Wa380-5 Sebm024710

SEBM024710
Machine model Serial number
WA380-5 60001 and up
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• WA380-5 mounts the SAA6D114E-2 engine.

For details of the engine, see the 114 Series Engine Shop Manual.
© 2005
All Rights Reserved 00-1
Printed in Japan 07-05 (03) (10)
00
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1
20 TESTING AND ADJUSTING ............................................................. 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1
90 OTHERS ............................................................................................ 90-1
00-2 WA380-5
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The affected pages are indicated by the use of the
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LIST OF REVISED PAGES
Revision Revision Revision Revision Revision

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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)
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q 10-222 (10) 10-275 q 20- 3 (10) 20-153 (7) 20-254 (7)
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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
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q 20-326 (10) q 20-384 (10) q 20-443 (10) q 20-555 (10) 20-615 (5)
q 20-327 (10) q 20-385 (10) q 20-444 (10) q 20-556 (10) q 20-616 (10)
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q 20-329 (10) q 20-387 (10) q 20-446 (10) q 20-558 (10) q 20-618 (10)
q 20-330 (10) q 20-388 (10) q 20-501 (10) q 20-559 (10) 20-619 (5)
q 20-331 (10) q 20-389 (10) q 20-502 (10) q 20-560 (10) q 20-701 (10)
q 20-332 (10) q 20-390 (10) q 20-502-1 (10) q 20-561 (10) q 20-702 (10)
q 20-333 (10) q 20-391 (10) 20-503 (5) q 20-562 (10) 20-703 (5)
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q 20-336 (10) q 20-394 (10) 20-506 (5) q 20-565 (10) 20-706 (5)
q 20-338 (10) q 20-395 (10) q 20-507 (10) q 20-566 (10) q 20-707 (10)
q 20-339 (10) q 20-396 (10) q 20-508 (10) q 20-567 (10) q 20-708 (10)
q 20-340 (10) q 20-397 (10) 20-509 (5) q 20-568 (10) 20-709 (5)
q 20-341 (10) q 20-398 (10) q 20-510 (10) q 20-569 (10) q 20-710 (10)
q 20-342 (10) q 20-399 (10) 20-512 q 20-570 (10) 20-712
q 20-344 (10) q 20-400 (10) 20-513 (5) q 20-571 (10) 20-713 (5)
WA380-5 00-2-3
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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)
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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)
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q 20-729 (10) q 20-790 (10) 20-927 (5) 30- 12 (9) q 30- 71 (10)
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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)
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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)
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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)
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q 30- 116 (10)
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30-135 (9) 90- 37 (4)
30-136 (9) 90- 39 (4)
30-137 (9)
30-138 (9)
30-139 (9)
q 30-140 (10)
q 30-141 (10)
q 30-142 (10)
q 30-143 (10)
q 30-144 (10)
q 30-145 (10)
q 30-146 (10)
30-147 (9)
30-148 (9)
q 30-149 (10)
q 30-150 (10)
q 30-151 (10)
q 30-152 (10)
q 30-153 (10)
q 30-154 (10)
30-155 (9)
q 30-156 (10)
q 30-157 (10)
30-158 (9)
q 30-159 (10)
q 30-160 (10)
q 30-161 (10)
30-162 (9)
q 30-163 (10)
q 30-164 (10)
30-165 (9)
30-166 (9)
30-167 (9)
30-168 (9)
q 30-169 (10)
q 30-170 (10)
q 30-171 (10)
q 30-172 (10)
q 30-173 (10)
WA380-5 00-2-5
(10)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

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

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

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

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to

LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
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
STANDARD TIGHTENING TORQUE

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

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

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

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

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

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

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

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

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

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

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
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
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
General assembly drawing . . . . . . . . . . . . . . . . . .01-2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-4
Weight table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-7
List of lubricants and coolant . . . . . . . . . . . . . . . . 01-9
WA380-5 01-1
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
Item Unit WA380-5
A Overall length mm 8,235

B Overall height mm 3,315
C Overall height when bucket is raised mm 5,565
D Overall width mm 2,695
E Min. ground clearance mm 390
F Bucket width mm 2,905
G Dumping clearance (tip of BOC) mm 2,885/2,800
H Dumping reach (tip of BOC) mm 1,165/1,210
I Bucket dump angle deg. 45
BOC: Bolt-on cutting edge.
01-2 WA380-5
(8)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA380-5
Serial No. 60001 and up
Operating weight kg 16,150

Weight
Distribution (front) SAE travel posture kg 7,785

Distribution (rear) SAE travel posture kg 8,365
Bucket capacity (piled) m³ 3.3
Rated load KN {kg} 51.8 {5,280}
N mode P mode
Travel speed FORWARD 1st km/h 4.8 6.3
FORWARD 2nd km/h 8.5 11.4
FORWARD 3rd km/h 15.3 20.2
FORWARD 4th km/h 24.7 31.5
Performance
REVERSE 1st km/h 5.2 6.7

REVERSE 2nd km/h 9.1 11.8
REVERSE 3rd km/h 16.2 21.0
REVERSE 4th km/h 25.5 32.5
Max. rimpull FORWARD kN {kg} 130 {13,240} 168 {17,170}
REVERSE kN {kg} 122 {12,400} 158 {16,075}
Gradeability deg 25
Min. turning (Center of outside
radius wheel) mm 5,620
SAE travel posture (tip of BOC) mm 6,540/6,580

Overall length (with BOC) mm 8,235
Overall width (chassis) mm 2,695
Bucket width (with BOC) mm 2,905
Overall height (top of cab) mm 3, 315
Overall height (Bucket approx. raised
to max.) mm 5,565
Wheel base mm 3,300

Dimensions
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)
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
Front axle Fixed to frame, semi-floating type

Rear axle Center pin support, semi-floating type
Tire size 20.5-25-16PR
Rim size 17.00x25-1.7
Tire
Inflation pressure Front tire kPa {kg/cm²} 343.2 {3.5}

Rear tire kPa {kg/cm²} 343.2 {3.5}
4 wheel braking, Front and rear wheel independent sys-
Braking system tem control
Main brake Brake type Sealed wet-type disc brake

Operation method Hydraulically controlled
Brakes
Control method Hydraulic power servo assisted brake

Braking system Speed change gear output shaft braking
Parking brake Operation method Wet type disc brake
Control method Hydraulically released spring type
*1:Battery capacity (Ah) shows the rate of 5 hours.
01-4 WA380-5
(9)

Steering
Type Articulated steering

control
Control Hydraulic control
Torque converter pump

• Type Gear type
• Delivery l /min 181

Steering pump
• Type Gear type
Hydraulic pump
Hydraulic pump
• Type Gear type

Switching pump
• Type Gear type
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
Cylinder inner diameter mm 80

Piston rod diameter mm 45
Stroke mm 442
Max. length between pins mm 1,209
Min. length between pins mm 767
Lift cylinder
Cylinder

Stroke mm 713
Min. length between pins mm 1,337
Bucket cylinder

Stroke mm 535
Min. length between pins mm 1,155
WA380-5 01-5
(10)
Work equipment control valve

• Type 2-spool type
Control valve
Hydraulic system
• Set pressure MPa {kg/cm²} 20.6 {210}

Steering valve
• Type Spool type
• Set pressure MPa {kg/cm²} 15.7 {160}

Cooling fan motor
Motor
• Type Fixed displacement piston type

equipment
Link type Single link

Work
Bucket edge type Flat blade with top BOC
01-6 WA380-5
(8)
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine (without coolant and oil) 870

Radiator (without coolant) 77
Transmission (including torque converter) 767
Transmission (including torque converter, with lockup clutch) 803
Center drive shaft 25
Front drive shaft 22
Rear drive shaft 9.8
Front axle 911
Rear axle 892
Axle pivot (rear axle) 102
Wheel (each) 110
Tire (each) 207
Steering valve 24
Steering cylinder assembly (each) 28
Orbit roll 5.7
Emergency steering pump (If equipped) 2.6
Emergency steering motor (If equipped) 13
Brake valve (R.H.) 8.5
Brake valve (L.H.) 5.3
Hydraulic tank (without hydraulic oil) 171
Torque converter, work equipment, pilot control pump (3 tandem pump) 35
Steering, switching pump (2 tandem pump) 29
Work equipment PPC valve 3
Work equipment control valve 72
Lift cylinder assembly (each) 158
Bucket cylinder assembly 172
Engine hood 160
Front frame 1,439
Rear frame 1,275
Bucket link 55
Bell crank 316
Lift arm (including bushing) 1,074
Bucket (width: 2,905 mm, with BOC) 1,618
Counterweight 1,200
Fuel tank (without fuel) 180
WA380-5 01-7
(10)
GENERAL WEIGHT TABLE
Unit: kg
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
TABLE OF FUEL, COOLANT AND LUBRICANT

