode 1.
★ The total number of trouble data
items recorded in memory is dis-
played in the [**] portion. (Recorded
up to a maximum of 20 items)
20-230 WA380-5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-231
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-232 WA380-5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-233
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-234 WA380-5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-235
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-236 WA380-5
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
1 Monitor ROM part No. MONTORING 20200 Arabic Numerals Status display
ROM
2 Engine speed ENG SPEED 01001 0 - 3000 rpm
3 Travel speed SPEED 40000 0 - 50 km/h
4 Fuel level FUEL SENSOR 04202 0 - 100 %
5 Hydraulic oil temperature HYD TEMP 04401 24 - 131 °C
6 Engine coolant temperature COOLANT TEMP 04103 24 - 131 °C
7 Engine coolant temperature (Low temperature) COOLANT Lo 04104 -31 - 91 °C
8 Torque converter oil temperature TC OIL TEMP 40100 24 - 131 °C
9 Battery charge ALTERNATOR R 04302 0.00 - 30.00 V
10 Side lamp voltage SMALL LAMP 40200 0.00 - 30.00 V
11 Battery electrolyte A BATTERY A2V 40300 0.00 - 30.00 V
12 Battery electrolyte B BATTERY B2V 40301 0.00 - 30.00 V
13 Lift arm angle BOOM ANG 06001 -41 - 46 deg.
14 Lift arm bottom pressure BTM PRESS 40400 0.00 - 50.00 MPa
15 Lift arm rod pressure ROD PRESS 40500 0.00 - 50.00 MPa
16 Load meter calibration pressure CAL PRESS 40600 0.00 - 50.00 MPa
17 Load meter calculation pressure MES PRESS 40700 0.00 - 50.00 MPa
18 Load meter calculation load MES LOAD 40800 0.00 - 50.00 MPa
19 Setting status of rotary switch SW1, SW2, SW3 30802 0 - F, 0 - F, 0 - F Status display
20 Setting status of dipswitch SW5-1, SW5-2 30904 ON/OFF, ON/OFF Status display
21 Setting status of dipswitch SW5-3, SW5-4 30905 ON/OFF, ON/OFF Status display
22 Setting status of dipswitch SW6-1, SW6-2 30906 ON/OFF, ON/OFF Status display
23 Setting status of dipswitch SW6-3, SW6-4 30907 ON/OFF, ON/OFF Status display
24 Input signal D_IN_0-7 D-IN--0------7 40900 See separate table Status display
25 Input signal D_IN_8-15 D-IN--8------15 40901 See separate table Status display
26 Input signal D_IN_16-23 D-IN--16------23 40902 See separate table Status display
27 Input signal D_IN_24-31 D-IN--24------31 40903 See separate table Status display
28 Input signal D_IN_32-39 D-IN--32------39 40904 See separate table Status display
WA380-5 20-237
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-238 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-239
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Monitor Panel
Input/
Monitoring
No. Code Output Display Item Content of ON/OFF Switch
Signal
D-IN-0 Head lamp Head lamp lights up ON=(24V)/OFF(OPEN)
D-IN-2 Starting switch output Starting motor started = ON(24V)/OFF(OPEN)
1 40900
D-IN-4 Auto grease A Tank empty or abnormal = ON(24V)/OFF(OPEN)
D-IN-5 Auto grease B Operating or abnormal = ON(24V)/OFF(OPEN)
D-IN-12 Turn signal right Right turn signal lights up = ON(24V)/OFF(OPEN)
D-IN-13 Turn signal left Left turn signal lights up = ON(24V)/OFF(OPEN)
2 40901
D-IN-14 ◊ Switch input Switch pressed = ON(24V)/OFF(OPEN)
D-IN-15 ■ Switch input Switch pressed = ON(24V)/OFF(OPEN)
D-IN-16 Brake oil pressure (Front) Oil pressure normal = ON(GND)/(OPEN)
3 40902 D-IN-17 Brake oil pressure (Rear) Oil pressure normal = ON(GND)/(OPEN)
D-IN-20 Air cleaner clogging No clogging = ON(GND)/(OPEN)
D-IN-26 Parking brake Parking brake applied = ON(GND)/(OPEN)
D-IN-27 Engine coolant level Coolant level normal = ON(GND)/(OPEN)
4 40903 D-IN-28 Engine oil pressure Drop in oil pressure = ON(GND)/(OPEN)
D-IN-29 Engine oil level Oil level normal = ON(GND)/(OPEN)
D-IN-30 Emergency steering motor normal Emergency steering motor actuated = ON(GND)/(OPEN)
D-IN-32 Load meter sub-total switch Switch pressed = ON(GND)/(OPEN)
D-IN-33 Load meter cancel switch Switch pressed = ON(GND)/(OPEN)
D-IN-34 High beam switch High beam = ON(GND)/(OPEN)
5 40904 D-IN-36 Service function 2 Switch pressed = ON(GND)/(OPEN)
D-IN-37 > Switch input Switch pressed = ON(GND)/(OPEN)
D-IN-38 < Switch input Switch pressed = ON(GND)/(OPEN)
D-IN-39 Drop in steering pressure Oil pressure normal = ON(GND)/(OPEN)
20-240 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Transmission controller
Input/
Monitoring
No. Code Output Display Item Content of ON/OFF Switch
Signal
D-IN-0 Steering pressure switch (N.O.) Pressure normal(exists)ON=(GND)/OFF(OPEN)
D-IN-1 Steering pressure switch (N.C.) Pressure normal(lowered)ON=(GND)/OFF(OPEN)
D-IN-2 Transmission cut-off switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-3 Transmission cut-off set switch Switch pressed = ON(GND)/OFF(OPEN)
1 40905
D-IN-4 E.C.S.S. selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-5 Lock-up selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-6 Kick-down switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-7 Engine power mode Power mode = ON(GND) /(OPEN)
D-IN-8 Shift range 1st 1st = ON(24V)/OFF(OPEN)
D-IN-9 Shift range 2nd 2nd = ON(24V)/OFF(OPEN)
D-IN-10 Shift range 3rd 3rd = ON(24V)/OFF(OPEN)
D-IN-11 Shift range 4th 4th = ON(24V)/OFF(OPEN)
2 40906
D-IN-12 Joystick shift up Switch pressed = ON(24V)/OFF(OPEN)
D-IN-13 Joystick shift down Switch pressed = ON(24V)/OFF(OPEN)
D-IN-14 Electric emergency steering manual switch Switch pressed = ON(24V)/OFF(OPEN)
D-IN-15 Starting switch output Starting motor started = ON(GND)/OFF(OPEN)
D-IN-16 Right FNR (Joystick) selector switch Switch pressed = ON(24V)/OFF(OPEN)
D-IN-17 Right seesaw switch & joystick FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-18 Right seesaw switch & joystick Neutral NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-19 Right seesaw switch & joystick REVERSE REVERSE = ON(24V)/OFF(OPEN)
3 40907
D-IN-20 Direction lever FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-21 Direction lever Neutral NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-22 Direction lever REVERSE REVERSE = ON(24V)/OFF(OPEN)
D-IN-23 Neutralizer (Parking brake) signal Parking switch ON = ON(24V)/OFF(OPEN)
D-IN-24 F clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-25 R clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-26 1st clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-27 2nd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
4 40908
D-IN-28 3rd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-29 4th clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-30 Lock-up clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-31 Shift hold switch Switch pressed = ON(GND)/OFF(OPEN)
D-OUT-0 Backup lamp relay Output ON (24V)/OFF(GND)
5 40915
D-OUT-1 Transmission cut-off indicator Output ON (24V)/OFF(GND)
SOL/O-0 Electric emergency steering relay Output ON (24V)/OFF(GND)
SOL/O-1 E.C.S.S. relay Output ON (24V)/OFF(GND)
SOL/O-2 Switch pump cut-off Output ON (24V)/OFF(GND)
6 40914
SOL/O-3 Neutral output Output ON (24V)/OFF(GND)
SOL/O-4 Fan pump reverse rotation solenoid Output ON (24V)/OFF(GND)
SOL/O-5 Fan pump neutral solenoid Output ON (24V)/OFF(GND)
WA380-5 20-241
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Monitor Panel
Input/
Monitoring
No. Code Output Display Item Content of ON/OFF Switch
Signal
D-IN-0 Joystick ON/OFF selector switch Joystick (right FNR) selected = ON(24V)/(OPEN)
1 40910 Working position = ON(24V)/LOCK position =
D-IN-1 Work equipment lock lever switch
OFF(OPEN)
Joystick Hi speed selected = ON(GND)/
D-IN-8 Joystick speed Hi/Lo selector switch
OFF(OPEN)
D-IN-9 Bucket proximity switch (horizontal) Horizontal position = ON(GND)/OFF(OPEN)
2 40911 D-IN-10 Bucket full stroke switch Stroke end position = ON(GND)/OFF(OPEN)
D-IN-12 Semi auto digging hard switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-13 Semi auto digging soft switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-28 Remote positioner RAISE set switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-29 Remote positioner LOWER set switch Switch pressed = ON(GND)/OFF(OPEN)
3 40913
D-IN-30 Remote positioner RAISE selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-31 Remote positioner LOWER selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-OUT-1 Remote positioner RAISE switch Output ON (24V)/OFF(GND)
4 40917
D-OUT-2 Remote positioner LOWER lamp Output ON (24V)/OFF(GND)
SOL/O-0 Joystick EPC cut relay Output ON (24V)/OFF(GND)
SOL/O-1 Detent lift arm RAISE Output ON (24V)/OFF(GND)
5 40916 SOL/O-2 Detent lift arm FLOAT Output ON (24V)/OFF(GND)
SOL/O-3 Detent TILT Output ON (24V)/OFF(GND)
SOL/O-4 Work equipment neutral lock solenoid Output ON (24V)/OFF(GND)
20-242 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
• Adjustment items
1) Setting initial training of transmission 7) Adjusting 3-tandem valve EPC valve (cylin-
2) Adjusting lift arm angle sensor der extension)
(RAISE) (for EPC lever) 8) Adjusting 3-tandem valve EPC valve (cylin-
3) Adjusting lift arm RAISE EPC valve der retraction)
4) Adjusting lift arm LOWER EPC valve 9) Adjusting joystick steering calibration
5) Adjusting bucket TILT EPC valve (right)
6) Adjusting bucket DUMP EPC valve 10) Adjusting joystick steering calibration (left)
11) Adjusting lift arm angle sensor (RAISE) (for
load meter)
12) Adjusting lift arm angle sensor (LOWER)
(for load meter)
BWW10324
★ For details, see "STRUCTURE AND FUNCTION, Settings needed when installing optional equipment".
20-244 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Table of filter and oil replacement interval set items [when shipping]
No. Item Code Display Replacement Interval
1 Engine oil 01 ENG OIL 500
2 Engine oil filter 02 ENG OIL FILTER 500
3 Fuel filter 03 FUEL FILTER 500
4 Corrosion resistor 06 CORR RESISTOR 1000
5 Transmission oil 12 TM OIL 1000
6 Transmission oil filter 13 TM OIL FILTER 1000
7 Hydraulic oil filter 04 HYD OIL FILTER 2000
8 Hydraulic tank breather element 05 BREATHER ELE 2000
9 Axle oil 15 AXLE OIL 2000
10 Hydraulic oil 10 HYD OIL 2000
WA380-5 20-245
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10328
20-246 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA380-5 20-247
(10)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Procedure of troubleshooting
If a phenomenon considered to be a failure occurs in the machine, select a proper troubleshooting No.
according to the following procedure, and then read the corresponding troubleshooting procedure.
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
recorded:
If a failure code is not recorded in the monitor panel (EMMS), a failure that the machine cannot find out
by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon considered to be failures again and select the same phenomenon
from the "Phenomena considered to be failures" table, and then carry out troubleshooting related to
that phenomenon in "TM mode", "MON mode", "WRK mode", or "E mode".
WA380-5 20-249
(7)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
20-249-1 WA380-5
(10)
5
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Troubleshooting
No. Phenomena considered to be failures Failure TM WRK MON H E
(Engine)
code mode mode mode mode mode
Failures related to work equipment controller (WRK mode)
Defective semi-automatic digging SOFT selection
31 WRK-9
switch system
32 Defective joystick ON/OFF switch system WRK-10
33 Defective joystick steering speed Hi/Lo switch system WRK-11
34 Defective joystick solenoid cut relay output system WRK-12
Hot short-circuited lift arm RAISE magnet detent out-
35 WRK-13
put system
Hot short-circuited lift arm FLOATING magnet detent
36 output system WRK-14
52 The brake oil pressure caution lamp does not light up MON-2,
when the emergency brake is applied 3
The air cleaner clogging indicator lamp does not light
53 MON-4
ON
54 The engine hydraulic caution lamp does not light ON MON-5
55 The engine oil level caution lamp does not light ON MON-6
The engine coolant temperature caution lamp does
56 not light ON MON-7
WA380-5 20-249-2
(10)
5
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Troubleshooting
No. Phenomena considered to be failures Failure TM WRK MON H E
(Engine)
code mode mode mode mode mode
Failures related to monitor panel (MON mode)
Input fault in monitor panel mode switch 1 [■] (Panel
61 MON-12
SW1)
Input fault in monitor panel mode switch 1 [◆] (Panel
62 MON-13
SW2)
Input fault in monitor panel mode switch 2 [<] (Panel
63 SW3) MON-14
86 The lift arm moves slowly or the lift arm rising force is H-16
insufficient
When rising, the lift arm comes to move slowly at
87 H-17
specific height
The lift cylinder cannot hold down the bucket (The
88 H-18
bucket rises in the air)
89 Hydraulic drifts of the lift arm occur often H-19
90 The lift arm wobbles during operation H-20
When the control lever is switched from "HOLD" to
91 H-21
"RAISE," the lift arm falls temporarily
92 The bucket does not tilt back H-22
The bucket moves slowly or the tilting-back force is
93 H-23
insufficient
20-249-3 WA380-5
(10)
5
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Troubleshooting
No. Phenomena considered to be failures Failure TM WRK MON H E
(Engine)
code mode mode mode mode mode
Failures related to hydraulic and mechanical system (H mode)
The bucket comes to operate slowly in he midst of tilt-
94 H-24
ing-back
95 The bucket cylinder cannot hold down the bucket H-25
96 Hydraulic drifts of the bucket occur often H-26
The bucket wobbles during travel with cargo (The
97 work equipment valve is set to "HOLD") H-27
WA380-5 20-249-4
5
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
5. Method of using troubleshooting table (TM mode, WRK mode, MON mode, E mode)
Controller
Action Code Failure Code Code Trouble Trouble displayed in trouble data
Panel display Panel display Panel display
Description of • Condition when monitor panel or controller detected trouble.
Trouble
Controller • Action to take to protect system or equipment when monitor or controller detected trouble.
Reaction
Effect on • Condition that appeared as problem on machine when action (given above) was taken by monitor panel or
Machine controller.
20-250 WA380-5
(10)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
6. Method of reading matrix-type troubleshoot- 1. Steering wheel does not turn ← Problem
ing chart (H mode) (example)
Ask the operator the following questions.
Step 1. Ask operator questions • Did the problem suddenly start?
Yes = Equipment related to steering broken
The questions to ask the operator are given • Was there previously any symptom, such as heaviness
under the problem. If the answer to the ques- of the steering wheel?
tion matches the content given, the cause Yes = Wear of equipment related to steering, defective
given after the arrow is the probable cause. seal
Keeping the content of the questions in mind,
read the matrix and proceed with Step 2 and Checks before troubleshooting (example)
Step 3 to pinpoint the correct cause. • Is the oil level in the hydraulic tank correct? Is the type
of oil correct?
Step 2. Checks before troubleshooting • Is there any leakage of oil from the steering valve or
Before measuring the oil pressure or starting Orbit-roll?
• Has the frame lock bar been removed from the frame?
the troubleshooting, confirm the checks
before starting items, check for leakage of oil,
or for loose bolts. <Example 1>
This will prevent wasting time when trouble- Remedy
shooting. No.
Problems
The items given under Checks before trouble-
Steering wheel does not turn in either direction (left
shooting are checks that are particularly 1 and right)
important to make about the condition of the In Item 1, movement of work equipment is abnor-
machine before starting the actual trouble- 2
mal
shooting. Steering wheel turns only in one direction (left or
3
right)
Step 3. Method of reading matrix 4 Steering wheel is heavy and does not turn
1) Operate the machine when carrying out
troubleshooting of the items in the Trou- <Example 2>
bleshooting column. If any problems Cause
occur as the result of the troubleshooting, a b c d e
put a check against the item.
Remedy ∆
★ When carrying out the troubleshoot- X C A X
ing, check the easier items first. It is Problems X
not necessary to follow the number 1 ❍ ❍ ❍ ❍
order. 2 ● ●
2) Find the matching cause in the Causes 3 ❍ ❍
column. 4 ❍ ❍
If a problem is found, the ❍ marks on the
5 ❍ ❍
same line as the troubleshooting are the
causes. (In Troubleshooting item 2 in the
same diagram on the right the cause is c
or e.)
When there is one ❍ mark
Carry out troubleshooting for the other
items marked with ❍ in the same Causes
column to check if the problem occurs,
then make repairs.
When there are two ❍ marks
Go to Step 3) to narrow down the cause.
WA380-5 20-251
(10)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
7) Remedy
After narrowing down the common
causes, taken the action given in the rem-
edy line.
X: Replace ∆: Repair A: Adjust C: Clean
20-252 WA380-5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing) Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040
20-254 WA380-5
(7)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04708
BWP04707
6 799-601-7050
BWP04710
BWP04709
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
WA380-5 20-255
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04715
16 BWP04716 799-601-7320
20-256 WA380-5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M Type Connector
Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
BWP04718
2 BWP04717 799-601-7090
BWP04719 BWP04720
3 799-601-7110
BWP04723 BWP04724
6 799-601-7130
WA380-5 20-257
(7)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
BWP04728
8 BWP04727 799-601-7140
BWP04731 BWP04732
12 (white) 799-601-7350
BWP04733 BWP04734
16 (white) 799-601-7330
20-258 WA380-5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
BWP04736
BWP04735
10 (blue) —
— —
BWP04737 BWP04738
12 (blue) 799-601-7160
BWP04739 BWP04740
16 (blue) 799-601-7170
WA380-5 20-259
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04742
BWP04741
5 799-601-2710
BWP04743 BWP04744
9 799-601-2950
BWP04745 BWP04746
13 799-601-2720
20-260 WA380-5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04748
BWP04747
17 799-601-2730
BWP04749 BWP04750
21 799-601-2740
WA380-5 20-261
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04752
BWP04751
8 799-601-7180
BWP04753 BWP047544
12 799-601-7190
BWP04755 BWP04756
16 799-601-7210
BWP04757 BWP04758
20 799-601-7220
20-262 WA380-5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04760
10 BWP04759 799-601-7510
WA380-5 20-263
(9)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
BWP04770
2 BWP04769 —
— —
PA Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
BWP04772
9 BWP04771 —
— —
BWP04774
10 BWP04773 799-601-3460
— —
20-264 WA380-5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04776
BWP04775
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
WA380-5 20-265
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04784
BWP04783
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
BWP04786
5 BWP04785 799-601-7360
— —
BWP04788
6 BWP04787 799-601-7370
— —
20-266 WA380-5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
WA380-5 20-267
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
20-268 WA380-5
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
WA380-5 20-269
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
20-270 WA380-5
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
WA380-5 20-271
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
20-272 WA380-5
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 <Galpha>@ (nor- Part number: 08192-1810 <Galpha>@ (nor-
mal type) mal type)
08192-2820 <Galpha>@ (fine 08192-2810 <Galpha>@ (fine
wire type) wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 <Galpha>@ (nor- Part number: 08192-1910 <Galpha>@ (nor-
mal type) mal type)
08192-2920 <Galpha>@ (fine 08192-2910 <Galpha>@ (fine
wire type) wire type)
WA380-5 20-273
(7)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DTM Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9010
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-274 WA380-5
5
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DRC26 Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
24 799-601-9360
40
799-601-9350
(A)
40
799-601-9350
(B)
WA380-5 20-274-1
(9)
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring
harness checker assemblies are shown in the lines.
KIT No.
799-601-3000
799-601-6000
799-601-7000
799-601-8000
799-601-9000
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-5500
799-601-6500
799-601-7500
799-601-9200
799-601-9300
799-601-7100
799-601-7400
799-601-9100
—
Port No. Connector type Pin No.
WA380-5 20-275
5
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-3000
799-601-6000
799-601-7000
799-601-8000
799-601-9000
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-5500
799-601-6500
799-601-7500
799-601-9200
799-601-9300
799-601-7100
799-601-7400
799-601-9100
—
Port No. Connector type Pin No.
20-276 WA380-5
5
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
WA380-5 20-277
(9)
TROUBLESHOOTING OF TRANSMISSION
CONTROL SYSTEM
(TM MODE)
WA380-5 20-301
(10)
TROUBLESHOOTING
Failure Code [DDT4LD] (Ground fault of transmission cut-off setting switch) is displayed. . . . . . . . 20-370
Failure Code [DDW9LD] (Ground fault of kickdown switch system) is displayed . . . . . . . . . . . . . . . . 20-371
Failure Code [DDWLLD] (Ground fault of hold switch system) is displayed . . . . . . . . . . . . . . . . . . . . 20-372
Failure Code [DF10KA] (No input of gear shift lever signal) is displayed . . . . . . . . . . . . . . . . . . . . . . 20-374
Failure Code [DF10KB] (Input of multiple gear shift lever signals) is displayed. . . . . . . . . . . . . . . . . 20-376
Failure Code [DGF1KX] (Transmission oil temperature sensor system failure) is displayed. . . . . . . 20-378
Failure Code [DGR2KA] (Rear brake oil temperature sensor system disconnection) is displayed . . 20-379
Failure Code [DGR2KB] (Ground fault of rear brake oil temperature sensor system)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-380
Failure Code [DHT1KX] Transmission cut-off (left brake pressure sensor) signal discontinuity)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-381
Failure Code [DLE2KA] (Engine revolution sensor system discontinuity) is displayed . . . . . . . . . . . 20-382
Failure Code [DLE2LC] (Engine revolution sensor failure) is displayed . . . . . . . . . . . . . . . . . . . . . . . 20-383
Failure Code [DLT3KA] (Speed sensor (transmission output shaft revolution) system discontinuity)
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-384
Failure Code [DT20KB] (Ground fault of built-in indicator lamp system of transmission cut-off switch)
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-385
Failure Code [DW7BKA] (Fan pump reverse solenoid system discontinuity) is displayed . . . . . . . . . 20-386
Failure Code [DW7BKB] (Fan pump reverse solenoid system short-circuiting) is displayed . . . . . . . 20-387
Failure Code [DW7CKA] (Switch pump cut-off relay discontinuity) is displayed . . . . . . . . . . . . . . . . . 20-388
Failure Code [DW7CKB] (Switch pump cut-off relay ground fault) is displayed . . . . . . . . . . . . . . . . . 20-389
Failure Code [DX16KA] (Fan pump EPC solenoid system discontinuity) is displayed . . . . . . . . . . . . 20-390
Failure Code [DX16KB] (Fan pump EPC solenoid system ground fault) is displayed . . . . . . . . . . . . 20-391
Failure Code [DXH1KA] (Lock-up clutch _ECMV solenoid system discontinuity) is displayed. . . . . . 20-392
Failure Code [DXH1KB] (Lock-up clutch _ECMV solenoid system short-circuiting) is displayed. . . . 20-393
Failure Code [DXH4KA] (1st_ECMV solenoid system discontinuity) is displayed . . . . . . . . . . . . . . . . 20-394
Failure Code [DXH4KB] (1st_ECMV solenoid system short-circuiting) is displayed . . . . . . . . . . . . . . 20-395
Failure Code [DXH5KA] (2nd_ECMV solenoid system discontinuity) is displayed . . . . . . . . . . . . . . . 20-396
Failure Code [DXH5KB] (2nd_ECMV solenoid system short-circuiting) is displayed . . . . . . . . . . . . . 20-397
Failure Code [DXH6KA] (3rd_ECMV solenoid system discontinuity) is displayed. . . . . . . . . . . . . . . . 20-398
Failure Code [DXH6KB] (3rd_ECMV solenoid system short-circuiting) is displayed. . . . . . . . . . . . . . 20-399
Failure Code [DXH7KA] (R_ECMV solenoid system discontinuity) is displayed . . . . . . . . . . . . . . . . . 20-400
Failure Code [DXH7KB] (R_ECMV solenoid system ground fault) is displayed. . . . . . . . . . . . . . . . . . 20-401
Failure Code [DXH8KA] (F_ECMV solenoid system discontinuity) is displayed . . . . . . . . . . . . . . . . . 20-402
Failure Code [DXH8KB] (F_ECMV solenoid system ground fault) is displayed . . . . . . . . . . . . . . . . . . 20-403
Failure Code [DXHHKA] (4th_ECMV solenoid system discontinuity) is displayed. . . . . . . . . . . . . . . . 20-404
Failure Code [DXHHKB] (4th_ECMV solenoid system short-circuiting) is displayed . . . . . . . . . . . . . . 20-405
Failure Code [DY30MA] (Motor-driven emergency steering pump failure (malfunction in manual mode)) . 20-406
Failure Code [DY30MC] (Motor-driven emergency steering pump failure (malfunction in manual mode)) . 20-408
Troubleshooting Code [TM-1] Discontinuity or hot short-circuiting of kickdown switch system . 20-410
Troubleshooting Code [TM-2] Hold switch system discontinuity or hot short-circuiting . . . . 20-410-2
Troubleshooting Code [TM-3] Torque converter lock-up switch system failure . . . . . . . . . . . . . 20-412
Troubleshooting Code [TM-4] Neutralizer signal (parking brake switch signal) system failure . 20-414
Troubleshooting Code [TM-5] Emergency steering switch (motor-driven emergency steering
operation switch) signal system failure . . . . . . . . . . . . . . . . . . . . 20-416
Troubleshooting Code [TM-6] Transmission cut-off switch system discontinuity or ground
fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-418
Troubleshooting Code [TM-7] Transmission cut-off setting switch system discontinuity
or hot short-circuiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-419
Troubleshooting Code [TM-8] Transmission cut-off (left brake sensor) signal short-circuiting . 20-420
Troubleshooting Code [TM-9a] Joystick SHIFT_UP/SHIFT_DOWN switch system failure
(discontinuity or ground fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-421
Troubleshooting Code [TM-9b] Joystick ON/OFF change over switch system failure. . . . . . . . . . 20-422
Troubleshooting Code [TM-10] FNR switch mode change over switch system failure . . . . . . . . . 20-424
Troubleshooting Code [TM-11] Starting switch "C" (IGN_C) signal system failure . . . . . . . . . . . . 20-426
Troubleshooting Code [TM-12] Engine power mode switch discontinuity or ground fault . . . . . 20-428
Troubleshooting Code [TM-13] E.C.S.S. ON/OFF switch discontinuity or ground fault [*] . . . . . . . 20-429
20-302 WA380-5
(10)
TROUBLESHOOTING
Troubleshooting Code [TM-14] Hydraulic fan reverse switch signal system hot short-circuiting
or discontinuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-430
Troubleshooting Code [TM-15] Motor-driven emergency steering relay output system hot
short-circuiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-431
Troubleshooting Code [TM-16] E.C.S.S. relay output system hot short-circuiting [*] . . . . . . . . . . 20-432
Troubleshooting Code [TM-17] Switch pump cut-off relay output system hot short-circuiting . . 20-433
Troubleshooting Code [TM-18] Back lamp relay output system hot short-circuiting . . . . . . . . . . 20-434
Troubleshooting Code [TM-19] Neutral output system hot short-circuiting . . . . . . . . . . . . . . . . . 20-435
Troubleshooting Code [TM-20] FECMV solenoid system hot short-circuiting . . . . . . . . . . . . . . . . 20-436
Troubleshooting Code [TM-21] RECMV solenoid system hot short-circuiting . . . . . . . . . . . . . . . . 20-437
Troubleshooting Code [TM-22] 1st ECMV solenoid system hot short-circuiting . . . . . . . . . . . . . . 20-438
Troubleshooting Code [TM-23] 2nd ECMV solenoid system hot short-circuiting . . . . . . . . . . . . . 20-439
Troubleshooting Code [TM-24] 3rd ECMV solenoid system hot short-circuiting. . . . . . . . . . . . . . 20-440
Troubleshooting Code [TM-25] 4th ECMV solenoid system hot short-circuiting . . . . . . . . . . . . . . 20-441
Troubleshooting Code [TM-26] Lock-up ECMV solenoid system hot short-circuiting . . . . . . . . . . 20-442
Troubleshooting Code [TM-27] Fan pump EPC solenoid system hot short-circuiting. . . . . . . . . . 20-443
Troubleshooting Code [TM-28] Fan reverse solenoid system hot short-circuiting . . . . . . . . . . . . 20-444
Troubleshooting Code [TM-29] Speed sensor (transmission output shaft revolution)
system failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-445
Troubleshooting Code [TM-30] E.C.S.S. solenoid system discontinuity or ground
fault[*] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-446
★ Referring to TESTING AND ADJUSTING, Adjusting machine monitor, check that the rotary switches
(SW1, SW2, and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set
correctly.
★ [*]: Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of
machine monitor, check that the optional selection of the E.C.S.S. is effective.