★ For details of the notes (Note 1, Note 2, ---) in the table, see the Operation and Maintenance Manual.
★ 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
Cooling system............................................... 10-2 Bucket ..........................................................10-183

Engine mount, transmission mount ............. 10-3 Bucket positioner, boom kick-out ..............10-184
Power train ..................................................... 10-4 Work equipment cylinder ...........................10-190
Power train system diagram ......................... 10-5 Cab ...............................................................10-191
Drive shaft (propeller shaft) .......................... 10-8 Air conditioner (If equipped) ......................10-192
Torque converter, transmission piping ........ 10-9 Machine monitoring system ......................10-193
Torque converter.......................................... 10-10 Machine monitor.........................................10-200
Transmission ................................................ 10-18 Transmission control system.....................10-260
Transmission control valve ......................... 10-34 Transmission controller..............................10-284
Axle ............................................................... 10-48 Work equipment control system
Differential .................................................... 10-50 (If equipped)..........................................10-286
Final drive ..................................................... 10-59 Work equipment controller ........................10-302
Axle mounting, center hinge pin ................ 10-62 Electric transmission control......................10-304
Steering piping ............................................. 10-66 Kick down, hold switch...............................10-308
Steering column, orbit-roll .......................... 10-67 Engine starting circuit.................................10-309
Steering valve............................................... 10-68 Engine stop circuit ......................................10-311
Orbit-roll valve.............................................. 10-83 Preheating circuit ........................................10-312
Stop valve ..................................................... 10-87 Engine power mode selector circuit..........10-313
Steering pump, switch pump...................... 10-88 Parking brake circuit ...................................10-314
Emergency steering pump (If equipped).... 10-90 Sensors ........................................................10-318
Emergency steering motor (If equipped) ... 10-91
Steering cylinder .......................................... 10-92
Joystick steering lever (If equipped)........... 10-94
Steering lever (If equipped)......................... 10-95
Steering switch valve (If equipped) ............ 10-97
Brake piping.................................................. 10-98
Brake valve ................................................. 10-100
Charge valve ............................................... 10-107
Accumulator (for brake)............................. 10-111
Brake ........................................................... 10-113
Parking brake control ................................. 10-118
Parking brake .............................................. 10-119
Parking brake solenoid valve .................... 10-121
Parking brake emergency release valve... 10-123
Hydraulic piping ......................................... 10-124
Work equipment control lever .................. 10-127
Hydraulic tank............................................. 10-129
Torque converter charging, work equipment,
and pilot control pumps..................... 10-131
PPC relief valve........................................... 10-133
E.C.S.S. valve (If equipped) ....................... 10-135
Work equipment control valve.................. 10-137
Work equipment PPC valve ....................... 10-154
PPC valve
(for multi function mono lever) ....... 10-159-1
EPC solenoid valve (If equipped) ............. 10-160
Shut off valve (If equipped) ....................... 10-163
Attachment PPC valve (If equipped) ......... 10-164
Cooling fan motor ...................................... 10-168
Cooling fan motor drive pump.................. 10-173
Work equipment linkage ........................... 10-181
WA380-5 10-1
(8)
(10)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
1. Radiator 5. Reservoir tank

2. After cooler 6. Cooling fan
3. Oil cooler 7. Cooling fan motor
4. Torque converter oil cooler
Specifications
Radiator Oil cooler After cooler Torque converter oil

cooler
Core type CF19-4 CF40-1 AL-CFT PTO-OL
Fin pitch (mm) 4.0/2 4.5/2 4.0/2

*1
100 X 558 X 12 Step
Total heat radiating area (m²) 60.08 2.90 17.55 1.291
Pressure valve opening pressure 68.6 — — —
(kPa {kg/cm²}) {0.7}
Vacuum valve opening pressure 0 - 4.9 — — —
(kPa {kg/cm²}) {0 - 0.05}
* 1: Shows the element size.
10-2 WA380-5
(10)
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
ENGINE MOUNT, TRANSMISSION MOUNT
Unit: mm
No. Check item Criteria Remedy
Clearance between transmis-

1 sion mount bracket and adjust- 1 - 1.5 Adjust
ment bolt
WA380-5 10-3
(10)
MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Transmission 4. Rear axle 7. Front drive shaft

2. Torque converter 5. Rear drive shaft 8. Front axle
3. Engine 6. Center drive shaft
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
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
POWER TRAIN SYSTEM DIAGRAM

Without torque converter lock-up clutch
WA380-5 10-5
With torque converter lock-up clutch
10-6 WA380-5
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
MAINTENANCE STANDARD DRIVE SHAFT (PROPELLER SHAFT)
DRIVE SHAFT (PROPELLER SHAFT)
1. Front drive shaft Outline

2. Flange bearing
3. Center drive shaft • The power from the transmission output shaft
4. Rear drive shaft passes through center drive shaft (3), front
drive shaft (1), and rear drive shaft (4), and is
transmitted to the front axle and rear axle.
• When the body is articulated, or when the
machine is traveling and there is shock from
the ground surface, or when there is shock dur-
ing operations, the position of the transmis-
sion and the front and rear axles changes. The
transmission is designed so that even if the
position of the components changes as a
result of such shock, power can be transmitted
without damage to any parts. With this design,
the drive shafts have universal joints and flange
bearings that enable them to handle any
changes in the angle and length.
10-8 WA380-5
MAINTENANCE STANDARD TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER, TRANSMISSION PIPING
1. Hydraulic oil tank 6. Last chance filter

2. Steering, switch pump 7. Transmission converter oil cooler
3. Torque converter charging, work equipment, 8. Transmission
pilot control pumps 9. Oil filter
4. Torque converter 10. Oil feeder pipe
5. Torque converter control valve
WA380-5 10-9
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
Unit: mm
Standard size Tolerance Repair limit

1 -0.010
Outside diameter of pilot 52 51.75 Repair hard chrome
-0.040 plating or replace
Inside diameter of PTO gear seal +0.035
2 110 110.5
ring sliding portion +0.035
-0.00
Width 3 2.7
Wear of stator shaft -0.10
3 seal ring
Thickness 4.3 ±0.1 3.9 Replace
Backlash of PTO drive gear and

4 0.17-0.45
drive gear
WA380-5 10-11
(10)
Path of power transmission

Flow of power Flow of oil
• 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
With lock-up clutch
1. Flywheel 9. Stator shaft

2. Clutch housing (Number of teeth: 72) 10. Guide
3. Boss (Number of teeth: 90) 11. Transmission input shaft
4. Turbine 12. One way clutch
5. Drive case 13. Race
6. Stator 14. Disc
7. Pump 15. Piston
8. PTO drive gear (Number of teeth: 97)
Specifications
Type 3-element, 1-stage, 2-phase
Stall torque ratio 2.98
WA380-5 10-13
10-14 WA380-5
Unit: mm

1 -0.010
Outside diameter of pilot 52 51.75
-0.040
Outside diameter of input shaft +0.025
2 35 35.5
seal ring sliding portion +0.035
Repair hard chrome
Inside diameter of clutch housing +0.089 plating or replace
3 340 340.1
Inside diameter of clutch piston +0.081
4 260 260.1
Inside diameter of PTO gear seal +0.035
5 120 120.5
ring sliding portion +0.035
-0.01
Width 5 4.5
Wear of clutch housing -0.04
6 seal ring
Thickness 6 ±0.15 5.85
-0.00
Width 3.95 3.55
Wear of stator shaft -0.1
7 seal ring
Thickness 4.6 ±0.1 4.14
Inside diameter of outer race one-

8 91.661 ±0.008 91.691
way clutch rolling surface
Replace
Outside diameter of outer race +0.008
9 72.661 72.631
one-way clutch rolling surface -0.005
Inside diameter of bushing sliding +0.015
10 72.775 72.855
portion +0.035
Thickness of bushing sliding por- -0.00
11 5 4.5
tion -0.1
12 Thickness of clutch disc 5 ±0.1 4.4
Backlash of input shaft and PTO

13 0.17-0.45
gear
WA380-5 10-15
(10)
Path of power transmission

Flow of power
Lock-up clutch disengaged Lock-up clutch engaged
• 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
Flow of oil
• The oil passes through the main relief valve and

its pressure is adjusted by the torque converter
relief valve so that it is less than the set pres-
sure. It then enters inlet port A, passes through
the passage in stator shaft (1) and guide (2), and
flows to pump (3).
The oil is given centrifugal force by pump (3). It
then enters turbine (4) and transmits the energy
of the oil to turbine (4).
The oil from turbine (4) is sent to stator (5), and
enters pump (3) again. However, part of the oil
is fed to the torque converter oil cooler from the
stator (5) passing through the outlet port B.
WA380-5 10-17
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Steering, switch, 5. Main relief,

cooling fan pump mounting section torque converter relief valve
2. Torque converter oil pressure, work equipment 6. Transmission case (Front)
oil pressure, pilot control pump mounting section 7. Transmission oil filter
3. Transmission case (Rear) 8. Oil level gauge
4. Transmission control valve 9. Flow valve
10-18 WA380-5
1. PTO driven gear (Number of teeth: 89) 9. Output shaft

2. PTO drive gear (Number of teeth: 97) 10. Parking brake
3. Torque converter 11. Front coupling
4. Transmission input shaft 12. Lower shaft
5. F clutch 13. 2nd clutch
6. 4th clutch 14. Upper shaft
7. 3rd clutch 15. 1st clutch
8. Rear coupling 16. R clutch
WA380-5 10-19
10-20 WA380-5
Unit: mm
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 —
Clearance between PTO driven +0.025 0. 00 -0.037 -

3 gear shaft and bearing (R) 45 +0.009 -0.012 -0.009 —
Clearance between PTO driven 0. 00 +0.030

4 gear bearing and housing (R) 85 -0.015 +0.035 0 - 0.045 —
Clearance between the input shaft 0. 00 +0.030

5 bearing and the housing (R) 110 -0.015 +0.035 0 - 0.045 —
Clearance between the input shaft 0. 00 +0.030

6 bearing and the housing (F) 110 -0.015 +0.035 0 - 0.045 —
Clearance between the upper 0. 00 +0.030

7 shaft bearing and the housing (R) 110 -0.015 +0.035 0 - 0.045 —
Clearance between the upper 0.00 +0.030

8 shaft bearing and the housing (F) 120 -0.015 +0.035 0 - 0.045 —
Clearance between the lower 0.00 0. 00 -0.035 -

9 shaft bearing and the housing (R) 100 -0.018 -0.035 0.018 —
Clearance between the lower 0.00 0. 00 -0.035 -

10 shaft bearing and the housing (F) 120 -0.018 -0.035 0.018 —
Clearance between the output 0.00 -0.018 -0.058 -

11 shaft bearing and the housing (R) 130 -0.020 -0.058 0.002 —
Clearance between the output +0.030 0. 00 -0.045 -

12 shaft and the bearing (R) 75 +0.011 -0.015 -0.011 —
Clearance between the output 0.00 -0.018 -0.058 -

13 shaft bearing and the housing (F) 130 -0.020 -0.058 0.002 — Replace
Clearance between the output +0.035 0. 00 -0.055 -
14 shaft and the bearing (F) 85 +0.013 -0.020 -0.013 —
Standard size Tolerance Clearance limit

Inner diameter of the seal ring
contact surface +0.050
60 60.1
+0.035
+0.076
15 Width of the seal ring groove 3.2 3.5
+0.035
Width of the seal ring 3.1 ±0.05 2.8
0.00
Thickness of the seal ring 2.29 2.1
-0.100
Inner diameter of the seal ring +0.050
50 50.1
contact surface +0.035
+0.076
Width of the seal ring groove 3.2 3.5
16 +0.035
Width of the seal ring 3.1 ±0.05 2.8
0.00
Thickness of the seal ring 2.29 2.1
-0.100
Inner diameter of the oil seal slid- 0.00
17 ing surface of the coupling (R) 95 -0.087 94.8
Inner diameter of the oil seal slid- 0.00

18 ing surface of the coupling (F) 95 -0.087 94.8
Standard clearance Clearance limit

Clearance between the retainer
19 and the housing 0.85 - 1.65 —
(Standard shim thickness: 1.10)
Clearance between the cage and 1.18 - 1.94
20 the case Standard shim thickness: 1.15) —
WA380-5 10-21
(10)
1. PTO driven gear (Number of teeth: 79)

2. R idler gear (Number of teeth: 28)
3. Spacer
4. Strainer
Unit: mm

Clearance between PTO Standard size
Shaft Hole clearance limit
5 driven gear shaft and bearing
(F) +0.030 0. 00 -0.045 -
65 —
+0.011 -0.015 -0.011
Clearance between PTO 0. 00 +0.030
6 driven gear bearing and hous- 120 0 - 0.045 —
-0.015 +0.035
ing (F)
Clearance between PTO +0.020 0. 00 -0.032 - Replace
7 driven gear shaft and bearing 50 —
+0.009 -0.012 -0.009
(R)
Clearance between PTO 0. 00 +0.030
8 driven gear bearing and hous- 90 0 - 0.045 —
-0.015 +0.035
ing (R)
Clearance between R idler +0.027 0. 00 -0.039 -
9 50 —
gear bearing and case +0.002 -0.012 -0.002
Clearance between R idler 0. 00 -0.021 -0.051 -
10 80 —
gear bearing and R idler gear -0.016 -0.051 -0.005
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)
F and R clutches (Without a lock-up clutch)
A: R clutch oil port C: Lubricating oil port

B: F clutch oil port
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

Standard size
Clearance at bearing press fit Shaft Hole clearance limit
11
part of shaft (F)
+0.039 0. 00 -0.054 -
60 +0.020 -0.015 -0.020 —
12 Clearance at bearing press fit 60 +0.030 0. 00 -0.045 - —

part of shaft (R) +0.011 -0.015 -0.011
13 Thickness 1.7 ±0.05 1.5

Separator plate
Distortion — 0.1 0.15
Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Load of wave spring 1,010 N ±101 N 859 N
15
(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Warp of spring plate 1.4 ±0.2 1.2
Thickness of thrust washer of
17 3 ±0.1 2.7
F and R clutches
18 End play of R gear 0.30 - 0.70
19 End play of F gear 0.24 - 0.76
WA380-5 10-23
(10)
F and R clutches (With a lock-up clutch)
A: R clutch oil port C: Lubricating oil port

B: F clutch oil port D: Lock-up clutch oil port
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

Standard size
Clearance at bearing press fit Shaft Hole clearance limit
11
part of shaft (F)
60 +0.039 0. 00 -0.054 - —
+0.020 -0.015 -0.020
Clearance at bearing press fit +0.030 0. 00 -0.045 -
12 part of shaft (R) 60 +0.011 -0.015 -0.011 —
13 Thickness 1.7 ±0.05 1.5

Separator plate
Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Load of wave spring 1,010 N ±101 N 859 N
15
(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Warp of spring plate 1.4 ±0.2 1.2
17 Thickness of thrust washer of 3 ±0.1 2.7

F and R clutches
18 End play of R gear 0.30 - 0.70
19 End play of F gear 0.24 - 0.76
10-24 WA380-5
(10)
1st•4th Clutch
A: 1st clutch oil port C: Lubricating oil port

B: 4th clutch oil port
1. Idler gear (Number of teeth: 37) 6. 4th clutch

2. Thrust washer 7. 4th gear (Number of teeth: 64)
3. 1st gear (Number of teeth: 26) 8. Thrust washer
4. 1st clutch 9. Spacer
5. 1st • 4th cylinder • Idler gear 10. Upper shaft
(Number of teeth: 51)
Unit: mm
Standard Tolerance Standard Clearance

Clearance at bearing press fit size Shaft Hole clearance limit
11 part of shaft (F)
+0.035 0. 00 -0.050 -
55 —
+0.025 -0.015 -0.025
Clearance at bearing press fit +0.039 0. 00 -0.054 -
12 part of shaft (R) 60 +0.020 -0.015 -0.020 —
13 Thickness 1.7 ±0.05 1.5

Separator plate
Thickness 2.2 ±0.08 1.6 Replace

14 Friction plate
Load of wave spring 1,010 N ±101N 859 N
15 (height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Thickness of 1st • 4th clutch 3 ±0.1 2.7

thrust washer
Thickness of 1st clutch thrust
17 3 ±0.1 2.7
washer
18 End play of 1st gear 0.26 - 0.74
19 End play of 4th gear 0.28 - 0.72
WA380-5 10-25
(10)
2nd•3rd Clutch
A: 2nd clutch oil port C: Lubricating oil port

B: 3rd clutch oil port
1. Output gear (Number of teeth: 49) 6. 3rd clutch

2. Thrust washer 7. 3rd gear (Number of teeth: 40)
3. 2nd gear (Number of teeth: 53) 8. Thrust washer
4. 2nd clutch 9. Idler gear (Number of teeth: 28)
5. 2nd • 3rd cylinder • Idler gear 10. Lower shaft
(Number of teeth: 66)
Unit: mm

Clearance at bearing press fit size Shaft Hole clearance limit
11
part of shaft (F)
55 +0.050 0. 00 -0.065 - —
+0.040 -0.015 -0.040
12 Clearance at bearing press fit 55 +0.039 0. 00 -0.054 - —

part of shaft (R) +0.020 -0.015 -0.020
13 Thickness 1.7 ±0.05 1.5

Separator plate
Replace
Thickness 2.2 ±0.08 1.6
14 Friction plate
Load of wave spring 1,010 N ±101N 859 N
15
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
Thickness of 2nd•3rd clutch
16 thrust washer 3 ±0.1 2.7
17 End play of 2nd gear 0.28 - 0.72
18 End play of 3rd gear 0.28 - 0.72
10-26 WA380-5
(10)
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.
★ Oil drain hole (5) is provided only in the 1st,