WA380-5 20-302-1
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
A23 Yazaki 2 Outside temperature sensor (Vehicle with automatic air W-4
conditioner)
A24 DT-T 2 Diode (Vehicle with automatic air conditioner) W-3
A25 DT-T 2 Diode (Vehicle with automatic air conditioner) V-3
Intermediate connector (Vehicle with automatic air
A26 DT-T 2 conditioner) W-3
WA380-5 20-303
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
C47 AMP040 20 A/C control AMP (Vehicle with automatic air conditioner) D-9
AMP1722
C48 45-2 12 A/C control AMP P-1
C48 AMP040 16 A/C control AMP (Vehicle with automatic air conditioner) D-9
C49 SWP 8 Left Servomotor R-1
C50 SWP 8 Right Servomotor M-3
C51 Yazaki 2 Diode (Vehicle with automatic air conditioner) M-3
CAN1 DT-T 3 Resistor N-1 F-1 J-8 B-2
CAN2 DT-T 3 Resistor R-9 J-9 K-8 B-2
CL1 S 8 Intermediate connector A-4 E-7
CL2 S (L) 12 Intermediate connector (Wiper motor) A-4
Intermediate connector (Vehicle with automatic air
CL5 S (W) 16 M-2
conditioner)
Intermediate connector (Vehicle with automatic air
CL6 M 6 conditioner) M-3 B-3 C-5
CL6 DT-T (G) 12 Intermediate connector (Monitor panel controller) W-4 K-4 C-4
CL7 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-2 B-4 K-4 C-5
CL8 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-1 B-4 C-5
CL9 DT-T (G) 8 Intermediate connector (Monitor panel controller) O-1 B-4 K-4 C-6 B-5
20-304 WA380-5
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
CL10 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-3 K-3 C-3
CL20 DT-T 2 Intermediate connector (Monitor panel controller) N-2 C-5
CN55 DT-T 2 Intermediate connector (Backup buzzer) K-8 P-2 V-8
COMBI M 3 Front combination lamp (Right) A-6 W-3
COMBI M 3 Front combination lamp (Left) E-1 W-2
DIODE DT-T 2 Diode (Parking brake solenoid) AG-8 P-8
DL DT-T (Gr) 12 Connector (S-NET) U-8 I-9 K-6 K-5
E01 DT-T 2 Intermediate connector (Starting motor) AB-1 W-4 B-1
E02 Terminal 1 Alternator R AD-3 X-5
E03 Terminal 1 Alternator B AD-3 X-5
E04 Terminal 1 Alternator E AD-3 X-5
E05 Terminal 1 Engine heater relay AC-9 Q-9 E-4
E06 Terminal 1 Engine heater relay AA-9 Q-9 F-4
E07 Terminal 1 Engine heater relay Z-9 Q-9 F-4
E08 DT-T 2 Engine coolant temperature sensor (Monitor) AC-1 O-8
E09 DT-T 2 Engine coolant temperature sensor (Preheater) AD-2 O-8 B-2
E10 DT-T 2 Air conditioner compressor magnet clutch AD-2
E11 DT-T 2 Diode (Air conditioner compressor) AD-4
E14 Terminal 1 Ground (Rear frame) AB-5 X-5 A-1
E26 DT-T 2 Engine oil level sensor AA-5 P-8
E27 DT-T 2 Engine speed sensor AC-6 L-8
E28 DT 2 Diode (Engine heater relay) AC-9 O-8 B-2
E29 Terminal 1 Engine oil pressure switch AB-5 P-8
E30 Terminal 1 Starting motor B AB-1 X-4
E31 DT-T 2 Diode AC-7 B-3
E32 DT-T 2 Diode (Fuel cut solenoid) AB-6 B-3
E33 DT-T 2 Dust indicator AB-9 P-8
E34 DT-T 3 Fuel cut solenoid AC-7 B-2
E36 Terminal 1 Air compressor magetic clutch Y-5
ER-1 DT-T (G) 8 Intermediate connector (Engine) Z-2 P-5 D-3
ER-3 DT-T (Gr) 8 Intermediate connector (Engine) AA-1 K-7 O-5 D-3
F01 M 6 Intermediate connector (R.H. Front lamp) A-5 U-3
F02 M 6 Intermediate connector (L.H. Front lamp) D-1 U-2
F03 Terminal 1 Horn (303 Hz) A-1 W-1
F04 Terminal 1 Horn (303 Hz) A-1 W-1
F05 Terminal 1 Horn (303 Hz) C-1 W-1
F06 Terminal 1 Horn (303 Hz) B-1 W-1
F07 DT-T 2 Switching pump cut-off solenoid C-1 R-8
F09 DT-T 3 Bucket positioner proximity switch A-3 Q-7 B-3
F10 DT-T 3 Bucket positioner proximity switch (Standard) A-3 Q-6 B-3
F13 DT-T 2 Lift arm damper solenoid C-1 R-8
F14 DT-T 2 Diode (Damper solenoid) D-1 R-7
F15 DT-T 3 Lift arm angle signal (For load meter) A-2 B-3 M-8
F16 DT-T 3 Lift arm bottom signal (For load meter) B-1 B-3 M-8
F17 DT-T 3 Lift arm rod signal (For load meter) B-1 B-3 M-8
WA380-5 20-305
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
F18 DT-T 3 Lift arm angle sensor (For boom EPC) A-5 H-8
F19 DT-T 3 Bucket positioner proximity switch (For bucket EPC) A-3 H-8
F20 DT-T 2 Lift arm RAISE EPC A-2 Q-4 G-8
F21 DT-T 2 Lift arm LOWER EPC A-1 G-8
F22 DT-T 2 Bucket CURL EPC A-1 G-8
F23 DT-T 2 Bucket DUMP EPC A-1 G-8
F24 DT-T 2 ATT. EXT. EPC (If equipped) A-3 I-8
F25 DT-T 2 ATT. RET. EPC (If equipped) A-2 I-8
F26 DT-T 2 Lift arm EPC cut-off solenoid B-1 H-8
F27 DT-T 2 Diode (For boom EPC cut-off solenoid) A-4 H-7
F30 Terminal 1 Ground (Front frame) C-1 Q-4 P-5 U-1 A-3
FF1 S 10 Intermediate connector (Front lamp) E-1 N-3
FF2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) D-1 K-4 N-6 C-3
FL1 S 12 Intermediate connector (Front lamp) W-1 J-3 K-3
FL2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) W-1 I-4 K-6 C-5
FL3 DT-T 6 Intermediate connector (Load meter) X-2 E-3 K-6
FL7 DT-T (Br) 12 Intermediate connector (Work equipment solenoid) N-2 E-7
FL8 DT-T (G) 8 Intermediate connector (Work equipment solenoid) N-2 E-6
FL9 DT-T 6 Intermediate connector (3rd lever solenoid) N-2 E-5
FS1 L 2 Intermediate connector (Fuse box) W-7 C-1 E-8
FS2 L 2 Intermediate connector (Fuse box) V-7 C-1 E-8
FS3 S (W) 16 Intermediate connector (Fuse box) V-8 C-1 K-7 G-8 E-8
FS4 S (W) 12 Intermediate connector (Fuse box) V-8 B-1 K-7 G-8 E-8
FS5 M 6 Intermediate connector (Fuse box) V-7 G-8
FS6 Plug 1 Intermediate connector (Fuse box) V-8
FS7 Plug 1 Intermediate connector (Fuse box) W-7
F.PS DT-T 2 Transmission F clutch solenoid AJ-6 N-8
F.SW DT 2 Transmission F clutch fill switch AJ-6 P-8
G01 Terminal 1 Backup buzzer J-9 Q-2 V-9
G02 Terminal 1 Backup buzzer J-9 Q-2 V-9
G04 M 2 Rear working lamp (Left) K-8 V-8
G05 M 2 Rear working lamp (Right) J-9 U-8
GR1 DT-T 4 Intermediate connector (Fan reverse solenoid, rear working L-7 O-4 U-6
lamp)
GR2 DT-T 2 Fan reverse solenoid L-7 Q-4
HEAD M 3 Head lamp (Right) A-6 W-3
HEAD M 3 Head lamp (Left) W-2
JT1 DT-T (B) 8 Centralized connector (Ground) AH-2 R-7 Q-7
JT2 DT-T (B) 8 Centralized connector (Shield) AG-2 R-6
JT3 DT-T 6 Centralized connector AF-8 R-5
L01 SWP 6 Parking brake switch M-5 B-7
L02 SWP 6 Dimmer switch, light switch M-5 B-1
L03 SWP 6 Turn signal and hazard switch M-6 B-1
L04 SWP 14 Shift switch M-3 B-6 A-8
L05 DT-T 2 Horn switch M-5 E-8
L07 DT-T 6 Machine monitor switch (Mode/Cancel selector switch) Q-1 B-8
20-306 WA380-5
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L08 DT-T 6 Machine monitor switch (Screen selector switch) Q-1 A-8
L09 DT-T 2 Stop lamp switch Q-1 D-8
L10 DT-T 3 Left brake pressure sensor R-1 B-6
L11 DT-T 2 Air suspension seat S-1
L12 DT-T 4 R direction switch O-7 J-7 E-3
L13 DT-T 2 Lift arm N lock switch O-7 D-8
L14 DT-T 4 Kickdown and hold switch O-7 B-8 G-2
L15 DT-T 4 Load meter cancel and sub-total switch O-7 H-2 D-8
L16 M 2 Intermediate connector (DC converter) V-2
L17 M 4 DC24V/DC12V converter W-5
L18 Yazaki 2 DC12V socket W-3
L19 M 4 Flasher unit U-8 H-8
L20 M 2 Alarm buzzer U-8 I-7
L21 S 10 Front and rear wiper switch N-1
L25E DT-T 2 Lift arm and bucket EPC lever M-6 E-8
L25S DT-T 2 Work equipment lever electrical detent N-7 G-2 C-8
L26E DT-T 2 Lift arm and bucket EPC lever P-8 E-8
L26S DT-T 2 Work equipment lever electrical detent N-6 G-2 B-8
L27 DT-T 2 Lift arm and bucket EPC lever N-6 D-8
L27S DT-T 2 Work equipment lever electrical detent N-7 G-2 B-8
L28 DT-T 4 Lift arm and bucket EPC lever P-8 D-8
L29 DT-T 4 Lift arm and bucket EPC lever O-7 E-8
L30 DT-T 4 3rd EPC lever P-8 D-8
L31 M 6 Intermittent wiper timer W-7
L34 DT-T 4 Joystick lever positioner W-6 B-1
L35 DT-T 2 Joystick EPC solenoid P-1 E-1
L36 DT-T 2 Joystick EPC solenoid P-1 D-1
L37 DTM 12 Joystick lever switch M-6 K-8
L38 DT-T 3 Joystick N lock switch W-7 K-1 B-2
L39 DT-T 6 Joystick ON/OFF switch S-1 K-2 B-2
L40 DT-T 6 Steering speed mode switch S-1 K-1 B-1
L41 Relay 6 Joystick cutoff relay N-6 D-1
L42 Plug 1 Connector (Spare power supply) A-5
L43 Plug 1 Connector (Spare power supply) A-5
L44 M 6 Intermediate connector (Printer) V-3 I-7
L45 D-sub 25 Printer (Load meter) I-8
L46 G 4 Printer (Load meter) H-9
L51 AMP070 20 Monitor panel controller M-5 A-2 O-2 B-7 B-4
L52 AMP070 18 Monitor panel controller M-4 B-6
L53 AMP070 12 Monitor panel controller M-2 A-2 B-5
L54 AMP070 18 Monitor panel controller M-4 A-2 O-2 B-4
L55 AMP070 12 Monitor panel controller M-4 A-2 O-2 B-4 B-4
L56 AMP070 12 Monitor panel controller M-5 B-2 O-2 B-3
L57 AMP070 14 Monitor panel controller M-4 B-2
L58 AMP040 8 Monitor panel controller M-2
WA380-5 20-307
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L61 DRC 24 Transmission and fan pump motor controller P-8 B-8 I-8 F-8 A-8
L62 DRC 40 Transmission and fan pump motor controller Q-8 C-8 J-8 F-8
L63 DRC 40 Transmission and fan pump motor controller Q-8 E-8 F-8 A-8
L71 DRC 24 Lift arm bucket and joystick controller Q-9 A-8
L72 DRC 40 Lift arm bucket and joystick controller Q-9 K-8 A-8 N-8
L73 DRC 40 Lift arm bucket and joystick controller R-9 K-8 B-8
L88 DT-T (Gr) 8 Engine mode selector motor P-1 B-8
L91 DT-T 6 Timer P-8 A-6
L92 DT-T 3 Intermediate connector (Pump bypass) Q-8 B-2
L93 Relay 5 Pump bypass relay Q-9 B-1
L100 Terminal 1 Ground (Floor) R-1 I-1 J-1 B-5
L101 S (W) 16 Intermediate connector (Relay sub-unit) T-9 D-2 I-7 E-7
L102 S (L) 16 Intermediate connector (Relay sub-unit) T-9 D-2 J-7 E-7
L103 S (W) 16 Intermediate connector (Relay sub-unit) S-9 E-2 J-7
L104 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 L-7 E-6
L105 S (W) 12 Intermediate connector (Relay sub-unit) T-9 F-2
L106 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 K-7
L111 — 5 Turn signal lamp and hazard relay X-7 I-9
L112 — 5 Air cleaner clogging relay W-7 I-9
L113 — 5 Steering selector relay W-8 D-1 J-9 F-7
L114 — 5 Automatic preheater relay V-8 J-9 F-7
L115 — 5 Engine controller power supply relay V-9 F-7
L116 — 4 Neutral safety relay W-7 D-1 J-9 F-6
L117 — 4 Backup lamp relay W-7 E-1 J-9
L118 — 4 Stop lamp relay V-8 K-9
L119 — 4 Horn relay V-8 K-9
L120 — 4 Parking brake relay V-8 E-1
L123 — 5 Lift arm detent relay (Standard) X-9 L-9 F-6
L124 — 5 Bucket detent relay (Standard) X-9 L-9 F-6
L125 — 5 Lift arm damper relay V-9 E-1
L126 — 4 Emergency steering relay X-8 F-1
L127 — 4 Front working lamp relay X-7 K-9
L128 — 4 Rear working lamp relay X-9 K-9
L129 — 4 Rear glass heater relay V-9
L130 — 4 Transmission pump cut-off relay V-9 F-1
L141 Relay 5 Printer relay T-1
L142 DT-T 2 Diode (Printer) W-3
L143 DT-T 2 Diode (Printer) W-4
L144 DT-T 2 Diode (Printer) W-4
L145 DT-T 2 Diode (Printer) W-4
L146 DT-T 2 Diode (Printer) T-1
L147 DT-T 2 Diode (Printer) T-1
LC.PS DT-T 2 Torque converter lockup solenoid (If equipped) AJ-5 N-8
LC.SW DT 2 Torque converter lockup fill switch (If equipped) AJ-5 P-8
LL5 DT 3 Intermediate connector (Vehicle with joystick) Q-1 F-5
LL6 DT-T (Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 E-4
20-308 WA380-5
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
LL7 DT-T (G) 12 Intermediate connector (Vehicle with joystick) Q-1 J-7 E-4 K-5
LL8 DT-T (Gr) 8 Intermediate connector (Joystick switch) R-1 K-2 C-2
LR1 DTHD#12 1 Intermediate connector (Slow-blow fuse) X-2 J-2 D-5
LR2 DT-T (G) 12 Intermediate connector (Engine) V-2 J-7 K-4 D-5
LR4 L 2 Intermediate connector (Slow-blow fuse) X-1 J-2 E-5
LR5 DT-T 6 Intermediate connector (Auto grease controller) X-2 K-1
LR6 L 2 Intermediate connector (Ground) X-2 J-2 K-1
LR8 DTHD#8 1 Intermediate connector (Ground) X-2 J-2 L-5 K-2 D-5
LR9 DT-T (G) 12 Intermediate connector (Steering and brake oil pressure X-1 I-3 K-2
switch)
LR10 DT-T (Gr) 12 Intermediate connector X-1 I-3 K-3 D-5
LR13 DT-T 2 Intermediate Connecter ( Pump bypass) AE-7 J-1
W-3,
LT1 HD-24 31 Intermediate connector (Transmission) AF-2 I-6 K-4
WA380-5 20-309
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
S13 DT-T 6 Upper remote positioner ON/OFF switch (Vehicle with joy- N-9 I-2
stick)
Lower remote positioner ON/OFF switch (Vehicle with joy-
S14 DT-T 6 N-8 I-2
stick)
S15 DT-T 6 Automatic digging switch (Vehicle with joystick) N-9 J-2
S16 DT-T 6 Hydraulic fan reverse switch M-9 G-2
S17 DT-T 6 Auto grease switch O-8 A-8
S19 DT-T 6 Emergency steering check switch M-9 H-2 C-8
S21 DT-T 4 Engine power mode switch M-9 G-8 C-8
S22 DT-T 4 Auto shift mode switch N-7 G-8
S31 DT 4 Starting switch N-7 G-2 K-2 L-7 D-8
S32 DT-T 2 Starting switch N-9 D-8
T20 Terminal 1 Ground AI-2 Q-4
T21 DT-T 2 Pump bypass solenoid AG-8 K-1
TC.T DT-T 2 Torque converter oil temperature sensor AH-8 Q-8 Q-8
TEL DT-T (Gr) 12 Intermediate connector (KOMTRAX) Q-1 I-9 K-1 C-5
TM.T DT-T 2 Transmission oil temperature sensor AJ-3 Q-8 Q-8
20-310 WA380-5
(10)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-312 WA380-5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-313
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-314 WA380-5
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-315
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-316 WA380-5
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-317
5
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIAGRAM
20-318 WA380-5
5
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIAGRAM
WA380-5 20-319
5
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIAGRAM
20-320 WA380-5
TROUBLESHOOTING FAILURE CODE [1500L1]
Possible Causes and Causes Standard Values in Normal State and Remarks on Troubleshooting
Standard Values ★ Refer to Failure Codes 15SAL1, 15 SBL1, 15SEL1, 15SFL1, 15SGL1 and 15SHL1.
WA380-5 20-321
(10)
TROUBLESHOOTING FAILURE CODE [15SAL1]
BWW10520
20-322 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SALH]
BWW10520
WA380-5 20-323
(10)
TROUBLESHOOTING FAILURE CODE [15SBL1]
BWW10520
20-324 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SBLH]
BWW10520
WA380-5 20-325
(10)
TROUBLESHOOTING FAILURE CODE [15SEL1]
Between L62 Gear shift lever = 1st speed Voltage 1 V and below
G - body Other than above Voltage 20 - 30 V
20-326 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SELH]
Between L62 Gear shift lever = 1st speed Voltage 1 V and below
G - body Other than above Voltage 20 - 30 V
WA380-5 20-327
(10)
TROUBLESHOOTING FAILURE CODE [15SFL1]
Between L62 Gear shift lever = 2nd speed Voltage 1 V and below
7 - body Other than above Voltage 20 - 30 V
20-328 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SFLH]
Between L62 Gear shift lever = 2nd speed Voltage 1 V and below
7 - body Other than above Voltage 20 - 30 V
WA380-5 20-329
(10)
TROUBLESHOOTING FAILURE CODE [15SGL1]
Between L62 Gear shift lever = 3rd speed Voltage 1 V and below
C - body Other than above Voltage 20 - 30 V
20-330 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SGLH]
WA380-5 20-331
(10)
TROUBLESHOOTING FAILURE CODE [15SHL1]
Between L62 Gear shift lever = 4th speed Voltage 1 V and below
3 - body Other than above Voltage 20 - 30 V
20-332 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SHLH]
WA380-5 20-333
(10)
TROUBLESHOOTING FAILURE CODE [15SJL1]
20-334 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SJLH]
WA380-5 20-335
(10)
TROUBLESHOOTING FAILURE CODE [989F00]
20-336 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@C7NS]
20-338 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D150KA]
BWW10522
WA380-5 20-339
(10)
TROUBLESHOOTING FAILURE CODE [D150KB]
BWW10522
20-340 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D160KA]
BWW10523
WA380-5 20-341
(10)
TROUBLESHOOTING FAILURE CODE [D160KB]
BWW10523
20-342 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D191KA]
20-344 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D191KA]
WA380-5 20-345
(10)
TROUBLESHOOTING FAILURE CODE [D191KB]
Possible Causes 3 Wiring harness ground fault Between L63 (Female) [/L101 Resistance 1 MΩ and above
and Standard Val- (Female) D - body
ues Between L101 (Female) C/L102
Resistance 1 MΩ and below
(Female) A - body
1) Turn starting switch OFF.
2) Disconnect connector L63.
3) Connect T-adapter.
4) Turn starting switch ON.
5) Turn forward-reverse lever to “N”.
When right FNR switch mounted (Right FNR switch = ON)
Right FNR switch =
Between L63 [ - N Voltage 17 - 30 V
body
Defective transmission and Other than above Voltage 1 V and below
4 fan pump motor controller
When joystick mounted (Arm rest lock and joystick switch = ON)
Joystick FNR switch
= “N” and joystick Voltage 17 - 30 V
lever = Neutral
Between L63 [ - Joystick FNR switch
body Voltage 1 V and below
≠N
Joystick lever being
operated Voltage 1 V and below
20-346 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D191KB]
WA380-5 20-347
(10)
TROUBLESHOOTING FAILURE CODE [D192KA]
BJW11503
20-348 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D192KB]
BJW11503
WA380-5 20-349
(10)
TROUBLESHOOTING FAILURE CODE [D198KB]
Action Code Failure Code Controller Code Ground fault in the low temperature bypass relay
Trouble
E03 D198KB TM system
Description of • Ground fault in wiring harness or relay between the transmission controller and the low temperature bypass
Trouble relay
Controller Reac- • Triggers an alarm.
tion
Effect on Machine • Function to improve starting ability at low temperature (at -20 °C or lower) does not work.
Related Informa- • This function works when the kit (If equipped) for improving low temperature starting is installed.
tion
BWW10523
20-349-1 WA380-5
(10)
5
TROUBLESHOOTING FAILURE CODE [D198KY]
Action Code Failure code Controller Code Hot-short in the low-temperature bypass relay sys-
Trouble
E03 D198KY TM tem
Description of • Hot-short in the wiring harness or relay between the TM controller and the low-temperature bypass relay
Trouble
Controller Reac- • Triggers an alarm.
tion
Effect on Machine • The torque converter pump does not operate (inability to travel).
Related Informa- • This function works when the kit (If equipped) for improving low-temperature starting is installed.
tion
BWW10523
WA380-5 20-349-2
(10)
5
TROUBLESHOOTING FAILURE CODE [DAQ0KK]
BWW10525
20-350 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DAQ2KK]
BWW10525
WA380-5 20-351
(10)
TROUBLESHOOTING FAILURE CODE [DAQ9KQ]
20-352 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK3KA]
20-354 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK3KA]
BWW10526
WA380-5 20-355
(10)
TROUBLESHOOTING FAILURE CODE [DDK3KB]
20-356 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK3KA]
BWW10526
T2W02834
WA380-5 20-356-1
(10)
TROUBLESHOOTING FAILURE CODE [DDK4KA]
WA380-5 20-357
(10)
TROUBLESHOOTING FAILURE CODE [DDK4KA]
20-358 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK4KB]
Description of • Multiple signals are input because of short circuit in joystick forward/reverse input signal system.
Trouble
Controller Reac- • Cannot judge input signal of joystick forward/reverse switch.
tion
Effect on Machine • After vehicle is stopped, operator can drive in steering wheel mode.
Related Informa- • This failure can be checked with monitoring function (Code: 40907, D-IN-17, DIN-18, D-IN-19).
tion
WA380-5 20-359
(10)
TROUBLESHOOTING FAILURE CODE [DDK4KB]
20-360 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK5LD]
WA380-5 20-361
(10)
TROUBLESHOOTING FAILURE CODE [DDK6KA]
Wiring harness discontinuity Wiring harness between L62 (Female) Z - L04 1 Ω and
Resistance below
2 (Disconnection or defective (Female) 2
contact) Wiring harness between L62 (Female) P - L04 Resistance 1 Ω and
(Female) 3 below
Wiring harness between L62 (Female) F - L04 1 Ω and
Resistance
(Female) 4 below
1) Turn starting switch OFF.
2) Disconnect connectors L62 and L04.
3) Connect T-adapter.
1 MΩ and
Between L62 (Female) Z/L04 (Female) 2 - body Resistance above
3 Wiring harness ground fault
Between L62 (Female) P/L04 (Female) 3 - body Resistance 1 MΩ and
above
1 MΩ and
Between L62 (Female) F/L04 (Female) 4 - body Resistance
above
1) Turn starting switch OFF.
2) Disconnect connector L04.
Possible Causes 3) Connect T-adapter.
and Standard Val- 4) Turn starting switch ON.
ues
Right FNR switch = F Voltage 20 - 30 V
Between L04 (Male)
2 - body Other than above Voltage 1 V and
Defective forward-reverse below
4 lever Right FNR switch = N Voltage 20 - 30 V
Between L04 (Male)
3 - body Other than above Voltage 1 V and
below
Right FNR switch = R Voltage 20 - 30 V
Between L04 (Male)
4 - body Other than above Voltage 1 V and
below
1) Turn starting switch OFF.
2) Disconnect connector L62.
3) Connect T-adapter.
4) Turn starting switch ON.
Right FNR switch = F Voltage 20 - 30 V
Between L62 Z -
body 1 V and
Other than above Voltage below
Defective transmission and
5 fan pump motor controller
Right FNR switch = N Voltage 20 - 30 V
Between L62 P -
body 1 V and
Other than above Voltage below
Right FNR switch = R Voltage 20 - 30 V
Between L62 F -
body 1 V and
Other than above Voltage below
20-362 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK6KA]
WA380-5 20-363
(10)
TROUBLESHOOTING FAILURE CODE [DDK6KB]
20-364 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK6KB]
WA380-5 20-365
(10)
TROUBLESHOOTING FAILURE CODE [DDS5KA]
C-A
Between R36 (Male)
Defective steering Open to atmosphere (Reference) Resistance 1 Ω and below
1 pressure switch
Engine started Resistance 1 MΩ and above
Engine stopped Resistance 1 MΩ and above
B-A
Between R36 (Male)
Open to atmosphere (Reference) Resistance 1 MΩ and above
Engine started Resistance 1 Ω and below
1) Turn starting switch OFF.
Possible Causes
and Standard 2) Disconnect connectors L61 and R36.
Values Wiring harness dis- 3) Connect T-adapter.
(Disconnection or Wiring harness between L61 (Female) G - R36 (Female) C Resistance 1 Ω and below
continuity
2
defective contact) Wiring harness between L61 (Female) M - R36 (Female) B Resistance 1 Ω and below
20-366 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDS5KB]
(Male) B - A
Between R36
1 MΩ and
Open to atmosphere (Reference) Resistance above
Engine started Resistance 1 Ω and below
Possible Causes
and Standard 1) Turn starting switch OFF.
Values 2) Disconnect connector L61 and R36.
3) Connect T-adapter.
WA380-5 20-367
(10)
TROUBLESHOOTING FAILURE CODE [DDT0L4]
20-368 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDT0L4]
WA380-5 20-369
(10)
TROUBLESHOOTING FAILURE CODE [DDT4LD]
Description of • Due to ground fault of the transmission cut-off setting switch system, a cut-off setting signal remains as
Trouble input.
Controller Reaction —
Effect on Machine • The transmission cut-off point cannot be reset.
Related Informa- • Can be checked with the monitoring function (Code: 40905, D-IN-3).
tion
20-370 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDW9LD]
WA380-5 20-371
(10)
TROUBLESHOOTING FAILURE CODE [DDW9LD]
WA380-5
20-371-1 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDWLLD]
20-372 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDWLLD]
12
Related circuit diagram
For standard
WA380-5 20-373
(10)
TROUBLESHOOTING FAILURE CODE [DF10KA]
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors L63 and L04. 3) Connect T-adapter.
1 discontinuity
connection or
(Dis-
Wiring harness between L63 (Female) 0 - L04 (Female) 5 Resistance 1 Ω and below
defective contact) Wiring harness between L63 (Female) J - L04 (Female) 6 Resistance 1 Ω and below
Wiring harness between L63 (Female) T - L04 (Female) 7 Resistance 1 Ω and below
Wiring harness between L63 (Female) _ - L04 (Female) 8 Resistance 1 Ω and below
1) Turn starting switch OFF. 2) Disconnect connectors L63 and L04. 3) Connect T-adapter.
Between L63 (Female) 0/L04 (Female) 5 - body Resistance 1 Ω and below
2 Wiring harness
ground fault Between L63 (Female) J/L04 (Female) 6 - body Resistance 1 Ω and below
Between L63 (Female) T/L04 (Female) 7 - body Resistance 1 Ω and below
Between L63 (Female) _/L04 (Female) 8 - body Resistance 1 Ω and below
1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Connect T-adapter. 4) Turn
starting switch ON.
20-374 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DF10KA]
BWW10528
WA380-5 20-375
(10)
TROUBLESHOOTING FAILURE CODE [DF10KB]
Description of • Due to disconnection of or ground fault of the gear shift lever system, no signal is input.
Trouble
Controller Reac- • Cannot determine the input signal in the relevant shift range. The shift range is fixed to that before disconnec-
tion tion occurred.
Effect on Machine • The relevant gear speed cannot be achieved.
Related Informa- • Can be checked with the monitoring function (Code: 40906, D-IN-8, D-IN-9, D-IN-10, D-IN-11).
tion
20-376 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DF10KB]
BWW10528
WA380-5 20-377
(10)
TROUBLESHOOTING FAILURE CODE [DGF1KX]
20-378 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DGR2KA]
Description of • Due to disconnection of the rear brake oil temperature sensor system, no rear brake oil temperature signal
Trouble can be input.
Controller Reaction • Assumes that the rear brake oil temperature is low.
Effect on Machine • Does not issue a brake oil temperature alarm.
Related Informa- • Can be checked with the monitoring function (Code: 30202, R BRAKE OIL).
tion
WA380-5 20-379
(10)
TROUBLESHOOTING FAILURE CODE [DGR2KB]
Description of • Due to ground fault of the rear brake oil temperature sensor system, no rear brake oil temperature signal can
Trouble be input.
Controller Reac- • Assumes that the rear brake oil temperature is high.
tion
Effect on Machine • Continues to issue a brake oil temperature alarm.
Related Informa- • Can be checked with the monitoring function (Code: 30202, R BRAKE OIL).
tion
20-380 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DHT1KX]
Description of • Due to discontinuity of the left brake pressure sensor signal system, no oil pressure sensor signal for the left
Trouble brake oil pressure can be input.
Controller Reaction • Cancels the transmission cut-off function.
• Does not perform transmission cut-off when the left brake is stepped on while the transmission cut-off func-
Effect on Machine tion is on.
Related Informa- • Left brake oil pressure can be checked with the monitoring function (Code: 41100, L.H. BRAKE).
tion • Can be checked by stepping on the left brake while the transmission cut-off function is on.
WA380-5 20-381
(10)
TROUBLESHOOTING FAILURE CODE [DLE2KA]
20-382 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DLE2LC]
WA380-5 20-383
(10)
TROUBLESHOOTING FAILURE CODE [DLT3KA]
Description of • Due to discontinuity of the speed sensor transmission output shaft revolution system, no speed sensor signal is
Trouble input.
Controller Reac- • Cannot recognize the travelling speed.
tion
Effect on • Indication of the vehicle speed stays at 0 km/h.
Machine • Shift up cannot be performed in the auto-shift mode.
Related Informa-
—
tion
Possible Causes Between wiring harnesses between L62 (Female) S - Resistance 1 Ω or below
and Standard REV.OUT (Female) 2
Values 1) Turn starting switch OFF.
2) Disconnect connector REV.OUT.
2 Defective speed sensor 3) Connect T-adapter.
Between REV.OUT (Male) 1 - 2 Resistance 500 - 1,000 Ω
1) Turn starting switch OFF.
Defective transmission 2) Disconnect connector L62.
3 and fan pump motor 3) Connect T-adapter.
controller
Between L62 (Female) J - S Resistance 500 - 1,000 Ω
20-384 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DT20KB]
Description of • Due to ground fault of the built-in indicator lamp system of transmission cut-off switch, no output goes to the
Trouble indicator lamp.
Controller Reac- • No action.
tion
Effect on • The indicator lamp built in the transmission cut-off switch does not come on.
Machine
Related Infor-
—
mation
WA380-5 20-385
(10)
TROUBLESHOOTING FAILURE CODE [DW7BKA]
BWW10533
20-386 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW7BKB]
BWW10533
WA380-5 20-387
(10)
TROUBLESHOOTING FAILURE CODE [DW7CKA]
BWW10533
20-388 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW7CKB]
BWW10532
WA380-5 20-389
(10)
TROUBLESHOOTING FAILURE CODE [DX16KA]
BWW10132
20-390 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DX16KB]
BWW10531
WA380-5 20-391
(10)
TROUBLESHOOTING FAILURE CODE [DXH1KA]
20-392 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXH1KB]
WA380-5 20-393
(10)
TROUBLESHOOTING FAILURE CODE [DXH4KA]
20-394 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXH4KB]
WA380-5 20-395
(10)
TROUBLESHOOTING FAILURE CODE [DXH5KA]
20-396 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXH5KB]
WA380-5 20-397
(10)
TROUBLESHOOTING FAILURE CODE [DXH6KA]
20-398 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXH6KB]
WA380-5 20-399
(10)
TROUBLESHOOTING FAILURE CODE [DXH7KA]
20-400 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXH7KB]
WA380-5 20-401
(10)
TROUBLESHOOTING FAILURE CODE [DXH8KA]
20-402 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXH8KB]
WA380-5 20-403
(10)
TROUBLESHOOTING FAILURE CODE [DXHHKA]
20-404 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXHHKB]
WA380-5 20-405
(10)
TROUBLESHOOTING FAILURE CODE [DY30MA]
Description of • An activation signal for the motor-driven emergency steering motor (pump) (S-NET) is issued although motor-
Trouble driven emergency steering output is turned OFF.
Controller Reac- • Turns motor-driven emergency steering output OFF.
tion
• The motor-driven emergency steering motor (pump) operates although the motor-driven emergency steering
Effect on switch is not operated.
Machine
• The emergency steering operation indicator comes on.
• Check operation of the emergency steering motor with the monitoring function (Code: 40903 D-IN-30).
Related Infor- • Check steering pressure drop with the monitoring function (Code: 40905 D-IN-0, D-IN-1).
mation
• Failure code documentation “DY30ME” related to monitoring.
20-406 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DY30MA]
BWW10527
WA380-5 20-407
(10)
TROUBLESHOOTING FAILURE CODE [DY30MC]
Description of • An activation signal for the motor-driven emergency steering motor (pump) (S-NET) is not issued although
Trouble motor-driven emergency steering output is turned ON.
Controller Reac- • Turns motor-driven emergency steering output OFF.
tion
Effect on • The motor-driven emergency steering motor (pump) does not operate although the motor-driven emergency
Machine steering switch is operated.
• Check operation of the emergency steering motor with the monitoring function (Code: 40903 D-IN-30).
Related Infor- • Check steering pressure drop with the monitoring function (Code: 40905 D-IN-0, D-IN-1).
mation
• See Failure code descriptions of “DY30ME” related to monitoring.
Possible Causes Line 396 (Emergency steering relay and emergency steer- Resistance 1 Ω or below
and Standard ing motor)
Values 1) Turn starting switch OFF. 2) Disconnect connectors L54 and R37. 3) Connect T-
3 Wiring harness adapter.
Between L54 (Female) 3/R37 (Female) c - body
ground fault
Resistance 1 MΩ or above
1) Turn starting switch OFF.
2) Disconnect connector R37.
3) Connect T-adapter.
20-408 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DY30MC]
BWW10527
WA380-5 20-409
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-1]
20-410 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-1]
WA380-5 20-410-1
5
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-2]
20-410-2 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-2]
WA380-5 20-411
5
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-3]
BWW10534
20-412 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-4]
20-414 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-4]
WA380-5 20-415
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-5]
Defective emergency 1) Turn starting switch OFF. 2) Disconnect connector L126. 3) Connect T-adapter.
2 steering relay (L126) Between L126 (Female) 3/L126 (Female) 5 - body Resistance 1 MΩ or above
1) Turn starting switch OFF.
Defective emergency 2) Disconnect connectors R15, R16 and both power lines (100sq).
3 steering operation relay
Between relay contacts. Resistance 1 MΩ or above
1) Turn starting switch OFF.
Wiring harness disconti- 2) Disconnect connectors L63 and S19.
4 nuity (Disconnection or 3) Connect T-adapter.
defective contact) Wiring harness between L63 (Female) S - S19 (Female) Resistance 1 Ω or below
1
1) Turn starting switch OFF.
Hot short-circuiting 2) Disconnect connectors L63 and S19.
between harnesses 3) Connect T-adapter.
5 (Contacting 24-V har-
Possible Causes 4) Turn starting switch ON.
and Standard ness)
Values Between L63 (Female) S/S19 (Female) 1 - body Voltage 1 V or below
1) Turn starting switch OFF.
Wiring harness ground 2) Disconnect connectors L63, L105, L126 and S19.
6 fault 3) Connect T-adapter.
Between L63 (Female) S/S19 (Female) 1 - body Resistance 1 MΩ or above
1) Turn starting switch OFF.
2) Disconnect connectors L63, L126 and S19.
3) Connect T-adapter.
4) Turn starting switch ON.
Between L63 (Female) S/L126 (Female) 1/S19 Resistance 1 MΩ or above
Wiring harness short- (Female) 4 - body
7 circuiting
1) Turn starting switch OFF.
2) Disconnect connectors L126 and R15.
3) Connect T-adapter.
4) Turn starting switch ON.
Between L126 5/R15 - body Resistance 1 MΩ or above
1) Turn starting switch OFF.
2) Disconnect connector L63.
Defective transmission 3) Connect T-adapter.
8 and fan pump motor 4) Turn starting switch ON.
controller Emergency steering switch = ON Voltage 20 - 30 V
Between L63 S -
body Other than above Voltage 1 V or below
20-416 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-5]
BWW10527
WA380-5 20-417
5
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-6]
20-418 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-7]
WA380-5 20-419
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-8]
20-420 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE
TROUBLESHOOTING CODE [TM-9A]
[TM-9a]
WA380-5 20-421
(10)
TROUBLESHOOTING TROUBLESHOOTINGCODE
TROUBLESHOOTING CODE[TM-9B]
[TM-9b]
20-422 WA380-5
(10)
TROUBLESHOOTING [TM-9b]
TROUBLESHOOTING CODE [TM-9B]
WA380-5 20-423
(7)
TROUBLESHOOTING TROUBLESHOOTINGCODE
TROUBLESHOOTING CODE[TM-10]
[TM-10]
Wiring harness disconti- Wiring harness between L62 (Female) Y - S04 (Female) Resistance 1 Ω or below
2 nuity (Disconnection or 4
defective contact) 1) Turn starting switch OFF. 2) Disconnect connectors L62 and S04.
3) Connect T-adapter. 4) Turn starting switch ON.
Possible Causes
and Standard Between S04 (Female) 3 - body Voltage 20 - 30 V
Values 1) Turn starting switch OFF. 2) Disconnect connectors L62 and S04.
Wiring harness hot
3 short-circuiting (Con- 3) Connect T-adapter. 4) Turn starting switch ON.
tacting 24-V harness) Between L62 (Female) Y/S04 (Female) e - body Voltage 1 V or below
Wiring harness ground 1) Turn starting switch OFF. 2) Disconnect connectors L62, S04 and L101.
fault 3) Connect T-adapter.
4 ★ In this case, fuse A-2
blows out when the Between L62 (Female) Y/S04 (Female) 4 - body Resistance 1 MΩ or above
switch is operated.
1) Turn starting switch OFF. 2) Disconnect connector L62.
3) Connect T-adapter. 4) Turn starting switch ON.
Defective transmission
5 and fan pump motor FNR switch mode change over Voltage 20 - 30 V
controller Between L62 Y - switch = ON
body
Other than above Voltage 1 V or below
20-424 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-11]
20-426 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-11]
bww10515.eps
WA380-5 20-427
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-12]
bww10166.eps
20-428 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-13]
BJW11504
WA380-5 20-429
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-14]
20-430 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-15]
WA380-5 20-431
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-16]
Wiring harness hot Between L63 (Female) (17)/L104 (Female) (11) - body Voltage 1 V or below
1 short-circuiting
Possible Causes 1) Turn starting switch OFF.
and Standard 2) Disconnect connectors F13 and L125.
Values 3) Connect T-adapter.
4) Turn starting switch ON.
Between F13 (Female) (1)/L125 (Female) (5) - body Voltage Max. 1V
1) Turn starting switch OFF.
Defective transmission 2) Disconnect connector L63.