2nd, 3rd, and 4th clutches.
WA380-5 10-27
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
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 transmitted 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.
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)
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 transmitted 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.
and is transmitted through 1st•4th cylinder gear
(7) to 3rd gear (14).
10-30 WA380-5
(10)
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).
and is transmitted to 1st•4th cylinder gear (7).
WA380-5 10-31
(10)
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).
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)
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

Without lock-up clutch
Serial No.: 60001 – (Transmission No. 110643)
A: 2nd clutch oil pressure detection port

B: 3rd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
C: 1st clutch oil pressure detection port 2. ECMV (for 3rd clutch)
D: 4th clutch oil pressure detection port 3. ECMV (for 1st clutch)
E: R clutch oil pressure detection port 4. ECMV (for 4th clutch)
F: F clutch oil pressure detection port 5. ECMV (for R clutch)
G: Main relief oil pressure detection port 6. ECMV (for F clutch)
H: Torque converter relief oil pressure detection port 7. Parking brake solenoid valve
J: Parking brake oil pressure detection port 8. Main relief, torque converter
relief valve
9. Last-chance filter
10-34 WA380-5
(10)
Serial No.: (Transmission No. 110644) and up
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)
ECMV actuation table
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
• The oil from the pump passes through the flow

valve, is filtered by the oil filter, enters the
transmission control valve, and is separated
into the main relief circuit and clutch actuation
circuit.
• The oil pressure adjusted by the main relief
valve and flowing to the clutch actuation circuit
passes through the last-chance filter and actu-
ates the clutch and parking brake. The oil
relieved by the main relief valve is supplied to
the torque converter.
• When the transmission shifts gear, the ECMV
uses the command current from the transmis-
sion controller to raise the clutch oil pressure
smoothly in order to reduce the transmission
shock. In addition, it keeps the clutch pressure
constant when the machine is traveling.
• By switching the F, R, and 1st-4th ECMVs, the
adjusted oil pressure is supplied to the selected
clutch to provide the necessary speed range.
WA380-5 10-35
(10)
With lock-up 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)
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)
ECMV actuation table (with lock-up clutch)
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
• The oil from the pump passes through the flow

valve, is filtered by the oil filter, enters the
transmission control valve, and is separated
into the main relief circuit and clutch actuation
circuit.
• The oil pressure adjusted by the main relief
valve and flowing to the clutch actuation circuit
passes through the last-chance filter and actu-
ates the clutch and parking brake. The oil
relieved by the main relief valve is supplied to
the torque converter.
• When the transmission shifts gear, the ECMV
uses the command current from the transmis-
sion controller to raise the clutch oil pressure
smoothly in order to reduce the transmission
shock. In addition, it keeps the clutch pressure
constant when the machine is traveling.
• By switching the F, R, and 1st-4th ECMVs, the
adjusted oil pressure is supplied to the selected
clutch to provide the necessary speed range.
• When traveling in 3rd or 4th, the lock-up ECMV
is actuated at a speed greater than the set
speed of the transmission controller.
WA380-5 10-37
(10)
ECMV (Electronic Control Modulation Valve)
A : To clutch 1. Connector for fill switch

P : From pump 2. Connector for proportional solenoid
T : Drain 3. Oil pressure detection valve
Dr : Drain 4. Fill switch
P1 : Clutch oil pressure detection port 5. Proportional solenoid
P2 : Pilot oil pressure detection port 6. Pressure control valve
10-38 WA380-5
(8)
ECMV for speed clutch

Outline of ECMV
ECMV and proportional solenoid
• The ECMV consists of two components: the
pressure control valve and the fill switch. • There is one proportional solenoid installed to
• Pressure control valve each ECMV.
The proportional solenoid receives the flow of It generates propulsion force as shown in the
electricity sent from the transmission controller, diagram below according to the command cur-
and the pressure control valve converts this rent from the controller.
into hydraulic pressure.
• Fill switch The propulsion force generated by the propor-
The fill switch detects when the clutch is filled tional solenoid acts on the pressure control
with oil. It has the following functions. valve spool and generates oil pressure as
1) When the clutch is filled with oil, it sends a shown in the diagram below. In this way, the
signal (fill signal) at the same time to the command current flow is controlled and the
controller to inform the controller that the propulsion force varies to actuate the pressure
filling is completed. control valve and control the oil flow and oil
2) While oil pressure is applied to the clutch, it pressure.
outputs a signal (fill signal) to the controller Characteristics of proportional solenoid
to inform the controller of the existence of
the oil pressure. current - propulsion force
Range A: Before shifting gear
(when draining)
Range B: During filling
Range C: Pressure adjustment
Range D: During filling (during trigger)
Range E: Fill started
Range F: Fill completed
Characteristics of propotional solenoid

propulsion - oil pressure
ECMV and fill switch
• There is one fill switch installed to each ECMV.

When the filling of the clutch is completed, the
fill switch is turned on by the clutch pressure.
★ The logic is so designed that the controller will With this signal, the oil pressure starts the
not recognize completion of filling even if the build-up.
fill switch is turned ON in the triggering range
(range D).
WA380-5 10-39
(8)
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
★ The logic is so designed that the controller will

not recognize completion of filling even if the
fill switch is turned ON in the triggering range
(range D).
10-40 WA380-5
(10)
2. Start of fill (ranges B in graph) 3. Adjusting pressure (range C in graph)

When there is no oil inside the clutch, if current When electric current flows to proportional
is applied to proportional solenoid (1), oil pres- solenoid (1), the solenoid generates a propul-
sure is applied in chamber B to balance with sion force proportional to the current. The total
the force of the solenoid, and pressure control of this propulsion force of the solenoid and the
valve (3) is pushed to the left. As a result, pump propulsion force of the oil pressure at the clutch
port P and clutch port A open, and oil starts to port and the reaction force of pressure control
fill the clutch. When the clutch is filled with oil, valve spring (2) is adjusted so that it is bal-
oil pressure detection switch (4) is actuated, anced.
and fill switch (6) comes ON.
WA380-5 10-41
(8)
ECMV for lock-up clutch Operation

Outline When traveling in torque converter drive
• This ECMV sets the lock-up clutch hydraulic • When the machine is traveling in torque con-
pressure to the specified pressure, and also verter drive, no electric current is flowing to
switches the lock-up clutch. proportional solenoid (1).
It has a modulation wave pattern, which Pressure control valve (3) drains the oil from
engages the lock-up clutch smoothly, and clutch port A through drain port T, and the lock-
reduces the shock when shifting gear. Further- up clutch is released.
more, it prevents the generation of peak torque At the same time, there is no hydraulic force
in the power train. As a result, the machine acting on oil pressure detection valve (4), so fill
gives a good ride, and the durability of the switch (6) goes OFF.
power train is greatly increased.
10-42 WA380-5
When traveling in direct drive

(Changing from torque converter drive
direct drive)
1. During filling 2. Adjusting pressure

When the transmission shifts to direct drive When electric current flows to proportional
(lock-up), if current is applied to proportional solenoid (1), the solenoid generates a propul-
solenoid (1) by an electric signal, oil pressure is sion force proportional to the current. The total
applied in chamber B to balance with the force of this propulsion force of the solenoid and the
of the solenoid, and pressure control valve (3) is propulsion force of the oil pressure at the clutch
pushed to the left. As a result, pump port P port and the reaction force of pressure control
and clutch port A open, and oil starts to fill the valve spring (2) is adjusted so that it is bal-
clutch. When the clutch is filled with oil, oil anced.
pressure detection switch (4) is actuated, and
fill switch (6) comes ON.
WA380-5 10-43
(10)
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A : Drain (torque converter relief) 1. Body

B : Drain 2. Piston
C : From pump 3. Torque convertor relief valve
D : Drain 4. Piston
E : To torque converter 5. Main relief valve
P1 : Main relief oil pressure detection port
P2 : Torque converter oil pressure detection port
Unit: mm

Clearance between main relief size Shaft Hole clearance limit
6 valve and valve body
-0.035 +0.013 0.035 -
28 0.078
-0.045 0 0.058
Clearance between torque con- -0.035 +0.013 0.035 -
7 verter relief valve and valve 22 0.078
-0.045 0 0.058
body
Standard size Repair limit Replace

Free Installed Installed Free Installed
8 Main relief valve spring (outer) length length load length load
371 N 352 N
122 83.5 118.3
{37.8 kg} {35.9 kg}
301 N 286 N
9 Main relief valve spring (inner) 108 83.5 104.8
{30.7 kg} {29.2 kg}
Torque converter relief valve 134 N 128 N
10 50 43 48.5
spring {13.7 kg} {13.0 kg}
10-44 WA380-5
(10)
Main relief valve