2 and fan pump motor 3) Connect T-adapter.
controller
Between L63 (Female) (17) - body Resistance 200 - 400 Ω
BJW11505
20-432 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-17]
WA380-5 20-433
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-18]
20-434 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-19]
WA380-5 20-435
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-20]
20-436 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-21]
WA380-5 20-437
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-22]
20-438 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-23]
WA380-5 20-439
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-24]
20-440 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-25]
WA380-5 20-441
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-26]
20-442 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-27]
WA380-5 20-443
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-28]
BWW10533
20-444 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-29]
WA380-5 20-445
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-30]
20-446 WA380-5
(10)
TROUBLESHOOTING OF WORK EQUIPMENT
CONTROL SYSTEM
(WRK MODE)
Failure Code [DK5FKM] (Joystick steering EPC lever neutral system caution) is displayed. . . . . . . . 20-548
Failure Code [DK5FL8] (Defective joystick steering EPC lever potentiometer system input signal
(deviation of positional signals of main and sub-circuits)) is displayed . . . . . . . 20-549
Failure Code [DG5GKA] (Defective joystick steering EPC lever potentiometer system (disconnection
or ground fault of sub-circuit)) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-550
Failure Code [DK5GKY] (Defective joystick steering EPC lever potentiometer system (sub-circuit
short circuit)) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-551
Failure Code [DKA0KA] (Defective lift arm angle sensor system (disconnection or ground fault))
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552
Failure Code [DKA0KY] (Defective lift arm angle sensor system (short circuit) is displayed. . . . . . . 20-553
Failure Code [DLE2LC] (Defective engine speed sensor system) is displayed . . . . . . . . . . . . . . . . . . 20-554
Failure Code [DLT3LC] (Defective transmission output axis speed sensor system (disconnected))
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-555
Failure Code [DUM1KB] (Remote positioner RAISE lamp system ground fault) is displayed . . . . . . 20-556
Failure Code [DUM2KB] (Remote positioner LOWER lamp system ground fault) is displayed . . . . . 20-557
Failure Code [DW4PKA] (Disconnected lift arm RAISE EPC solenoid system) is displayed . . . . . . . . 20-558
Failure Code [DW4PKB] (Lift arm RAISE EPC solenoid system ground fault) is displayed. . . . . . . . . 20-559
Failure Code [DW4QKA] (Disconnected lift arm LOWER EPC solenoid system) is displayed . . . . . . . 20-560
Failure Code [DW4QKB] (Lift arm LOWER EPC solenoid system ground fault) is displayed . . . . . . . 20-561
Failure Code [DW4RKA] (Disconnected bucket TILT EPC solenoid sytem) is displayed . . . . . . . . . . . 20-562
Failure Code [DW4RKB] (Bucket TILT EPC solenoid sytem ground fault) is displayed . . . . . . . . . . . . 20-563
Failure Code [DW4SKA] (Bucket DUMP EPC solenoid sytem disconnection) is displayed . . . . . . . . . 20-564
Failure Code [DW4SKB] (Bucket DUMP EPC solenoid sytem ground fault) is displayed . . . . . . . . . . 20-565
Failure Code [DWM1KA] (Work equipment neutral lock solenoid system disconnection) is
displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-566
Failure Code [DWM1KB] (Work equipment neutral lock solenoid system ground fault) is displayed . . . . 20-567
Failure Code [DWN6KA] (Lift arm RAISE magnet detent system disconnection) is displayed . . . . . . 20-568
Failure Code [DWN6KB] (Lift arm RAISE magnet detent system ground fault) is displayed . . . . . . . 20-569
Failure Code [DWN7KA] (Lift arm FLOATING magnet detent system disconnection) is displayed . . 20-570
Failure Code [DWN7KB] (Lift arm FLOATING magnet detent system ground fault) is displayed. . . . 20-571
Failure Code [DWN8KA] (Bucket TILT magnet detent system disconnection) is displayed. . . . . . . . . 20-572
Failure Code [DWN8KB] (Bucket TILT magnet detent system failure (power supply system ground
fault)) is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-573
Failure Code [DXHJKA] (3rd valve extension EPC solenoid system disconnection) is displayed . . . 20-574
Failure Code [DXHJKB] (3rd valve extension EPC solenoid system ground fault) is displayed . . . . 20-575
Failure Code [DXHKKA] (3rd valve retraction EPC solenoid system disconnection) is displayed . . . 20-576
Failure Code [DXHKKB] (3rd valve retraction EPC solenoid system ground fault) is displayed. . . . . 20-577
Failure Code [DXHLKA] (Joystick steering right-hand EPC solenoid system disconnection) is
displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-578
Failure Code [DXHLKB] (Joystick steering right-hand EPC solenoid system ground fault) is
displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-579
Failure Code [DXHMKA] (Joystick steering left-hand EPC solenoid system disconnection) is
displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-580
Failure Code [DXHMKB] (Joystick steering left-hand EPC solenoid system ground fault) is
displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-581
Troubleshooting Code [WRK-1] Defective lift arm lock switch system . . . . . . . . . . . . . . . . . . . . . . 20-582
Troubleshooting Code [WRK-2] Defective remote positioner RAISE setting switch system . . . . . 20-583
Troubleshooting Code [WRK-3] Defective remote positioner LOWER setting switch system . . . . 20-584
Troubleshooting Code [WRK-4] Defective remote positioner RAISE selection switch system . . . 20-586
Troubleshooting Code [WRK-5] Defective remote positioner LOWER ON/OFF switch system . . . 20-588
Troubleshooting Code [WRK-6] Defective bucket cylinder proximity switch system. . . . . . . . . . . 20-590
Troubleshooting Code [WRK-7] Defective bucket cylinder full stroke detection switch system . . 20-592
Troubleshooting Code [WRK-8] Defective semi-automatic digging HARD selection switch system 20-593
Troubleshooting Code [WRK-9] Defective semi-automatic digging SOFT selection switch system . 20-594
Troubleshooting Code [WRK-10] Defective joystick ON/OFF switch system. . . . . . . . . . . . . . . . . . . 20-596
Troubleshooting Code [WRK-11] Defective joystick steering speed Hi/Lo switch system . . . . . . . . 20-598
Troubleshooting Code [WRK-12] Defective joystick solenoid cut relay output system . . . . . . . . . . 20-599
20-502 WA380-5
(10)
TROUBLESHOOTING
Troubleshooting Code [WRK-13] Hot short-circuited lift arm RAISE magnet detent output system. . 20-600
Troubleshooting Code [WRK-14] Hot short-circuited lift arm FLOATING magnet detent output
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-601
Troubleshooting Code [WRK-15] Hot short-circuited bucket TILT magnet detent output system . 20-602
Troubleshooting Code [WRK-16] Hot short-circuited work equipment neutral lock solenoid output
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-603
Troubleshooting Code [WRK-17] Hot short-circuited lift arm RAISE EPC solenoid system . . . . . . . 20-604
Troubleshooting Code [WRK-18] Hot short-circuited lift arm LOWER EPC solenoid system . . . . . 20-605
Troubleshooting Code [WRK-19] Hot short-circuited bucket TILT EPC solenoid system . . . . . . . . . 20-606
Troubleshooting Code [WRK-20] Hot short-circuited bucket DUMP EPC solenoid system . . . . . . . 20-607
Troubleshooting Code [WRK-21] Hot short-circuited 3 valves extension EPC solenoid system . . . 20-608
Troubleshooting Code [WRK-22] Hot short-circuited 3 valves retraction EPC solenoid system . . . 20-609
Troubleshooting Code [WRK-23] Hot short-circuited joystick steering right EPC solenoid system 20-610
Troubleshooting Code [WRK-24] Hot short-circuited joystick steering left EPC solenoid system. . 20-611
Troubleshooting Code [WRK-25] Defective bucket positioner, boom kick-out and FLOATING
holding function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-612
Troubleshooting Code [WRK-26] Defective boom kick-out function and cancellation . . . . . . . . . . . 20-614
Troubleshooting Code [WRK-27] Defective bucket leveler function and cancellation . . . . . . . . . . . 20-616
Troubleshooting Code [WRK-28] Defective lift arm FLOATING holding and cancellation . . . . . . . . 20-618
WA380-5 20-502-1
(10)
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
A21 Yazaki 2 Water temperature sensor (Vehicle with automatic air W-3
conditioner)
Inside temperature sensor (Vehicle with automatic air
A22 Yazaki 2 conditioner) U-2
WA380-5 20-503
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
C48 AMP040 16 A/C control AMP (Vehicle with automatic air conditioner) D-9
C49 SWP 8 Left Servomotor R-1
C50 SWP 8 Right Servomotor M-3
C51 Yazaki 2 Diode (Vehicle with automatic air conditioner) M-3
CAN1 DT-T 3 Resistor N-1 F-1 J-8 B-2
CAN2 DT-T 3 Resistor R-9 J-9 K-8 B-2
CL1 S 8 Intermediate connector A-4 E-7
CL2 S (L) 12 Intermediate connector (Wiper motor) A-4
Intermediate connector (Vehicle with automatic air
CL5 S (W) 16 M-2
conditioner)
CL6 M 6 Intermediate connector (Vehicle with automatic air M-3 B-3 C-5
conditioner)
CL6 DT-T (G) 12 Intermediate connector (Monitor panel controller) W-4 K-4 C-4
CL7 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-2 B-4 K-4 C-5
CL8 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-1 B-4 C-5
CL9 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-4 K-4 C-6 B-5
20-504 WA380-5
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
CL10 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-3 K-3 C-3
CL20 DT-T 2 Intermediate connector (Monitor panel controller) N-2 C-5
CN55 DT-T 2 Intermediate connector (Backup buzzer) K-8 P-2 V-8
COMBI M 3 Front combination lamp (Right) A-6 W-3
COMBI M 3 Front combination lamp (Left) E-1 W-2
DIODE DT-T 2 Diode (Parking brake solenoid) AG-8 P-8
DL DT-T (Gr) 12 Connector (S-NET) U-8 I-9 K-6 K-5
E01 DT-T 2 Intermediate connector (Starting motor) AB-1 W-4 B-1
E02 Terminal 1 Alternator R AD-3 X-5
E03 Terminal 1 Alternator B AD-3 X-5
E04 Terminal 1 Alternator E AD-3 X-5
E05 Terminal 1 Engine heater relay AC-9 Q-9 E-4
E06 Terminal 1 Engine heater relay AA-9 Q-9 F-4
E07 Terminal 1 Engine heater relay Z-9 Q-9 F-4
E08 DT-T 2 Engine coolant temperature sensor (Monitor) AC-1 O-8
E09 DT-T 2 Engine coolant temperature sensor (Preheater) AD-2 O-8 B-2
E10 DT-T 2 Air conditioner compressor magnet clutch AD-2
E11 DT-T 2 Diode (Air conditioner compressor) AD-4
E14 Terminal 1 Ground (Rear frame) AB-5 X-5 A-1
E26 DT-T 2 Engine oil level sensor AA-5 P-8
E27 DT-T 2 Engine speed sensor AC-6 L-8
E28 DT 2 Diode (Engine heater relay) AC-9 O-8 B-2
E29 Terminal 1 Engine oil pressure switch AB-5 P-8
E30 Terminal 1 Starting motor B AB-1 X-4
E31 DT-T 2 Diode AC-7 B-3
E32 DT-T 2 Diode (Fuel cut solenoid) AB-6 B-3
E33 DT-T 2 Dust indicator AB-9 P-8
E34 DT-T 3 Fuel cut solenoid AC-7 B-2
E36 Terminal 1 Air compressor magetic clutch Y-5
ER-1 DT-T (G) 8 Intermediate connector (Engine) Z-2 P-5 D-3
ER-3 DT-T (Gr) 8 Intermediate connector (Engine) AA-1 K-7 O-5 D-3
F01 M 6 Intermediate connector (R.H. Front lamp) A-5 U-3
F02 M 6 Intermediate connector (L.H. Front lamp) D-1 U-2
F03 Terminal 1 Horn (303 Hz) A-1 W-1
F04 Terminal 1 Horn (303 Hz) A-1 W-1
F05 Terminal 1 Horn (303 Hz) C-1 W-1
F06 Terminal 1 Horn (303 Hz) B-1 W-1
F07 DT-T 2 Switching pump cut-off solenoid C-1 R-8
F09 DT-T 3 Bucket positioner proximity switch A-3 Q-7 B-3
F10 DT-T 3 Bucket positioner proximity switch (Standard) A-3 Q-6 B-3
F13 DT-T 2 Lift arm damper solenoid C-1 R-8
F14 DT-T 2 Diode (Damper solenoid) D-1 R-7
F15 DT-T 3 Lift arm angle signal (For load meter) A-2 B-3 M-8
F16 DT-T 3 Lift arm bottom signal (For load meter) B-1 B-3 M-8
F17 DT-T 3 Lift arm rod signal (For load meter) B-1 B-3 M-8
WA380-5 20-505
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
F18 DT-T 3 Lift arm angle sensor (For boom EPC) A-5 H-8
F19 DT-T 3 Bucket positioner proximity switch (For bucket EPC) A-3 H-8
F20 DT-T 2 Lift arm RAISE EPC A-2 Q-4 G-8
F21 DT-T 2 Lift arm LOWER EPC A-1 G-8
F22 DT-T 2 Bucket CURL EPC A-1 G-8
F23 DT-T 2 Bucket DUMP EPC A-1 G-8
F24 DT-T 2 ATT. EXT. EPC (If equipped) A-3 I-8
F25 DT-T 2 ATT. RET. EPC (If equipped) A-2 I-8
F26 DT-T 2 Lift arm EPC cut-off solenoid B-1 H-8
F27 DT-T 2 Diode (For boom EPC cut-off solenoid) A-4 H-7
F30 Terminal 1 Ground (Front frame) C-1 Q-4 P-5 U-1 A-3
FF1 S 10 Intermediate connector (Front lamp) E-1 N-3
FF2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) D-1 K-4 N-6 C-3
FL1 S 12 Intermediate connector (Front lamp) W-1 J-3 K-3
FL2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) W-1 I-4 K-6 C-5
FL3 DT-T 6 Intermediate connector (Load meter) X-2 E-3 K-6
FL7 DT-T (Br) 12 Intermediate connector (Work equipment solenoid) N-2 E-7
FL8 DT-T (G) 8 Intermediate connector (Work equipment solenoid) N-2 E-6
FL9 DT-T 6 Intermediate connector (3rd lever solenoid) N-2 E-5
FS1 L 2 Intermediate connector (Fuse box) W-7 C-1 E-8
FS2 L 2 Intermediate connector (Fuse box) V-7 C-1 E-8
FS3 S (W) 16 Intermediate connector (Fuse box) V-8 C-1 K-7 G-8 E-8
FS4 S (W) 12 Intermediate connector (Fuse box) V-8 B-1 K-7 G-8 E-8
FS5 M 6 Intermediate connector (Fuse box) V-7 G-8
FS6 Plug 1 Intermediate connector (Fuse box) V-8
FS7 Plug 1 Intermediate connector (Fuse box) W-7
F.PS DT-T 2 Transmission F clutch solenoid AJ-6 N-8
F.SW DT 2 Transmission F clutch fill switch AJ-6 P-8
G01 Terminal 1 Backup buzzer J-9 Q-2 V-9
G02 Terminal 1 Backup buzzer J-9 Q-2 V-9
G04 M 2 Rear working lamp (Left) K-8 V-8
G05 M 2 Rear working lamp (Right) J-9 U-8
GR1 DT-T 4 Intermediate connector (Fan reverse solenoid, rear working L-7 O-4 U-6
lamp)
GR2 DT-T 2 Fan reverse solenoid L-7 Q-4
HEAD M 3 Head lamp (Right) A-6 W-3
HEAD M 3 Head lamp (Left) W-2
JT1 DT-T (B) 8 Centralized connector (Ground) AH-2 R-7 Q-7
JT2 DT-T (B) 8 Centralized connector (Shield) AG-2 R-6
JT3 DT-T 6 Centralized connector AF-8 R-5
L01 SWP 6 Parking brake switch M-5 B-7
L02 SWP 6 Dimmer switch, light switch M-5 B-1
L03 SWP 6 Turn signal and hazard switch M-6 B-1
L04 SWP 14 Shift switch M-3 B-6 A-8
L05 DT-T 2 Horn switch M-5 E-8
L07 DT-T 6 Machine monitor switch (Mode/Cancel selector switch) Q-1 B-8
20-506 WA380-5
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L08 DT-T 6 Machine monitor switch (Screen selector switch) Q-1 A-8
L09 DT-T 2 Stop lamp switch Q-1 D-8
L10 DT-T 3 Left brake pressure sensor R-1 B-6
L11 DT-T 2 Air suspension seat S-1
L12 DT-T 4 R direction switch O-7 J-7 E-3
L13 DT-T 2 Lift arm N lock switch O-7 D-8
L14 DT-T 4 Kickdown and hold switch O-7 B-8 G-2
L15 DT-T 4 Load meter cancel and sub-total switch O-7 H-2 D-8
L16 M 2 Intermediate connector (DC converter) V-2
L17 M 4 DC24V/DC12V converter W-5
L18 Yazaki 2 DC12V socket W-3
L19 M 4 Flasher unit U-8 H-8
L20 M 2 Alarm buzzer U-8 I-7
L21 S 10 Front and rear wiper switch N-1
L25E DT-T 2 Lift arm and bucket EPC lever M-6 E-8
L25S DT-T 2 Work equipment lever electrical detent N-7 G-2 C-8
L26E DT-T 2 Lift arm and bucket EPC lever P-8 E-8
L26S DT-T 2 Work equipment lever electrical detent N-6 G-2 B-8
L27 DT-T 2 Lift arm and bucket EPC lever N-6 D-8
L27S DT-T 2 Work equipment lever electrical detent N-7 G-2 B-8
L28 DT-T 4 Lift arm and bucket EPC lever P-8 D-8
L29 DT-T 4 Lift arm and bucket EPC lever O-7 E-8
L30 DT-T 4 3rd EPC lever P-8 D-8
L31 M 6 Intermittent wiper timer W-7
L34 DT-T 4 Joystick lever positioner W-6 B-1
L35 DT-T 2 Joystick EPC solenoid P-1 E-1
L36 DT-T 2 Joystick EPC solenoid P-1 D-1
L37 DTM 12 Joystick lever switch M-6 K-8
L38 DT-T 3 Joystick N lock switch W-7 K-1 B-2
L39 DT-T 6 Joystick ON/OFF switch S-1 K-2 B-2
L40 DT-T 6 Steering speed mode switch S-1 K-1 B-1
L41 Relay 6 Joystick cutoff relay N-6 D-1
L42 Plug 1 Connector (Spare power supply) A-5
L43 Plug 1 Connector (Spare power supply) A-5
L44 M 6 Intermediate connector (Printer) V-3 I-7
L45 D-sub 25 Printer (Load meter) I-8
L46 G 4 Printer (Load meter) H-9
L51 AMP070 20 Monitor panel controller M-5 A-2 O-2 B-7 B-4
L52 AMP070 18 Monitor panel controller M-4 B-6
L53 AMP070 12 Monitor panel controller M-2 A-2 B-5
L54 AMP070 18 Monitor panel controller M-4 A-2 O-2 B-4
L55 AMP070 12 Monitor panel controller M-4 A-2 O-2 B-4 B-4
L56 AMP070 12 Monitor panel controller M-5 B-2 O-2 B-3
L57 AMP070 14 Monitor panel controller M-4 B-2
L58 AMP040 8 Monitor panel controller M-2
WA380-5 20-507
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L61 DRC 24 Transmission and fan pump motor controller P-8 B-8 I-8 F-8 A-8
L62 DRC 40 Transmission and fan pump motor controller Q-8 C-8 J-8 F-8
L63 DRC 40 Transmission and fan pump motor controller Q-8 E-8 F-8 A-8
L71 DRC 24 Lift arm bucket and joystick controller Q-9 A-8
L72 DRC 40 Lift arm bucket and joystick controller Q-9 K-8 A-8 N-8
L73 DRC 40 Lift arm bucket and joystick controller R-9 K-8 B-8
L88 DT-T (Gr) 8 Engine mode selector motor P-1 B-8
L91 DT-T 6 Timer P-8 A-6
L92 DT-T 3 Intermediate connector (Pump bypass) Q-8 B-2
L93 Relay 5 Pump bypass relay Q-9 B-1
L100 Terminal 1 Ground (Floor) R-1 I-1 J-1 B-5
L101 S (W) 16 Intermediate connector (Relay sub-unit) T-9 D-2 I-7 E-7
L102 S (L) 16 Intermediate connector (Relay sub-unit) T-9 D-2 J-7 E-7
L103 S (W) 16 Intermediate connector (Relay sub-unit) S-9 E-2 J-7
L104 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 L-7 E-6
L105 S (W) 12 Intermediate connector (Relay sub-unit) T-9 F-2
L106 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 K-7
L111 — 5 Turn signal lamp and hazard relay X-7 I-9
L112 — 5 Air cleaner clogging relay W-7 I-9
L113 — 5 Steering selector relay W-8 D-1 J-9 F-7
L114 — 5 Automatic preheater relay V-8 J-9 F-7
L115 — 5 Engine controller power supply relay V-9 F-7
L116 — 4 Neutral safety relay W-7 D-1 J-9 F-6
L117 — 4 Backup lamp relay W-7 E-1 J-9
L118 — 4 Stop lamp relay V-8 K-9
L119 — 4 Horn relay V-8 K-9
L120 — 4 Parking brake relay V-8 E-1
L123 — 5 Lift arm detent relay (Standard) X-9 L-9 F-6
L124 — 5 Bucket detent relay (Standard) X-9 L-9 F-6
L125 — 5 Lift arm damper relay V-9 E-1
L126 — 4 Emergency steering relay X-8 F-1
L127 — 4 Front working lamp relay X-7 K-9
L128 — 4 Rear working lamp relay X-9 K-9
L129 — 4 Rear glass heater relay V-9
L130 — 4 Transmission pump cut-off relay V-9 F-1
L141 Relay 5 Printer relay T-1
L142 DT-T 2 Diode (Printer) W-3
L143 DT-T 2 Diode (Printer) W-4
L144 DT-T 2 Diode (Printer) W-4
L145 DT-T 2 Diode (Printer) W-4
L146 DT-T 2 Diode (Printer) T-1
L147 DT-T 2 Diode (Printer) T-1
LC.PS DT-T 2 Torque converter lockup solenoid (If equipped) AJ-5 N-8
LC.SW DT 2 Torque converter lockup fill switch (If equipped) AJ-5 P-8
LL5 DT 3 Intermediate connector (Vehicle with joystick) Q-1 F-5
LL6 DT-T (Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 E-4
20-508 WA380-5
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
LL7 DT-T (G) 12 Intermediate connector (Vehicle with joystick) Q-1 J-7 E-4 K-5
LL8 DT-T (Gr) 8 Intermediate connector (Joystick switch) R-1 K-2 C-2
LR1 DTHD#12 1 Intermediate connector (Slow-blow fuse) X-2 J-2 D-5
LR2 DT-T (G) 12 Intermediate connector (Engine) V-2 J-7 K-4 D-5
LR4 L 2 Intermediate connector (Slow-blow fuse) X-1 J-2 E-5
LR5 DT-T 6 Intermediate connector (Auto grease controller) X-2 K-1
LR6 L 2 Intermediate connector (Ground) X-2 J-2 K-1
LR8 DTHD#8 1 Intermediate connector (Ground) X-2 J-2 L-5 K-2 D-5
LR9 DT-T (G) 12 Intermediate connector (Steering and brake oil pressure X-1 I-3 K-2
switch)
LR10 DT-T (Gr) 12 Intermediate connector X-1 I-3 K-3 D-5
LR13 DT-T 2 Intermediate Connecter ( Pump bypass) AE-7 J-1
W-3,
LT1 HD-24 31 Intermediate connector (Transmission) AF-2 I-6 K-4
WA380-5 20-509
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
S13 DT-T 6 Upper remote positioner ON/OFF switch (Vehicle with joy- N-9 I-2
stick)
Lower remote positioner ON/OFF switch (Vehicle with joy-
S14 DT-T 6 N-8 I-2
stick)
S15 DT-T 6 Automatic digging switch (Vehicle with joystick) N-9 J-2
S16 DT-T 6 Hydraulic fan reverse switch M-9 G-2
S17 DT-T 6 Auto grease switch O-8 A-8
S19 DT-T 6 Emergency steering check switch M-9 H-2 C-8
S21 DT-T 4 Engine power mode switch M-9 G-8 C-8
S22 DT-T 4 Auto shift mode switch N-7 G-8
S31 DT 4 Starting switch N-7 G-2 K-2 L-7 D-8
S32 DT-T 2 Starting switch N-9 D-8
T20 Terminal 1 Ground AI-2 Q-4
T21 DT-T 2 Pump bypass solenoid AG-8 K-1
TC.T DT-T 2 Torque converter oil temperature sensor AH-8 Q-8 Q-8
TEL DT-T (Gr) 12 Intermediate connector (KOMTRAX) Q-1 I-9 K-1 C-5
TM.T DT-T 2 Transmission oil temperature sensor AJ-3 Q-8 Q-8
20-510 WA380-5
(10)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-512 WA380-5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-513
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-514 WA380-5
(9)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-515
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-515-1 WA380-5
(9)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-515-2
(9)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-516 WA380-5
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-517
5
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
20-518 WA380-5
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
WA380-5 20-519
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
20-520 WA380-5
TROUBLESHOOTING FAILURE CODE [D193KA]
Description of • The joystick steering solenoid cut relay output system is disconnected (Defective).
Trouble
Controller • Stops the joystick steering solenoid cut relay output and joystick steering EPC solenoid output (Both left and
Reaction right).
Effect on Machine • The joystick steering cannot be operated.
Related
Information —
WA380-5 20-521
(10)
TROUBLESHOOTING FAILURE CODE [D193KB]
Description of • The joystick solenoid cut relay output system is grounded properly.
Trouble
Controller • Stops joystick solenoid cut relay and joystick solenoid output.
Reaction
Effect on Machine • The joystick steering cannot be operated.
Related
Information —
20-522 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB90KK]
WA380-5 20-523
(10)
TROUBLESHOOTING FAILURE CODE [DB92KK]
20-524 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB95KX]
20-526 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB95KX]
BWW10245
WA380-5 20-527
(10)
TROUBLESHOOTING FAILURE CODE [DD1ALD]
Description of • Cannot be set to up because the remote positioner UP set switch system is grounded improperly.
Trouble
• Cancels the UP set position setting and the remote UP stop setting.
Controller Reac- • The UP set indicator is switched off the light.
tion
• UP set indicator goes out.
Effect on Machine • The UP set position cannot be set.
Related • Can be checked with the monitoring function (Code: 40917).
Information
20-528 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DD1BLD]
Description of • Cannot be set to DOWN because the remote positioner DOWN set switch system is grounded improperly.
Trouble
• Cancels the DOWN set position setting and the remote DOWN stop setting.
Controller Reaction • The DOWN set indicator is switched off the light.
• DOWN set indicator goes out.
Effect on Machine • The DOWN set position cannot be set.
Related • Can be checked with the monitoring function (Code: 40917).
Information
WA380-5 20-529
(10)
TROUBLESHOOTING FAILURE CODE [DFAOKM]
Description Of • The neutral system for joystick work equipment lever is operated mistakenly.
Trouble
Controller • Stops the joystick EPC solenoid output (Process after resetting from error: Return the lever to neutral position
Reaction once).
Effect on Machine • The work equipment cannot be operated.
Related • Can be checked with the monitoring function (Code: 42000).
Information
20-530 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK59KA]
Description Of • The lift arm EPC lever potentiometer signal system is disconnected (Main circuit discontinuity or ground
Trouble fault).
Controller Reaction • Stops the lift arm EPC solenoid output and the lift arm lever magnet detent output.
Effect on Machine • The lift arm cannot be operated.
Related • Can be checked with the monitoring function (Code: 42001).
Information
WA380-5 20-531
(10)
TROUBLESHOOTING FAILURE CODE [DK59KY]
Description Of • The electrical power supply is contacted to the lift arm EPC lever potentiometer signal system.
Trouble
Controller • Stops the lift arm EPC solenoid output and the lift arm EPC lever magnet detent output.
Reaction
Effect on Machine • The lift arm cannot be operated.
Related • Can be checked with the monitoring function (Code: 42000).
Information
20-532 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK59L8]
Description Of • The input signal for the lift arm EPC lever potentiometer system (Main and sub circuit) is not coincided.
Trouble
Controller Reaction • Stops the lift arm EPC solenoid output and the lift arm EPC lever magnet detent output.
Effect on Machine • The lift arm cannot be operated.
Related • Can be checked with the monitoring function (Code: 42000 and 42001).
Information
Possible Causes 1) Turn starting switch OFF. 2) Disconnect connectors L71 and L28.
and Standard Val- 3) Connect T-adapter.
ues Wiring harness disconti- Wiring harness between L71 (Female) I - L28
2 nuity (Disconnection or Resistance 1 Ω and below
defective contact) (Female) 3
Wiring harness between L71 (Female) C - L28
(Female) 2 Resistance 1 Ω and below
WA380-5 20-533
(10)
TROUBLESHOOTING FAILURE CODE [DK5AKA]
20-534 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5AKY]
Description Of • The electric power supply harness is contacted to the lift arm EPC lever potentiometer sub circuit signal sys-
Trouble tem harness.
Controller Reaction • Stops the lift arm EPC solenoid output.
Effect on Machine • The lift arm cannot be operated.
Related • Can be checked with the monitoring function (Code: 42001).
Information
WA380-5 20-535
(10)
TROUBLESHOOTING FAILURE CODE [DK5BKA]
Description Of • The bucket EPC lever potentiometer signal system is disconnected (Main circuit discontinuity or ground fault).
Trouble
Controller Reac- • Turns off the bucket EPC solenoid output and the bucket magnet detent output.
tion
Effect on Machine • The bucket cannot be operated.
Related Informa- • Can be checked with the monitoring function (Code: 42002).
tion
20-536 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5BKY]
Description Of • The electric power supply harness is contacted to the bucket EPC lever potentiometer signal system.
Trouble
Controller Reaction • Turns off the bucket EPC solenoid output and the bucket magnet detent output.
Effect on Machine • The bucket cannot be operated.
Related Informa- • Can be checked with the monitoring function (Code: 42002).
tion
WA380-5 20-537
(10)
TROUBLESHOOTING FAILURE CODE [DK5BL8]
Related • Can be checked with the monitoring function (Codes: 42002 and 42003).
Information
20-538 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5CKA]
Description Of • The bucket EPC lever potentiometer signal system is disconnected (Sub circuit discontinuity or ground fault).
Trouble
Controller Reaction • Turns off the bucket EPC solenoid output.
Effect on Machine • The bucket cannot be operated.
Related Informa- • Can be checked with the monitoring function (Code: 42003).
tion
WA380-5 20-539
(10)
TROUBLESHOOTING FAILURE CODE [DK5CKY]
Description Of • The electric power supply harness is contacted to the bucket EPC lever potentiometer signal system.
Trouble
Controller • Turns off the bucket EPC solenoid output.
Reaction
Effect on Machine • The bucket cannot be operated.
Related • Can be checked with the monitoring function (Code: 42003).
Information
20-540 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5DKA]
Description Of • The 3rd valve lever potentiometer signal system is disconnected (Main circuit discontinuity or ground fault).
Trouble
Controller Reaction • Turns off the 3rd RPC solenoid output.
Effect on Machine • The 3rd valve cannot be operated.
Related • Can be checked with the monitoring function (Code: 42003).
Information
WA380-5 20-541
(10)
TROUBLESHOOTING FAILURE CODE [DK5DKY]
Description Of • The electric power supply harness is contacted to the 3rd valve lever potentiometer signal system.
Trouble
Controller • Turns off the 3rd valve RPC solenoid output.
Reaction
Effect on Machine • The 3rd valve cannot be operated.
Related • Can be checked with the monitoring function (Code: 42006).
Information
20-542 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5DL8]
Between L30 Lever = Full stroke at the exten- Voltage 1.1 - 1.5 V
sion side
3-1
Defective potentiometer Lever = Full stroke at the shrink-
Voltage 3.4 - 4.0 V
1 ★ Defective installa- age side
tion (Loose and play) Lever = Neutral Voltage 2.4 - 2.6 V
Lever = Full stroke at the exten-
Between L30 Voltage 3.5 - 4.0 V
2-1 sion side
Lever = Full stroke at the shrink-
age side Voltage 1.1 - 1.5 V
3 Defective work equip- Lever = Full stroke at the shrink- Voltage 3.4 - 4.0 V
ment controller age side
Lever = Neutral Voltage 2.4 - 2.6 V
Lever = Full stroke at the exten- Voltage 3.4 - 4.0 V
L71 D - K sion side
Lever = Full stroke at the shrink-
Voltage 1.1 - 1.5 V
age side
WA380-5 20-543
(10)
TROUBLESHOOTING FAILURE CODE [DK5EKA]
Description Of • The 3rd valve EPC lever potentiometer signal system is disconnected (Sub circuit discontinuity or ground
Trouble fault).
Controller • Turns off the 3rd valve EPC solenoid output.
Reaction
Effect on Machine • The 3rd valve cannot be operated.
Related • Can be checked with the monitoring function (Code: 42007).
Information
20-544 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5EKY]
Description Of • The electric power supply harness is contacted to the 3rd valve EPC lever potentiometer signal system.
Trouble
Controller Reaction • Turns off the 3rd valve EPC solenoid output.
Effect on Machine • The 3rd valve cannot be operated.
Related • Can be checked with the monitoring function (Code: 42007).
Information
WA380-5 20-545
(10)
TROUBLESHOOTING FAILURE CODE [DK5FKA]
20-546 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5FKY]
Description Of • The electric power supply harness is contacted to the joystick steering EPC lever magnet detent output.
Trouble
Controller Reaction • Turns off the joystick steering EPC solenoid output and the joystick steering EPC lever magnet detent output.
Effect on Machine • The steering cannot be operated by the joystick lever.
Related • Can be checked with the monitor system function (Codes: 42004).
Information
WA380-5 20-547
(10)
TROUBLESHOOTING FAILURE CODE [DK5FKM]
20-548 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5FL8]
Possible Causes 1) Turn starting switch ON. 2) Disconnect connectors L71 and L34.
3) Connect T-adapter.
and Standard Val-
ues Wiring harness disconti- Between wiring harnesses between L71
2 nuity (Disconnection or Resistance 1 Ω and below
defective contact) (Female) 9 - L34 (Female) 3
Between wiring harnesses between L71
(Female) 3 - L34 (Female) 2 Resistance 1 Ω and below
WA380-5 20-549
(10)
TROUBLESHOOTING FAILURE CODE [DK5GKA]
20-550 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5GKY]
Description Of • The power supply line is contacting the joystick steering EPC lever potentiometer signal (Sub), which pre-
Trouble vents output to the joystick EPC solenoid.
Controller Reaction • Stops joystick steering EPC solenoid output until lever’s neutral position will be detected.
Effect on Machine • The steering cannot be operated by using the joystick. It is operable by using the handle in the handle mode.
Related • Can be checked with the monitoring function (Code 42005).
Information
WA380-5 20-551
(10)
TROUBLESHOOTING FAILURE CODE [DKAOKA]
Related Information • Can be checked with the monitoring function (Code: 06002).
1
connection or defective contact)
B
Wiring harness discontinuity (Dis- Wiring harness between L71 (Female) 8 - F18 (Female) Resistance 1 Ω and below
C
Wiring harness between L71 (Female) L - F18 (Female)
Resistance 1 Ω and below
1) Turn starting switch OFF. 2) Disconnect connectors L71 and F18. 3) Connect T-adapter.
B - body
Wiring harness between L71 (Female) 8,F18 (Female) Resistance 1 MΩ and above
2 Wiring harness ground fault
C - body
Wiring harness between L71 (Female) L,F18 (Female)
Resistance 1 MΩ and above
20-552 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DKAOKY]
B - body
tacts the power supply harness) Wiring harness between L71 (Female) 8, F18 (Female)
Voltage 1 V and below
Wiring harness discontinuity (Dis- 1) Turn starting switch OFF. 2) Disconnect connectors L71 and F18. 3) Connect T-adapter.
connection or defective contact) Wiring harness between F18 (Female) A - body
2
Resistance 1 Ω and below
1) Turn starting switch OFF.
2) Disconnect connector F18.
3) Connect T-adapter.
4) Turn starting switch ON.
Between F18 C - A Voltage 4.75 - 5.25 V
Possible Causes and
Standard Values 3 Defective lift arm angle sensor At the time of boom RAISE
Voltage 3.5 - 4.0 V
Between F18 B - A
stroke end
At the time of boom LOWER
Voltage 1.0 - 2.0 V
stroke end
1) Turn starting switch OFF. 2) Disconnect connector F18. 3) Connect T-adapter.
Between F18 C - A Resistance 4 - 6 kΩ
1) Turn starting switch OFF. 2) Disconnect connector L71.
3) Connect T-adapter. 4) Turn starting switch ON.
Between L71 L - body The whole gamut Voltage 4.75 - 5.25 V
Defective work equipment con-
4
troller At the time of the boom maxi- Voltage
3.5 - 4.0 V
mum raising
Between L71 8 - body
At the time of the boom maxi- Voltage
1.0 - 2.0 V
mum lowering
WA380-5 20-553
(10)
TROUBLESHOOTING FAILURE CODE [DLE2LC]
20-554 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DLT3LC]
Description Of • Speed sensor system disconnection prevents the speed sensor signal from being input.
Trouble
Controller • Cannot detect travel speed. (Recognizes the speed is low)
Reaction
• The semi-auto excavator cannot be used.
Effect on Machine
• Feeling of the joystick steering decreases.
Related • Can be checked with the monitoring function (Code: 01003).
Information
WA380-5 20-555
(10)
TROUBLESHOOTING FAILURE CODE [DUM1KB]
20-556 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DUM2KB]
Description Of • The remote positioner LOWER lamp system ground fault prevents output to the indicator lamp.
Trouble
Controller • No reaction.
Reaction
Effect on Machine • The remote positioner LOWER indicator lamp cannot be turned on.
Related • Can be checked with the monitoring function (Code: 40917).
Information
WA380-5 20-557
(10)
TROUBLESHOOTING FAILURE CODE [DW4PKA]
20-558 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4PKB]
Description Of • The lift arm RAISE EPC solenoid system ground fault prevents output to the lift arm RAISE EPC solenoid.
Trouble
Controller • Stops the output to the lift arm RAISE EPC solenoid.
Reaction • Stops the output to the lift arm RAISE detent.
Effect on Machine • The lift arm cannot raise.
Related • Can be checked with the monitoring function (Code: 41900).
Information
WA380-5 20-559
(10)
TROUBLESHOOTING FAILURE CODE [DW4QKA]
20-560 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4QKB]
Description Of • The lift arm LOWER EPC solenoid system ground fault prevents output to the lift arm LOWER EPC solenoid.
Trouble
Controller • Stops the output to the lift arm LOWER EPC solenoid.
Reaction • Stops the output to the lift arm LOWER detent.
Effect on Machine • The lift arm cannot lower.
Related • Can be checked with the monitoring function (Code: 41901).
Information
WA380-5 20-561
(10)
TROUBLESHOOTING FAILURE CODE [DW4RKA]
20-562 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4RKB]
WA380-5 20-563
(10)
TROUBLESHOOTING FAILURE CODE [DW4SKA]
20-564 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4SKB]
Description Of • The bucket DUMP EPC solenoid system ground fault prevents output to the bucket DUMP EPC solenoid.
Trouble
Controller Reaction • Stops the output to the bucket DUMP EPC solenoid.
Effect on Machine • The bucket DUMP cannot move.
Related • Can be checked with the monitoring function (Code: 41903).
Information
WA380-5 20-565
(10)
TROUBLESHOOTING FAILURE CODE [DWM1KA]
Description Of • Work equipment neutral lock solenoid power supply system is disconnected.
Trouble
Controller • No reaction.
Reaction
Effect on Machine • Normal operation is possible (Does not affect the lock lever).
Related
Information —
20-566 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DWM1KB]
Description Of • Work equipment neutral lock solenoid power supply system ground fault.
Trouble
Controller Reaction • Stops output to the neutral lock solenoid.
Effect on Machine • Normal operation is possible (Does not affect the lock lever).
Related —
Information
WA380-5 20-567
(10)
TROUBLESHOOTING FAILURE CODE [DWN6KA]
20-568 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DWN6KB]
WA380-5 20-569
(10)
TROUBLESHOOTING FAILURE CODE [DWN7KA]
20-570 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DWN7KB]
WA380-5 20-571
(10)
TROUBLESHOOTING FAILURE CODE [DWN8KA]
20-572 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DWN8KB]
Description of • The detent cannot be controlled due to the ground fault of the power supply system of the bucket TILT magnet
Trouble detent system.
• Stops output to the magnet detent solenoid.
Controller • Stops the remote bucket TILT function.
Reaction
• Stops the output of the remote positioner bucket TILT lamp.
Effect on • The detent does not work but normal operation is possible.
Machine
Related • Can be checked with the monitoring function (Code: 40916).
Information
WA380-5 20-573
(10)
TROUBLESHOOTING FAILURE CODE [DXHJKA]
20-574 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXHJKB]
WA380-5 20-575
(10)
TROUBLESHOOTING FAILURE CODE [DXHKKA]
20-576 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXHKKB]
WA380-5 20-577
(10)
TROUBLESHOOTING FAILURE CODE: [DXHLKA]
Action Code Failure Code Controller Code Joystick steering right-hand EPC
Trouble solenoid system disconnection
E03 DXHLKA WRK
• Joystick steering right-hand EPC solenoid system disconnection prevents output to the joystick steering
Description of Trouble
right-hand EPC solenoid.
Controller Reaction • Stops output to the joystick steering right-hand EPC solenoid (Both sides).
• Stops output to the joystick steering right-hand EPC solenoid (Both sides).
Effect on Machine
• Stops output to the joystick solenoid cutoff relay.
Related Information —
20-578 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE: [DXHLKB]
Action Code Failure Code Controller Code Joystick steering right-hand EPC
Trouble solenoid system ground fault
E03 DXHLKB WRK
• Joystick steering right-hand EPC solenoid system ground fault prevents output to the joystick steering
Description of Trouble
right-hand EPC solenoid.
• Stops output to the joystick steering right-hand EPC solenoid (Both sides).
Controller Reaction • Stops output to the joystick solenoid cutoff relay.
Effect on Machine • Cannot operate the steering with the joystick steering lever.
Related Information —
WA380-5 20-579
(10)
TROUBLESHOOTING FAILURE CODE: [DXHMKA]
Action Code Failure Code Controller Code Joystick steering left-hand EPC
Trouble solenoid system disconnection
E03 DXHMKA WRK
• Joystick steering left-hand EPC solenoid system disconnection prevents output to the joystick steering
Description of Trouble
left-hand EPC solenoid.
Controller Reaction • Stops output to the joystick steering left-hand EPC solenoid (Both sides).
• Stops output to the joystick steering left-hand EPC solenoid (Both sides).
Effect on Machine
• Stops output to the joystick solenoid cutoff relay.
Related Information —
20-580 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE: [DXHMKB]
Action Code Failure Code Controller Code Joystick steering left-hand EPC
Trouble solenoid system ground fault
E03 DXHMKB WRK
• Joystick steering left-hand EPC solenoid system ground fault prevents output to the joystick steering left-
Description of Trouble
hand EPC solenoid.
Controller Reaction • Stops output to the joystick steering left-hand EPC solenoid (Both sides).
• Stops output to the joystick steering left-hand EPC solenoid (Both sides).
Effect on Machine
• Stops output to the joystick solenoid cutoff relay.
Related Information —
WA380-5 20-581
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-1]
Troubleshooting Code Failure Code Controller Code Defective lift arm lock switch sys-
Trouble tem
WRK-1 — (WRK)
• The work equipment (Lift arm and bucket) does not operate due to incorrectly disconnected, short-cir-
Description of Trouble
cuited or grounded lift arm lock (Work equipment lock lever) switch system or cannot be locked.
Controller Reaction • No reaction.
Effect on Machine • The work equipment (Lift arm and bucket) does not operate or cannot be locked.
Related Information • Can be checked with the monitoring function (Code: 40917_D_IN_1).
20-582 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-2]
WA380-5 20-583
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-3]
20-584 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-3]
WA380-5 20-585
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-4]
20-586 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-4]
WA380-5 20-587
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-5]
20-588 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-5]
WA380-5 20-589
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-6]
Troubleshooting Code Failure Code Controller Code Defective bucket cylinder proxim-
Trouble ity switch system
WRK-6 — (WRK)
• The bucket leveler does not function due to incorrectly disconnected, grounded or short-circuited bucket
Description of Trouble
cylinder proximity switch system.
Controller Reaction • No reaction.
Effect on Machine • The bucket leveler does not function.
Related Information • Can be checked with the monitoring function (Code: 40911_D-IN-9).
20-590 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-6]
WA380-5 20-591
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-7]
Troubleshooting Code Failure Code Controller Code Defective bucket cylinder full
Trouble stroke detection switch system
WRK-7 — (WRK)
• The semi-automatic digging mode is not available or cannot be cancelled due to incorrectly disconnected,
Description of Trouble
grounded or short-circuited bucket cylinder full stroke detection switch system.
Controller Reaction • No reaction.
Effect on Machine • Semi-automatic general operation mode is not available or cannot be cancelled.
Related Information • Can be checked with the monitoring function (Code: 40911_D-IN-10).
20-592 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-8]
WA380-5 20-593
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-9]
20-594 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-10]
Troubleshooting Code Failure Code Controller Code Defective joystick ON/OFF switch
Trouble system
WRK-10 — (WRK)
Description of Trouble • The joystick mode cannot be used or be cancelled due to defective joystick ON/OFF switch system.
Controller Reaction • No reaction.
Effect on Machine • The joystick mode cannot be used or cancelled.
Related Information • Can be checked with the monitoring function (Code: 40910_D-IN-0).
20-596 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-10]
WA380-5 20-597
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-11]
Troubleshooting Code Failure Code Controller Code Defective joystick steering speed
Trouble HI/LO switch system
WRK-11 — (WRK)
• The joystick steering speed slows or accelerates (Cannot be switched between HI/LO) due to defective joy-
Description of Trouble
stick steering speed HI/LO switch system.
Controller Reaction • No reaction.
Effect on Machine • The joystick steering speed slows or accelerates (Cannot be switched between HI/LO).
Related Information • Can be checked with the monitoring function (Code: 40910_D-IN-8).
20-598 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-12]
Troubleshooting Code Failure Code Controller Code Defective joystick solenoid cut
Trouble relay output system
WRK-12 — (WRK)
Description of Trouble • The joystick mode cannot be used or be cancelled due to defective joystick ON/OFF switch system.
Controller Reaction • No reaction.
Effect on Machine • The joystick steering solenoid cannot be turned OFF.
Related Information —
WA380-5 20-599
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-13]
Troubleshooting Code Failure Code Controller Code Hot short-circuited lift arm RAISE
Trouble magnet detent output system
WRK-13 — (WRK)
Description of Trouble • RAISE detent cannot be cancelled due to hot short-circuited lift arm RAISE magnet detent output system.
Controller Reaction • No reaction.
• RAISE detent left turned ON.
Effect on Machine
• Normal operation is possible excluding automatic cancel of detent.
Related Information —
20-600 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-14]
Troubleshooting Code Failure Code Controller Code Hot short-circuited lift arm
Trouble FLOATING magnet detent output
WRK-14 — (WRK) system
• FLOATING detent cannot be cancelled due to short-circuited lift arm FLOATING magnet detent output sys-
Description of Trouble tem.
Controller Reaction • No reaction.
• RAISE detent left turned ON.
Effect on Machine • Normal operation is possible excluding automatic cancel of detent.
Related Information —
WA380-5 20-601
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-15]
Troubleshooting Code Failure Code Controller Code Hot short-circuited bucket TILT
Trouble magnet detent output system
WRK-15 — (WRK)
Description of Trouble • TILT detent cannot be cancelled due to hot short-circuited bucket TILT magnet detent output system.
Controller Reaction • No reaction.
• TILT detent left turned ON.
Effect on Machine
• Normal operation is possible excluding automatic cancel of detent.
Related Information —
20-602 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-16]
Troubleshooting Code Failure Code Controller Code Hot short-circuited work equip-
Trouble ment neutral lock solenoid output
WRK-16 — (WRK) system
• Neutral lock solenoid cannot be turned OFF due to hot short-circuited work equipment neutral lock sole-
Description of Trouble noid output system.
Controller Reaction • No reaction.
Effect on Machine • Working equipment locked even when the lock lever is free.
Related Information —
WA380-5 20-603
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-17]
Troubleshooting Code Failure Code Controller Code Hot short-circuited lift arm RAISE
Trouble EPC solenoid system
WRK-17 — (WRK)
Description of Trouble • Lift arm RAISE EPC solenoid gets turned on due to hot short-circuited lift arm RAISE EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Lift arm raises in full speed.
Related Information —
20-604 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-18]
Troubleshooting Code Failure Code Controller Code Hot short-circuited lift arm
Trouble LOWER EPC solenoid system
WRK-18 — (WRK)
• Lift arm LOWER EPC solenoid gets turned on due to hot short-circuited lift arm LOWER EPC solenoid sys-
Description of Trouble
tem.
Controller Reaction • No reaction.
Effect on Machine • Lift arm lowers in full speed.
Related Information —
WA380-5 20-605
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-19]
Troubleshooting Code Failure Code Controller Code Hot short-circuited bucket TILT
Trouble EPC solenoid system
WRK-19 — (WRK)
Description of Trouble • Bucket TILT EPC solenoid gets turned on due to hot short-circuited bucket TILTEPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Lift arm tilts in full speed.
Related Information —
20-606 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-20]
Troubleshooting Code Failure Code Controller Code Hot short-circuited bucket DUMP
Trouble EPC solenoid system
WRK-20 — (WRK)
Description of Trouble • Bucket DUMP EPC solenoid gets turned on due to hot short-circuited bucket DUMP EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Bucket dumps in full speed.
Related Information —
WA380-5 20-607
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-21]
20-608 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-22]
WA380-5 20-609
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-23]
Troubleshooting Code Failure Code Controller Code Hot short-circuited joystick steer-
Trouble ing right EPC solenoid system
WRK-23 — (WRK)
• The joystick steering right EPC solenoid gets turned on due to hot short-circuited joystick steering speed
Description of Trouble
right EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Steering all the way to the right is possible.
Related Information —
20-610 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-24]
Troubleshooting Code Failure Code Controller Code Hot short-circuited joystick steer-
Trouble ing left EPC solenoid system
WRK-24 — (WRK)
• The joystick steering left EPC solenoid gets turned on due to hot short-circuited joystick steering speed left
Description of Trouble
EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Steering all the way to the left is possible.
Related Information —
WA380-5 20-611
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-25]
20-612 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-25]
WA380-5 20-613
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-26]
B
Wiring harness between L104 (Female) 2 - F10 (Female)
Resistance 1 Ω and below
Wiring harness disconti-
Wiring harness between F10 (Female) C - body
4 nuity
Resistance 1 Ω and below
Wiring harness between L104 (Female) 5 - L26S (Female)
Possible Causes 1 Resistance 1 Ω and below
and Standard
Values Wiring harness between L26S (Female) 2 - body Resistance 1 Ω and below
★ Boom kick-out does not function in all items
1) Turn starting switch OFF. 2) Disconnect connectors L104, F10, and FS4.
3) Connect T-adapter.
Between L104 (Female) 2, F10 (Female) B - body
1 MΩ and
★ Boom kick-out detent function is not effective in this Resistance above
case (Lever returns to neutral)
Wiring harness ground Between L104 (Female) 5, L26S (Female) 1 and body
5 fault
1 MΩ and
★ Fuse A-2 blows and all detents will not function (Lever Resistance above
returns to neutral)
Between FS4 (Female) 5, F10 (Female) A - body
1 MΩ and
★ Fuse A-2 blows and all detents will not function (Lever Resistance above
returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connectors L104 and F10. 3) Connect
T-adapter. 4) Turn starting switch ON.
Between L104 (Female) 2, F10 (Female) B - body
Voltage 1 V and below
★ Fuse of hot-shorted circuit blows in this case
6 Hot-shorted wiring har- 1) Turn starting switch OFF. 2) Disconnect connectors L104 and L26S. 3) Con-
ness
nect T-adapter. 4) Turn starting switch ON.
Between L104 (Female) 5, L26S (Female) 1 - body
★ Boom kick-out does not function in this case (Lever Voltage 1 V and below
does not return to neutral).
20-614 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-26]
WA380-5 20-615
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-27]
★ Bucket leveler does not function in this case (Lever Voltage 1 V and below
does not return to neutral).
20-616 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-27]
WA380-5 20-617
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-28]
Troubleshooting Code Failure Code Controller Code Defective lift arm FLOATING
Trouble holding and cancellation
WRK-28 — —
• Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOATING
Description of Trouble
PPC detent system.
Controller Reaction • No reaction.
Effect on Machine • Lift arm FLOATING holding does not function or cannot be cancelled.
Related Information —
Wiring harness between L27S (Female) 2 and body Resistance 1 Ω and below
20-618 WA380-5
(10)
TROUBLESHOOTING OF MONITOR SYSTEM
(MON MODE)
★ Referring to TESTING AND ADJUSTING, Adjusting machine monitor, check that the rotary switches
(SW1, SW2, and SW3) and DIP switches (SW5 AND SW6) on the back side of the monitor panel are set
correctly.
*: Applied to the load meter specification
20-702 WA380-5
(10)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
A21 Yazaki 2 Water temperature sensor (Vehicle with automatic air W-3
conditioner)
Inside temperature sensor (Vehicle with automatic air
A22 Yazaki 2 conditioner) U-2
WA380-5 20-703
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
C48 AMP040 16 A/C control AMP (Vehicle with automatic air conditioner) D-9
C49 SWP 8 Left Servomotor R-1
C50 SWP 8 Right Servomotor M-3
C51 Yazaki 2 Diode (Vehicle with automatic air conditioner) M-3
CAN1 DT-T 3 Resistor N-1 F-1 J-8 B-2
CAN2 DT-T 3 Resistor R-9 J-9 K-8 B-2
CL1 S 8 Intermediate connector A-4 E-7
CL2 S (L) 12 Intermediate connector (Wiper motor) A-4
Intermediate connector (Vehicle with automatic air
CL5 S (W) 16 M-2
conditioner)
CL6 M 6 Intermediate connector (Vehicle with automatic air M-3 B-3 C-5
conditioner)
CL6 DT-T (G) 12 Intermediate connector (Monitor panel controller) W-4 K-4 C-4
CL7 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-2 B-4 K-4 C-5
CL8 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-1 B-4 C-5
CL9 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-4 K-4 C-6 B-5
20-704 WA380-5
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
CL10 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-3 K-3 C-3
CL20 DT-T 2 Intermediate connector (Monitor panel controller) N-2 C-5
CN55 DT-T 2 Intermediate connector (Backup buzzer) K-8 P-2 V-8
COMBI M 3 Front combination lamp (Right) A-6 W-3
COMBI M 3 Front combination lamp (Left) E-1 W-2
DIODE DT-T 2 Diode (Parking brake solenoid) AG-8 P-8
DL DT-T (Gr) 12 Connector (S-NET) U-8 I-9 K-6 K-5
E01 DT-T 2 Intermediate connector (Starting motor) AB-1 W-4 B-1
E02 Terminal 1 Alternator R AD-3 X-5
E03 Terminal 1 Alternator B AD-3 X-5
E04 Terminal 1 Alternator E AD-3 X-5
E05 Terminal 1 Engine heater relay AC-9 Q-9 E-4
E06 Terminal 1 Engine heater relay AA-9 Q-9 F-4
E07 Terminal 1 Engine heater relay Z-9 Q-9 F-4
E08 DT-T 2 Engine coolant temperature sensor (Monitor) AC-1 O-8
E09 DT-T 2 Engine coolant temperature sensor (Preheater) AD-2 O-8 B-2
E10 DT-T 2 Air conditioner compressor magnet clutch AD-2
E11 DT-T 2 Diode (Air conditioner compressor) AD-4
E14 Terminal 1 Ground (Rear frame) AB-5 X-5 A-1
E26 DT-T 2 Engine oil level sensor AA-5 P-8
E27 DT-T 2 Engine speed sensor AC-6 L-8
E28 DT 2 Diode (Engine heater relay) AC-9 O-8 B-2
E29 Terminal 1 Engine oil pressure switch AB-5 P-8
E30 Terminal 1 Starting motor B AB-1 X-4
E31 DT-T 2 Diode AC-7 B-3
E32 DT-T 2 Diode (Fuel cut solenoid) AB-6 B-3
E33 DT-T 2 Dust indicator AB-9 P-8
E34 DT-T 3 Fuel cut solenoid AC-7 B-2
E36 Terminal 1 Air compressor magetic clutch Y-5
ER-1 DT-T (G) 8 Intermediate connector (Engine) Z-2 P-5 D-3
ER-3 DT-T (Gr) 8 Intermediate connector (Engine) AA-1 K-7 O-5 D-3
F01 M 6 Intermediate connector (R.H. Front lamp) A-5 U-3
F02 M 6 Intermediate connector (L.H. Front lamp) D-1 U-2
F03 Terminal 1 Horn (303 Hz) A-1 W-1
F04 Terminal 1 Horn (303 Hz) A-1 W-1
F05 Terminal 1 Horn (303 Hz) C-1 W-1
F06 Terminal 1 Horn (303 Hz) B-1 W-1
F07 DT-T 2 Switching pump cut-off solenoid C-1 R-8
F09 DT-T 3 Bucket positioner proximity switch A-3 Q-7 B-3
F10 DT-T 3 Bucket positioner proximity switch (Standard) A-3 Q-6 B-3
F13 DT-T 2 Lift arm damper solenoid C-1 R-8
F14 DT-T 2 Diode (Damper solenoid) D-1 R-7
F15 DT-T 3 Lift arm angle signal (For load meter) A-2 B-3 M-8
F16 DT-T 3 Lift arm bottom signal (For load meter) B-1 B-3 M-8
F17 DT-T 3 Lift arm rod signal (For load meter) B-1 B-3 M-8
WA380-5 20-705
(10)
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
F18 DT-T 3 Lift arm angle sensor (For boom EPC) A-5 H-8
F19 DT-T 3 Bucket positioner proximity switch (For bucket EPC) A-3 H-8
F20 DT-T 2 Lift arm RAISE EPC A-2 Q-4 G-8
F21 DT-T 2 Lift arm LOWER EPC A-1 G-8
F22 DT-T 2 Bucket CURL EPC A-1 G-8
F23 DT-T 2 Bucket DUMP EPC A-1 G-8
F24 DT-T 2 ATT. EXT. EPC (If equipped) A-3 I-8
F25 DT-T 2 ATT. RET. EPC (If equipped) A-2 I-8
F26 DT-T 2 Lift arm EPC cut-off solenoid B-1 H-8
F27 DT-T 2 Diode (For boom EPC cut-off solenoid) A-4 H-7
F30 Terminal 1 Ground (Front frame) C-1 Q-4 P-5 U-1 A-3
FF1 S 10 Intermediate connector (Front lamp) E-1 N-3
FF2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) D-1 K-4 N-6 C-3
FL1 S 12 Intermediate connector (Front lamp) W-1 J-3 K-3
FL2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) W-1 I-4 K-6 C-5
FL3 DT-T 6 Intermediate connector (Load meter) X-2 E-3 K-6
FL7 DT-T (Br) 12 Intermediate connector (Work equipment solenoid) N-2 E-7
FL8 DT-T (G) 8 Intermediate connector (Work equipment solenoid) N-2 E-6
FL9 DT-T 6 Intermediate connector (3rd lever solenoid) N-2 E-5
FS1 L 2 Intermediate connector (Fuse box) W-7 C-1 E-8
FS2 L 2 Intermediate connector (Fuse box) V-7 C-1 E-8
FS3 S (W) 16 Intermediate connector (Fuse box) V-8 C-1 K-7 G-8 E-8
FS4 S (W) 12 Intermediate connector (Fuse box) V-8 B-1 K-7 G-8 E-8
FS5 M 6 Intermediate connector (Fuse box) V-7 G-8
FS6 Plug 1 Intermediate connector (Fuse box) V-8
FS7 Plug 1 Intermediate connector (Fuse box) W-7
F.PS DT-T 2 Transmission F clutch solenoid AJ-6 N-8
F.SW DT 2 Transmission F clutch fill switch AJ-6 P-8
G01 Terminal 1 Backup buzzer J-9 Q-2 V-9
G02 Terminal 1 Backup buzzer J-9 Q-2 V-9
G04 M 2 Rear working lamp (Left) K-8 V-8
G05 M 2 Rear working lamp (Right) J-9 U-8
GR1 DT-T 4 Intermediate connector (Fan reverse solenoid, rear working L-7 O-4 U-6
lamp)
GR2 DT-T 2 Fan reverse solenoid L-7 Q-4
HEAD M 3 Head lamp (Right) A-6 W-3
HEAD M 3 Head lamp (Left) W-2
JT1 DT-T (B) 8 Centralized connector (Ground) AH-2 R-7 Q-7
JT2 DT-T (B) 8 Centralized connector (Shield) AG-2 R-6
JT3 DT-T 6 Centralized connector AF-8 R-5
L01 SWP 6 Parking brake switch M-5 B-7
L02 SWP 6 Dimmer switch, light switch M-5 B-1
L03 SWP 6 Turn signal and hazard switch M-6 B-1
L04 SWP 14 Shift switch M-3 B-6 A-8
L05 DT-T 2 Horn switch M-5 E-8
L07 DT-T 6 Machine monitor switch (Mode/Cancel selector switch) Q-1 B-8
20-706 WA380-5
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L08 DT-T 6 Machine monitor switch (Screen selector switch) Q-1 A-8
L09 DT-T 2 Stop lamp switch Q-1 D-8
L10 DT-T 3 Left brake pressure sensor R-1 B-6
L11 DT-T 2 Air suspension seat S-1
L12 DT-T 4 R direction switch O-7 J-7 E-3
L13 DT-T 2 Lift arm N lock switch O-7 D-8
L14 DT-T 4 Kickdown and hold switch O-7 B-8 G-2
L15 DT-T 4 Load meter cancel and sub-total switch O-7 H-2 D-8
L16 M 2 Intermediate connector (DC converter) V-2
L17 M 4 DC24V/DC12V converter W-5
L18 Yazaki 2 DC12V socket W-3
L19 M 4 Flasher unit U-8 H-8
L20 M 2 Alarm buzzer U-8 I-7
L21 S 10 Front and rear wiper switch N-1
L25E DT-T 2 Lift arm and bucket EPC lever M-6 E-8
L25S DT-T 2 Work equipment lever electrical detent N-7 G-2 C-8
L26E DT-T 2 Lift arm and bucket EPC lever P-8 E-8
L26S DT-T 2 Work equipment lever electrical detent N-6 G-2 B-8
L27 DT-T 2 Lift arm and bucket EPC lever N-6 D-8
L27S DT-T 2 Work equipment lever electrical detent N-7 G-2 B-8
L28 DT-T 4 Lift arm and bucket EPC lever P-8 D-8
L29 DT-T 4 Lift arm and bucket EPC lever O-7 E-8
L30 DT-T 4 3rd EPC lever P-8 D-8
L31 M 6 Intermittent wiper timer W-7
L34 DT-T 4 Joystick lever positioner W-6 B-1
L35 DT-T 2 Joystick EPC solenoid P-1 E-1
L36 DT-T 2 Joystick EPC solenoid P-1 D-1
L37 DTM 12 Joystick lever switch M-6 K-8
L38 DT-T 3 Joystick N lock switch W-7 K-1 B-2
L39 DT-T 6 Joystick ON/OFF switch S-1 K-2 B-2
L40 DT-T 6 Steering speed mode switch S-1 K-1 B-1
L41 Relay 6 Joystick cutoff relay N-6 D-1
L42 Plug 1 Connector (Spare power supply) A-5
L43 Plug 1 Connector (Spare power supply) A-5
L44 M 6 Intermediate connector (Printer) V-3 I-7
L45 D-sub 25 Printer (Load meter) I-8
L46 G 4 Printer (Load meter) H-9
L51 AMP070 20 Monitor panel controller M-5 A-2 O-2 B-7 B-4
L52 AMP070 18 Monitor panel controller M-4 B-6
L53 AMP070 12 Monitor panel controller M-2 A-2 B-5
L54 AMP070 18 Monitor panel controller M-4 A-2 O-2 B-4
L55 AMP070 12 Monitor panel controller M-4 A-2 O-2 B-4 B-4
L56 AMP070 12 Monitor panel controller M-5 B-2 O-2 B-3
L57 AMP070 14 Monitor panel controller M-4 B-2
L58 AMP040 8 Monitor panel controller M-2
WA380-5 20-707
(10)
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L61 DRC 24 Transmission and fan pump motor controller P-8 B-8 I-8 F-8 A-8
L62 DRC 40 Transmission and fan pump motor controller Q-8 C-8 J-8 F-8
L63 DRC 40 Transmission and fan pump motor controller Q-8 E-8 F-8 A-8
L71 DRC 24 Lift arm bucket and joystick controller Q-9 A-8
L72 DRC 40 Lift arm bucket and joystick controller Q-9 K-8 A-8 N-8
L73 DRC 40 Lift arm bucket and joystick controller R-9 K-8 B-8
L88 DT-T (Gr) 8 Engine mode selector motor P-1 B-8
L91 DT-T 6 Timer P-8 A-6
L92 DT-T 3 Intermediate connector (Pump bypass) Q-8 B-2
L93 Relay 5 Pump bypass relay Q-9 B-1
L100 Terminal 1 Ground (Floor) R-1 I-1 J-1 B-5
L101 S (W) 16 Intermediate connector (Relay sub-unit) T-9 D-2 I-7 E-7
L102 S (L) 16 Intermediate connector (Relay sub-unit) T-9 D-2 J-7 E-7
L103 S (W) 16 Intermediate connector (Relay sub-unit) S-9 E-2 J-7
L104 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 L-7 E-6
L105 S (W) 12 Intermediate connector (Relay sub-unit) T-9 F-2
L106 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 K-7
L111 — 5 Turn signal lamp and hazard relay X-7 I-9
L112 — 5 Air cleaner clogging relay W-7 I-9
L113 — 5 Steering selector relay W-8 D-1 J-9 F-7
L114 — 5 Automatic preheater relay V-8 J-9 F-7
L115 — 5 Engine controller power supply relay V-9 F-7
L116 — 4 Neutral safety relay W-7 D-1 J-9 F-6
L117 — 4 Backup lamp relay W-7 E-1 J-9
L118 — 4 Stop lamp relay V-8 K-9
L119 — 4 Horn relay V-8 K-9
L120 — 4 Parking brake relay V-8 E-1
L123 — 5 Lift arm detent relay (Standard) X-9 L-9 F-6
L124 — 5 Bucket detent relay (Standard) X-9 L-9 F-6
L125 — 5 Lift arm damper relay V-9 E-1
L126 — 4 Emergency steering relay X-8 F-1
L127 — 4 Front working lamp relay X-7 K-9
L128 — 4 Rear working lamp relay X-9 K-9
L129 — 4 Rear glass heater relay V-9
L130 — 4 Transmission pump cut-off relay V-9 F-1
L141 Relay 5 Printer relay T-1
L142 DT-T 2 Diode (Printer) W-3
L143 DT-T 2 Diode (Printer) W-4
L144 DT-T 2 Diode (Printer) W-4
L145 DT-T 2 Diode (Printer) W-4
L146 DT-T 2 Diode (Printer) T-1
L147 DT-T 2 Diode (Printer) T-1
LC.PS DT-T 2 Torque converter lockup solenoid (If equipped) AJ-5 N-8
LC.SW DT 2 Torque converter lockup fill switch (If equipped) AJ-5 P-8
LL5 DT 3 Intermediate connector (Vehicle with joystick) Q-1 F-5
LL6 DT-T (Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 E-4
20-708 WA380-5
(10)
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
LL7 DT-T (G) 12 Intermediate connector (Vehicle with joystick) Q-1 J-7 E-4 K-5
LL8 DT-T (Gr) 8 Intermediate connector (Joystick switch) R-1 K-2 C-2
LR1 DTHD#12 1 Intermediate connector (Slow-blow fuse) X-2 J-2 D-5
LR2 DT-T (G) 12 Intermediate connector (Engine) V-2 J-7 K-4 D-5
LR4 L 2 Intermediate connector (Slow-blow fuse) X-1 J-2 E-5
LR5 DT-T 6 Intermediate connector (Auto grease controller) X-2 K-1
LR6 L 2 Intermediate connector (Ground) X-2 J-2 K-1
LR8 DTHD#8 1 Intermediate connector (Ground) X-2 J-2 L-5 K-2 D-5
LR9 DT-T (G) 12 Intermediate connector (Steering and brake oil pressure X-1 I-3 K-2
switch)
LR10 DT-T (Gr) 12 Intermediate connector X-1 I-3 K-3 D-5
LR13 DT-T 2 Intermediate Connecter ( Pump bypass) AE-7 J-1
W-3,
LT1 HD-24 31 Intermediate connector (Transmission) AF-2 I-6 K-4
WA380-5 20-709
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
S13 DT-T 6 Upper remote positioner ON/OFF switch (Vehicle with joy- N-9 I-2
stick)
Lower remote positioner ON/OFF switch (Vehicle with joy-
S14 DT-T 6 N-8 I-2
stick)
S15 DT-T 6 Automatic digging switch (Vehicle with joystick) N-9 J-2
S16 DT-T 6 Hydraulic fan reverse switch M-9 G-2
S17 DT-T 6 Auto grease switch O-8 A-8
S19 DT-T 6 Emergency steering check switch M-9 H-2 C-8
S21 DT-T 4 Engine power mode switch M-9 G-8 C-8
S22 DT-T 4 Auto shift mode switch N-7 G-8
S31 DT 4 Starting switch N-7 G-2 K-2 L-7 D-8
S32 DT-T 2 Starting switch N-9 D-8
T20 Terminal 1 Ground AI-2 Q-4
T21 DT-T 2 Pump bypass solenoid AG-8 K-1
TC.T DT-T 2 Torque converter oil temperature sensor AH-8 Q-8 Q-8
TEL DT-T (Gr) 12 Intermediate connector (KOMTRAX) Q-1 I-9 K-1 C-5
TM.T DT-T 2 Transmission oil temperature sensor AJ-3 Q-8 Q-8
20-710 WA380-5
(10)
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-712 WA380-5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-713
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-714 WA380-5
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-715
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-716 WA380-5
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-717
5
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
20-718 WA380-5
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
WA380-5 20-719
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
20-720 WA380-5
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
WA380-5 20-721
TROUBLESHOOTING FAILURE CODE [2F00MA]
20-722 WA380-5
(10)
5
TROUBLESHOOTING FAILURE CODE [2F00MA]
WA380-5 20-723
(10)
5
TROUBLESHOOTING FAILURE CODE [2G42ZG]
20-724 WA380-5
(10)
5
TROUBLESHOOTING FAILURE CODE [2G43ZG]
WA380-5 20-725
(10)
5
TROUBLESHOOTING FAILURE CODE [AA1ANX]
1 Clogged air —
cleaner
1) Turn starting switch OFF.
2) Disconnect connector E33.
Defective dust Dust indicator is not
2 indicator 1 This failure code (AA1ANX) issued defective.
Short-circuit between
E33 (Female) 1 - 2 Dust indicator is defective
This failure code (AA1ANX) not issued
(Air cleaner clogged).
1) Turn starting switch OFF.
2) Disconnect connector E33.
3) Connect t-adapter.
Between L112 (Male) 1 - 2 Resistance 200 - 400 Ω
Defective dust
3 indicator relay 1) Turn starting switch OFF.
2) Replace relay.
3) Start engine.
This failure code (AA1ANX) issued Dust indicator relay 1 is not defective.
This failure code (AA1ANX) not issued Dust indicator relay 1 is defective.
Possible Causes 1) Turn starting switch OFF.
and Wiring harness 2) Disconnect connectors L53 and L112.
Standard discontinuity 3) Connect t-adapter.
Values 4 (Disconnection
or defective Wiring harness between L112 (Female) 3 - body Resistance 1 Ω and below
contact)
Wiring harness between L53 (Female) 3 - L112 (Female) 4 Resistance 1 Ω and below
1) Turn starting switch OFF.
Wiring harness 2) Disconnect connectors L112 and E33.
5 3) Connect t-adapter.
ground fault
Between L112 (Female) 2/E33 (Female) 1 - body Resistance 1 MΩ and above
1) Turn starting switch OFF.
Wiring harness 2) Disconnect connectors L51 and L112.
6 hot-shorted 3) Connect t-adapter.
incorrectly 4) Turn starting switch ON.
Between L51 (Female) 6/L112 (Female) 1 - body Voltage 1 V or below
1) Turn starting switch OFF.
2) Disconnect connectors L51 and L53.
3) Insert t-adapter.
4) Start engine.
Defective
7 monitor panel Dust indicator is not defective (Air
Voltage 20 - 30 V
Between L53 cleaner not clogged)
(Female) 3 - body Dust indicator is defective (Air cleaner
clogged) Voltage 1 V or below
20-726 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [AA1ANX]
WA380-5 20-727
(10)
TROUBLESHOOTING FAILURE CODE [AB00L6]
Description of • The alternator terminal R input voltage is 12 V or higher before the engine started.
Trouble
Controller • Triggers an alarm.
Reaction
Effect on • The engine cannot be started.
Machine • The service meter increases simply by key-on.
Related • Can be checked with the monitoring function (Code: 04302).
Information
Defective Between alternator Engine started (Throttle 1/2 or more) Voltage 27.5 - 29.5 V
1 terminal R (E02) -
alternator body Engine stopped Voltage 1 V or below
1) Turn starting switch OFF.
Wiring harness 2) Disconnect connectors L52, ER1 and alternator terminal R.
2 hot-shorted 3) Connect t-adapter.
incorrectly Wiring harness between connector L52 (Female) H ER1 Voltage 1 V or below
(Female) 3 - alternator terminal R (E02)
Possible Causes
and 1) Turn starting switch OFF.
Standard 2) Disconnect connector L52.
Values Defective 3) Insert t-adapter.
3
monitor panel Engine started (Throttle 1/2 or more) Voltage 27.5 - 29.5 V
Between L52 H -
body Engine stopped Voltage 1 V or below
1) Turn starting switch OFF.
2) Disconnect connectors L52, ER1 and alternator terminal R.
3) Connect t-adapter.
4 Defective diode 4) Turn starting switch ON.
R24
Wiring harness between connector L52 (Female) H, ER1
Voltage 1 V or below
(Female) 3 - alternator terminal R (E02)
20-728 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [AB00MA]
Description of • During engine operation, the input voltage to the alternator R terminal is below 5V.
Trouble
Controller • Alarm sounds.
Reaction
Effect on • The battery is deteriorated, the engine does not start and the service meter does not work.
Machine
Related • The monitoring function (Code 04302) can check the failure.
Information
Defective Between alternator R Engine start (Throttle : 1/2 or more) Voltage 27.5 - 29.5 V
2 terminal (E02) and
alternator machine body Engine stop Voltage 1 V or below
WA380-5 20-729
(10)
TROUBLESHOOTING FAILURE CODE [B@BAZG]
20-730 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@BAZK]
WA380-5 20-731
(10)
TROUBLESHOOTING FAILURE CODE [B@BCNS]
20-732 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@BCZK]
WA380-5 20-733
(10)
TROUBLESHOOTING FAILURE CODE [B@HANS]
20-734 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@CENS]
1 Overheating —
torque converter
1) Turn starting switch OFF.
Defective torque 2) Disconnect connector TC.C.
converter oil 3) Connect t-adapter.
2
temperature Resistance 35 - 50 kΩ
sensor Between TC.T (Male) Normal temperature (25 °C)
1-2 100 °C Resistance 3.1 - 4.5 kΩ
Possible Causes
and 1) Turn starting switch OFF.
Standard 2) Disconnect connectors L55 and TC.C.
Values Wiring harness 3) Connect t-adapter.
3 ground fault
Wiring harness between L55 (Female) 2 /TC.C (Female) 1 -
body Resistance 1 MΩ and above
WA380-5 20-735
(10)
TROUBLESHOOTING FAILURE CODE [D182KZ]
Defective The failure code "D182KZ" is displayed. The relay (L114) is normal.
1 preheater relay
(L114) The failure code "D182KZ" is not displayed. The relay (L114) is abnormal.
1) Starting switch OFF.
2) Disconnect the connectors L51 and L114.
3) Connect a T-adaptor.
Between L114(male) 1 and 2 Resistance 100 - 500 Ω
Possible Causes 1) Starting switch OFF.
and Disconnection of
Standard 2) Disconnect the connectors L51 and L102.
harness 3) Connect a T-adapter.
Values 2 (Disconnection,
defective Harness between the fuse B. 0 and L102 (female) 1. Resistance 1 Ω and below
contact)
Harness between L51 (female) B and L102 (female) 2. Resistance 1 Ω and below
1) Starting switch OFF.
Ground fault of 2) Disconnect the connectors L51 and L102.
3 3) Connect a T-adapter.
harness
Machine body between L51 (female) B and L102 (female) 2. Resistance 1 MΩ and above
1) Starting switch OFF.
2) Disconnect the connector L51.
Defective 3) Insert a T-adaptor.
4
monitor panel 4) Starting switch ON.
Between L51 B - body. Voltage 20 - 30 V
20-736 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D182KZ]
WA380-5 20-737
(10)
TROUBLESHOOTING FAILURE CODE [D5ZHL6]
20-738 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DA80L4]
WA380-5 20-739
(10)
TROUBLESHOOTING FAILURE CODE [DAF3KK]
Description of • When the SW power supply (for operation) voltage is over 17V, the NSW power supply (& the memory power
Trouble supply) voltage is less than 17V.
Controller • Alarm sounds.
Reaction
Effect on • Service meter time is not accurate, the odometer value (accumulated travel distance value) does not advance
Machine and trouble record data is not stored.
Related
—
Information
20-740 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DAF3KK]
WA380-5 20-741
(10)
TROUBLESHOOTING FAILURE CODE [DAF5KP]
Between F15 B - A
When the lift arm is raised maximum. Voltage 3.5 - 4.0 V
Possible Causes When the lift arm is lowered maximum. Voltage 1.0 - 2.0 V
and
Standard 1) Starting switch OFF.
Ground fault of 2) Disconnect the connectors L52 and F15.
Values 2 harness 3) Connect a T-adaptor.
Among L51 (female) F, F15 (female) C - body. Resistance 1 MΩ and above
1) Starting switch OFF.
2) Disconnect the connector L51 and L55.
3) Insert a T-adaptor.
Between L51 (male) F - body Resistance 4 - 6 kΩ
3 Defective 1) Starting switch OFF. 2) Disconnect the connector L51 and L55. 3) Insert a T-adaptor. 4)
monitor panel Starting switch ON.
Between L51 F - body Voltage 4.75 - 5.25 V
Between L55 0 - When the lift arm is raised maximum. Voltage 3.5 - 4.0 V
body When the lift arm is lowered maximum. Voltage 1.0 - 2.0 V
20-742 WA380-5
(10)
5
TROUBLESHOOTING FAILURE CODE [DAF6KP]
20-744 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DAF6KP]
WA380-5 20-745
(10)
TROUBLESHOOTING FAILURE CODE [DAFBKM]
20-746 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DAFSKQ]
WA380-5 20-747
(10)
TROUBLESHOOTING FAILURE CODE [DAQSKR]
Description of • The S-NET (+) signal line between the monitor panel and the transmission controller is disconnected, short-cir-
Trouble cuited with the ground or hot short-circuited.
Controller • Alarm sounds.
Reaction
Effect on • The monitor does not display normally. (The shift indicator, travel speed/engine speed are not displayed.)
Machine
Related
—
Information
20-748 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DBQSKR]
Description of • Disconnection, ground fault, or hot-short has occurred in the S-NET (+) signal line between the monitor panel
Trouble and the engine controller.
Controller • Activates an alarm.
Reaction
Effect on • The joystick indicator pilot lamp does not turn ON.
Machine • The work equipment controller functions with WA380-5. (A faulty joystick feeling.)
Related
—
Information
20-750 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB9SKR]
Description of • Disconnection, ground fault, or hot-short has occurred in the S-NET (+) signal line between the monitor panel
Trouble and the work equipment controller.
Controller • Activates an alarm.