Outline
• The oil from the hydraulic pump passes
Torque converter relief valve through the filter, enters port A of the main
The torque converter relief valve is installed in the relief valve, and then passes through orifice a in
torque converter inlet port circuit. It acts to keep spool (6) and enters chamber B.
the oil pressure in the torque converter inlet port When the oil from the pump fills the circuit, the
circuit at or below the set pressure and protects the oil pressure starts to rise.
torque converter from abnormally high pressure.
Set pressure: 0.84 MPa {8.55 kg/cm²}
(cracking pressure)
Main relief valve

The main relief valve maintains the oil pressure in
the transmission and parking brake at the set pres-
sure.
Set pressure: 2.86 MPa {29.2 kg/cm²}
(engine at rated speed)
Operation
Torque converter relief valve

• The oil relieved from the main relief valve flows • When the oil pressure in the circuit rises, the oil
from port C into the torque converter, and at entering port B pushes piston (4). The reaction
the same time, passes through orifice b of compresses valve spring (7) and moves spool
spool (2) and enters port D. (6) to the left to open port A and port C.
When the oil fills the circuit to the torque con- When this happens, the oil from the pump is
verter, the oil pressure starts to rise. relieved from port A to port C, and flows from
port C into the torque converter.
• When the oil pressure in the circuit to the
The oil pressure at port A at this point is 2.86
torque converter rises, the oil entering port D
MPa {29.2 kg/cm} (engine at rated speed).
pushes piston (9). The reaction compresses
valve spring (3), and moves spool (2) to the
right to open port C and port E.
When this happens, the oil from port C is
relieved to port E and is drained to the oil tank.
The oil pressure at port C at this point is 0.84
MPa {8.55 kg/cm²} (cracking pressure)
WA380-5 10-45
4
FLOW VALVE
A : To transmission valve circuit

B : From pump
C : To transmission lubrication circuit
1. Valve body
2. Valve spool
Unit: mm

Clearance between flow con- size Shaft Hole clearance limit
3 trol valve and body
-0.020 +0.013 0.020 -
25 0.06
-0.030 0 0.043

4 Flow control valve spring length length load length load
79.5 N 75.5 N
63.8 47 61.9
{8.11 kg} {7.7 kg}
Operation
• The oil from the pump flows to the transmis-

sion valve circuit, but if it goes above the speci-
fied amount, the flow valve acts to send it to the
transmission lubrication circuit.
• If the flow of oil from the pump goes above the
specified amount, valve spool (2) moves and
sends part of the oil from the pump to the trans-
mission lubrication circuit.
10-46 WA380-5
(10)
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
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
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
1. Pinion gear (Number of teeth: 12)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
6. Side gear (Number of teeth: 24)
10-50 WA380-5
REAR DIFFERENTIAL
1. Pinion gear (Number of teeth: 12)

2. Shaft
3. Bevel gear (Number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
6. Side gear (Number of teeth: 24)
WA380-5 10-51
Unit: mm
7 Backlash of differential gear 0.13 - 0.18

Adjust
8 Starting torque of bevel gear 13.7 - 37.2 Nm {1.4 - 3.8 kgm}(At outside surface of bevel gear)

9 Pinion gear washer thickness
3 ±0.08 2.8 Replace
10 Side gear washer thickness 4 ±0.05 3.8
Thickness of shim at differential

11 0.3 - 1.25
side bearing carrier
12 Backlash of bevel gear 0.25 - 0.33

Adjust
13 End play of pinion gear 0.182
Thickness of shim at differential

14 1.05 ± 0.35
housing and gauge assembly
10-52 WA380-5
(10)
Outline When turning

• The power from the engine passes through the
• When turning, the rotating speed of the left and
torque converter, transmission, and drive
right wheels is different, so pinion gear (4) and
shafts, and is transmitted to the front and rear
side gear (3) inside the differential transmit the
axles.
power of carrier (6) to sun gear shaft (2) while
• Inside the axle, the power is transmitted from
rotating in accordance with the difference
bevel pinion (1) to bevel gear (5) and the
between the left and right rotating speeds.
direction is changed 90°. It is also reduced and
passes through pinion gear (4) and is transmit-
ted to sun gear shaft (2).
• The power of the sun gear is further reduced by
the planetary gear type final drive and is trans-
mitted to the axle shaft and wheels.
When traveling in a straight line
• When traveling in a straight line, the rotating

speed of the left and right wheels is the same,
so pinion gear (4) inside the differential assem-
bly does not rotate. The power of carrier (6)
passes through pinion gear (4) and side gear
(3), and is transmitted equally to the left and
right sun gear shafts (2).
WA380-5 10-53
LIMITED SLIP 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)
WA380-5 10-55
Unit: mm
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)
Operation of limited slip differential When traveling in a straight line

The power transmitted from the transmission is
1. When there is no imbalance between drive
transmitted from bevel gear (6) to case (9), pres-
force of left and right wheels [Road surface
sure ring (8), shaft (7), pinion (3), and gear (5), and
condition (friction coefficient) and load for left and
is divided to the left and right shafts.
right wheels are uniform and load on bucket is cen-
The brake system, consisting of discs (2) and plates
tered exactly]
(1) is installed at the rear face of side gear (5). A
The power from the transmission is divided
brake torque is generated that is proportional
equally to the left and right by the differential gear.
to the torque transmitted from pressure ring (8) to
In this case, the wheel slip limit of the left and right
shaft (7).
wheels is the same, so even if the power from the
This brake torque acts to limit the rotation in rela-
transmission exceeds the wheel slip limit, both
tion to side gear (5) and case (9), so it is difficult
wheels will slip and the differential will not be actu-
for left and right side gears (5) to rotate mutually
ated.
and the operation of the differential is limited.
There is no load on the brake at the rear face of the
side gears.
Brake torque generation mechanism of left
and right side gears (5).
Shaft (7) is supported at the cam surface cut into
the facing surfaces of left and right pressure rings
(8).
The power (torque) transmitted from pressure rings
(8) to shaft (7) is transmitted at the cam surface,
but force Fa separating left and right pressure
rings (8) is generated in proportion to the torque
transmitted according to the angle of this cam sur-
face.
This separation load Fa acts on the brake at the rear
face of left and right side gears (5) and generates
the brake torque.
WA380-5 10-57
(10)
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)
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1. Planet gear (No. of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (No. of teeth: 69)
5. Sun gear shaft (No. of teeth: 15)
WA380-5 10-59
Unit: mm
Tolerance
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
Clearance at press- Outer race -0 -0.045 -0.085-

180 —
fitting portion of -0.025 -0.085 -0.020
10 Replace
axle housing bear- +0.045 -0 -0.065 -
ing Inner race 120 —
+0.023 -0.020 -0.023
Clearance at press- Outer race +0.025 -0.012 -0.077 -

157.162 —
fitting portion of +0 -0.052 -0.012
11 axle housing bear- +0.059 +0.025 -0.059 -
ing Inner race 98.425 —
+0.037 +0 -0.012
12 End play of axle shaft 0 - 0.1 Adjust
+0.025 +0.207 0.120 -

13 Clearance of guide pin 12 — Replace
+0.007 +0.145 0.200
10-60 WA380-5
(10)
Outline
• The final drive reduces the speed of the power

from the engine and increases the drive force.
• Ring gear (4) is press fitted to the axle housing
and is fixed in position by a pin.
• The power transmitted from the differential and
passing through sun gear shaft (5) has its
speed reduced by the planetary gear mecha-
nism and the drive force increased.
The increased drive force passes through plan-
etary carrier (2) and axle shaft (3) and is trans-
mitted to the wheels.
WA380-5 10-61
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
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
Unit: mm

1 Thickness of thrust plate
22 ±0.5 —
2 Thickness of wave plate 5 +0.3 —

-0.1
Tolerance Replace
Clearance between hole and size Shaft Hole clearance limit
3 shaft at front support end
190 -0.050 +0.472 0.050 - —
-0.122 +0 0.594
Clearance between hole and -0.005 +0.522 0.055 -
4 shaft at rear support end 170 -0.124 +0.050 0.646 —
WA380-5 10-63
(10)
10-64 WA380-5
Unit: mm
Tolerance
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

Height of upper hinge spacer
12 (small)
25.5 ±0.1 —
Height of upper hinge spacer

13 56 ±0.1 —
(large)
Standard size
Shim value for upper hinge and
14 retainer
2.5
Shim value for upper hinge and

15 2.5
retainer
Shim value for lower hinge and
16 2
retainer
Adjust
20±2 Nm {2±0.2kgm} (When adjusting shim)
Tightening torque for upper
17 hinge retainer mounting bolt
98 - 123 Nm {10 - 12.5 kgm} (Final value)
20±2 Nm {2±0.2kgm} (When adjusting shim)