Reaction
Effect on • The joystick indicator pilot lamp does not turn ON.
Machine • The work equipment controller functions with WA380-5. (A faulty joystick feeling.)
Related
—
Information
WA380-5 20-751
(10)
TROUBLESHOOTING FAILURE CODE [DD15LD]
Description of • The monitor panel mode selector switch 1 [■] (Panel SW1) input circuit remains closed for more than one
Trouble minute.
Controller • Activates an alarm.
Reaction
Effect on • The monitor does not work (Service mode cannot be activated).
Machine
• The input signal (0 or 1)of the monitor panel mode selector switch 1 ¦ (Panel SW1) can be verified with the mon-
Related itoring function (Code: 40901, D-IN-15).
Information
• Since switch is faulty, the monitoring function may not be activated.
20-752 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DD16LD]
Description of • The monitor panel mode selector switch 1 [◊] (Panel SW2) input circuit remains closed for more than one
Trouble minute.
Controller • Activates an alarm.
Reaction
Effect on • The monitor cannot be operated.
Machine
• The input signal (0 or 1)of the monitor panel mode selector switch 1 [◊] (Panel SW2) can be verified with the
Related monitoring function (Code: 40901, D-IN-14).
Information
• Since [◊] switch is faulty, the monitoring function may not be activated.
WA380-5 20-753
(10)
TROUBLESHOOTING FAILURE CODE [DD17LD]
Description of • The monitor panel mode selector switch 2 < (Panel SW3) input circuit remains closed for more than one minute.
Trouble
Controller • Activates an alarm.
Reaction
Effect on • The monitor cannot be operated.
Machine
• The input signal (0 or 1) of the monitor panel mode selector switch 2 [<] (Panel SW3) can be verified with the
Related monitoring function (Code: 40904, D-IN-38).
Information
• Since [<] switch is faulty, the monitoring function may not be activated.
20-754 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DD18LD]
Description of • The monitor panel mode selector switch 2 [>] (Panel SW4) input circuit remains closed for more than one
Trouble minute.
Controller • Activates an alarm.
Reaction
Effect on • The monitor cannot be operated.
Machine
• The input signal (0 or 1) of the monitor panel mode selector switch 2 [>] (Panel SW4) can be verified with the
Related monitoring function (Code: 40904, D-IN-37).
Information
• Since [<] switch is faulty, the monitoring function may not be activated.
WA380-5 20-755
(10)
TROUBLESHOOTING FAILURE CODE [DD1CLD]
20-756 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DD1CLD]
12
Related circuit diagram
WA380-5 20-757
(10)
TROUBLESHOOTING FAILURE CODE [DDS5L6]
C-A
sensor Between T36 (Male) With pressure released to air (For
reference purpose) Resistance 1 MΩ and above
Possible Causes
and Engine started Resistance 1 MΩ and above
Standard
Values 1) Turn starting switch OFF.
Wiring harness 2) Disconnect connectors L54, R36 and L61.
3 3) Connect T-adapter.
Between L54 (Female) F /R36 (Female) C - body
ground fault
Resistance 1 MΩ and above
1) Turn starting switch OFF.
2) Disconnect connector L54.
3) Connect T-adapter.
Defective
4 monitor panel Normal temperature (25 °C) Resistance 35 - 50 kΩ
Between L54
(Female) F - body 100 °C Resistance 3.1 - 4.5 kΩ
Engine started Resistance 1 MΩ and above
20-758 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDS5L6]
12
Related circuit diagram
WA380-5 20-759
(10)
TROUBLESHOOTING FAILURE CODE [DDY0LD]
20-760 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDY0LD]
12
Related circuit diagram
WA380-5 20-761
(10)
TROUBLESHOOTING FAILURE CODE [DGE2KX]
Description of • The engine coolant temperature is more than 150 °C (The engine coolant temperature sensor input voltage is
Trouble less than 0.98 V)
Controller • Activates the engine coolant temperature overheat alarm. The failure is stored in the electrical system failure
Reaction history only; not in the machine system failure history.
Effect on • The engine coolant temperature gauge is in the MAX position.
Machine
Related • Can be verified with the monitoring function (Code: 04103).
Information
20-762 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DGE3L6]
Description of • Engine coolant temperature (low temperature) sensor signals are not input.
Trouble
Controller • It operates for normal control.
Reaction
Effect on • The machine does not start smoothly at low temperature.
Machine
Related • The monitoring function (Code : 04104) is useful for check.
Information
Ground fault of 1) Starting switch OFF. 2) Disconnect L82 and TWL. 3) Insert a T-adaptor.
3 harness
Among L55 (female) 3, E09 (female) 1 and machine body. Resistance 1 MΩ and above
1) Starting switch OFF. 2) Disconnect the connector L55. 3) Connect a T-adaptor.
Defective
4 10 °C Resistance 9 kΩ approx.
monitor panel Between L55 (female) 3 - 6
100 °C Resistance 0.3 kΩ approx.
WA380-5 20-763
(10)
TROUBLESHOOTING FAILURE CODE [DGH2KX]
20-764 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DGT1KX]
WA380-5 20-765
(10)
TROUBLESHOOTING FAILURE CODE [DHE4L6]
20-766 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DHPCKX]
20-768 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DHPCKX]
WA380-5 20-769
(10)
TROUBLESHOOTING FAILURE CODE [DHPDKX]
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors L51, L55, F16 and F17.
discontinuity 3) Connect T-adapter.
Possible Causes
2 (Broken wires or
and
loose Between L55 (Female) (4) - F17 (Female) (C) Resistance 1 Ω and below
Standard
Values connections) Between L51 (Female) (15) - F17 (Female) (B) Resistance 1 Ω and below
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors L55, F16, F17. 3) Connect T-adapter.
3
ground fault Between L55 (Female) (4), F17 (Female) (C) - body Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connectors L51 and F17.
3) Insert T-adapter. 4) Turn starting switch ON.
Defective Between L51 (15) - body Voltage 20 - 30 V
4 monitor panel
Between L55 (4) - When machine is in operation Voltage 0.7 - 5.3 V
body When pressure is released to air Voltage 0.5 - 1.5 V
20-770 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DHPDKX]
WA380-5 20-771
(10)
TROUBLESHOOTING FAILURE CODE [DKA0KX]
1) Turn starting switch OFF. 2) Disconnect connectors L51, L71 and F15.3) Connect T-adapter.
3 Wiring harness Between L55 (Female) (10) L71 (Female) (8), F15 (Female) (B) -
ground fault Resistance 1 MΩ and above
body
1) Turn starting switch OFF.
2) Disconnect connectors L51 and L55.
3) Insert T-adapter.
4) Connect connector.
Defective 5) Turn starting switch ON.
4
monitor panel
Between L51 (16) - body Voltage 4.75 - 5.25 V
Between L55 (10) - With boom fully raised Voltage 3.5 - 4.0 V
body With boom fully lowered Voltage 1.0 - 2.0 V
20-772 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DV00KB]
WA380-5 20-773
(10)
TROUBLESHOOTING FAILURE CODE [DY30ME]
Description of • The emergency steering detector circuit remains open for more than one minute.
Trouble
Controller • Activates an alarm.
Reaction
• An alarm is issued if the emergency steering remains actuated for more than one minute (the emergency steering motor may
be defective or burn out).
Effect on Machine • Even though the emergency steering motor is not in operation, the indicator lights up.
• The emergency steering always actuates.
Related • Can be verified with the monitoring function (Code: 40903, D-IN-30).
Information
20-774 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DY30ME]
WA380-5 20-775
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-1]
Description of • The parking brake detector circuit remains CLOSED when the parking brake switch is operated.
Trouble
Controller • No reaction.
Reaction
Effect on • When the parking brake switch is turned ON (parking), neither the parking brake indicator lamp light up nor the
Machine parking brake is applied.
Related • Can be verified with the monitoring function (Code: 40903, D-IN-26).
Information • The state of the parking brake switch can be verified with the monitoring function (Code: 40907, D-IN-23).
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connector L54 and PB.SW. 3) Connect T-adapter.
3
ground fault Between L54 (Female), PB.SW (Female) 1 - body Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connector L54. 3) Connect T-adapter. 4) Start engine.
When parking brake oil pressure is above
Defective Voltage 1 V or less
4 monitor panel Between L54 (Female) 0.6 MPa {6.1 kg/cm2}
1 - body When parking brake oil pressure is below
Possible Causes 0.34 MPa {3.5 kg/cm2} Voltage 20 - 30 V
and
Standard 1) Turn starting switch OFF. 2) Disconnect connector L01. 3) Connect T-adapter.
Values
Between L01 (Male) When parking brake switch is turned ON Resistance 1 Ω and below
1-3 When parking brake switch is turned OFF Resistance 1 MΩ and above
Faulty parking
5 brake switch When parking brake switch is turned ON Resistance 1 MΩ and above
Between L01 (Male)
2-3 When parking brake switch is turned OFF Resistance 1 Ω and below
Between L01 (Male)
At all times Resistance 1 MΩ and above
1-2
1) Turn starting switch OFF. 2) Disconnect PB.PS connectors. 3) Connect T-adapter.
20-776 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-1]
WA380-5 20-777
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-2]
20-778 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-3]
WA380-5 20-779
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-4]
20-780 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-4]
WA380-5 20-781
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-5]
20-782 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-6]
WA380-5 20-783
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-7]
Description of • The engine coolant temperature sensor circuit is always in the OPEN state.
Trouble
Controller • No reaction.
Reaction
Effect on • The engine coolant temperature caution lamp does not light ON.
Machine • After the engine starts, the engine coolant temperature gauge does not rise.
Related • Can be checked with the monitoring function (Code: 04103).
Information
20-784 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-8]
WA380-5 20-785
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-9]
Description of • The hydraulic oil temperature sensor circuit is always in the OPEN state.
Trouble
Controller • No reaction.
Reaction
Effect on • The hydraulic oil temperature caution lamp does not light ON.
Machine • After the engine starts, the hydraulic oil temperature gauge does not rise.
Related • Can be checked with the monitoring function (Code: 04401).
Information
20-786 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-10]
WA380-5 20-787
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-11]
20-788 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-12]
WA380-5 20-789
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-13]
20-790 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-14]
WA380-5 20-791
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-15]
20-792 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-16]
WA380-5 20-793
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-17]
20-794 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-18]
WA380-5 20-795
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-19]
20-796 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-20]
WA380-5 20-797
(10)
5
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
WA380-5 20-801
(10)
TROUBLESHOOTING H-1
• Have the wheel brake and the parking brake Clogging of strainer
been locked?
Remedy ∆ ∆ ∆ ∆ ∆ ∆ ∆
No. X X *1 *1 *1 X X X
Diagnosis X C X X X X X
1 The machine does not start at all gear speeds { { { { { { { { { { {
The machine does not start at specific gear
2 { { { { {
speeds
When the transmission oil temperature is low,
3 the charging pump or the transmission filter { {
causes abnormal noise(s)
When the transmission oil temperature rises,
4 the machine comes not to start { { { {
*1 Proceed to the paragraph of "Defective clutch and ECMV Specifying Method (Check by Failure Code)."
20-802 WA380-5
(8)
TROUBLESHOOTING H-1
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
1 The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 { {
When the failure code is 15SALI after the diagnosis in 1, the failure
1 code comes not to be displayed when the F fill switch connector (CN-
2 F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
1 The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 { {
When the failure code is 15SBLI after the diagnosis in 1, the failure
2 code comes not to be displayed when the R fill switch connector (CN-
2 R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
1 The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 { {
When the failure code is 15SELI after the diagnosis in 1, the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
2 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
1 The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 { {
When the failure code is 15SFLI after the diagnosis in 1, the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
2 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
1 The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 { {
When the failure code is 15SGLI after the diagnosis in 1, the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
2 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
1 The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 { {
When the failure code is 15SHLI after the diagnosis in 1, the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
2 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
WA380-5 20-803
(10)
TROUBLESHOOTING H-2
The lock-up clutch is not released (The engine stops) (When the lock-up clutch is pro-
H-2 vided)
Inspection before diagnosis Cause
• Is the oil level in the transmission case appropriate? a b
20-804 WA380-5
(8)
TROUBLESHOOTING H-3
a The travel speed is slow, the thrusting force is weak, the uphill traveling power is
H-3 weak, and the gear is not shifted
Ask the operator about the following: Cause
• Has an abnormality occurred suddenly?
→ Breakage of related equipment Torque
Did any abnormal noise occur at the time and Torque Con- Torque
Converter Main Relief Parking
verter Oil Con- ECMV Transmission Others
where? Charging
Cooler verter
Valve Brake
• Have any abnormal signs come to occur gradu- Pump
ally?
→ Wear of related equipment, defective seal a b c d e f g h i j k l m n o p q r
Clogging of breather
• Are the tire air pressure and the tread shape
Clogging of strainer
Engine degradation
appropriate?
• Is the operating method correct?
Note: When the inspection result was "Engine
Degradation," proceed to Engine System
Troubleshooting (S Mode).
Remedy C ∆ ∆ ∆ ∆ ∆ ∆ ∆ C ∆
No. X X X *1 *1 X X Note
Diagnosis X X X X X X X X X X
1 Any abnormality occurs at all gear speeds { { { { { { { { { { { { { { {
2 Any abnormality occurs at specific gear { { { {
speeds
When the transmission oil temperature is low,
3 the charging pump or the transmission filter { {
causes any abnormal noise
The torque converter oil temperature rises
4 { { { { { { { { { { {
abnormally high
5 The transmission oil level rises or falls { { { { {
Metal (Aluminum, copper, iron, etc.) powers
6 are adhered to the transmission filter or the { { {
strainer
The engine low idling and high idling speeds
7 { { {
are measured to be abnormal
8 When the stall speed of The speed is high { { { { { { { { { {
the torque converter is
9 measured The speed is low {
The oil pressure
10 drops as the tempera- { { { {
ture rises
The oil pressure is
11 low at all gear speeds { { { { { { { { {
When the ECMV output
(Clutch) oil pressure is The oil pressure is
12 measured low at specific gear { { { {
speeds
The oil pressure does
not become stable as
13 the gauge touches the { {
oil
When the torque converter relief (Inlet) oil
14 pressure is measured, the oil pressure is low. { { {
(Nos. 11-13 are normal.)
When the oil pressure at the torque converter
15 outlet is measured, the oil pressure is low. {
(No. 14 is normal.)
*1 Proceed to the paragraph of "Defective clutch and ECMV Specifying Method (Check by Failure Code)."
WA380-5 20-805
(10)
TROUBLESHOOTING H-3
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
1 The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 { {
When the failure code is 15SALI after the diagnosis in 1, the failure
1 code comes not to be displayed when the F fill switch connector (CN-
2 F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
1 The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 { {
When the failure code is 15SBLI after the diagnosis in 1, the failure
2 code comes not to be displayed when the R fill switch connector (CN-
2 R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
1 The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 { {
When the failure code is 15SELI after the diagnosis in 1, the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
2 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
1 The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 { {
When the failure code is 15SFLI after the diagnosis in 1, the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
2 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
1 The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 { {
When the failure code is 15SGLI after the diagnosis in 1, the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
2 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
1 The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 { {
When the failure code is 15SHLI after the diagnosis in 1, the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
2 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
20-806 WA380-5
(10)
TROUBLESHOOTING H-3
b The torque converter lock-up clutch is not let in (When the lock-up clutch is pro-
H-3 vided)
Check of abnormality
• Oil pressure of main relief valve
• Oil pressure of lock-up clutch
• Traveling speed
Remedy ∆
No. Diagnosis Self-diagnosis X X X X C X
Display of Transmission Controller X
1 The main relief valve oil pressure is low {
2 No. 1 is normal but the lock-up clutch oil pressure is low or 0 { { { { {
3 The oil pressure is normal in No. 2 {
Letting the lock-up clutch in
4 takes a long time 15SJLH {
WA380-5 20-807
(10)
TROUBLESHOOTING H-4
H-4 Shocks are large at the times of starting and shifting gear
Remedy C ∆ ∆
No. X X *1 *2 *1 *1 X X *2
Diagnosis X X X
1 Shocks are large at all gear speeds { { { { { { { {
2 Shocks are large at specific gear speeds { { { { { {
The oil pressure is low
3 at all gear speeds { { { { { {
When the ECMV output
4 (Clutch) oil pressure is The oil pressure is low { { {
at specific gear speeds
measured
The oil pressure is high
5 {
at all gear speeds
★ Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*1 Proceed to the paragraph of "Defective Clutch and ECMV Specifying Method (Check by Failure Code)."
*2 Proceed to the paragraph of "Troubleshooting of Transmission Controller System (TM Mode)."
20-808 WA380-5
(8)
TROUBLESHOOTING H-4
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
1 The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 { {
When the failure code is 15SALI after the diagnosis in 1, the failure
1 code comes not to be displayed when the F fill switch connector (CN-
2 F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
1 The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 { {
When the failure code is 15SBLI after the diagnosis in 1, the failure
2 code comes not to be displayed when the R fill switch connector (CN-
2 R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
1 The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 { {
When the failure code is 15SELI after the diagnosis in 1, the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
2 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
1 The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 { {
When the failure code is 15SFLI after the diagnosis in 1, the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
2 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
1 The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 { {
When the failure code is 15SGLI after the diagnosis in 1, the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
2 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
1 The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 { {
When the failure code is 15SHLI after the diagnosis in 1, the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
2 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
WA380-5 20-809
(10)
TROUBLESHOOTING H-5
H-5 Time lag is large at the times of starting and shifting gear
Remedy C ∆ ∆
No. X X *1 *1 X X *2
Diagnosis X X X
1 Time lag is large at all gear speeds { { { { { { {
2 Time lag is large at specific gear speeds { { { {
When the transmission oil temperature is low,
3 any abnormal noise occurs from the charging { {
pump or the transmission filter
The torque converter oil temperature is heated
4 abnormally high { { { {
★ Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*1 Proceed to the paragraph of "Defective Clutch and ECMV Specifying Method (Check by Failure Code)."
*2 Proceed to the paragraph of "Troubleshooting of Transmission Controller System (TM Mode)."
20-810 WA380-5
(8)
TROUBLESHOOTING H-5
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
1 The code is not displayed at R1-R4 but is displayed at F1-F4 15SAL1 { {
When the failure code is 15SALI after the diagnosis in 1, the failure
1 code comes not to be displayed when the F fill switch connector (CN-
2 F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
1 The code is not displayed at F1-F4 but is displayed at R1-R4 15SBL1 { {
When the failure code is 15SBLI after the diagnosis in 1, the failure
2 code comes not to be displayed when the R fill switch connector (CN-
2 R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
1 The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 { {
When the failure code is 15SELI after the diagnosis in 1, the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
2 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
1 The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 { {
When the failure code is 15SFLI after the diagnosis in 1, the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
2 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
1 The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 { {
When the failure code is 15SGLI after the diagnosis in 1, the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
2 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
1 The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 { {
When the failure code is 15SHLI after the diagnosis in 1, the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
2 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
WA380-5 20-811
(10)
TROUBLESHOOTING H-6
Clogging of breather
Clogging of strainer
Engine degradation
Remedy C ∆ ∆ ∆ ∆ ∆ ∆ C ∆
No. X X Note
Diagnosis X X X X X X X X X
When the transmission oil temperature is low, the
1 charging pump or the transmission filter causes any { {
abnormal noise
20-812 WA380-5
(10)
TROUBLESHOOTING H-7
steering valve
• Breakage of steering gear box and steering linkage
Defect inside
• Is the frame lock bar off?
• Has the steering linkage been properly adjusted?
Demand spool
Safety valve
Remedy ∆ ∆ ∆ ∆ ∆ ∆
No.
Diagnosis X X X X X X
1 The steering wheel does not turn both right and left { { { { {
2 The work equipment operates abnormally in No. 1 {
3 The steering wheel turns either right or left { {
4 The steering wheel is too heavy to turn { { { {
5 The steering circuit oil pressure does not rise at all { {
★ Since the steering circuit is closely related to the work equipment circuit, check how the work equip-
ment operates when the steering is felt abnormal.
WA380-5 20-813
(10)
TROUBLESHOOTING H-8
The hydraulic oil return side filter is clogged or the bypass valve is defective
Inspection before diagnosis
Demand spool
Safety valve
Remedy ∆ ∆A ∆ ∆ ∆ ∆C ∆C A ∆
No.
Diagnosis X X X X X X X X
1 The steering wheel is heavy to turn both right and left { { { { {
2 The steering wheel is heavy to turn right or left { {
3 The steering wheel is heavy when the engine rotates slowly { {
4 When the engine rotates at full throttle, the boom raising speed is {
insufficient
5 The steering wheel is heavy and jerks {
6 The hydraulic oil temperature is heated abnormary high {
7 The steering circuit oil pressure is low { { { {
8 The oil pressure rises in the pipe on the steering cylinder return side { {
20-814 WA380-5
(10)
TROUBLESHOOTING H-9
Defect inside steering cylinder (Cylinder inner plane, piston seal, nut, bolt)
The steering valve is defective
• Play of center hinge pin bearing, steering cylinder pin and bushing?
• Irregular tire air pressure?
• Play of steering wheel?
Check of Abnormality
• Operate the machine in a safe place and check how the steering wheel fluc-
tuates under which conditions
★ When the steering wheel fluctuates and is heavy as well, see "H-8, The
steering wheel is heavy."
Remedy ∆ A ∆ ∆
No.
Diagnosis X X X
1 When traveling, the machine fluctuates on rough roads { { {
When the steering wheel is turned quickly in operation or travel, the
2 machine fluctuates {
WA380-5 20-815
(8)
TROUBLESHOOTING H-12
H-12 The brake does not work or does not work well
20-816 WA380-5
(10)
TROUBLESHOOTING H-13
2 When the brake pedal is released, oil is drained from the air bleeder, {
the circuit pressure drops and the brake is released
The four wheels are jacked up, the axle is placed on a table, the
3 engine is stopped, the parking brake is released and the tires are { {
rotated by hand but a specific tire hardly rotates
WA380-5 20-817
(8)
TROUBLESHOOTING H-14
Remedy ∆ ∆ ∆ ∆
No. ∆
Diagnosis X X X X
1 When the parking brake switch is off, the parking brake is not released { { { { {
When the parking brake switch is off, the brake is not applied even if
2 the engine stops {
3 When the parking brake switch is on, the parking brake does not work { {
well
• The parking brake is not released even if the emergency parking brake release valve is opened. The
following causes are considered:
a. Defective operation of emergency parking brake release valve
b. Insufficient gas pressure of accumulator for brake or breakage of piston seal
20-818 WA380-5
(8)
TROUBLESHOOTING H-15
2 The Lift arm can lift the machine but cannot rise, or the bucket oper- { { {
ates but the Lift arm cannot rise
3 The Lift arm can rise without load but cannot rise when loaded { { {
4 The hydraulic pump causes an abnormal noise { { {
5 Large hydraulic drift of Lift cylinder { {
When the engine is at full throttle, the steering operation is light
6 {
and too fast
When the engine is at full throttle, the steering operation is heavy
7 and slow { {
WA380-5 20-819
(10)
TROUBLESHOOTING H-16
H-16 The Lift arm moves slowly or the Lift arm rising force is insufficient
Check of Abnormality a b c d e f g h i
1 The bucket tilting force and speed are abnormal, and the Lift { { { { {
arm rising speed is slow
The bucket tilting force and speed are normal, and the Lift arm
2 { { {
rising speed is slow
When the oil temperature rises in No. 1, the Lift arm speed
3 becomes very slow {
8 The relief oil pressure from the relief valve of the work equip- { { { {
ment valves is low
The relief oil pressure from the relief valve of the work equip-
9 {
ment valves is too high
20-820 WA380-5
(10)
TROUBLESHOOTING H-17
H-17 When rising, the Lift arm comes to move slowly at specific height
Cause
• Expansion of Lift cylinder tube or damage inside
★ For other abnormal phenomena during Lift arm rise, see "H-16. The Lift arm moves slowly or the Lift arm rising force is insufficient."
H-18 The Lift cylinder cannot hold down the bucket (The bucket rises in the air)
See "H-16. The Lift arm moves slowly or the Lift arm rising force is insufficient."
Cause
• Defective seat of suction valve on the Lift cylinder rod side of work equipment valve
• Oil leak from Lift cylinder piston seal
The bucket and the Lift arm moves up and down as the topography goes in digging or leveling with the Lift arm control lever in the
"HOLD" position.
★ Frequent hydraulic drifts → The suction valve on the Lift cylinder rod side is defective
WA380-5 20-821
(10)
TROUBLESHOOTING H-21
H-21 When the control lever is switched from "HOLD" to "RAISE," the Lift arm falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the Lift arm falls temporarily due
to its own weight. When the control lever is completely set to "RAISE," the Lift arm returns to normal.
Cause
• Improper adhesion of Lift arm spool check valve of the work equipment valve
20-822 WA380-5
(8)
TROUBLESHOOTING H-22
The bucket can tilt back without load but cannot in digging or scoop-
3 { {
ing up
4 The hydraulic pump causes an abnormal noise { { {
5 Large hydraulic drift of bucket cylinder { {
When the engine is at full throttle, the steering operation is light
6 and too fast {
WA380-5 20-823
(8)
TROUBLESHOOTING H-23
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
Check of Abnormality
• Make sure in an actual operation that the tilting-back force is insufficient.
• Measure the operating speed of the bucket, and make sure referring to
the criterion value table that the speed is abnormal
Remedy C ∆ ∆ ∆ ∆ ∆Α ∆ ∆
No.
Diagnosis ∆ X X X X X X X X X
The Lift arm rising force and speed are abnormal, and the bucket
1 tilting force and speed are abnormal { { { { { {
The Lift arm rising force and speed are normal, and the bucket tilt-
2 { { { {
ing force and speed are abnormal
When the oil temperature rises in No. 1, the bucket speed {
3
becomes worse
4 The hydraulic pump is causing an abnormal noise { {
When the engine is at full throttle, the steering operation is light
5 {
and too fast
When the engine is at full throttle, the steering operation is heavy
6 {
and slow
7 Large hydraulic drift of bucket cylinder { { {
The relief oil pressure from the relief valve of the work equipment
8 { { { {
valves is low
9 The relief oil pressure from the relief valve of the work equipment { {
valves is too high
20-824 WA380-5
(8)
TROUBLESHOOTING H-24
Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-23. The bucket moves slowly or the tilting-back force is insuffi-
cient."
See "H-23. The bucket moves slowly or the tilting-back force is insufficient."
Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal
Check of Abnormality
• Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
• Improper oil tight of bucket spool
WA380-5 20-825
(8)
TROUBLESHOOTING H-27
The bucket wobbles during travel with cargo (The work equipment valve is set to
H-27 "HOLD")
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to
diagnoses for relevant abnormal phenomena.
H-28 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the bucket falls temporarily due
to its own weight. When the control lever is completely set to "TILT," the bucket returns to normal.
Cause
• Improper adhesion of bucket spool check valve of the work equipment valve
20-826 WA380-5
(8)
TROUBLESHOOTING H-29
H-29 The control levers of Lift arm and bucket do not move smoothly and heavy
Remedy ∆ ∆ C
No.
Diagnosis X X X ∆
When the machine is loaded and the oil pressure rises, the levers
1 come not to move smoothly { { { { {
2 The levers come not to move smoothly as the oil pressure rises { { { { {
The levers partly come not to move smoothly during operation
3 irrespective of oil pressure and oil temperature {
WA380-5 20-827
(8)
TROUBLESHOOTING H-30
H-30 E.C.S.S. does not work, and there is pitcing and bouncing
Remedy
No. X X X X
Problems
Speed (3 km/h) for start of actuation of E.C.S.S. is greatly out of adjust-
1 ment Q Q
20-828 WA380-5
(10)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
WA380-5 20-901
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
A21 Yazaki 2 Water temperature sensor (Vehicle with automatic air W-3
conditioner)
Inside temperature sensor (Vehicle with automatic air
A22 Yazaki 2 conditioner) U-2
WA380-5 20-903
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
C48 AMP040 16 A/C control AMP (Vehicle with automatic air conditioner) D-9
C49 SWP 8 Left Servomotor R-1
C50 SWP 8 Right Servomotor M-3
C51 Yazaki 2 Diode (Vehicle with automatic air conditioner) M-3
CAN1 DT-T 3 Resistor N-1 F-1 J-8 B-2
CAN2 DT-T 3 Resistor R-9 J-9 K-8 B-2
CL1 S 8 Intermediate connector A-4 E-7
CL2 S (L) 12 Intermediate connector (Wiper motor) A-4
Intermediate connector (Vehicle with automatic air
CL5 S (W) 16 M-2
conditioner)
CL6 M 6 Intermediate connector (Vehicle with automatic air M-3 B-3 C-5
conditioner)
CL6 DT-T (G) 12 Intermediate connector (Monitor panel controller) W-4 K-4 C-4
CL7 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-2 B-4 K-4 C-5
CL8 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-1 B-4 C-5
CL9 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-4 K-4 C-6 B-5
20-904 WA380-5
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
CL10 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-3 K-3 C-3
CL20 DT-T 2 Intermediate connector (Monitor panel controller) N-2 C-5
CN55 DT-T 2 Intermediate connector (Backup buzzer) K-8 P-2 V-8
COMBI M 3 Front combination lamp (Right) A-6 W-3
COMBI M 3 Front combination lamp (Left) E-1 W-2
DIODE DT-T 2 Diode (Parking brake solenoid) AG-8 P-8
DL DT-T (Gr) 12 Connector (S-NET) U-8 I-9 K-6 K-5
E01 DT-T 2 Intermediate connector (Starting motor) AB-1 W-4 B-1
E02 Terminal 1 Alternator R AD-3 X-5
E03 Terminal 1 Alternator B AD-3 X-5
E04 Terminal 1 Alternator E AD-3 X-5
E05 Terminal 1 Engine heater relay AC-9 Q-9 E-4
E06 Terminal 1 Engine heater relay AA-9 Q-9 F-4
E07 Terminal 1 Engine heater relay Z-9 Q-9 F-4
E08 DT-T 2 Engine coolant temperature sensor (Monitor) AC-1 O-8
E09 DT-T 2 Engine coolant temperature sensor (Preheater) AD-2 O-8 B-2
E10 DT-T 2 Air conditioner compressor magnet clutch AD-2
E11 DT-T 2 Diode (Air conditioner compressor) AD-4
E14 Terminal 1 Ground (Rear frame) AB-5 X-5 A-1
E26 DT-T 2 Engine oil level sensor AA-5 P-8
E27 DT-T 2 Engine speed sensor AC-6 L-8
E28 DT 2 Diode (Engine heater relay) AC-9 O-8 B-2
E29 Terminal 1 Engine oil pressure switch AB-5 P-8
E30 Terminal 1 Starting motor B AB-1 X-4
E31 DT-T 2 Diode AC-7 B-3
E32 DT-T 2 Diode (Fuel cut solenoid) AB-6 B-3
E33 DT-T 2 Dust indicator AB-9 P-8
E34 DT-T 3 Fuel cut solenoid AC-7 B-2
E36 Terminal 1 Air compressor magetic clutch Y-5
ER-1 DT-T (G) 8 Intermediate connector (Engine) Z-2 P-5 D-3
ER-3 DT-T (Gr) 8 Intermediate connector (Engine) AA-1 K-7 O-5 D-3
F01 M 6 Intermediate connector (R.H. Front lamp) A-5 U-3
F02 M 6 Intermediate connector (L.H. Front lamp) D-1 U-2
F03 Terminal 1 Horn (303 Hz) A-1 W-1
F04 Terminal 1 Horn (303 Hz) A-1 W-1
F05 Terminal 1 Horn (303 Hz) C-1 W-1
F06 Terminal 1 Horn (303 Hz) B-1 W-1
F07 DT-T 2 Switching pump cut-off solenoid C-1 R-8
F09 DT-T 3 Bucket positioner proximity switch A-3 Q-7 B-3
F10 DT-T 3 Bucket positioner proximity switch (Standard) A-3 Q-6 B-3
F13 DT-T 2 Lift arm damper solenoid C-1 R-8
F14 DT-T 2 Diode (Damper solenoid) D-1 R-7
F15 DT-T 3 Lift arm angle signal (For load meter) A-2 B-3 M-8
F16 DT-T 3 Lift arm bottom signal (For load meter) B-1 B-3 M-8
F17 DT-T 3 Lift arm rod signal (For load meter) B-1 B-3 M-8
WA380-5 20-905
(10)
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
F18 DT-T 3 Lift arm angle sensor (For boom EPC) A-5 H-8
F19 DT-T 3 Bucket positioner proximity switch (For bucket EPC) A-3 H-8
F20 DT-T 2 Lift arm RAISE EPC A-2 Q-4 G-8
F21 DT-T 2 Lift arm LOWER EPC A-1 G-8
F22 DT-T 2 Bucket CURL EPC A-1 G-8
F23 DT-T 2 Bucket DUMP EPC A-1 G-8
F24 DT-T 2 ATT. EXT. EPC (If equipped) A-3 I-8
F25 DT-T 2 ATT. RET. EPC (If equipped) A-2 I-8
F26 DT-T 2 Lift arm EPC cut-off solenoid B-1 H-8
F27 DT-T 2 Diode (For boom EPC cut-off solenoid) A-4 H-7
F30 Terminal 1 Ground (Front frame) C-1 Q-4 P-5 U-1 A-3
FF1 S 10 Intermediate connector (Front lamp) E-1 N-3
FF2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) D-1 K-4 N-6 C-3
FL1 S 12 Intermediate connector (Front lamp) W-1 J-3 K-3
FL2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) W-1 I-4 K-6 C-5
FL3 DT-T 6 Intermediate connector (Load meter) X-2 E-3 K-6
FL7 DT-T (Br) 12 Intermediate connector (Work equipment solenoid) N-2 E-7
FL8 DT-T (G) 8 Intermediate connector (Work equipment solenoid) N-2 E-6
FL9 DT-T 6 Intermediate connector (3rd lever solenoid) N-2 E-5
FS1 L 2 Intermediate connector (Fuse box) W-7 C-1 E-8
FS2 L 2 Intermediate connector (Fuse box) V-7 C-1 E-8
FS3 S (W) 16 Intermediate connector (Fuse box) V-8 C-1 K-7 G-8 E-8
FS4 S (W) 12 Intermediate connector (Fuse box) V-8 B-1 K-7 G-8 E-8
FS5 M 6 Intermediate connector (Fuse box) V-7 G-8
FS6 Plug 1 Intermediate connector (Fuse box) V-8
FS7 Plug 1 Intermediate connector (Fuse box) W-7
F.PS DT-T 2 Transmission F clutch solenoid AJ-6 N-8
F.SW DT 2 Transmission F clutch fill switch AJ-6 P-8
G01 Terminal 1 Backup buzzer J-9 Q-2 V-9
G02 Terminal 1 Backup buzzer J-9 Q-2 V-9
G04 M 2 Rear working lamp (Left) K-8 V-8
G05 M 2 Rear working lamp (Right) J-9 U-8
GR1 DT-T 4 Intermediate connector (Fan reverse solenoid, rear working L-7 O-4 U-6
lamp)
GR2 DT-T 2 Fan reverse solenoid L-7 Q-4
HEAD M 3 Head lamp (Right) A-6 W-3
HEAD M 3 Head lamp (Left) W-2
JT1 DT-T (B) 8 Centralized connector (Ground) AH-2 R-7 Q-7
JT2 DT-T (B) 8 Centralized connector (Shield) AG-2 R-6
JT3 DT-T 6 Centralized connector AF-8 R-5
L01 SWP 6 Parking brake switch M-5 B-7
L02 SWP 6 Dimmer switch, light switch M-5 B-1
L03 SWP 6 Turn signal and hazard switch M-6 B-1
L04 SWP 14 Shift switch M-3 B-6 A-8
L05 DT-T 2 Horn switch M-5 E-8
L07 DT-T 6 Machine monitor switch (Mode/Cancel selector switch) Q-1 B-8
20-906 WA380-5
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L08 DT-T 6 Machine monitor switch (Screen selector switch) Q-1 A-8
L09 DT-T 2 Stop lamp switch Q-1 D-8
L10 DT-T 3 Left brake pressure sensor R-1 B-6
L11 DT-T 2 Air suspension seat S-1
L12 DT-T 4 R direction switch O-7 J-7 E-3
L13 DT-T 2 Lift arm N lock switch O-7 D-8
L14 DT-T 4 Kickdown and hold switch O-7 B-8 G-2
L15 DT-T 4 Load meter cancel and sub-total switch O-7 H-2 D-8
L16 M 2 Intermediate connector (DC converter) V-2
L17 M 4 DC24V/DC12V converter W-5
L18 Yazaki 2 DC12V socket W-3
L19 M 4 Flasher unit U-8 H-8
L20 M 2 Alarm buzzer U-8 I-7
L21 S 10 Front and rear wiper switch N-1
L25E DT-T 2 Lift arm and bucket EPC lever M-6 E-8
L25S DT-T 2 Work equipment lever electrical detent N-7 G-2 C-8
L26E DT-T 2 Lift arm and bucket EPC lever P-8 E-8
L26S DT-T 2 Work equipment lever electrical detent N-6 G-2 B-8
L27 DT-T 2 Lift arm and bucket EPC lever N-6 D-8
L27S DT-T 2 Work equipment lever electrical detent N-7 G-2 B-8
L28 DT-T 4 Lift arm and bucket EPC lever P-8 D-8
L29 DT-T 4 Lift arm and bucket EPC lever O-7 E-8
L30 DT-T 4 3rd EPC lever P-8 D-8
L31 M 6 Intermittent wiper timer W-7
L34 DT-T 4 Joystick lever positioner W-6 B-1
L35 DT-T 2 Joystick EPC solenoid P-1 E-1
L36 DT-T 2 Joystick EPC solenoid P-1 D-1
L37 DTM 12 Joystick lever switch M-6 K-8
L38 DT-T 3 Joystick N lock switch W-7 K-1 B-2
L39 DT-T 6 Joystick ON/OFF switch S-1 K-2 B-2
L40 DT-T 6 Steering speed mode switch S-1 K-1 B-1
L41 Relay 6 Joystick cutoff relay N-6 D-1
L42 Plug 1 Connector (Spare power supply) A-5
L43 Plug 1 Connector (Spare power supply) A-5
L44 M 6 Intermediate connector (Printer) V-3 I-7
L45 D-sub 25 Printer (Load meter) I-8
L46 G 4 Printer (Load meter) H-9
L51 AMP070 20 Monitor panel controller M-5 A-2 O-2 B-7 B-4
L52 AMP070 18 Monitor panel controller M-4 B-6
L53 AMP070 12 Monitor panel controller M-2 A-2 B-5
L54 AMP070 18 Monitor panel controller M-4 A-2 O-2 B-4
L55 AMP070 12 Monitor panel controller M-4 A-2 O-2 B-4 B-4
L56 AMP070 12 Monitor panel controller M-5 B-2 O-2 B-3
L57 AMP070 14 Monitor panel controller M-4 B-2
L58 AMP040 8 Monitor panel controller M-2
WA380-5 20-907
(10)
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L61 DRC 24 Transmission and fan pump motor controller P-8 B-8 I-8 F-8 A-8
L62 DRC 40 Transmission and fan pump motor controller Q-8 C-8 J-8 F-8
L63 DRC 40 Transmission and fan pump motor controller Q-8 E-8 F-8 A-8
L71 DRC 24 Lift arm bucket and joystick controller Q-9 A-8
L72 DRC 40 Lift arm bucket and joystick controller Q-9 K-8 A-8 N-8
L73 DRC 40 Lift arm bucket and joystick controller R-9 K-8 B-8
L88 DT-T (Gr) 8 Engine mode selector motor P-1 B-8
L91 DT-T 6 Timer P-8 A-6
L92 DT-T 3 Intermediate connector (Pump bypass) Q-8 B-2
L93 Relay 5 Pump bypass relay Q-9 B-1
L100 Terminal 1 Ground (Floor) R-1 I-1 J-1 B-5
L101 S (W) 16 Intermediate connector (Relay sub-unit) T-9 D-2 I-7 E-7
L102 S (L) 16 Intermediate connector (Relay sub-unit) T-9 D-2 J-7 E-7
L103 S (W) 16 Intermediate connector (Relay sub-unit) S-9 E-2 J-7
L104 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 L-7 E-6
L105 S (W) 12 Intermediate connector (Relay sub-unit) T-9 F-2
L106 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 K-7
L111 — 5 Turn signal lamp and hazard relay X-7 I-9
L112 — 5 Air cleaner clogging relay W-7 I-9
L113 — 5 Steering selector relay W-8 D-1 J-9 F-7
L114 — 5 Automatic preheater relay V-8 J-9 F-7
L115 — 5 Engine controller power supply relay V-9 F-7
L116 — 4 Neutral safety relay W-7 D-1 J-9 F-6
L117 — 4 Backup lamp relay W-7 E-1 J-9
L118 — 4 Stop lamp relay V-8 K-9
L119 — 4 Horn relay V-8 K-9
L120 — 4 Parking brake relay V-8 E-1
L123 — 5 Lift arm detent relay (Standard) X-9 L-9 F-6
L124 — 5 Bucket detent relay (Standard) X-9 L-9 F-6
L125 — 5 Lift arm damper relay V-9 E-1
L126 — 4 Emergency steering relay X-8 F-1
L127 — 4 Front working lamp relay X-7 K-9
L128 — 4 Rear working lamp relay X-9 K-9
L129 — 4 Rear glass heater relay V-9
L130 — 4 Transmission pump cut-off relay V-9 F-1
L141 Relay 5 Printer relay T-1
L142 DT-T 2 Diode (Printer) W-3
L143 DT-T 2 Diode (Printer) W-4
L144 DT-T 2 Diode (Printer) W-4
L145 DT-T 2 Diode (Printer) W-4
L146 DT-T 2 Diode (Printer) T-1
L147 DT-T 2 Diode (Printer) T-1
LC.PS DT-T 2 Torque converter lockup solenoid (If equipped) AJ-5 N-8
LC.SW DT 2 Torque converter lockup fill switch (If equipped) AJ-5 P-8
LL5 DT 3 Intermediate connector (Vehicle with joystick) Q-1 F-5
LL6 DT-T (Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 E-4
20-908 WA380-5
(10)
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
LL7 DT-T (G) 12 Intermediate connector (Vehicle with joystick) Q-1 J-7 E-4 K-5
LL8 DT-T (Gr) 8 Intermediate connector (Joystick switch) R-1 K-2 C-2
LR1 DTHD#12 1 Intermediate connector (Slow-blow fuse) X-2 J-2 D-5
LR2 DT-T (G) 12 Intermediate connector (Engine) V-2 J-7 K-4 D-5
LR4 L 2 Intermediate connector (Slow-blow fuse) X-1 J-2 E-5
LR5 DT-T 6 Intermediate connector (Auto grease controller) X-2 K-1
LR6 L 2 Intermediate connector (Ground) X-2 J-2 K-1
LR8 DTHD#8 1 Intermediate connector (Ground) X-2 J-2 L-5 K-2 D-5
LR9 DT-T (G) 12 Intermediate connector (Steering and brake oil pressure X-1 I-3 K-2
switch)
LR10 DT-T (Gr) 12 Intermediate connector X-1 I-3 K-3 D-5
LR13 DT-T 2 Intermediate Connecter ( Pump bypass) AE-7 J-1
W-3,
LT1 HD-24 31 Intermediate connector (Transmission) AF-2 I-6 K-4
WA380-5 20-909
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
S13 DT-T 6 Upper remote positioner ON/OFF switch (Vehicle with joy- N-9 I-2
stick)
Lower remote positioner ON/OFF switch (Vehicle with joy-
S14 DT-T 6 N-8 I-2
stick)
S15 DT-T 6 Automatic digging switch (Vehicle with joystick) N-9 J-2
S16 DT-T 6 Hydraulic fan reverse switch M-9 G-2
S17 DT-T 6 Auto grease switch O-8 A-8
S19 DT-T 6 Emergency steering check switch M-9 H-2 C-8
S21 DT-T 4 Engine power mode switch M-9 G-8 C-8
S22 DT-T 4 Auto shift mode switch N-7 G-8
S31 DT 4 Starting switch N-7 G-2 K-2 L-7 D-8
S32 DT-T 2 Starting switch N-9 D-8
T20 Terminal 1 Ground AI-2 Q-4
T21 DT-T 2 Pump bypass solenoid AG-8 K-1
TC.T DT-T 2 Torque converter oil temperature sensor AH-8 Q-8 Q-8
TEL DT-T (Gr) 12 Intermediate connector (KOMTRAX) Q-1 I-9 K-1 C-5
TM.T DT-T 2 Transmission oil temperature sensor AJ-3 Q-8 Q-8
20-910 WA380-5
(10)
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-912 WA380-5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-913
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-914 WA380-5
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-915
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-916 WA380-5
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA380-5 20-917
5
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM
20-918 WA380-5
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-A]
[E-1-a]
Troubleshooting Code Failure Code Controller Code The engine does not start. (Start-
Trouble ing system)
E-1-a) — —
Description of Trouble The starting motor system is defective, and the engine does not start.
Controller Reaction —
Effect on Machine The starting motor system is defective, and the engine does not start.
Related Information Check that the fuses A-2 and B-2 are not blown. (If they are blown, check if the related harness is short-cir-
cuited with the ground.).
20-920 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-1-a]
Troubleshooting Code Failure Code Controller Code The engine does not start.
Trouble
E-1-a) — — (Starting system)
Disconnection between relay Harness between L113 (female) 3 and Resistance 1 Ω and
7 L116 (female) 1. below
(L113) and related harness
Between the relays L113 (male) 1 and
Resistance 200 - 400 Ω
2.
1) Stating switch OFF. 2) Disconnect the connector L04.
3) Connect a T-adapter.
Harness between L113 (female) 4 and Resistance 1 Ω and
L04 (female) 1. below
Possible Causes and Stan- 1) Stating switch OFF. 2) Disconnect the connectors L101 and L102.
dard Values 3) Connect a T-adapter.
Harness between L101 (female) B and 1 Ω and
L102 (female) B. Resistance below
1) Stating switch OFF. 2) Disconnect the connectors L102 and E01.
3) Connect a T-adapter.
Harness between L102 (female) D and
E01 (female) 1.
★ Measure the continuity from L102 D Continuity Yes
8 Disconnection between relay
(L116) and related harness side in the diode range.
1) Stating switch OFF. 2) Disconnect the relay L116. 3) Connect a T-
adapter.
Between the relays L116 (male) 1 and Resistance 200 - 400 Ω
2.
1) Stating switch OFF. 2) Disconnect the connector L04.
3) Connect a T-adapter. 4) Starting switch "ON."
Among L04 1, 3 and machine body. Voltage 20 - 30 V
9 Disconnection between shift 1) Stating switch OFF. 2) Disconnect the connectors L04 and FS4.
switch and related harness
3) Connect a T-adapter.
Harness between L04 (female) 1 and 1 Ω and
FS4 (female) 2. Resistance below
1) Stating switch OFF. 2) Disconnect the connector R26.
3) Connect a T-adapter.
Between R26 (male) 2 and 1.
Disconnection among ★ Measure the continuity from the 2
10 diodes R26, R27 and related Continuity Yes
harness side in the diode range.
★ Measure the continuity from the 1
side in the diode range. Continuity No
★ The diode R26 can be replaced.
WA380-5 20-921
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-1-a]
Troubleshooting Code Failure Code Controller Code The engine does not start.
Trouble (Starting system)
E-1-a) — —
Causes Standard Value in Normal State and Remarks on Troubleshooting
1) Stating switch OFF. 2) Disconnect the connector R27.
3) Connect a T-adapter.
Between R27 (male) 2 and 1.
★ Measure the continuity from the 2
side in the diode range. Continuity Yes
★ Measure the continuity from the 1
Continuity No
side in the diode range.
★ The diode R27 can be replaced.
1) Stating switch OFF. 2) Disconnect the connectors L102, R26 and
Disconnection among R27.
10 diodes R26, R27 and related 3) Connect a T-adapter.
harness
Harness between L102 (female) D and Resistance 1 Ω and
R26 (female) 2. below
Harness between L102 (female) D and 1 Ω and
Resistance
R27 (female) 2. below
1) Stating switch OFF. 2) Disconnect the connectors E01, R26 and R27.
3) Connect a T-adapter.
Harness between E01 (female) 1 and Resistance 1 Ω and
R26 (female) 1. below
Harness between E01 (female) 1 and 1 Ω and
Resistance
R27 (female) 1. below
1) Stating switch OFF. 2) Disconnect the connectors FS2 and FS4.
3) Connect a T-adapter. 4) Starting switch ON.
Between FS3 1 and machine body. Voltage 20 - 30 V
Between FS4 2 and machine body. Voltage 20 - 30 V
Between FS2 1 and machine body. Voltage 20 - 30 V
Possible Causes and Stan- Among FS1 1, 2 and machine body. Voltage 20 - 30 V
dard Values 1) Stating switch OFF. 2) Disconnect the connectors LR1 and LR4.
3) Connect a T-adapter. 4) Starting switch ON.
Between LR1 1 and machine body. Voltage 20 - 30 V
Among LR4 1, 2 and machine body. Voltage 20 - 30 V
1) Stating switch OFF. 2) Disconnect the connectors FS1, FS2, LR1 and LR4.
3) Connect a T-adapter.
Harness between FS1 (female) 1 and 1 Ω and
LR1 (male) 1. Resistance below
Disconnection between fuse
11
and related harness Harness between FS1 (female) 2 and Resistance 1 Ω and
LR4 (male) 1. below
Harness between LR4 (male) 2 and FS2 1 Ω and
Resistance
(female) 1. below
1) Stating switch ON. 2) Slow blow fuse (firm power supply).
Among terminal R02, R03 and machine 1 Ω and
Resistance
body. below
1) Starting switch OFF. 2) Disconnect the flow blow fuse (firm power
supply) terminal R02 and the battery relay terminal R01.
Harness between the flow blow fuse 1 Ω and
(firm power supply) terminal R02 and the Resistance
battery relay terminal R01 below
1) Starting switch OFF. 2) Disconnect the flow blow fuse (firm power
supply) terminal R05 and the battery relay terminal R04.
Harness between the flow blow fuse
1 Ω and
(firm power supply) terminal R05 and the Resistance below
battery relay terminal R04
1) Stating switch OFF. 2) Disconnect the connector S04.
3) Insert a T-adapter. 4) Starting switch ON.
12 Defective FNR switch mode
selector switch 1 V and
Between S04 4 and machine body. Voltage below
20-922 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-1-a]
WA380-5 20-923
5
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
Troubleshooting Code Failure Code Controller Code The engine does not start.
Trouble (Engine stop solenoid system)
E-1-b) — —
Description of Trouble The engine stop solenoid system is out of order, and the engine does not start.
Controller Reaction —
The engine stop solenoid system is out of order, and the engine does not start. (The starting motor rotates,
Effect on Machine
but the engine does not start.)
Related Information —
20-924 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
WA380-5 20-925
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-2]
20-926 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-2]
WA380-5 20-927
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-3]
Related Information When any failure code appears, diagnose the machine referring to the failure code "D182KZ" related to the
monitor. The monitoring function (Code : 04104) enables to check engine coolant temperature.
The machine does not operate normally. The preheater relay (L114) is
normal.
1) Starting switch OFF. 2) Disconnect the connectors L151 and L114.
Disconnection of harness (Dis- 3) Connect a T-adapter.
9 connection, defective contact)
(Preheater relay system) Harness between L114 (female) 2 and Resistance 1 Ω and below
L51 (female) B
1) Starting switch OFF. 2) Disconnect the connectors L52 and S32.
Disconnection of harness (Dis- 3) Connect a T-adapter.
10 connection, defective contact)
(Starting switch R1 system) Harness between L52 (female) A and Resistance 1 Ω and below
S32 (female) 1
20-928 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-3]
WA380-5 20-929
(7)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-4]
Description of Trouble The engine power mode system is out of order, and the power modes cannot be selected.
Controller Reaction —
Effect on Machine The engine power modes cannot be selected.
Related Information —
2 Defective power mode It returned to normal. The power mode selector relay is
selector relay out of order.
The power mode selector relay is
It does not return to normal.
normal.
1) Starting switch OFF. 2) Disconnect the connectors S21, L102, L88, L61
and FS33. 3) Connect a T-adapter.
Harness between S21 (female) 4, L61 Resistance 1 Ω and below
(female) 6 and L102 (female) 7
Harness between S21 (female) 1 and
Resistance 1 Ω and below
machine body
Harness between L102 (female) 9 and
L88 (female) 5 Resistance 1 Ω and below
★ In the above three cases, the power mode cannot be selected.
Harness between FS3 (female) 5 and Resistance 1 Ω and below
3 Disconnection of harness L88 (female) 4, L102 (female) 6
Possible Causes and
Harness between L88 (female) 3 and
Standard Values Resistance 1 Ω and below
L102 (female) 0
★ In the above two cases, the economy mode cannot be selected.
Harness between L88 (female) 8 and
machine body Resistance 1 Ω and below
20-930 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-4]
Troubleshooting Code Failure Code Controller Code The engine power modes
Trouble
E-4 — — cannot be selected.
WA380-5 20-931
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-5]
20-932 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-5]
Troubleshooting Code Failure Code Controller Code The front wiper does not func-
Trouble
E-5 — — tion
WA380-5 20-933
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-5]
20-934 WA380-5
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-6]
WA380-5 20-935
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-7]
Troubleshooting Code Failure Code Controller Code The side wiper does not function
Trouble (If equipped)
E-7 — —
Description of Trouble • Since a fault occurs in the side wiper, switch, or harness, the side wiper does not function.
Controller Reaction —
Effect on Machine • The side wiper does not function.
Related Information —
20-936 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-8]
Troubleshooting Code Failure Code Controller Code The wind washer does not func-
Trouble tion
E-8 — —
• Since a fault occurs in the window washer motor, switch, timer (Front only), or harness, the wind washer
Description of Trouble
does not function.
Controller Reaction —
Effect on Machine • The wind washer does not function.
• When the wiper function is normal (When the wiper function is also abnormal, first diagnose the wiper
Related Information function fault in E-5).
WA380-5 20-937
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-8]
Troubleshooting Code Failure Code Controller Code The wind washer does not func-
Trouble
E-8 — — tion
20-938 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-8]
WA380-5 20-939
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-9]
Troubleshooting Code Failure Code Controller Code The headlamp (Lo beam) does
Trouble not light on
E-9 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
Description of Trouble
headlamp (Lo beam) does not light on.
Controller Reaction —
Effect on Machine • The headlamp (Lo beam) does not light on.
Related Information —
20-940 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-9]
Troubleshooting Code Failure Code Controller Code The headlamp (Lo beam) does
Trouble
E-9 — — not light on
WA380-5 20-941
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-9]
20-942 WA380-5
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-10]
Troubleshooting Code Failure Code Controller Code The headlamp (Hi beam) does not
Trouble function
E-10 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
Description of Trouble
headlamp (Hi beam) does not light on.
Controller Reaction —
Effect on Machine • The headlamp (Hi beam) does not light on.
Related Information —
WA380-5 20-943
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-10]
Troubleshooting Code Failure Code Controller Code The headlamp (Hi beam) does
Trouble
E-10 — — not light on
20-944 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-11]
Troubleshooting Code Failure Code Controller Code The clearance lamp does not light
Trouble on (Small lamp)
E-11 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the clearance lamp system,
Description of Trouble
the clearance lamp does not light on.
Controller Reaction —
Effect on Machine • The clearance lamp does not light on (Small lamp).
Related Information —
Possible Causes and Harness between L02 (Female) 1 - FS4 Resistance 1 Ω and below
Standard Values (Female) A
Between L02 (Female) 1 - FS4 (Female) A
Resistance 1 MΩ and above
harness - body
Harness between L02 (Female) 2 - FS5
(Female) 4 Resistance 1 Ω and below
WA380-5 20-945
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-12]
20-946 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-12]
WA380-5 20-947
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-13]
1 Horn relay fault Between L119 2 - body (Horn switch: ON) Voltage 1 V and below
Between L119 5 - body (Horn switch: ON) Voltage 20 - 30 V
1) Turn starting switch OFF.
2) Disconnect connector L119.
3) Connect T-adapter.
Between L119 (Male) 1 - 2 (Coil resistance) Resistance 200 - 400 Ω
Between L119 (Male) 3 - 5 (Between pints) Resistance 1 MΩ and above
1) Turn starting switch ON.
Between horn switch pin - body (Horn Voltage 1 V and below
switch: ON)
Between horn switch pin - body (Horn
Voltage 20 - 30 V
2 Horn switch fault switch: OFF)
Possible Causes and
Standard Values 1) Turn starting switch OFF.
2) Disconnect the horn switch pin.
Between horn switch pin - body (Switch: Resistance 1 Ω and below
ON)
1) Turn starting switch ON.
3 Horn fault
Between horn pin - body (Horn switch: ON) Resistance 35 - 45 Ω
1) Turn starting switch OFF.
2) Disconnect the horn pin, horn switch pin, and connectors L103 and FS4.
3) Connect T-adapter.
Harness between FS4 (Female) 1 - L103
(Female) 9, A Resistance 1 Ω and below
Harness disconnection Between FS4 (Female) 1, L103 (Female) 9, Resistance 1 MΩ and above
or ground fault A - body
4 ★ Fuse A-1 blows at
Harness between horn switch pin - L103
occurrence of a Resistance 1 Ω and below
(Female) 0
ground fault.
Between horn switch pin, L103 (Female) 0 -
body Resistance 1 MΩ and above
20-948 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-13]
WA380-5 20-949
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-14]
Troubleshooting Code Failure Code Controller Code The air conditioner does not work
Trouble or does not stop.
E-14 — —
Description of Trouble The air conditioning system is out of order, and the air conditioner does not work or does not stop.
Controller Reaction —
Effect on Machine The air conditioner does not work or does not stop.
Related Information This troubleshooting is only for the connection between the air conditioner and the operator cab. For trou-
bleshooting of air conditioner body, refer to the Shop Manual of Air Conditioner.
In cases other than the above, the relay A7, the blower motor and the con-
nection harness are out of order.
Ground fault of power Check the fuse B-E. When the fuse is blown,
1
supply harness 1) Starting switch OFF. 2) Disconnect the connectors FS3, C47, A7, A8, A9,
A10, A11 and A14. 3) Insert a T-adapter.
Among FS3 (female) F, C47 (female) 8, A7
(female) 1, A8 (female) 1, A9 (female) 1, Resistance 1 MΩ and above
A10 (female) 1, A11 (female) 1, A14
(female) 1 2 and machine body
In cases other than the above, each relay, the control amplifier and the con-
nection harness are out of order.
1) Starting switch OFF. 2) Disconnect the connector C47. 3) Insert a T-
adapter.
20-950 WA380-5
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-14]
Troubleshooting Code Failure Code Controller Code The air conditioner does not
Trouble
E-14 — — work or does not stop.
WA380-5 20-951
(10)
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-14]
20-952 WA380-5
(10)
5
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE
(S MODE)
WA380-5 20-1001
(7)
(10)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-1002 WA380-5
(9)
(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
)n
ctio
for locating the cause of the failure. However,
inje
do not use this when marking calculations to
sive
narrow down the causes.
zle
renc
xces
2. Use the in the Cause column as reference
ner
noz
for [Degree of use (Operated for long period)]
ent
erfe
er li
p (e
g
ion
m
in the [Questions] section as reference.
imin
d
, int
pum
e
n
ject
l
i
er e
As a rule, do not use it when calculating be
, cyl
rger
on t
d in
ion
included if necessary to determine the order
lean
ring
cha
ecti
ject
eize
for troubleshooting.
air c
urbo
r inj
ston
e in
, s
rope
ged
ctiv
ged
n pi
ed t
Defe
Clog
Clog
Wor
Seiz
Imp
1 Confirm recent repair history
2 Degree of use Operated for long period
WA380-5 20-1003
(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
d)
ad
n)
• Excessive injection of fuel
eize
d he
ctio
er s
inje
r an
lung
at
arge
sive
e se
e
ck, p
renc
xces
zzle
och
valv
p (ra
ent
n no
turb
erfe
p (e
lve,
r
r
e
inde
lem
uffle
imin
ranc
, int
pum
pum
ctio
een
f va
er e
, cyl
ed m
rger
inje
clea
on t
etw
ct o
ion
ion
lean
ring
cha
air b
ecti
zed
onta
ject
ject
lve
logg
Legend
air c
urbo
r inj
r va
, sei
ston
e in
e in
c
e of
: Possible causes (judging from Questions and check items)
d, c
e
rope
rope
ged
ctiv
ctiv
ged
ctiv
: Most probable causes (judging from Questions and Check items)
n pi
ed t
she
kag
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-1004 WA380-5
(9)
(7)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Five causes
Step 1
Three symptoms
Step 2
Step 3
WA380-5 20-1005
(7)
(9)
TROUBLESHOOTING S-1
uck)
temperature
er st
20°C 1.28 1.26 1.24 1.23 1.22
ank
t
0°C 1.29 1.27 1.25 1.24 1.23
ung
l
elem alve sea
ping
ance
r
eate
t
–10°C 1.30 1.28 1.26 1.25 1.24
ttery
k, pl
fuel
r
el pi
or c
air h
filte
(rac
ve, v
ent
le in
d ba
nsat
in fu
er
• The specific gravity should exceed the value for the
uze
r
ake
le
inde
rain
g
p
o
nozz
rate
f val
min
mpe
p ga
pum
h
charging rate of 70% in the above table.
l int
, air
, cyl
ump
r, st
her
erio
r
i
aner
tor
act o
nato
t
tion
st co
pum
trica
ging
• In cold areas the specific gravity must exceed the
tion
tion
reat
filte
ring
gula
ed p
t
r de
ir cle
injec
alter
cont
elec
value for the charging rate of 75% in the above table.
boo
clog
injec
injec
air b
feed
fuel
ston
e
o
r
f
a
ctive
ctive
ctive
ctive
ctive
ctive
ctive
ctive
age,
ged
tive
tive
ged
ged
ged
n pi
Defe
Defe
Defe
Defe
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Wor
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
»Adjust
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-1006 WA380-5
(10)
(7)
TROUBLESHOOTING S-2
n
★ For seizure inside the engine, carry out the trou-
witc
ctio
it
bleshooting for S-4 Engine stops during opera-
nne
ery
ircu
ty s
tion.
batt
al co
safe
ng c
id
ated
itch
leno
tarti
• Failure in power train
min
r
y or
o
y
o t
rela
g sw
• Defective electrical system
rior
of s
t so
r
rela
gm
te
ttery
dete
ttery
el cu
ar
artin
iring
artin
fety
g ge
e ba
e ba
e sa
e or
e fu
e st
e st
ew
r i n
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ken
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Bro
Confirm recent repair history
Questions
move out
Remedy
—
WA380-5 20-1007
(7)
(9)
TROUBLESHOOTING S-2
d)
–30 –20 –10 0 10 20 30 40°C
eize
er s
ASTM D975 No. 2
key
lung
nk
Diesel oil
el ta
aft,
ASTM D975A
ck, p
on
No. 1
e sh
in fu
pist
p (ra
ng
iner
driv
d
ump
hole
pipi
i
leno
rain
stra
pum
nk
mp
ed p
fuel
r, st
her
t so
in ta
mp
n pu
ed
ion
reat
e
filte
king
l cu
l us
u
en f
fuel
ject
p
ctio
air b
feed
e
r fue
fuel
, lea
brok
e fu
e in
inje
ent
ged
rope
ged
ged
ged
ctiv
ctiv
ffici
ed,
ken
Clog
Defe
Clog
Defe
Clog
Clog
Insu
Seiz
Imp
Bro
Remedy
20-1008 WA380-5
(9)
(7)
TROUBLESHOOTING S-2
.)
r, etc
General causes why exhaust smoke comes out
)
tuck
but engine does not start
leve
cap
er s
y
spra
cker
• Lack of rotating force due to defective electri-
lung
tank
em
ater
e, ro
e
cal system
syst
ctiv
k, p
ttery
fuel
i r he
(valv
r
• Insufficient supply of fuel
defe
(rac
fuel
nt
er
le in
d ba
i
ke a
• Insufficient intake of air
l
tem
er
e
r
rain
e
ump
zle,
elem
rain
r in
d
r ho
• Improper selection of fuel and oil
rate
e sys
inta
n
p st
noz
i
i
, cyl
r, st
a
on p
terio
e
ner
valv
ed
ical
ing,
h
pum
tion
reat
filte
ring
l us
a
i
ectr
ject
e
ken
ogg
e
d
l
njec
air b
eed
air c
r fue
uel
ston
e or
, bro
e in
e el
e, cl
f
f
rope
ged
ged
ged
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly failed to start
Questions
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner 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
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA380-5 20-1009
(7)
(9)
TROUBLESHOOTING S-3
ap
y
seat
spra
nk c
• Improper fuel used
lve
el ta
tive
nce
d va
er
efec
ger
in fu
fere
r lin
e an
ent
ng
er
n
d
r
nter
rain
aine
pipi
e
hole
e
lem
zle,
p pl
valv
ranc
d
cylin
er, i
p st
noz
r
er e
fuel
pum
r, st
her
clea
t of
pum
harg
n
lean
ing,
reat
filte
king
ntac
ctio
tion
lve
c
r
air b
eed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
f
f
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Engine pick-up suddenly became poor
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Noise of interference is heard from around turbocharger
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Check items
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-1010 WA380-5
(7)
TROUBLESHOOTING S-4
c.)
r , et
• Insufficient supply of fuel
)
tuck
leve
• Overheating
er s
cker
★ If the engine is overheating and the engine
rod
lung
nk
e, r o
el ta
nt
stops, carry out troubleshooting for over-
ey
ring
ting
ck, p
ston
(valv
e
ft, k
ui pm
in fu
heating.
a
nec
p pi
ft be
p ( ra
ng
iner
sha
(See S-14 Coolant temperature becomes
stem
iner
con
y eq
ole
pipi
pum
in
stra
ksha
pum
e
too high)
stra
nk
r tra
er h
v
e sy
in
on,
iliar
fuel
p dr
in ta
r t ra
• Failure in power train
ump
feed
cran
valv
eath
gea
ion
pist
ter,
x
king
pum
p au
owe
uel
ject
ed p
l
zed
i
a If the engine stops because of a failure in
c
zed
zed
r
zed
f
i
air b
ynam
fuel
, lea
f
pum
e in
in p
fuel
, sei
ent
, sei
, sei
, sei
e
the power train, carry out troubleshooting
ged
ged
ged
ged
ctiv
en d
ffici
ken
ure
ken
for the chassis.
ken
ken
ken
ken
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
WA380-5 20-1011
(7)
(10)
TROUBLESHOOTING S-5
p
zzle
pum
• Defective governor mechanism
d no
eed
• Defective electrical governor mechanism
p an
nd f
(engine with electrical governor)
pum
nk a
nk
el ta
★
k
If hunting stops when electrical governor rod is
el ta
r
c
erno
feed
ol ra
rnor
in fu
disconnected, carry out troubleshooting for the
n fu
iner
gov
een
ontr
ove
troubleshooting for electric system.
er
tw ee
hole
in ta w
betw
rain
stra
of g
t of
of c
o
k
l
it be
n
o
r, st
her
men
ump
is to
rcuit
ion
ion
circu
reat
filte
erat
erat
just
i
fuel
ed p
c
e d
air in
air b
air in
fuel
spe
e ad
e op
e op
ent
f e
ged
ged
ged
idle
ged,
ctiv
ged,
ctiv
ctiv
ffici
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low
Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Questions
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-1012 WA380-5
(9)
(7)
TROUBLESHOOTING S-6
ent
stm
m
y
seat
• Insufficient intake of air
spra
hrag
adju
tank
• Insufficient supply of fuel
lve
tive
diap or diap
e
• Improper condition of fuel injection
d va
fuel
renc
ctiv
efec
m
er
• Improper fuel used
e an
hrag
ung
g
n
ent
defe
er
erfe
sat
le, d
i pi n
i
pum ainer
(if non-specified fuel is used, output drops)
rain
hol e
e
inde
lem
p pl
valv
pen
ranc
, int
p
ge,
z
• Lack of output due to overheating
p st
noz
tr
fuel
er e
pum
, cyl
her
com
rger
er, s
nka
t of
clea
ate
ion
reat
lean
★ If there is overheating and lack of output,
king
ring
ntac
er li
estg
cha
tion
t
ost
lve
l
ject
f i
air b
carry out troubleshooting for S-14 overheat-
feed
air c
l lev
fuel
urbo
, lea
e bo
e co
r va
ston
njec
ew
n
ing.
t fue
rope
ged
ged
ged
ctiv
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
Defe
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly
Power was lost
Gradually
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
WA380-5 20-1013
(7)
(9)
TROUBLESHOOTING S-7
d)
ad
)
• Improper condition of fuel injection
tion
eize
d he
• Excessive injection of fuel
njec
er s
at
ray
r an
e se
lung
e sp
ve i
arge
valv
essi
e
ctiv
ck, p
renc
och
er
and
(exc
defe
r lin
p ( ra
ent
turb
erfe
lve
g
r
ce
i nde
mp
lem
zle,
uffle
imin
, int
pum
een
aran
f va
u
z
er e
, cyl
n no
ed m
rger
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
ctio
cha
ecti
onta
ject
ject
logg
valv
air c
a
inje
urbo
r inj
ston
e in
e in
c
e of
d, c
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
20-1014 WA380-5
(7)
TROUBLESHOOTING S-8
r
arge
General causes why oil consumption is excessive
och
• Abnormal combustion of oil
Turb
al
d
• External leakage of oil
hea
n se
ce
em
e
oler
• Wear of lubrication system
urfa
hos
der
oke
syst
er
s
r lin
cylin
her
), br
seal
pl ug
r oi l
e
reat
k
inde
d
nd
uide
inta
n or
ter o
pi ng
eal,
n
ain
e
er e
or b
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
il fil
ing
low
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
mo
on r
at b
brea
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
a l
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Confirm recent repair history Bro
Degree of use of machine Operated for long period
Oil consumption suddenly increased
Engine oil must be added more frequently
Questions
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA380-5 20-1015
(7)
(10)
TROUBLESHOOTING S-9
end
• Improper oil used
e
rbin
• Operation under excessive load
tube
er tu
ose
er
ain
r lin
harg
i l dr
r
athe
inde
er o
ui de
boc
lack
, bre
, cyl
harg
t tur
g
is b
r
e
ther
o ol e
ring
valv
r
al a
e
rboc
oke
t
il fil
brea
oil c
ston
e se
lve,
t sm
u
o
t
ged
n va
ged
ged
ged
ctiv
n pi
aus
Clog
Defe
Clog
Clog
Clog
Wor
Wor
Exh
Confirm recent repair history
Questions
None
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
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-1016 WA380-5
(9)
(7)
TROUBLESHOOTING S-10
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
r
er
ce ss
cove
l con
pipin
d pu
n g
ng
y
p plu
p (ex
spra
f fue
ead
timi
e
fuel
f e
pum
h
pum
e
lder
nt o
tion
nsid
from
side
le ho
stme
injec
tion
eal i
el in
o
age
t i
injec
injec
nozz
adju
oil s
fuel
of fu
leak
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Confirm recent repair history
Questions
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
WA380-5 20-1017
(7)
TROUBLESHOOTING S-11
et
gask
k
bloc
ing
ler
head
l coo
, O-r
der
g
cylin
ittin
core
ead,
in oi
by p
er h
r tra
oler
s in
ylind
rack
used
owe
il co
nal c
en o
en p
en c
s ca
Brok
Brok
Hole
Brok
Inter
Confirm recent repair history
Questions
Remedy
20-1018 WA380-5
(10)
(7)
TROUBLESHOOTING S-12
SAE30CD
SAE10WCD
Engine oil
g
ipin
SAE10W-30CD
n
n
il pa
sor
l pa
lic p
ing
SAE15W-40CD
sen
e oi
r
alve
de o
drau
braz
nso
l
ure
d
urna
e
tor v
el se
insi
insi
d hy
n
ipe
valv
mp
il pa
ress
g, jo
on p
il
ilter
iner
gula
ipe
l lev
she
l pu
in o
lief
in o
p
oil p
stra
oil f
l
arin
, cru
e oi
e re
e re
e oi
e oi
suct
uel
i l
of o
n be
ctiv
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
WA380-5 20-1019
(7)
(9)
TROUBLESHOOTING S-13
ver
General causes why oil level rises
d co
seal
hea
• Water in oil (milky white)
ent
mp
ket
side
• Fuel in oil (diluted, and smells of diesel fuel)
i pm
ace
n pu
gas
• Entry of oil from other component
g in
surf
-ring
equ
leev
ctio
k
ead
bloc
n
seal
pi pi
ary
s
e
re, O
d, h
j
r
n
e
g
i
der
hold
l
from
ittin
stat
rear
side
aux
hea
r co
cylin
rmo
by p
rt in
zzle
oole
ged
mp
der
fuel
side
e
e no
e pu
cylin
e pa
ama
ade
e th
oil c
e of
ks in
sm
ctiv
ctiv
ctiv
ctiv
n, d
kag
ken
ken
Defe
Hole
Defe
Defe
Defe
Crac
Wor
Lea
Bro
Confirm recent repair history Bro
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1020 WA380-5
(10)
(7)
TROUBLESHOOTING S-14
re
• Defective cooling circulation system
ratu
en)
• Rise in oil temperature in power train
ket
mpe
t op
aug
lley
gas
★ Carry out troubleshooting for chassis.
re g
ns
s no
n pu
il te
or fi
ead
u
er o
doe
oole
rn fa
t
alve
pera
diat
d, h
tat (
vert
g
core
er
oil c
, wo
ittin
re v
d ra
hea
ump
tem
wat
mos
con
ator
by p
essu
ping
ken
she
der
ater
er p
ing
rque
ther
, bro
radi
, cru
cylin
p
e pr
l
ade
ew
wat
o
l i
o
s
in to
e
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
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
Check items
is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
WA380-5 20-1021
(7)
(10)
TROUBLESHOOTING S-15
ead
etc.)
)
General causes why abnormal noise is made
ition
d)
der h
i on)
ver,
eize
f pos
ject
cylin
er le
• Abnormality due to defective parts
er s
ce
n
out o
r
• Abnormal combustion
rock
aran
r line
l ung
r and
ive
e
• Air sucked in from intake system
c
e
oard
e cle
cess
linde
alve
eren
ck, p
enc
arge
pum oz z l e
m (v
ing b
sh
x
r
g, cy
valv
f
p (ra
boch
e
r
p (e
inte
f
nn
ckla
nter
yste
divid
n rin
i ng
t of
pum
n tur
ctio
a
belt
er, i
b
lve s
ush
n
pisto
fler (
i nj e
train
wee
e
i on
i on
harg
n
m
ic va
b
n, fa
just
muf
r bet
d
r of
ject
ject
zed
r
e
a
c
ynam
z
wea
urbo
r ge
d fa
e ad
, sei
e in
of ai
side
, sei
e in
rme
rope
ssive
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
age
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Leak
Seiz
Imp
Exce
Mis
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1022 WA380-5
(7)
TROUBLESHOOTING S-16
tuck)
n)
Abnormal noise is made”.
ctio
etc. s
i on
ned
i nj e
General causes why vibration is excessive
ush
ver,
alig
per)
fuel
en c
ker le
• Defective parts (abnormal wear, breakage)
mis
dam
sive
ring
brok
, roc
• Improper alignment
n
aft (
xces
bea
a i
valve
• Abnormal combustion
er tr
lts,
h
t sh
klas
ain
p (e
g bo
(
pow
m
utpu
d, m
e
bac
pum
st
ntin
y
and
lve s
de o
g ro
n
ing
u
i on
i
r tra
o
ic va
g i ne
m
ctin
insi
ject
s
gea
u
ynam
e
nne
ngin
b
f en
e in
part
m
r
d
n co
rope
ter o
n ca
ctiv
se e
ctive
ken
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Replace
Correct
Correct
Adjust
Remedy
WA380-5 20-1023
(7)
30 DISASSEMBLY AND ASSEMBLY
WA380-5 30-1
(10)
(7)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
k:
available, can be substituted with com-
This mark indicates safety-related pre-
mercially available tools.