Tightening torque for lower
18 hinge retainer mounting bolt
98 - 123 Nm {10 - 12.5 kgm} (Final value)
WA380-5 10-65
b
(10)
MAINTENANCE STANDARD STEERING PIPING
STEERING PIPING
1. Work equipment valve 7. Switch pump

2. Steering valve 8. Steering pump
3. Steering cylinder (right) 9. Steering cylinder (left)
4. Hydraulic oil tank 10. Orbit-roll
5. Emergency steering pump 11. Stop valve (right)
6. Emergency steering motor 12. Stop valve (left)
13. PPC accumulator
10-66 WA380-5
MAINTENANCE STANDARD STEERING COLUMN, ORBIT-ROLL
STEERING COLUMN, ORBIT-ROLL
1. Steering wheel 4. Joint

2. Steering column 5. Orbit-roll
3. Tilt lever
Unit: mm

Clearance between steering size Shaft Hole Clearance limit
6 Replace
shaft and column bearing
-0 +0.15
19 0.05 - 0.23 0.4
-0.08 -0.05
WA380-5 10-67
b
(10)
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
10-68 WA380-5
1. Overload safety valve

2. Check valve
3. Steering spool
4. Flow control spool
5. Main relief 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
Standard size Repair limit
Free Installed Free Installed

6 Steering spool return spring Installed load
length length length load
56.9N 47.1 N
37.2 32.0 —
{5.8 kg} {4.8 kg}
9.3±4.9 N 7.85 N
7 Poppet spring 20.9 13.2 — Replace
{0.95±0.5 kg} {0.8 kg}
136.1 N 114.7 N
8 Demand spool return spring 75.1 68.5 —
{13.88 kg} {11.7 kg}
182 kN 145 kN
9 Relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
2.26 N 1.77 N
10 Check valve return spring 21.6 17.0 —
{0.23 kg} {0.18 kg}
WA380-5 10-69
(10)
OVERLOAD RELIEF VALVE

Operation
Functioning as relief valve
• Port A is connected to the cylinder circuit and

port B is connected to the drain circuit. Oil
passes through the center of the hole in poppet
(1) and acts on diameters d1 and d2, which
have different areas. Check valve poppet (3)
and relief valve poppet (2) are seated securely.
• When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens, and the oil flows around pilot poppet
(4), passes through the drill hole, and flows to
1. Poppet port B.
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
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
Functioning as suction 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.
• The pressure on the inside is lower than the

pressure at port A, so relief valve poppet (2)
opens. When this happens, the oil flows from
port A to port B to prevent any abnormal pres-
sure.
WA380-5 10-71
STEERING RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The steering relief valve is inside the steering
valve. 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
Operation of steering relief 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
Operation of demand valve

When steering spool is at neutral
• 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
When steering spool is operated

• Engine running at low speed
• When steering spool (2) is pushed (operated), • The merged oil passes through notches c and
pressure-receiving chamber (II) and the drain 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
• Engine running at high speed
• 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
FLOW AMP
1. Steering spool 5. Cap A : From Orbit-roll valve

2. Valve housing (body) 6. Capscrew B : From Orbit-roll valve
3. Spring seat 7. Orifice C : Passage (inside housing)
4. Return spring
• Operation of flow amp
1. Spool at neutral (Orbit-roll valve not actuated)
• When the Orbit-roll valve is not actuated, both

pilot port PiA and pilot port PiB are connected
through the Orbit-roll to the drain (return) cir-
cuit, so steering spool (1) is kept at neutral by
return spring (4).
WA380-5 10-77
(10)
2. Spool actuated (oil flows to port PiA)
• 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
3. Spool returning (steering wheel stopped)
• When the steering wheel (Orbit-roll valve) is

stopped, ports PiA and PiB are both connected
to the drain circuit through the Orbit-roll valve.
For this reason, steering spool (1) is returned to
the neutral position by return spring (4).
WA380-5 10-79
Operation of steering valve

Neutral
• 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
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
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
MAINTENANCE STANDARD ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Cover 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve
WA380-5 10-83
Outline
• The steering valve is connected directly to the

shaft of the steering wheel. It switches the flow
of oil from the steering pump to the left and
right steering cylinders to determine the direc-
tion of travel of the machine.
• The orbit-roll valve, broadly speaking, consists
of the following components: rotary type spool
(9) and sleeve (8), which have the function of
selecting the direction, and the Girotor set (a
combination of rotor (5) and stator (10)), which
acts as a hydraulic motor during normal steer-
ing operations, and as a hand pump (in fact, the
operating force of the steering wheel is too
high, so it cannot be operated) when the steer-
ing pump or engine have failed and the supply
of oil has stopped.
Structure
• Spool (9) is directly connected to the drive shaft

of the steering wheel, and is connected to
sleeve (8) by center pin (7) (it does not contact
the spool when the steering wheel is at neutral)
and centering spring (2).
• The top of drive shaft (3) is meshed with center
pin (7), and forms one unit with sleeve (8),
while the bottom of the drive shaft is meshed
with the spline of rotor (5) of the Girotor.
• There are four ports in valve body (4), and they
are connected to the pump circuit, tank circuit,
and the circuits at the head end and bottom end
of the steering cylinders. The pump port and
tank port are connected by the check valve
inside the body. If the pump or engine fail, the
oil can be sucked in directly from the tank by
this check valve.
10-84 WA380-5
CONNECTION BETWEEN HAND PUMP AND SLEEVE
• The diagrams above show the connections with

the sleeve ports used to connect the suction
and discharge ports of the Girotor.
• If the steering wheel has been turned to the
right, ports a, c, e, g, i and k are connected by
the vertical grooves in the spool to the pump
side. At the same time, ports b, d, f, h, j, and l
are connected to the head end of the left steer-
ing cylinder in the same way.
In the condition in Fig.1, ports 1, 2, and 3 are
the discharge ports of the Girotor set. They are
connected to ports l, b, and d, so the oil is sent
to the cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If steering wheel is turned 90°, the condition
changes to the condition shown in Fig. 2. In this
case, ports 1, 2, and 3 are the suction ports,
and are connected to ports i, k, and c. Ports 5,
6, and 7 are the discharge ports, and are con-
nected to ports d, f, and h.
WA380-5 10-85
• In this way, the ports of the Girotor acting as

delivery ports are connected to ports which are
connected to the end of the steering valve
spool. The ports acting as suction ports are con-
nected to the pump circuit.
• Adjusting delivery in accordance with angle of
steering wheel:
For every 1/7 turn of the steering wheel, the
inner teeth of the Girotor gear advance one
position so the oil flow from the pump is
adjusted by this movement. In this way, the oil
delivered from the pump is directly propor-
tional to the amount the steering wheel is
turned.
FUNCTION OF CENTER SPRING
• Centering spring (2) consists of four layers of

leaf springs crossed to form an X shape. The
springs are assembled in spool (9) and sleeve
(8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is
compressed and a difference in rotation (angle
variation) arises between the spool and the
sleeve.
Because of this, the ports in the spool and
sleeve are connected and oil is sent to the cylin-
der. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no
more oil is sent to the cylinder and the oil pres-
sure rises.
To prevent this, when the turning of the steer-
ing wheel is stopped, the action of the centering
spring only allows it to turn by an amount equal
to the difference in angle of rotation (angle vari-
ation) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.
10-86 WA380-5
MAINTENANCE STANDARD STOP VALVE
STOP VALVE
1. Boot A : From orbit-roll

2. Wiper B : To steering valve
3. Seal DR : To drain
4. Poppet
5. Spring
6. Spool
7. Spring
WA380-5 10-87
(10)
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP
STEERING PUMP, SWITCH PUMP

SAL (3) 45+45
1. Steering pump Outline

2. Switch pump • The steering pump and switch pump are
installed to the PTO shaft of the torque con-
verter. When the shaft rotates, the pumps are
driven and supply pressure oil to the steering
circuit.
• The pressure of the oil supplied from the switch
pump is adjusted by the steering valve, and
when the pressure in the steering circuit is suf-
ficient to meet the demand, the oil from the
switch pump is diverted to the work equip-
ment hydraulic circuit.
10-88 WA380-5
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP
Unit: mm
Model Standard clearance Clearance limit
3 Side clearance SAL(3)45

0.10 - 0.15 0.19
SAL(3)45
Clearance between inside SAL(3)45

4 diameter of plain bearing and 0.06 - 0.149 0.20 Replace
outside diameter of gear shaft SAL(3)45
Repair
Model Standard size Tolerance limit
5 Driving depth of pin SAL(3)45

-0
14 —
-0.5
SAL(3)45
6 Spline rotating torque 13.8 - 23.6 Nm {1.4 - 2.4 kgm}
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)
MAINTENANCE STANDARD EMERGENCY
EMERGENCY STEERING
STEERING PUMP (IF(If
PUMP equipped)
EQUIPPED)
EMERGENCY STEERING PUMP (If equipped)

SBL (1)21
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
Standard clearance Clearance limit

1 Side clearance
0.10 - 0.15 0.19
Clearance between inside

2 diameter of plain bearing and 0.060 - 0.119 0.20 Replace
outside diameter of gear shaft

3 Driving depth of pin -0
10 —
-0.5
4 Spline rotating torque 2.0 - 4.9 Nm {0.2 -0.5 kgm}
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)
MAINTENANCE STANDARD EMERGENCY
EMERGENCY STEERING
STEERING MOTOR(IF(IfEQUIPPED)
MOTOR equipped)
EMERGENCY STEERING MOTOR (If 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
Rated voltage 24V
Rated output 0.9kW
WA380-5 10-91
(10)
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm
Tolerance
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)
MAINTENANCE STANDARD STEERING CYLINDER
Unit: mm
Tolerance
Clearance between piston rod size Clearance limit
1 Shaft Hole
and bushing
45 +0.025 +0.141 0.021 - 0.505

+0.064 -0.004 0.205 Replace pin,
bushing
2 Clearance between piston rod 50 -0 +0.142 0.080 - 1.0
support shaft and bushing -0.025 +0.080 0.167
Clearance between cylinder -0 +0.142 0.080 -
3 bottom support shaft and bush- 50 -0.025 +0.080 0.167 1.0
ing
4 Tightening torque of cylinder 677 ± 67.5 Nm {69 ± 6.9 kgm}

head
5 Tightening torque of cylinder 1.25 ± 0.13 kNm {127 ± 12.7 kgm} (Width across flats: 50 mm) Tighten
piston
6 Tightening torque of nipple 9.8 - 12.74 Nm {1.0 - 1.3 kgm}

plug on cylinder head side
WA380-5 10-93
(10)
MAINTENANCE STANDARD JOYSTICK
JOYSTICK STEERING
STEERING LEVER
LEVER (IF(IfEQUIPPED)
equipped)
JOYSTICK STEERING LEVER (If equipped)
1. Shift UP switch 9. Console lock lever

2. Shift DOWN switch 10. Height adjustment lock lever
3. F-N-R switch 11. Angle/Position adjustment lock lever
4. Joystick steering lever 12. Console
5. Joystick ON/OFF switch 13. Block
6. Hi/Lo switch 14. Solenoid valve
7. Horn switch 15. Orbit-roll
8. Steering electrical lever
10-94 WA380-5
(10)
MAINTENANCE STANDARD STEERING
STEERING LEVER
LEVER (IF(IfEQUIPPED)
equipped)
STEERING LEVER (If equipped)

(FOR JOYSTICK STEERING LEVER)
1. Body 5. Retainer
2. Piston 6. Lever
3. Lever 7. Potentiometer
4. Disc 8. Connector
Function
• The steering potentiometer is installed to the

left side part of the floor, and is interconnected
by a link to the steering end of the monolever.
When the monolever is operated in the steering
direction, disc (4) is rotated through the link,
pushes piston (2) down, and rotates potentiom-
eter (7).
• Steering lever potentiometers sense lever angle
and output angle signal to HSS controller.
• Two potentiometers are attached to the steer-
ing lever and they output a signal as shown in
the diagram.
WA380-5 10-95
(10)
STEERING LEVER
LEVER (IF(If equipped)
EQUIPPED)
Unit: mm
1 Spring Free length Installed Installed Free Installed Replace

length load length load spring if
5.88 N 4.71 N damaged of
49 x 7.0 25 — deformed
{0.6 kg} {0.48 kg}
2 Spring 45.8 x 15.5 32 73.5 N — 58.8 N
{7.5 kg} {6.0 kg}
10-96 WA380-5
(10)
STEERING SWITCH
SWITCH VALVE
VALVE (IF(IfEQUIPPED)
equipped)
STEERING SWITCH VALVE (If equipped)

(FOR JOYSTICK STEERING LEVER)
Operation
• Steering switch valve switches oil circuit from

R.H. steering cylinder circuit to L.H. steering cyl-
inder circuit or in reverse according to the oper-
ated direction of steering lever.
• According to the angle of steering lever, steer-
ing switch valve controls the oil flow amount.
WA380-5 10-97
b
(10)
MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
10-98 WA380-5
MAINTENANCE STANDARD BRAKE PIPING
1. Brake valve (L.H.)

2. Brake valve (R.H.)
3. Hydraulic oil tank
4. Accumulator (for the front side)
5. Accumulator (for the rear side)
6. Accumulator (for the rear side)
7. Accumulator (for the front side)
8. Charge valve
9. Parking brake emergency release valve
10. Pilot control pump
11. Rear brake
12. Transmission control valve
13. Parking brake solenoid valve
14. Parking brake
15. Front brake
WA380-5 10-99
(10)
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (LEFT)
T : Drain port 1. Brake pedal

A : To the R.H. brake valve PP 2. Rod
P : From the charge valve ACC2 3. Spool
4. Cylinder
10-100 WA380-5
(10)
Unit: mm
Tolerance
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

7 Outside diameter of roller
-0
30 29.2
-0.5
Replace
Installed Installed Installed

8 Control spring Free length Free length
length load load
0 Nm
34.7 34.7 33.7 —
{0 kg}
40.3 Nm
9 Control spring 51.8 49.7 50.8 —
{4.12 kg}
116.4 Nm
10 Return spring 197.8 58 178 —
{11.88 kg}
16.7 Nm
11 Return spring 31.5 19.5 28 —
{1.7 kg}
WA380-5 10-101
(10)
BRAKE VALVE (RIGHT)
T : Drain port 1. Brake pedal

A : To the rear brake 2. Rod
B : To the front brake 3. Piston (Pilot)
PA : From the charge valve ACC1 4. Spool
PB : From the charge valve ACC2 5. Cylinder (Upper)
PP : From the L.H. brake valve A 6. Spool
7. Cylinder (Lower)
10-102 WA380-5
(10)
Unit: mm
Tolerance
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

10 Outside diameter of roller
-0
30 29.2
-0.5

11 Control spring length length load length load
0 Nm
34.7 34.7 33.7 —
{0 kg}
40.3 Nm
12 Control spring 51.8 49.7 50.8 —
{4.12 kg}
116.4 Nm
13 Return spring 197.8 58 178 —
{11.88 kg}
16.7 Nm
14 Return spring 31.5 19.5 28 —
{1.7 kg}
17.7 Nm
15 Return spring 17 16.5 — —
{1.8 kg}
WA380-5 10-103
(10)
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
Applying brake (right brake valve) when there Balanced operation

is failure in upper valve Upper portion
• When the oil fills the rear brake cylinder and the
• Even if there is leakage of oil from the upper oil pressure between port A and port C
piping, when pedal (1) is depressed, spool (5) becomes high, the oil entering port H through
is moved down mechanically, so the lower orifice e of spool (3) pushes against spring (4)
portion is actuated normally. and pushes spool (3) up to shut off port A and
The brake for the upper portion is not actuated. port C. When this happens, drain port a
Applying brake (right brake valve) when there remains closed and the oil entering the brake
is failure in lower valve cylinder is maintained, so the brake remains
applied.
• Even if there is leakage of oil from the lower Lower portion
piping, when pedal (1) is depressed, the lower • Spool (a) in the upper portion moves up, and at
portion is actuated normally. the same time as port A and port C are shut
off, the front brake cylinder is also filled with oil
and the oil pressure between port B and port D
becomes high. The oil entering port J through
orifice f of spool (5) pushes up the spool by the
same amount that spool (3) moves and shuts
off port B and port D.
Drain port b is closed, so the oil entering the
brake cylinder is maintained and the brake is
applied.
• The pressure in the space in the upper portion
is balanced with the operating effort of the
pedal, and the pressure in the space in the
lower portion is balanced with the pressure in
the space in the upper portion. Spools (3) and
(5) move the full stroke, and ports A - C and
ports B - D are opened completely, so the oil
pressure in the space in the lower portion and
the left and right brake cylinders becomes the
same as the oil pressure from the pump.
Therefore, the amount that the brake is applied
can be adjusted by the amount that the pedal
is depressed, up to the point where the piston
is operated fully.
WA380-5 10-105
Brake released (right 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
MAINTENANCE STANDARD CHARGE VALVE
CHARGE VALVE
A1 : To the PPC (*EPC) valve

A2 : Plug
ACC1: To the R.H. brake valve PA
ACC2: To the R.H. brake valve PB
To the L.H. brake valve P
P : From the pump
PP : To the accumulator
T : Drain
* EPC valves are optional parts.
WA380-5 10-107
(10)
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC (EPC*) relief valve (R2)
5. Relief valve (H1)
*EPC valves are optional parts.
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
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)
2) When cut-out pressure is reached