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly
developed for this model. This mark gives guidance or precau-
a: tions when doing the procedure.
R: Tools with upgraded part numbers,
2:
remodeled from already available tools
This mark stands for a specific coating
for other models.
agent to be used.
Blanks: Tools already available for other models,
3:
used without any modification. This mark indicates the specified
3) Circle mark (Q) in sketch column: torque.
5:
A circle mark means that a sketch of the spe-
This mark indicates an amount of oil or
cial tool is presented in the section of
water to be added.
Sketches for Special Tools.
a Part No. of special tools starting with 79*T
Sketches of special tools
means that they are locally made parts and as
• Various special tools are illustrated for the con-
such not interchangeable with those made by
venience of local manufacture.
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k:
This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
6:
This mark shows oil or water to be
drained.
30-2 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
k:
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com-
mercially available tools. This mark gives guidance or precau-
a: tions when doing the procedure.
2) Distinction of new and existing special tools
2:
N: Tools with new part numbers, newly This mark stands for a specific coating
developed for this model. agent to be used.
R: Tools with upgraded part numbers,
3:
remodeled from already available tools This mark indicates the specified
for other models. torque.
Blanks: Tools already available for other models,
5:
used without any modification. This mark indicates an amount of oil or
water to be added.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketches of special tools
Sketches for Special Tools. • Various special tools are illustrated for the con-
a Part No. of special tools starting with 79*T venience of local manufacture.
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Disassembly
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or water
to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k:
This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
6:
This mark shows oil or water to be
drained.
WA380-5 30-3
(5
10)
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
3) If the part is not under hydraulic pressure, the following corks can be used.
30-4 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
WA380-5 30-5
(10)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New/
Nece Sket
Component Symbol Part No. Part Name ssity
Q’ty remo
ch Nature of work, remarks
del
A 1 790-331-1110 Wrench z 1 Tightening of cylinder head bolt
1 795-799-1130 Gear z 1
Engine assembly 2 795-799-1900 Pin z 1
G Removal of fuel injection pump
3 795-799-1950 Lock pin z 1
4 795-799-1390 Plate z 1
1 793T-607-1190 Bracket z 1 {
Removal, installation of parking
K 2 722-14-13130 Plate z 1 brake disc and plate
3 01011-62020 Bolt z 1
793T-607-1190 Bracket z 1 {
1 722-14-13130 Plate z 1
01011-62020 Bolt z 1
793T-607-1130 Push tool z 1 {
3 790-101-5421 Grip z 1
Parking brake assembly 01010-81240 Bolt z 1
4 793T-607-1140 Spacer z 1 { Disassembly, assembly of parking
brake assembly
H
5 792T-446-1150 Push tool z 1 {
6 797T-423-1141 Push tool z 1 {
793T-512-1110 Push tool z 1 N {
8 790-101-5421 Grip z 1
01010-81240 Bolt z 1
9 793T-607-1160 Spacer z 1 {
10 793T-607-1180 Push tool z 1 { Press-fitting of front coupling cover
793T-607-1210 Lifting tool z 2 {
Transmission assembly F 2 Lifting up of clutch pack assembly
793-607-1230 Pin z 2
1 790-201-2170 Plate 1
2 790-201-2730 Spacer 1
C2 Press fitting of bearing
3 796-465-1120 Push tool 1
Transmission assembly
(continued) 4 790-201-2740 Spacer 1
1 793-607-1110 Seal holder 1 N
C3 Assembly of piston seal
2 793-607-1120 Seal holder 1 N
C12 799-301-1500 Oil leak tester kit 1 Check of operation of piston
790-501-5000 Unit repair stand z 1
790-901-2150 Plate z 1
WA380-5 30-7
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
30-8 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Vacuum pump
799-703-1120 (240V) 1
WA380-5 30-9
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
D3-2 Spacer
30-10 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D5 Push tool
F2 Lifting tool
WA380-5 30-11
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H1 Bracket
H3 Push tool
30-12 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H4 Spacer
H5 Push tool
WA380-5 30-13
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H6 Push tool
H8 Push tool
30-14 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H9 Spacer
CWW10424
WA380-5 30-15
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
J1-2 Spacer
30-16 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
J2 Push tool
J3 Push tool
WA380-5 30-17
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
J4 Seal support
K1 Bracket
30-18 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
CPW10703
CPW10701
WA380-5 30-19
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
5) Disconnect the dust indicator hose and 10) Lift the bulkhead assembly (14) slowly
the air intake hose (9) and remove the air and remove it.
cleaner assembly (10). ★ Lift the air conditioner hoses and the
rubber sheet at the same time and
remove them.
4 Bulkhead Assembly: 92 kg
CPW10704
CPW10706
CPW10705
CPW10707
CPW10708
30-20 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
9. Lift and remove the muffler assembly (24). 15. Disconnect the turbo outlet hose (37).
4 Muffler assembly: 36 kg
CPW10709
CPW10713
WA380-5 30-21
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
4 Engine assembly:
★ Hold the nuts for the lower side to
820 kg
prevent them from turning
together. [*4]
[*5]
CPW10714 CPW10717
3) Use the hydraulic jack [1] and the block [2] INSTALLATION
to support the torque converter side of
the torque converter and transmission • Carry out the installation in the reverse order
assembly. to removal.
[*1]
• Fill the air conditioner with gas (R134a).
[*2]
• See the paragraph of "Adjustment of
Accelerator Pedal" in Testing and Adjust-
ing engine speed.
[*3]
• Bleed air from the fuel system.
[*4]
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
[*5]
★ Check that and o-ring is nested in the
4) Remove the flywheel case (46) and 12 torque converter housing.
pieces of the mounting bolts (47) on the
★ Adjust the height of the pilot cover very
torque converter side.
5) Turn the drain tube of the engine oil pan carefully so that it enters the hole of the
aside until it comes to the fuel tank. flywheel smoothly. Never insert it in the
hole by force.
• Coolant supply
Feed coolant up to the neck of the radiator.
Start the engine to circulate coolant and
check the coolant level in the reservoir tank.
• Oil supply
CPW10716
Feed engine oil (designated one) up to the
specified level.
30-22 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CYLINDER
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
New/Modified
Necessity
Quantity
Sketch
Part
Symbol Part Number Name
A1 790-331-1110 Wrench ● 1
REMOVAL
1. Drain coolant.
2. Engine hood assembly
1) Disconnect the exhaust pipe (1). 5) Remove the connector (8) and then
2) Disconnect the hose (2) between the res- remove the back buzzer (9).
ervoir tank and the radiator on the reserve 6) Remove the connector (10).
tank side and remove it from the engine 7) Remove the cover and then remove the
hood clamp. connector (11) of the fan motor.
CPW10718 CPW10721
3) Remove the rubber sheet (3) and the baf- 8) Remove the stays (12) and (13) and then
fle (4). remove the rear mounting bolts (14) and
(15).
CPW10719
CPW10722
WA380-5 30-23
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CYLINDER
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
9) Use a lever block to sling the engine hood 4. Lift and remove the muffler assembly (21).
and remove the right and left mounting
4
bolts (16) and (17). Muffler assembly: 36 kg
CPW10726
4
Engine hood assembly: 260 kg tor (22).
2) Disconnect the ground wiring harness
(23), and remove the heater relay (24).
3) Disconnect the breather hose (25) from
the head cover, remove the clamps (26)
and (27) and bring it to the left side of the
engine.
CPW10724 4) Remove the fuel filter (28). [*2]
5) Remove the air cleaner bracket (29).
CPW10727
CPW10725
30-24 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CYLINDER
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
6. Disconnect the aftercooler outlet pipe 13. Remove the turbocharger and exhaust mani-
(30). [*3] fold assembly (39). [*7]
7. Remove the muffler mounting bracket (31). 14. Disconnect the aeration hose (40).
8. Remove the air intake connector (32).
CPW10731
CPW10729
CPW10732
CPW10730
CPW10733
WA380-5 30-25
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CYLINDER
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
[*2]
• Bleed air from the fuel system.
[*3]
[*4]
[*5]
30-26 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CYLINDER
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
WA380-5 30-27
(9)
2
(7)
RADIATOR AND
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION FAN MOTOR
OF RADIATOR ASSEMBLY
AND FAN MO-
CPW10739
• Coolant supply
Feed coolant up to the neck of the radiator.
Start the engine to circulate coolant, and CPW10740
check the coolant level in the reservoir tank
again.
30-28 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF RADIATOR
RADIATOR AND AND
FAN MOTOR FAN MO-
ASSEMBLY
7. Disconnect the radiator outlet hose (7) on the 11. Lift and remove the radiator fan motor
torque converter cooler side. assembly (14).
8. Disconnect the radiator inlet hose (8) and the
4
aeration hose (9). Radiator fan motor assembly:
9. Disconnect the aftercooler inlet hose (10) and 195 kg
the outlet hose (11).
CPW10744
CPW10741
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
CPW10742 [*2]
★ See the paragraph of "Bleeding Air from
Fan Motor Circuit" in TESTING AND
ADJUSTMENT and bleed air from the fan
motor circuit.
10. Use a lever block to sling the radiator fan • Coolant supply
motor assembly, and remove the left mount- Feed coolant up to the neck of the radiator.
ing bolt (12) and the right mounting bolt (13). Start the engine to circulate coolant, and
check the coolant level in the reservoir tank
again.
CPW10743
WA380-5 30-29
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY
New/Modified
Necessity
See Paragraph 2 of "Removal of Cylinder
Quantity
Sketch
Symbol Part Number Part Name
Head Assembly" and remove the engine hood
assembly.
2. Sling the aftercooler assembly (3) and discon- 1 795-799-1130 Gear ● 1
nect the aftercooler inlet hose (1) and the out-
2 795-799-1900 Pin ● 1
let hose (2). G
3. Remove the mounting bolts and then remove 3 795-799-1950 Lock pin ● 1
the aftercooler assembly (3). 4 795-799-1390 Plate ● 1
4
Aftercooler assembly: 31 kg REMOVAL
CPW10746
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
2. Remove the engine stop solenoid (3). [*1]
Hose clamping bolt:
3. Disconnect the accelerator cable (4). [*2]
5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
4. Disconnect the fuel tube (5). [*3]
5. Disconnect the lubrication hose (6). [*4]
6. Remove the oil filler port (7).
7. Disconnect the muffler drain tube (8).
CPW10747
30-30 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
8. Disconnect the fuel return hose (9). [*5] 12. Remove the cap (14).
13. Remove the nut (15) and the washer
(16). [*7]
★ Remove the nut and the washer carefully
so that they do not drop in the case.
CPW10751
CPW10752
CPW10750 CPW10753
WA380-5 30-31
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
Joint bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
[*4]
Joint bolt:
8 ± 2 Nm {0.8 ± 0.2 kgm}
[*5]
[*7] [*8]
• Install the fuel injection pump by following
the procedures below:
1) Check that No. 1 cylinder is at the position
of the compression top dead point. CPW10753
★ See Paragraph 10 of Removal.
2) Remove the plug (19) and then remove
the timing pin (20).
30-32 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION NOZZLE HOLDER
OF NOZZLE ASSEMBLY
HOLDER ASSEM-
5) Set the washer (16) in and tighten the nut REMOVAL AND INSTALLATION
(15) temporarily.
★ Attach the washer and the nut care- OF NOZZLE HOLDER ASSEM-
fully so that they do not drop in the BLY
case.
★ Tighten the nut temporarily by apply- REMOVAL
ing the torque of about:
50 Nm {4.9 kgm), disengage the tim- WARNING! Disconnect the battery (-)
ing pin and tighten the nut by apply- terminal in advance.
ing the specified torque.
6) Disengage the timing pin (10).
1. Engine hood assembly
See Paragraph 2 of "Removal of Cylinder
Head Assembly" and remove the engine hood
assembly.
2. Disconnect the dust indicator hose and the air
intake hose (1), and remove the air cleaner
CPW10754 assembly (2). [*1]
CPW10755
8) Tighten the drive nut (15) of the fuel injec- 3. Remove the muffler assembly (3).
tion pump permanently.
CPW10756
WA380-5 30-33
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION NOZZLE
OF NOZZLE HOLDER
HOLDER ASSEM-
ASSEMBLY
4) Remove the fuel filter (10) from the 10. Remove the holder (17) and then remove the
bracket (11). [*2] nozzle holder assembly (18). [*5]
5) Remove the air cleaner bracket
(11).
CPW10760
CPW10757
INSTALLATION
5. Disconnect the aftercooler outlet pipe • Carry out installation in the reverse order to
(12). [*3] removal.
6. Remove the muffler mounting bracket (13). [*1]
[*2]
• Bleed air from the fuel system.
[*3]
[*4]
CPW10759
30-34 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
FANOF FAN
AND AND
FAN FAN MOTOR
MOTOR AS-
ASSEMBLY
1. Grille
1) Open the grille and sling it. Then, remove
the right and left dampers (1).
2) Remove the connectors (2) and (3) of the
working lamp and then remove the wiring
harness clamp. CPW10763
CPW10761
CPW10764
CPW10762
WA380-5 30-35
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
7. Sling the fan and fan motor assembly (16) REMOVAL AND INSTALLATION
and remove the right and left mounting bolts
to remove it. [*1] [*2] OF FUEL TANK ASSEMBLY
1. Drain fuel.
2. Disconnect the air bleeding hose (1) of the
fuel tank from the radiator.
3. Remove the engine oil drain valve (2) from
the fuel tank.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1] CPW10792
• Install the fan and fan motor assembly so
that the clearance between the fan out-
side diameter and the shroud inside
diameter become even all around.
[*2]
★ See the paragraph of "Bleeding Air of Fan
Motor Circuit" in Testing and Adjusting,
and bleed air of the fan motor circuit.
4. Disconnect the fuel sensor connector (3).
5. Remove the coolant drain valve (4) and the
hose clamp (5) from the fuel tank.
CPW10793
30-36 WA380-5
(10)
2
5
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
6. Remove the clamp (6) of the fuel tank air 11. Fuel tank assembly
bleeding hose (1) from the frame (7). 1) Support the front of the fuel tank (16)
7. Remove the clamps (8) and (9) of the fan from below with the transmission jack [1].
motor hose from the fuel tank. 2) Sling the rear part of the fuel tank (16).
★ Since the sling is apt to slip backward,
prevent it from slipping with bolts.
CPW10794
CPW10797
CPW10798
CPW10795
CPW10796
WA380-5 30-37
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF PARKING
PARKING BRAKEBRAKE DISC
DISC PLATE
4) Lower the transmission jack [1] and the REMOVAL AND INSTALLATION
crane at the same time, and remove the
fuel tank assembly (16).
OF PARKING BRAKE DISC
PLATE
4 Fuel tank dry weight: 180 kg
SPECIAL TOOL
New/Modified
Necessity
Quantity
Sketch
Symbol Part Number Part Name
1 793T-607-1190 Bracket ● 1
CPW10800 K 2 722-14-13130 Plate ● 1
3 01011-62020 Bolt ● 1
REMOVAL
WARNING! Park the machine on a flat
ground and set the frame lock bar to
the frame. Then, lower the work equip-
ment to the ground completely and
stop the engine. Put the blocks under
INSTALLATION the wheels.
CPW10766
CPW10767
30-38 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF PARKING
PARKING BRAKEBRAKE DISC
DISC PLATE
4. Remove the mounting bolt (8) of the cage (7), 9. Attach 2 pieces of the bolt [3] to the piston (15)
and use the forcing screw [1] to remove the and pry the bolts with the bar [4] to remove
cage (7). [*3] the piston. [*4]
★ Check the thickness and the quantity of ★ Be careful so that the o-ring does not
the shims in advance. come off, because the piston will drop
5. Remove the level gauge cover (9). without the o-ring.
CPW10768
CPW10771
CPW10772
7. Keep the guide bolt [2] attached to the hous- 11. Remove the hub (17) and then remove the
ing (13). plate (18), the spring (19) and the disc
8. Remove the bearing assembly (14). (20). [*5]
★ 10 plates, 9 springs, and 9 discs
CPW10770
CPW10773
WA380-5 30-39
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF PARKING
PARKING BRAKEBRAKE DISC
DISC PLATE
INSTALLATION [*5]
★ Set the hub (17) first and then set the
• Carry out installation in the reverse order to plate (18), the spring (19) and the disc (20)
removal. in this order.
[*1] ★ Be careful so that the spring (19) is not
★ When installing the drive shaft, check that pinched between them.
the spider cap key is perfectly nested in
the key slot of the counter yoke, and then
tighten the bolt.
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
[*2]
[*3]
★ Set the shim to where it was. • Oil supply
Supply transmission oil (the designated oil)
Mounting bolt: up to the specified level.
98 - 123 Nm {10 - 12.5 kgm}
Note: When replacing any parts other than the
[*4] disc and the plate, see the paragraph of
"Disassembly and Assembly of Parking
Brake Assembly".
Piston o-ring: Grease (G2-LI)
CPW10774
30-40 WA380-5
(9)
2
5
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION
TORQUE CONVERTER ANDOFTRANSMISSION
TORQUE CONVERTER AND
ASSEMBLY
CPW10776
CPW10778
WA380-5 30-41
(10)
2
(7)
DISASSEMBLY AND ASSEMBLYREMOVAL AND CONVERTER
TORQUE INSTALLATION OFTRANSMISSION
AND TORQUE CONVERTER AND
ASSEMBLY
9. Remove the oil filler port (8). 15. Pump outlet piping
10. Disconnect the hoses (9) and (10). 1) Remove the clamp (17) and disconnect
★ Disconnect the hose (9) because it the steering pump outlet pipe (18), switch
touches the transmission assembly when pump outlet pipe (19) and the work equip-
the assembly is lifted. ment pump outlet pipe (20).
11. Remove the cover (11).
CPW10782
CPW10779
CPW10783
CPW10780
CPW10784
CPW10781
30-42 WA380-5
(9)
2
5
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION
TORQUE CONVERTER ANDOF TRANSMISSION
TORQUE CONVERTER AND
ASSEMBLY
CPW10785
CPW10786
WA380-5 30-43
(9)
2
(7)
DISASSEMBLY AND ASSEMBLYREMOVAL AND CONVERTER
TORQUE INSTALLATION OFTRANSMISSION
AND TORQUE CONVERTER AND
ASSEMBLY
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
[*4]
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
CPW10790
DJW05922
4 mission assembly:
Torque converter and trans- [*6]
910 kg ★ Check that an o-ring is set in the torque
converter housing.
★ Adjust the height carefully so that the
pilot cover enters the flywheel hole
smoothly, and never assemble them by
force.
CPW10791
BLEEDING AIR OF BRAKE CIRCUIT
• After completing the installation, see the
paragraph of "Bleeding Air of Brake Circuit" in
Inspection and Adjustment to bleed air of the
brake circuit.
• Oil supply
Supply hydraulic oil (the designated one) up
to the specified level. Supply transmission oil
(the designated oil) up to the specified level.
30-44 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
TRANSMISSION ASSEM-
ASSEMBLY
New/Modified
Necessity
2 pieces of the mounting bolt (7).
Quantity
Sketch
Symbol Part Number Part Name
DISASSEMBLY CPW10802
CPW10801
CPW10803
WA380-5 30-45
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
CPW10804 CPW10807
CPW10805
CPW10808
CPW10806
30-46 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
TRANSMISSION ASSEM-
ASSEMBLY
8. Speed sensor and oil temperature sensor 10. Torque converter assembly
Remove the speed sensor (27) and the trans- 1) Face the torque converter side down and
mission oil temperature sensor (28). lift the rear case assembly (31). Then, set
the block [7] below the torque converter
assembly (32).
★ Keep the case upright.
2) Remove the stator shaft mounting bolt
(33) and lift the rear case to remove the
torque converter (32) assembly.
CPW10809
CPW10813
CPW10810
CPW10814
CPW10811
WA380-5 30-47
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
2) Face the PTO side up and set the rear case ★ Repeat the same procedures to
to the block. remove the PTO gear on the opposite
3) Remove the snap ring (37), the plate (38) side.
and the woodruff thrust plate (39).
CPW10815
CPW10816
CPW10819
30-48 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
TRANSMISSION ASSEM-
ASSEMBLY
13. Yoke 15. Bearing (on the 1st speed clutch side)
Remove the yoke (48). Remove the bearing (54).
16. Cover (on the 2nd speed clutch side)
1) Remove the cover (55).
CPW10821
CPW10824
CPW10822
CPW10825
WA380-5 30-49
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
CPW10827
Bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10822
30-50 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
TRANSMISSION ASSEM-
ASSEMBLY
CPW10819
CPW10821
WA380-5 30-51
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
4) Set the PTO gear (41) to the case and 6) Attach the snap ring (34).
attach the shaft (40). ★ Repeat the same procedures to attach
the PTO gear on the opposite side.
CPW10814
CPW10816
CPW10831
Bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10813
30-52 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
TRANSMISSION ASSEM-
ASSEMBLY
CPW10832
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10839
CPW10833
WA380-5 30-53
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
30-54 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
TRANSMISSION ASSEM-
ASSEMBLY
Mounting bolt:
9.8 - 12.7 Nm {1.0 - 1.3 kgm}
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
29.4 - 39.2 Nm {3 - 4 kgm}
CPW10805
CPW10807
CPW10806
WA380-5 30-55
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
17. Steering, switch and fan pump assembly 3) Connect the hoses (4) and (3) and the
Lift and install the pump assembly (8), and breather hose (5).
tighten 2 pieces for the mounting bolt (9). 4) Connect the suction tube (2).
CPW10803 CPW10801
CPW10802
30-56 WA380-5
(9)
2
WA380-
5 TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND OFCLUTCH
ASSEMBLY CYLINDER PACK
TRANSMISSION CLUTCH
HEAD ASSEMBLY
Simplified Drawing
New/Revised
and dismount forward gear (2).
Necessity
Quantity
Part
Symbol Number Part Name 2) Dismount needle bearing (5) from the for-
ward gear.
1 790-201-2170 Plate ■ 1
2 790-201-2730 Spacer ■ 1
C2
3 796-465-1120 Push tool ■ 1
4 790-201-2740 Spacer ■ 1
DISASSEMBLY
cpw10972
WA380-5 30-57
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
4. Clutch plate
1) Dismount spring plate (8) from the hous-
ing.
cpw10577
cpw10574
cpw10575
5. Piston
Make air blow into the forward side oil hole of
the shaft and dismount piston (14).
cpw10576
30-58 WA380-5
(9)
2
TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH PACK ASSEMBLY
TRANSMISSION CLUTCH
cpw10586
cpw10579
cpw10585
cpw10588
WA380-5 30-59
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
cpw10589
cpw10975
5. Piston
7. 4th gear
Make air blow into the reverse side oil hole of
1) Dismount spacer (44), thrust washer (45)
the shaft and dismount piston (42).
and 4th gear (46).
2) Dismount needle bearing (47) from the
4th gear.
cpw10590
cpw10593
8. End plate
9. Clutch plate
10. Piston
cpw10591
★ Disassemble procedures 8. - 10. in the
same manner as the procedures 3. - 5. at
the 1st clutch side.
30-60 WA380-5
(10)
2
TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH PACK ASSEMBLY
TRANSMISSION CLUTCH
1. Bearing
1) Apply puller [10] to 3rd gear (53) and dis-
mount bearing (49) and 4th gear (50).
cpw10598
cpw10976
4. Clutch plate
1) Dismount plate (56), disc (57) and spring
(58) from the housing.
2. 3rd gear
1) Dismount thrust washer (52) and 3rd gear
(53).
cpw10599
cpw10596
cww10977
WA380-5 30-61
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
cpw10600 cpw10979
cpw10602
cpw10605
cpw10978
30-62 WA380-5
(10)
2
TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH PACK ASSEMBLY
TRANSMISSION CLUTCH
cww10606
2) Mount spring plate (71)
★ Mount it facing identification mark U
upward.
cpw10607
cpw10610
WA380-5 30-63
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
cpw10576
cww10980
cpw10575
cpw10574
30-64 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
cpw10573
cww10982
cww10617
cww10981
WA380-5 30-65
(9)2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
cpw10620
cpw10618
cpw10619
30-66 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
cpw10589
8. End plate
1) Mount end plate (36).
2) Use C clamp [8] or the like to press end
[1ST CLUTCH SIDE] plate (36) and mount snap ring (37).
6. 1st side piston
1) Make the piston seal run in the same
manner as the 4th clutch side and assem-
ble piston (42).
2) Assemble piston (42) in the same manner
as the 4th clutch side piston.
cpw10588
Piston sliding surface:
Transmission oil
9. 1st gear
1) Assemble needle bearing (35) in 1st gear
(34).
cpw10590 2) Mount the 1st gear fitting the internal
gear of the disc.
cpw10587
WA380-5 30-67
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
3) Assemble thrust washer (33) and snap 2) Check that the clearance d between idler
ring (32). gear (31) and thrust washer (33) is within
a standard value.
Standard value d: 0.26 - 0.74 mm
★ Measure the clearance d using a dial
gauge or clearance gauge.
cpw10586
30-68 WA380-5
(9)
2
TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH PACK ASSEMBLY
TRANSMISSION CLUTCH
cpw10631
4. End plate
1) Mount end plate (91).
2) Use C clamp [15] or the like to press end
plate (91) and mount snap ring (92).
5. 2nd gear
1) Assemble needle bearing (64) in 2nd gear
cpw10630
(63) and mount it fitting the internal gear
of the disc.
★ If the internal gear of the disc is not fit,
assemble needle bearing gently turn-
ing the disc. Take care never to press
it strongly.
WA380-5 30-69
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
2) Mount thrust washer (62). 3) Check that the clearance e between idler
gear (60) and thrust washer (62) is within
a standard value.
Standard value e: 0.28 - 0.72 mm
★ Measure the clearance e using a dial
gauge or clearance gauge.
cpw10605
cpw10633
cwp10600
30-70 WA380-5
(10)
2
TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH PACK ASSEMBLY
TRANSMISSION CLUTCH
cpw10599
cpw10598
WA380-5 30-71
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF PARKING
PARKING BRAKE
BRAKE ASSEM-
ASSEMBLY
Simplified Drawing
New/Revised
bly (7) and shim (8).
Necessity
Quantity
Part
Symbol Number Part Name
★ For the shim, check the thickness and
the number of shims.
2) Dismount dust seal (9), oil seal (10) and
793T-607-1190 Bracket ● 1 |
outer race (11) from gauge (7).
1 722-14-13130 Plate ● 1
01011-62020 Bolt ● 1
01010-81240 Bolt ● 1
4 793T-607-1140 Spacer ● 1 |
H
5 792T-446-1150 Push tool ● 1 |
6 797T-423-1141 Push tool ● 1 | cpw10931
793T-512-1110 Push tool ● 1 N |
8 790-101-5421 Grip ● 1
01010-81240 Bolt ● 1
9 793T-607-1160 Spacer ● 1 |
10 793T-607-1180 Push tool ● 1 |
DISASSEMBLY
1. Coupling (rear drive) 4. Bearing assembly
Dismount coupling (2). 1) Dismount bearing assembly (12).
2. Coupling (front drive) 2) Dismount bearing (14) from boss (13).
1) Dismount bolt (3) and dismount washer
(4) and holder (5).
2) Dismount coupling (6).
cpw10932
cpw10930
30-72 WA380-5
(10)
2
PARKING
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF BRAKE
PARKING ASSEMBLY
BRAKE ASSEM-
cpw10935
cpw10933
7. Piston
Use eyebolt [2] to hang and dismount piston
(18).
cpw10936
cpw10934
9. Brake housing
Use eyebolt [3] to hang and dismount brake
housing (24).
cpw10937
WA380-5 30-73
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF PARKING
PARKING BRAKE
BRAKE ASSEM-
ASSEMBLY
cpw10938
30-74 WA380-5
(10)
2
PARKING
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF BRAKE
PARKING ASSEMBLY
BRAKE ASSEM-
cpw10942 cpw10944
cpw10946
WA380-5 30-75
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF PARKING
PARKING BRAKE
BRAKE ASSEM-
ASSEMBLY
cpw11189
cpw10947
cpw10950
30-76 WA380-5
(9)
2
PARKING
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF BRAKE
PARKING ASSEMBLY
BRAKE ASSEM-
3 Mounting bolt:
5) Adjust the shim thickness so that the rota-
tion torque of the shaft becomes 0.49 -
9.8 ± 0.98 {1 ± 0.1 kgm}
0.98 Nm {0.05 - 0.1kgm}.
★ When adjusting the shim after install- 6) Make sure that there is no looseness after
ing the coupling, tighten the bolts per- the shim is adjusted.
manently. ★ Perform the above adjustment while
parking brake P.B. is not installed.
10. Coupling (front drive) ★ Perform the above adjustment while
1) Mount coupling (6). the dust seal and oil seal S are not
2) Attach holder (5) and washer (4) and installed.
tighten bolt (3). ★ Replace O-ring (Part No. 07000 - 15140).
3 Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
AJS01617
WA380-5 30-77
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF PARKING
PARKING BRAKE
BRAKE ASSEM-
ASSEMBLY
12. Install 2 parking brake release bolts B (M12, 2) Use tool H1 to press down the plate and
L = 45 mm). to mount snap ring (19).
13. Remove the assembly of cover K and piston ★ Take care so that the spring will not
P. be loaded on the disc.
★ Do not remove cage mounting bolts (40). ★ Check that the snap ring is correctly
inserted in the groove.
cpw10935
30-78 WA380-5
(10)
2
PARKING
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF BRAKE
PARKING ASSEMBLY
BRAKE ASSEM-
Mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
17. Coupling (rear drive)
Raise the transmission case assembly and
mount coupling (2).
cpw10930
WA380-5 30-79
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER ASSEMBLYOF TORQUE CONVERTER
(STANDARD AS-
SPECIFICATION)
Simplified Drawing
New/Revised
i) Dismount pilot (4).
Necessity
Quantity
Symbol Part
Number Part Name ii) Remove snap ring (5) and dismount
plate (1).
790-901-2150 Plate ● 1
DISASSEMBLY
1. With reference to up to item 10 of the disas-
sembly of "Disassembly and Assembly of
Transmission Assembly", dismount the
torque converter and load it on the block or
mount it on tool B.
2. Turbine and case assembly
1) Mount the eyebolt on the stator shaft and
dismount bolt (2a), then dismount stator
shaft pump assembly (2) from turbine iii) Press the boss portion of turbine (6)
case assembly (3). and dismount it from case (7).
cpw10378
30-80 WA380-5
(9)
2
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY DISASSEMBLY ASSEMBLY OF
AND ASSEMBLY (STANDARD SPECIFICATION)
TORQUE CONVERTER AS-
3. Stator 6. Bearing
1) Dismount snap ring (9). Dismount bearing (15) from gear (13).
2) Dismount stator (10).
ASSEMBLY
4. Stator shaft
Use eyebolt [1] to press it from the side of sta- 1. Bearing
tor shaft (11) and disconnect it from pump Mount bearing (15) on gear (13).
assembly (12).
Bearing: Engine oil
5. Gear
Dismount gear (13) from pump (14). 2. Gear
Mount gear (13) on pump (14).
Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
WA380-5 30-81
(9)
2
DISASSEMBLY AND ASSEMBLY TORQUE
DISASSEMBLY AND ASSEMBLY
CONVERTER ASSEMBLY OF TORQUE CONVERTER
(STANDARD AS-
SPECIFICATION)
Mounting bolt:
Adhesive (LT-2)
2) Press the inner race side of the bearing
and mount pump assembly (12) on shaft Mounting bolt:
(11). 58.8 - 73.5 Nm
{6.0 - 7.5 kgm}
4. Stator
1) Mount stator (10). iii) Press the inner race of the bearing
2) Mount snap ring (9). and mount turbine (6) on case (7).
30-82 WA380-5
(9)
2
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY DISASSEMBLY ASSEMBLY OF
AND ASSEMBLY (STANDARD SPECIFICATION)
TORQUE CONVERTER AS-
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
27.5 - 34.3 Nm
{2.8 - 3.5 kgm}
Mounting bolt:
21.6 - 28.4 Nm {2.2 - 2.9 kgm}
cpw10378
WA380-5 30-83
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER OF(LOCK-UP
ASSEMBLY TORQUE CONVERTER AS-
SPECIFICATION)
Simplified Drawing
New/Revised
i) Use tool B2 to dismount nut (4).
Necessity
Quantity
Part
Symbol Number Part Name
★ Screw the bolt in the stator shaft and
loosen the nut not so as to turn it with
bar [3].
1 790-501-5000 Unit repair stand ● 1
B1 2 790-901-2110 Bracket ● 1
3 790-901-4240 Plate ● 1 R
B2 793-647-1110 Wrench ● 1 N
DISASSEMBLY
1. Execute disassembly procedures 1. - 8. of
item "Disassembling and Assembling Trans-
mission Assembly".
★ Subsequently, perform work loading the
torque assembly on the block (or mount it
on tool B1).
2. Stator shaft and pump assembly
1) Dismount pump mounting bolt (1).
2) Use eyebolt [2] to hang stator shaft and
pump assembly (2) and dismount it from ii) Use eyebolt [4] to pull out stator shaft
turbine and case assembly (3). (5).
iii) Dismount seal ring (6) from stator
shaft (5).
30-84 WA380-5
(9)
2
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY DISASSEMBLY ASSEMBLY
AND ASSEMBLY OF(LOCK-UP SPECIFICATION)
TORQUE CONVERTER AS-
iv) Remove mounting bolt (7) and dis- 4. Disassembly of turbine and case assembly
mount gear (10) and guide and bear- 1) Remove bolt (17a) and dismount pilot
ing assembly (8) from pump (9). (22).
v) Dismount bearing (11) from guide 2) Remove snap ring (23) and dismount
(12). plate (24).
3. Stator assembly
3) Press the boss portion of turbine (25) and
1) Dismount stator assembly (13).
dismount it from case (26).
2) Fine disassembly of stator assembly
i) Remove upper and bottom snap rings
(14) and dismount race and free wheel
assembly (15).
WA380-5 30-85
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER OF(LOCK-UP
ASSEMBLY TORQUE CONVERTER AS-
SPECIFICATION)
1. Complete turbine
Mount turbine (25) on boss (27) and tighten
bolt (25a).
Bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
30-86 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER OF(LOCK-UP
ASSEMBLY TORQUE CONVERTER AS-
SPECIFICATION)
3. Disc
Mount disc (40).
★ Coat the sliding surface of the disc with
engine oil and mount the disc.
5. Bearing
Use push tool [10] to press-fit bearing (28).
★ After having press-fit the bearing, drop
the engine oil by 6 cc and rotate the bear-
ing ten times.
WA380-5 30-87
(9)2
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY DISASSEMBLY ASSEMBLY
AND ASSEMBLY OF(LOCK-UP SPECIFICATION)
TORQUE CONVERTER AS-
6. Plate, snap ring ii) Mount snap ring (17) on stator (16).
Assemble spacer (24) and mount snap ring iii) Attach race free wheel association
(23). (15) to stator (16) and mount snap
ring (14).
7. Pilot
Mount pilot (22) and tighten bolt (17a).
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
30-88 WA380-5
(9)
2
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY DISASSEMBLY ASSEMBLY
AND ASSEMBLY OF(LOCK-UP SPECIFICATION)
TORQUE CONVERTER AS-
iii) Mount seal ring (6) on stator shaft (5). ★ When the direction of stator rota-
tion differs from the above
External surface of seal
description, reverse the race and
ring:
the free wheel assembly and rear-
Grease (G2-LI)
range them in the stator, then
iv) Use push tool [13] to press the inner recheck the direction of rotation.
race side of the bearing and mount
pump assembly (9) on stator shaft (5).
djw05925
WA380-5 30-89
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR
REARAXLE
AXLE ASSEMBLY
ASSEMBLY
cpw10889
cpw10892
cpw10890
30-90 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
ASSEMBLY
4 Rear support:
of mounting bolt (13). [*4]
140 kg
cpw10894
4
Rear axle assembly (with a sup-
port): 4) Remove cover (20) from the front support
1,050 kg and dismount dust seals (21) and (22) and
busing (23).
cpw10895
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
Mounting bolt:
823 - 1,029 Nm {84 - 105 kgm}
[*2]
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
WA380-5 30-91
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR
REARAXLE
AXLE ASSEMBLY
ASSEMBLY
[*3] [*10]
★ With reference to the item of Testing and
★ Mount dust seal (21) facing the "thick lip"
Adjusting "Air Bleeding of Brake Circuit",
bleed air from the brake circuit. outwards.
• (20) is a cover.
[*4] ★ Mount dust seal (22) facing the lip out-
wards.
Mounting bolt: • (23) is a bushing.
1,029 ± 98 Nm {105 ± 10 kgm}
[*5]
★ With reference to the item of Testing and
Adjusting "Air Bleeding of Brake Circuit",
bleed air from the brake circuit.
[*6]
djw05927
Busing portion of support:
Grease (G2-LI)
[*7]
djw05926
30-92 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
ASSEMBLY
cpw10884
INSTALLATION
• Carry out installation in reverse order of
removal.
cpw10885 [*1] Mounting bolt:
823 - 1,029 Nm {84 - 105 kgm}
[*2]
★ With reference to the item of the testing
and adjusting "Air Bleeding of Brake Sys-
tem", bleed air from the brake system.
[*3]
★ When mounting the propeller shaft,
tighten the bolt after having checked that
the key of the standby cap is completely
inserted in the key groove of the mating
[*4] yoke.
Mounting bolt of front axle
assembly:
1,029 ± 98 Nm {105 ± 10 kgm}
WA380-5 30-93
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF AXLE
AXLE HOUSING
HOUSING ASSEM-
ASSEMBLY
Simplified Drawing
1) Temporarily hang axle housing assembly
New/Revised
Necessity
(8) and remove the housing mounting
Quantity
Part
Symbol Part Name
Number bolt.
★ When dismounting the axle housing
assembly on both left and right,
793T-522-1140 Push tool ■ 1 N |
1 attach a counter mark to the housing
793T-522-1150 Spacer ■ 1 N |
and the differential case not so as to
2 797T-423-1290 Push tool ■ 1 |
J be mixed.
3 793T-522-1160 Push tool ■ 2 N |
793T-522-1171 Seal support ■ 2 N |
2) Dismount axle housing assembly (8).
4
01016-30860 • Bolt ■ 6
DISASSEMBLY
★ The subsequent photographs and illustra-
tions are shown using the front axle assembly
as an example.
Need cpw10299
★ The front axle housing and the rear axle
housing have the same internal structure
except their external appearance shape.
1. Oil drain
Dismount plug (1) and extract oil.
(Front, rear)
Need cpw10295
Need cpw10300
2. Axle assembly
Load the axle assembly on block [1].
★ When one-sided housing assembly is dis-
mounted, load the axle assembly on block
[1] so that it will not be tilted.
Need cpw10296
30-94 WA380-5
(9)
2
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
Need cpw10301
Need cpw10302
6. Axle shaft
1) Lift axle housing (14)
2) Punch and pull out the end surface of axle
shaft (15) using a copper hammer or the
like.
Need cpw10303
WA380-5 30-95
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF AXLE
AXLE HOUSING
HOUSING ASSEM-
ASSEMBLY
30-96 WA380-5
(10)
2
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
5) Dismount bearing (25) from pinion gear ★ Make the flange of the oil seal adhere
(23). to the housing end surface.
• Clearance between the flange of
the oil seal and the housing sur-
face:
Less than 0.2 mm
ASSEMBLY
1. Axle housing
1) Press-fit bearing outer races (18) and (19) 2. Axle housing, shaft
in axle housing (14). 1) Use tool J3 to mount oil seal sleeve (17a)
on shaft (15).
Sleeve mounting surface:
Axle oil or anti-friction
composition (LM-P)
★ Check that the dimension a from the
bearing mounting surface is
10.1 ± 0.2 mm.
WA380-5 30-97
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF AXLE
AXLE HOUSING
HOUSING ASSEM-
ASSEMBLY
30-98 WA380-5
(10)
2
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
2) Hold 2 parts axle shaft and housing 7) Dismount planetary carrier (20) and
assembly (8) and sling it by 20 - 30 mm, spacer (24) after having determined the
as you installed the axle housing. shim.
3) Rotating axle shaft (15), hit the flange with
a copper hammer in the direction of the
arrow several times to drive out axle shaft
(15).
4) Adjust the turning force to the standard
value according to step 1).
4. Planetary carrier
1) Previously assemble spacer (24) in plane-
tary carrier (20).
★ Assemble the spacer from the brake
housing side.
9JS02296 2) Assemble bearing (25) in gear (23) and lift
spacer (24), then assemble gear (23).
WA380-5 30-99
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF AXLE
AXLE HOUSING
HOUSING ASSEM-
ASSEMBLY
3
4) Tap on the end surface of shaft (22) and Mounting bolt:
the differential side of gear (23) and push 662 - 829 {67.5 - 84.5 kgm}
back bearing (25), then check that the gear
rotates gently. ★ Thoroughly clean and assemble the
shaft end surface and the planetary
carrier spline portion.
30-100 WA380-5
(10)
2
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
3) After having made the bearing run in 2) Horizontally hang axle hosing assembly
fully, check the activation turning force (8) and quietly assemble it fitting the
"X" in the drill hole h portion of axle hous- spline groove and guide bolt [5].
ing (14). ★ Assemble the axle housing assembly
★ Refer to the item of procedure 3. not to damage the brake piston sur-
Selecting shims. face and the plate surface.
4) Mount stand [4] of the dial gauge on axle
housing (14) and measure the end play of
the planetary carrier on the end surface of
the planetary carrier.
★ Reference value.
• End play of planetary carrier:
0 - 0.1 mm cpw10328
cpw10299
8. Lubrication
1) Tighten the drain plug and lubricate to a
specified level from the oil filler port.
WA380-5 30-101
(10)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
New/Improved
Illustration
Necessity
2. Oil temperature sensor (rear differential)
Quantity
Symbol Product No. Product Name
1) Remove the cover (3).
2) Disconnect the connector and remove the
oil temperature sensor (5).
790-501-5000
1 or Unit repair stand ● 1
790-501-5200
D1
2 790-901-2110 Bracket ● 1
3 790-901-1331 Plate ● 1
D2 2 790-101-5421 Grip ■ 1
3 01010-81240 Bolt ■ 1
2 793T-522-1120 Spacer ■ 1 N {
D3
3 790-101-5421 Grip ■ 1
4 01010-81240 Bolt ■ 1
CPW10332
30-102 WA380-5
(10)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
CPW10336
CPW10333
4) Blow air into the brake tube joint unit (15) CPW10337
and remove the piston (16).
CPW10335
WA380-5 30-103
(9)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
CPW10338
8. Bearing carrier
1) Temporarily lift the differential carrier 2) Remove the gear cover (26) from the dif-
assembly (23). ferential case.
CPW10339 CPW10342
CPW10340
30-104 WA380-5
(9)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
10. Detailed disassembly of differential carrier 4) Remove the pinion gear (35), spider shaft
assembly (standard spec.) (36), and spherical bush (37) together.
★ Identify so that the parts on the left and
right are not mixed.
1) Remove the plane half cover (28) together
with the bearing (27).
★ Mark index symbols on the plane half
cover (28) and bevel gear case flange
half (29).
WA380-5 30-105
(9)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
30-106 WA380-5
(10)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
5) Remove the side gear (67) and pressure 9) Using push tool [8], remove outer race
ring (68). (75) from inside of case (59).
6) Remove the 2 disks (69) and 2 plates (70). 10) Using puller [9], remove bearing (76)
7) Remove the washer (71). from bearing carrier (24).
8) Reverse the case (59) and remove the bolt 12. Pinion gear and cage
(72) to detach the bevel gear (73). 1) Use the press to pull out the pinion gear
(45) from the cage (44).
WA380-5 30-107
(9)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
2) Remove the dust seal (49), oil seal (50), 2) Use tool D5 to press the bearing inner
spacer (42), bearing (46), and outer races race (52) in the pinion gear (45).
(47), (48) from the cage (44).
★ The spacer is attached only to the front.
30-108 WA380-5
(9)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
6) Use the push-pull gauge [5] to turn the 9) Use tool D3 to press the dust seal (49) in
cage (44) and measure the activation rota- the cage (44) until its end surface
tion power. becomes equal to the one of the cage.
★ Activation rotation power:
58.8 N {6 kg} or less Dust seal lip unit:
Grease (G2-LI)
★ When the activation rotation power
exceeds the reference value or the
cage does not rotate by hand (rotates
heavily), replace the bearing and
spacer. Then confirm the activation
rotation power again.
CPW10357
2. Coupling
Attach the coupling (19), o-ring (19a), and
holder (17a) to the pinion gear (45), and fas-
ten the attachment bolt (17).
★ In this case, temporarily fasten the attach-
7) Assemble the spacer (42). ment bolt (17). After the coupling is
★ The spacer is attached only to the assembled in the differential case,
front. securely fasten the bolt.
8) Use tool D2 to press the oil seal (50) in ★ Take care not to damage the seal at inser-
the cage (44). tion of the coupling (19).
★ Confirm that dimension C is
Attachment bolt:
10 ± 0.5 mm.
Adhesive (LT-2)
Oil seal lip unit: (At actual fastening)
Grease (G2-LI)
Attachment bolt:
490 - 608 Nm {50 - 62 kgm}
(At actual fastening)
WA380-5 30-109
(10)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3. Detailed assembly of differential carrier 4) Put the bevel gear (43) on the block [6],
assembly (standard spec.) turning down the gear side.
★ Assemble the parts on the left and right 5) Attach the guide bolt [7] to the bevel gear
according to the identification determined (43).
at disassembly. 6) Lift the flange half (29), attach it to the
1) Press the bearing outer race (24a) in the bevel gear (43), and fasten the bevel gear
bearing carriers (24) on the left and right attachment bolt (42).
until it reaches the carriers.
Attachment bolt:
Adhesive (LT-2)
Attachment bolt:
157 - 196 Nm {16 - 20 kgm}
30-110 WA380-5
(9)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
8) Attach the pinion gear (35) and spherical 12) Attach the plane half (28) to the flange
washer (37) to the spider shaft (36). half (29).
★ At attachment, match the index marks
set at disassembly.
Attachment bolt:
157 - 196 Nm {16 - 20 kgm}
CWW10903
Thrust washer:
Grease (G2-LI)
WA380-5 30-111
(10)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
2) Press fit outer race (75) to case (59). 7) Reverse the case (59) and install the
3) Press fit cover (58) similarly. washer (71), plate (70), and disk (69) in
this order.
★ When installing the disk, set cuts a
and b accurately.
★ Part No. of disc (t : 3 mm only)
(Part No. 423-22-37410)
9JS02261
4) Place the bevel gear (73) on the block [6]
with the gear side down.
5) Install guide bolt [7] to bevel gear (73).
6) Lower the case (59) and install it in the
bevel gear (73) and tighten the bevel
gear mounting bolts.
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
157 - 196 Nm {16 - 20 kgm}
AJS01639
9JS02425
AJS01638
30-112 WA380-5
(10)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
AJS01635
AJS01637
9JS02261
WA380-5 30-113
(10)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
13) Install the washer (60) on the cover (58). 15) Adjust the axial clearance of the side
★ Coat the washer with grease thinly gear.
and stick it to the cover. i) Using feeler gauges, measure clear-
ance e between the side gear and
washer through the shaft holes on the
right and left sides of the anti-slip dif-
ferential.
• Clearance e:
: 0.15 - 0.35 mm (Both front and rear)
AJS01634 ii) If clearance e is out of the standard
range, replace the washer with the
one with proper thickness so that the
clearance will be in the standard
range.
★ When replacing the washer, per-
form the above procedure from
step 7).
• Thicknesses of washers (Both front
14) Install the cover (58) on the case (59). and rear)
★ Install them by aligning the mating
marks put when disassembling. : 2.0 mm (Part No. 423-22-27370)
: 2.1 mm (Part No. 423-22-27380)
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
AJS01650
AJS01644
9JS02429
30-114 WA380-5
(10)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
16) Measure the differential torque while no 6. Adjustment of bearing carrier shim
load is applied. 1) Lift the differential carrier assembly (23)
i) Install and fix sun gear shaft (81) to and set it to the differential case (25)
either side of the differential carrier attachment unit.
assembly.
ii) Install wrench D7 to the side gear on
the opposite side with the M6 bolt.
iii) Install torque wrench [12] and mea-
sure the rotation torque.
★ When measuring, let the case turn
freely.
• Rotation torque (Both front and
rear)
Max. 10 Nm {Max. 1.0 kgm}
iv) If the rotation torque exceeds the
above value, disassemble the differ-
ential carrier again and perform steps
12) and 15).
9JS02427
5. Gear cover
Attach the gear cover (26) to the differential
case.
CPW10342
CPW10366
WA380-5 30-115
(10)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
Mounting bolt:
157 - 196 Nm {16 - 20 kgm}
Attachment bolt:
Adhesive (LT-2)
Attachment bolt:
490 - 608 Nm {50 - 62 kgm}
CPW10368
30-116 WA380-5
(10)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
CPW10372
WA380-5 30-117
(9)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
DEW00910
The bevel pinion gear is too separate Decrease the shim from the pinion gear and
from the gear. approach to the bevel gear.
Separate the bevel gear from the pinion gear and
correctly adjust the back rash.
DEW00904 DEW00908
The bevel pinion gear is too near the Increase the shim of the pinion gear and separate
gear. it from the bevel gear.
Approach the bevel gear to the pinion gear and
correctly adjust the back rash.
DEW00905
The bevel gear is too near the pinion Decrease the shim of the pinion gear and
gear. approach it to the bevel gear.
Separate the bevel gear from the pinion gear and
correctly adjust the back rash.
DEW00906 DEW00908
The bevel gear is too separate from the Increase the shim of the pinion gear and separate
pinion gear. it from the bevel gear.
Approach the bevel gear to the pinion gear and
correctly adjust the back rash.
DEW00907
★ When adjusting the bevel gear in-out state, do not change the total thickness of the left and right by
moving the shim.
30-118 WA380-5
(9)
2
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
10. Brake 3) Attach the outer plate (11) and shaft (9),
1) Assemble the seal in the piston (16) and then fasten the bolt (10).
attach it to the differential carrier assem-
bly.
★ (15) is the brake tube joint unit.
CPW10333
CPW10335
CPW10334
11. Cover
Attach the cover (8) to the differential case (7).
Mounting bolt:
157 - 196 Nm {16 - 20 kgm}
CPW10332
WA380-5 30-119
(9)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
16. Oiling
Fasten the drain plug, and pour the oil up to
the specified level from the oiling port.
Axle oil:
38 liters
30-120 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
New/Improved
Illustration
Necessity
Remove four bolts (5a) and disconnect the
Quantity
Symbol Product No. Product Name
center drive shaft (5).
E1 4 793-520-2540 Guide ■ 1
5 793-520-2360 Bar ■ 2
REMOVAL
5. Harness connector
WARNING! Park the machine in a horizon- Disconnect the connectors (15), (FF1), (16),
tal place and put down the bucket on the (FF2), and earth (17).
ground.
★ For the machine with load meter, also dis-
connect (FL3).
WARNING! Disconnect the battery (-) ter-
minal.
WA380-5 30-121
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
2) Detach the hoses (10), (11), (12), (13), and 2) Jack up the front frame (17b). While
(14) in the front frame side. adjusting the height, insert the block [2]
on the left and right of the rear frame.
3) Insert the roller [3] between the block [2]
and frame so that the front frame can be
pulled out.
30-122 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
WA380-5 30-123
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
2) Remove the retainer (24) from the front 12. Upper hinge
frame. 1) Remove the attachment bolt and detach
★ Confirm the number of shims inserted the retainer (27).
between the retainer and frame, and ★ Confirm the number of shims inserted
their thickness. between the retainer and frame, and
their thickness.
30-124 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
WA380-5 30-125
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
Mounting bolt:
19.6 ± 2.0 Nm {2.0 ± 0.2 kgm}
3
incline. Mounting bolt:
★ Sufficiently grease the bearing. 98 - 123 Nm {10 - 12.5 kgm}
30-126 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
3. Frame coupling
WA380-5 30-127
(9)
2
5
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CAB
CAB ASSEMBLY
ASSEMBLY
5. Wiring connectors
1) Disconnect 11 pairs of connectors (4) in
9. Cab assembly
front of the cab. 1) Temporarily lift the cab assembly and
★ Connector numbers: SO1, SO2, SO3, remove the attachment bolts: (14) three
SO7, CL6, CL7, CL8, CL9, CL10, LO7, for each on the left and right, (15) one for
and LO8. each on the left and right, and (16) two for
each on the left and right.
30-128 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY CAB AND
REMOVAL AND INSTALLATION OFFLOOR FRAME
CAB AND ASSEMBLY
FLOOR FRAME
2) Remove the mounting bolts (17) one for REMOVAL AND INSTALLATION
each on the left and right, in the lower
front of the cab. OF CAB AND FLOOR FRAME
★ Width across flats for only this bolt: ASSEMBLY
19 mm
REMOVAL
4
3. Bulk head assembly
Cab assembly: Remove the engine assembly, referring to
690 kg item 4 in "Removal of Engine Assembly."
4. Remove the left and right covers under the
cab assembly.
5. Left ladder and fender assembly
1) Remove the stay (1).
2) Disconnect two hoses (2) of the washer
tank, motor connector (3), R43 and R45,
and then detach the clamp (4).
INSTALLATION
• Carry out installation in reverse order to
removal.
[*1]
Mounting bolt:
471 - 530 Nm {48 - 54 kgm}
[*2]
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
WA380-5 30-129
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
CAB ANDOFFLOOR
CAB AND FLOOR
FRAME FRAME
ASSEMBLY
3) Temporarily lift the left ladder and fender 8. Detach the steering rod (8).
assembly (5), and remove the attachment 9. Detach the accelerator cable (9) from the
bolts. injection pump and remove the clamp of the
torque converter case.
4
Left ladder and fender assem-
bly:
86 kg
30-130 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY CAB AND
REMOVAL AND INSTALLATION OFFLOOR FRAME
CAB AND ASSEMBLY
FLOOR FRAME
12. Brake valve hose 14. Cab and floor frame assembly
1) Detach the left brake valve inlet hose (15). 1) Remove the left and right mounting bolt
2) Detach the brake valve outlet hose rear and covers (26) in front of the floor frame.
brake (16) and front brake (17). 2) Remove the lock bolt (27) and remove the
3) Detach the right brake valve inlet hose lock plate (28). Then detach the mounting
bolt nuts (29) on the left and right.
rear brake (18) and front brake (19).
4) Detach the brake valve return hose right
brake (20) and left brake (21).
4 bly:
★ Mark index symbols on each hose before
detaching. Cab and floor frame assem-
1,290 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
★ Adjust the engine rotation speed, refer-
ring to the section "Adjustment of Accel-
erator Pedal" in "Testing and Adjusting."
[*2]
★ Bleed the brake circuit, referring to the
section "Bleeding of Brake Circuit" in
"Testing and Adjusting."
[*3]
Nut of mounting bolt:
1,175 - 1,470 Nm {120 - 150 kgm}
WA380-5 30-131
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS)
GLASS
New/Remodel
Necessity
a fine wire [2] (piano wire, etc.) in the
Sketch
Q'ty
Symbol Part No. Part Name adhesive and grip its both ends with pri-
ors [3], etc. (or hold them by winding
them onto something) and cut the adhe-
1 793-498-1120 Clear plate t 2 sive with the wire.
2 2 793-498-1130 Plate t 2
X
3 793-498-1110 Magnet t 2
3 793-498-1210 Lifter (Suction cups) t 2
REMOVAL
CPW11602
a All sides of each glass of the operator's cab of
this vehicle are stuck.
a Remove the window glass to be replaced
according to the following procedure.
CPW11607
30-132 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS
GLASS)
INSTALLATION
1. Using scraper [5], remove the remaining 3. When the adhesive was removed with the
adhesive. scraper, if any paint was flaked off, coat the
a Do not scratch the paint. bare part with paint.
a If the glass is installed without repairing the
bare part, that part will be rusted.
a Do not apply paint to a part which will be
coated with primer.
CPW11603
CPW11605
CPW11604
CPW11606
WA380-5 30-133
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS)
GLASS
CPW11614
CPW11633
CPW11615
CWW11608
CPW11613 CPW11616
30-134 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS
GLASS)
CWW11624
CPW11609
2
(If it is applied more than 2 times, its
Paint primer: SUNSTAR PAINT performance will be lowered.)
PRIMER 580 SUPRE a Parts to be coated with primer: Apply
the primer to the sticking surface of
a Do not apply the primer more than 2
window glass (3) and all over dimen-
times.
sion (d) on both-sided adhesive tape
(If it is applied more than 2 times, its
(4) and operator's cab (2).
performance will be lowered.)
• Dimension to apply primer (d):
23 mm
WA380-5 30-135
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS)
GLASS
a Do not apply the primer to the 1) Break aluminum seal (10) of the outlet of
boarder about 5 mm wide between adhesive cartridge (9) and install the nozzle.
the black part and transparent part of
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mis-
take, wipe it off with white gasoline. CPW11612
(If wrong primer is applied, the glass
will not be stuck.)
CPW11617
CPW11611
2 Adhesive (Summer):
SUNSTAR PENGUINE SEAL 580
SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE SEAL 580
SUPER "W" CPW11618
a The using limit of the adhesive is 4
months after the date of manufacture. Do
not use the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
30-136 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS
GLASS)
4) Remove release tape (13) of the both- 8. Install window glass (3).
sided adhesive tape on the glass side.
a If the glass is positioned wrongly, the
adhesive must be removed and cleaned,
and then the primer and adhesive must
be applied again. Accordingly, position
the glass carefully when sticking it.
1) Similarly to step 1, match tools X2-1, X2-
2, and X2-3 and set them to the 2 lower
CPW11621 places of the window glass sticking part
of operator's cab (2).
CWW11620
WA380-5 30-137
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS)
GLASS
a Check clearance ( k ) between the front 10. If the front glass and both front glasses are
side of the front glass and each side replaced, seal them.
and adjust it evenly. 1) Stick masking tapes (14) along the parts
• Clearance ( k ) : 5 mm to be sealed shown in the figure.
a Stick the masking tapes to both inside
and outside of the operator's cab.
CWW11626
CPW11628
CPW11623
30-138 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS
GLASS)
CPW11631
CPW11632
WA380-5 30-139
(9)
2
TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP
DISASSEMBLY AND ASSEMBLY ASSEMBLY
REMOVAL AND INSTALLATION OF TRANSMISSION, WORK
REMOVAL
INSTALLATION
• Carry out installation in the reverse order to
removal.
• Filling hydraulic oil
Pour the hydraulic oil (specified oil) up to the
predetermined level.
30-140 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL
STEERING,
AND INSTALLATION
SWITCHING, AND
OF STEERING,
FAN PUMP SWITCHING,
ASSEMBLY
4 assembly:
pump outlet hose (2), steering pump outlet Steering, switching, and fan pump
tube (3), and switch pump outlet tube (4). 57 kg
★ For tube (1), remove the clamp (5), in
advance.
INSTALLATION
6. Detach the fan pump wiring connector (6), • Carry out installation in reverse order to
pump outlet hose (7), control pressure supply removal.
hose (8), fan motor drain hose (9), and fan • Filling hydraulic oil
pump drain hose (10). Pour the hydraulic oil (specified oil) up to the
predetermined level.
WA380-5 30-141
(10)
2
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OFDEMAND
STEERING STEERINGVALVE
DEMAND VALVE
ASSEMBLY
REMOVAL
4. Use the lift bolt [1] and shackle [2] to tempo-
rarily lift the steering demand valve assembly
WARNING! Park the machine in a horizon-
(9), and remove the plate bolts.
tal place, set the frame lock bar in the
4
frame, and ground the work equipment. Steering demand valve assembly:
Then stop the engine, apply the parking 26 kg
brake, and put blocks under the wheels.
INSTALLATION
• Carry out installation in reverse order to
removal.
3. Detach the steering pump outlet tube (4),
• Filling hydraulic oil
switch pump outlet tube (5), work equipment
valve hose (6), steering cylinder head tube (7), Pour the hydraulic oil (specified oil) up to the
and bottom tube (8). predetermined level.
30-142 WA380-5
(10)
2
E.C.S.S. VALVE
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF E.C.S.S. VALVE ASSEMBLY
ASSEMBLY
REMOVAL 4. Use the lift bolt [1] and shackle [2] to tempo-
rarily lift the E.C.S.S. valve assembly (7) and
remove the plate attachment bolts.
WARNING! Park the machine in a horizon-
4
tal place, set the steering to the full right, E.C.S.S. valve assembly:
and ground the work equipment. Then stop 27 kg
the engine, apply the parking brake, and
put blocks under the wheels.
INSTALLATION
• Carry out installation in reverse order to
removal.
• Filling hydraulic oil
Pour the hydraulic oil (specified oil) up to the
predetermined level.
WA380-5 30-143
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF WORK EQUIPMENT
WORK EQUIPMENT VALVE
VALVE ASSEMBLY
30-144 WA380-5
(10)
2
WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION VALVE ASSEMBLY
OF WORK EQUIPMENT VALVE
7. Detach the PPC tube for bucket side (8) and 10. Detach the bucket cylinder head-side hose
lift arm side (9) from the rear of the work (17) and bottom-side hose (18).
equipment valve. 11. Detach the lift cylinder head-side tube (11)
8. Loosen the mounting bolts of the work equip- and bottom-side tube (12).
ment pump outlet tube (10), lift cylinder head- ★ Remove the tubes (11) and (12) first loos-
side tube (11), and bottom-side tube (12) up ened in the rear of the valve, and shift
to the arrow-indicated level of the drawn line. backward.
★ For tube (10), remove the clamp.
4
Then detach the E.C.S.S. valve return hose Work equipment valve assembly:
(15) and work equipment valve return hose 78 kg
(16).
★ Remove the bolts first loosened in the
rear of the valve and shift the work equip-
ment pump outlet tube (10) backward.
INSTALLATION
• Carry out installation in reverse order to
removal.
• Filling hydraulic oil
Pour the hydraulic oil (specified oil) up to the
predetermined level.
WA380-5 30-145
(10)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
New/Improved
Illustration
Necessity
Quantity
• Steering cylinder assembly
Symbol Product No. Product Name
1) Use tool l2 to detach the cylinder head (2)
from the cylinder.
790-502-1003 Repair stand ● 1
1
790-101-1102 Hydraulic pump ● 1
790-102-2303
Wrench
2 or assembly ● 1
790-330-1100
Socket
3 790-302-1270 (Width across ● 1
flats: 50 mm)
Wrench
790-102-4300 ● 1
assembly
4
790-102-4310 Pin ● 1
5 790-720-1000 Expander ● 1
796-720-1640 Ring ● 1
07281-00909 Clamp ● 1
• 790-101-5021 Grip ● 1
7 • 01010-80816 Bolt ● 1
• 790-101-5021 Grip ● 1
8 • 01010-80816 Bolt ● 1
• 790-201-1560 Plate ● 1
• 790-201-1650 Plate ● 1
30-146 WA380-5
(10)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
Lift cylinder 24
Bucket cylinder 27
WA380-5 30-147
(9)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
★ When the screw (7) is too tightened 4. Detailed disassembly of piston assembly
and it is not removed, insert the screw • Steering cylinder assembly
into the inside once, and apply a tap Detach the wearing (8) and piston ring (9)
to the screwing part. Then remove it. from the piston (6).
30-148 WA380-5
(9)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
WA380-5 30-149
(10)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
30-150 WA380-5
(10)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
3. Cylinder head piston rod assembly 3) Assemble the piston assembly (6) in the
• Steering cylinder assembly • When reusing the rod and piston
1) Set the piston rod (3) to tool l1. assembly (6)
2) Assemble the cylinder head (2) and piston ★ Carefully clean them to eliminate
(6) in the piston rod. chips and dusts.
3) Assemble the nut (5). Use tool l3 to i) Use screwing tool I4 to tighten the
tighten the nut with the specified torque. piston assembly (6) until the screw
★ Width across flats of nut: 50 mm. hole positions match.
Piston rod screw unit: ★ Use a file to eliminate burrs and
Adhesive (LT-2) returns of the screw.
ii) Tighten the screw (7).
Nut: 1,250 ± 125 Nm {127 ± 12.7 kgm}
Screw:
66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
iii) Fasten the screw at four portions
using a drift.
WA380-5 30-151
(10)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
• When one or either of pistons are new iv) Fasten the screw (7).
i) Use screwing tool l4 to tighten the
Screw:
piston assembly (6) with the specified
66.2 ± 7.35 Nm {6.75 ± 0.75 kgm}
torque until it is pressed against the
rod end. v) Tighten the screw part at four por-
tions using a punch.
Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
4. Cylinder head
• Steering cylinder assembly
ii) Process one tapped hole for mounting
1) Set the cylinder (4) to tool l1.
the screw (7).
2) Lift the cylinder head piston rod assembly
★ Use a drill to horizontally process (3) and assemble it in the cylinder (4).
the V grooves of the screw parts
of the piston (6) and rod (3).
• Dimensions of screw hole (mm)
10.3 27 12 X 1.75 20
30-152 WA380-5
(10)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
3) Use tool l2 to attach the cylinder head 4) Remove the cylinder assembly (1) from
assembly (2) to the cylinder. tool l1.
Cylinder head:
676 ± 67.6 Nm
{69 ± 6.9 kgm}
4) Remove the cylinder assembly (1) from
tool l1.
Attachment bolt:
Cylinder Nm {kgm}
WA380-5 30-153
(10)
2
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF HYDRAULIC
HYDRAULIC TANK
TANK ASSEM-
ASSEMBLY
REMOVAL
30-154 WA380-5
(10)
2
HYDRAULIC
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF TANK
HYDRAULIC ASSEMBLY
TANK ASSEM-
4
Hydraulic tank assembly:
175 kg
WA380-5 30-155
(9)
2
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF
WORK
WORK
EQUIPMENT
EQUIPMENT
ASSEMBLY
ASSEM-
REMOVAL
2. Bucket cylinder rod pin
WARNING! Park the machine in a horizon- Temporarily lift the bucket cylinder (3) and
tal place, set the frame lock bar in the pull out the rod pin (4). Then detach the cylin-
frame, and ground the work equipment. der rod and bell crank.
Then stop the engine, apply the parking
★ Install the block [1] between the cylinder
brake, and put blocks under the wheels.
bottom and frame.
[*3]
1. Bucket
4 Bucket cylinder:
1) Remove the bucket link attachment pin
(1). 170 kg
[*1]
★ Fix the bucket link to the bell crank
using a wire.
★ If shims are inserted, check the num-
ber of shims.
30-156 WA380-5
(10)
2
DISASSEMBLY AND
AND ASSEMBLY
ASSEMBLY WORK EQUIPMENT ASSEMBLY
4 link:
2) Temporarily raise the lift cylinder (6) and Lift arm, bell crank, and bucket
detach the attachment pin (5). 1,450 kg
[*4]
★ If shims are inserted, check the num- ★ If shims are inserted, check the num-
ber of shims. ber of shims.
★ When lowering the cylinder, put the
block into the top of the accelerator.
4 Bucket link:
4. Lift arm, bell crank, and bucket link
1) Remove the boom kick-out switch (7). 55 kg
[*5]
WA380-5 30-157
(10)2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY
3) Pull out the dust seal (18) and bush (19) [*2]
from the bucket link (9). • Bucket
1) Use the operation lever to fit the hole
of the bucket attachment pin (2), then
attach the cord ring (20). Next insert
shims so that clearance b is equal on
the left and right, assemble the pin
(1), and tighten the bolt.
★ Take care that the cord ring is not
engaged.
★ Clearance b: 1.5 mm or less.
30-158 WA380-5
2(9)
DISASSEMBLY AND ASSEMBLY
ASSEMBLY WORK EQUIPMENT ASSEMBLY
[*6]
• Perform the calibration, referring to "Han-
dling of Road Meter" in the instruction
manual.
[*7]
[*3]
• Bucket cylinder
[*5]
★ Confirm the operation, referring to
"Inspection and Adjustment of boom • Greasing
Kick-Out" in Inspection and Adjustment. Grease each pin.
WA380-5 30-159
(10)2
REMOVAL AND INSTALLATION OF COUNTER WEIGHT
DISASSEMBLY AND ASSEMBLY COUNTER WEIGHT
4
1. Grill Counter weight:
1) Open the grill and temporarily lift it. Then 1,210 kg
disconnect the damper gas cylinders (1)
on the left and right.
2) Disconnect connectors (2) and (3) of the
work lamp, and remove the clamp of the
harness.
INSTALLATION
• Installation is in reverse order to removal.
[*1]
3) Remove four attachment bolts, and
detach the grill (4). Attachment bolt:
824 - 1,030 Nm {84 - 105 kgm}
30-160 WA380-5
2(10)
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT AS-
DISASSEMBLY AND ASSEMBLY
ASSEMBLY SEMBLY
AIR CONDITIONER UNIT ASSEMBLY
New/Modified
Necessity
Quantity
1) Remove the cover (2) on the lower left of
sketch
Symbol Part Number Part Name
the operator seat.
799-703-1200 Service tool kit ■ 1
Vacuum pump
799-703-1100 (100V) ■ 1
Vacuum pump
X 799-703-1110 (220V) ■ 1
Vacuum pump
799-703-1120 (240V) ■ 1
REMOVAL
CPW10235
WA380-5 30-161
(10)2
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT AS-
DISASSEMBLY AND ASSEMBLY
ASSEMBLY SEMBLY
AIR CONDITIONER UNIT ASSEMBLY
CPW10236
CPW10237
CPW10240
CPW10238
30-162 WA380-5
2(9)
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT AS-
DISASSEMBLY AND ASSEMBLY
ASSEMBLY SEMBLY
AIR CONDITIONER UNIT ASSEMBLY
7. Inside diameter switching damper 3) Remove the mounting bolts of the air con-
1) Disconnect the connector (25) (CN-A4). ditioner unit assembly.
2) Remove the attachment bolts, and shift 4) Lift the air conditioner unit assembly (32),
the inside-outside switching damper (26) detach the hose (33), then remove the air
to the side. conditioner unit assembly.
CPW10241 CPW10243
WA380-5 30-163
(10)2
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRES-
DISASSEMBLY AND ASSEMBLY SOR ASSEMBLY
AIR CONDITIONER COMPRESSOR
New/Modified
6. Disconnect the air conditioner unit hoses (6)
Necessity
Quantity
sketch
Symbol Part Number Part Name and (7). [*3]
7. Remove four bolts (8) or attachment bolts in
799-703-1200 Service tool kit ■ 1
the bottom, and nuts. Then, detach the com-
Vacuum pump pressor assembly.
799-703-1100 (100V) ■ 1
Vacuum pump
X 799-703-1110 (220V) ■ 1
Vacuum pump
799-703-1120 (240V) ■ 1
REMOVAL
30-164 WA380-5
2(10)
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
DISASSEMBLY
1. Headrest
1) Referring to the figure, check the posi-
tions of 2 clips (2) of headrest stay (1) on
both sides.
CJH12302
WA380-5 30-165
(9).. .
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
2) Apply force (b) to part (a) of each clip (2) 2. Back seat
in the direction of the arrow to turn the 1) Disconnect 3 air hoses (5) from the rear
clip and release it from part (d) of head- left of back seat (4).
rest stay (1), and then pull out up headrest
★ Before disconnecting the air hoses, check
(3).
their types.
CJH12305
CJH12303
CJH12306
CJH12304
CJF12307
30-166 WA380-5
(9)
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
4) Apply force (E) to the right side of back 2) Push cushion slide stopper wire (9) down
seat (4) in the direction of the arrow. with screwdriver [1], etc.
5) Applying the force to back seat (4), pull its 3) Keeping the state in 2), pull out cushion
right side up. seat (8) forward and remove it.
6) Slide back seat (4) sideway and remove it.
CJH12310
CJH12308
4. Armrest
3. Cushion seat • The procedure for disassembling right-hand
1) Push cushion adjuster lever (7) inward armrest (10) is shown below.
and slide cushion seat (8) to the front end. (Disassemble left-hand armrest (11) simi-
larly.)
CJH12309
CJH12311
WA380-5 30-167
(9).. .
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
1) Remove plastic cap (12) from the armrest 6) Remove right-hand armrest (10).
hinge. ★ There are 2 position adjustment
★ Use a flat-head screwdriver, etc. to washers (16) installed to each bolt
remove the cap. between the armrest and back seat.
2) Loosen armrest hinge mounting bolt (13). Take care not lose them.
CJH12312 CJH12315
CJH12313
CJH12314
30-168 WA380-5
(9)
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
CJH12317 Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
★ If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
CJH12318
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
CJH12321
CJH12319
WA380-5 30-169
(10) .
(9)..
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
CJH12322
CJH12324
CJH12323
CJH12323
CJH12324
30-170 WA380-5
(10)
(9)
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
3) Set rails (28) to the rear end and install 1 2) Install 3 metallic suspension cover clips
lock washer (30) and 1 hexagon socket (24).
head bolt (29) to each rail.
CJH12319
CJH12322
CJH12317
WA380-5 30-171
(10) .
(9)..
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
5) Install plastic plate (18) to the rear. 2) Tighten lower mounting bolt (15A) lightly
6) Install right-hand hinge cover (17). and turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15A) permanently.
CJH12326
3. Armrest
• The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) simi-
larly.)
CJH12315
30-172 WA380-5
(10)
(9)
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
CJH12328
CJH12327
CJH12306
WA380-5 30-173
(10) .
(9)..
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
CJH12305
6. Headrest
1) Insert headrest (3) in back seat (4).
★ Check that 2 clips (2) on both sides are
locked securely.
CJH12329
30-174 WA380-5
(9)
90 OTHERS
WA380-5 90-1
4
POWER TRAIN OIL CIRCUIT DIAGRAM
(WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)
WA380-5 90-3
4
POWER TRAIN OIL CIRCUIT DIAGRAM
(WITH TORQUE CONVERTER LOCKUP CLUTCH)
WA380-5 90-5
4
BRAKE OIL CIRCUIT DIAGRAM
WA380-5 90-7
ELECTRICAL CIRCUIT DIAGRAM 1/8 (4/4)
*1. Serial No.: 60208 and up
WA380-5 90-19
(8)
ELECTRICAL CIRCUIT DIAGRAM 2/8 (4/4)
*1. Serial No.: 60208 and up
WA380-5 90-27
(8)