• When the pressure at port B (accumulator
pressure) reaches the set pressure of relief
valve R1, poppet (1) separates from valve
seat (9), the oil flows, and the relief is actu-
ated.
• A difference in pressure at the top and bot-
tom of piston (2) is created by the relief
action, so piston (2) moves up or down,
forcibly opens poppet (1), and port C and
port T are connected.
• The spring chamber at the right end of
spool (6) is connected to port C of relief
valve R1, so it is the tank pressure.
• The pressure at port P goes down in the
same way to a pressure equivalent to the
load of spring (5), and the supply of oil to
port B is also stopped.
3. Safety relief valve (R3)

• When the pressure at port P (pump pressure)
goes above the set pressure of relief valve R3,
the oil from the pump pushes against spring
(10), pushes up ball (11), and sends the oil to
the tank circuit to set the maximum pressure in
the brake circuit and protect the circuit.
10-110 WA380-5
(10)
MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)
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
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
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)
Unit: mm

10 Thickness of inner ring
6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) — Replace
Wear of brake outer ring disc

12 23.3 ±0.1 0.3
contact surface
13 Spring load Installed height Installed load Installed load
6.5 460 N {47 kg} 372 N {38 kg}
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
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)
Unit: mm

10 Thickness of inner ring
6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) — Replace
12 Wear of brake outer ring disc 23.3 ±0.1 0.3

contact surface
13 Spring load Installed height Installed load Installed load
6.5 460 N {47 kg} 372 N {38 kg}
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
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
MAINTENANCE STANDARD PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake switch

2. Parking brake emergency release valve
3. Transmission control valve
4. Parking brake solenoid valve
5. Parking brake
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
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1. Output shaft Outline

2. Spring
3. Spring • The parking brake is a wet-type multiple-disc
4. Piston brake and is applied mechanically by a spring
5. Parking brake oil port to apply braking force to transmission output
6. Plate shaft (1).
7. Disc • The tension of spring (3) uses piston (4) to push
8. Wave spring discs (7) and plates (6) together and stop output
shaft (1).
• When the brake is released, oil pressure from
parking brake oil port (5) actuates piston (4) to
release the force pushing discs (7) and plates
(6) together.
WA380-5 10-119
MAINTENANCE STANDARD PARKING BRAKE
Unit: mm

9 Parking brake spring (outer) length length load length load
1,113 N 1,058 N
94 75.2 91.2
{113.5 kg} {107.8 kg}
583 N 553 N
10 Parking brake spring (inner) 94 75.2 91.2
{59.4 kg} {56.4 kg}
Standard size Tolerance Repair limit Replace

Thickness
11 Separate plate 4.0 ±0.05 3.9
12 Brake disc Thickness 3.2 ±0.08 2.97
Wave spring load ±57 N

13 1,106 N {112.8 kg} 940 N {95.9 kg}
(Height: 3.2 mm) {±5.8 kg}
10-120 WA380-5
(10)
MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE

1. Movable iron core

2. Coil
3. Bushing pin
4. Spring
5. Spool
6. Valve seat
7. Check valve
WA380-5 10-121
(10)
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)
MAINTENANCE STANDARD PARKING BRAKE EMERGENCY RELEASE VALVE
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)
MAINTENANCE STANDARD HYDRAULIC PIPING
HYDRAULIC PIPING
10-124 WA380-5
WA380-5 10-125
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)
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER
WORK EQUIPMENT CONTROL LEVER

For PPC valve
1. Lift arm control lever

2. Bucket control lever
3. Kick down switch
4. Holding switch
5. Canceling switch
(When equipped with load meter)
6. Sub-totaling switch
7. Wrist rest
8. Wrist rest height adjusting lever
9. Lever stand angle adjusting lever
10. Work equipment PPC valve
11. Work equipment lock lever
WA380-5 10-127
(10)
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER
For EPC valve (If equipped)
1. Lift arm control lever 7. Wrist rest

2. Bucket control lever 8. Wrist rest adjusting lever
3. Kick-down switch 9. Lever stand tilt adjusting lever
4. Hold switch 10. EPC valve
5. Cancel switch 11. Work equipment lock lever
(When equipped with load meter) 12. Travel direction selector switch
6. Sub-totaling switch
10-128 WA380-5
(10)
MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Oil filler port

2. Breather Specifications
3. Hydraulic oil tank Tank capacity (l) 195
4. Sight gauge Oil quantity inside the tank (l) 129
5. Bypass valve
Bypass valve setting pressure 0.125
6. Oil filter (MPa{kg/cm²}) {1.27}
WA380-5 10-129
MAINTENANCE STANDARD HYDRAULIC TANK
Breather
1. Nut
2. Filter element
3. Poppet
4. Sleeve
Prevention of negative pressure in tank
• Since the tank is pressurized and enclosed, if

the hydraulic oil level in it lowers, negative
pressure is generated. At this time, sleeve (4) is
opened by the differential pressure between the
tank pressure and the atmospheric pressure to
prevent generation of the negative pressure.
(Set pressure of suction valve: 2.0 ± 0.3 kPa
{0.02 ± 0.003 kg/cm²})
Prevention of pressure rise in tank
• While the hydraulic circuit is in operation, the

hydraulic oil level in the tank varies as the
hydraulic cylinders operate and the tempera-
ture rises. Consequently, the pressure in the
tank varies, too. If the pressure in the tank rises
above the set level, poppet (3) operates to
release the pressure from the tank.
(Set pressure of exhaust valve: 0.1 ± 0.015 MPa
{1.0 ± 0.15 kg/cm²})
10-130 WA380-5
(8)
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND

PILOT CONTROL PUMPS
SAL (3) 80 + 90 + (1)22
1. Torque converter charging pump

2. Work equipment pump Outline
3. Pilot control pump
• The torque converter charging, work equip-
ment, and pilot control pumps are installed to
the PTO shaft of the torque converter and
driven by shafts to supply oil to the transmis-
sion, work equipment, and PPC circuit.
WA380-5 10-131
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS
Unit: mm
Model Standard clearance Clearance limit
SAL(3)80
4 Side clearance 0.10 - 0.15
SAL(3)90 0.19
SAL(1)20 0.08 - 0.13
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
7 Spline rotating torque 17.7 - 33.3 Nm {1.8 -3.4 kgm}
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
SAL(1)20 2.9 {30} 47 42
10-132 WA380-5
(10)
MAINTENANCE STANDARD PPC RELIEF VALVE
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.
Note: If EPC valve is installed, change "PPC valve"

to "EPC valve" when reading.
WA380-5 10-133
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
MAINTENANCE STANDARD E.C.S.S.
E.C.S.S. (IF(IfEQUIPPED)
VALVE
VALVE equipped)
E.C.S.S. VALVE (If equipped)

★ E.C.S.S.: Abbreviation for – Electronically Controlled Suspension System
A : From lift cylinder bottom

B : From lift cylinder head
P : From work equipment pump
SP : To E.C.S.S. accumulator
T : To tank
WA380-5 10-135
(10)
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)
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT CONTROL VALVE

1. 2-spool 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)
1. Cutoff valve assembly 7. Cutoff relief valve

2. Unload valve 8. Screen
3. Bucket spool 9. Safety valve with suction valve
4. Lift arm spool 10. Check valve
5. Check valve 11. Main relief valve
6. Suction valve
10-138 WA380-5
Unit: mm
Spool return spring Installed Installed Installed

12 Free length Free length
(For bucket) length load load
125 N
54.8 53.5 — —
{12.7 kg}
Spool return spring 235 N
13 54.8 52.2 — —
(For bucket and lift arm) {24 kg}
14 30.7 26.8 — —
If spring is
Spool return spring 233 N damaged or
15 55.3 40.0 — —
(For lift arm) {23.8 kg} deformed,
replace it
16 86.8 83.5 — —
(For lift arm) {21.2 kg}
Main valve spring of main 33.3 N
17 39.5 23.2 — —
relief valve {3.4 kg}
259 N 208 N
18 Poppet spring of relief valve 49.3 41.9 47.8
{26.4 kg} {21.2 kg}
44.1 N
19 Check valve spring 32.6 24.5 — —
{4.5 kg}
6.86 N
20 Suction valve spring 27.9 19.0 — —
{0.7 kg}
WA380-5 10-139
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)
1. Cutoff valve assembly 7. Suction valve

2. Unload valve 8. Cutoff relief valve
3. Attachment spool 9. Screen
4. Bucket spool 10. Safety valve with the suction valve
5. Lift arm spool 11. Check valve
6. Check valve 12. Main relief valve
WA380-5 10-141
Unit: mm
Spool return spring Free Installed Installed Free Installed

13 (For bucket and attachment) length length load length load
54.8 53.5 125 N — —

{12.7 kg}
14 Spool return spring 54.8 52.2 235 N — —


If spring is
16 Spool return spring 55.3 40.0 233 N — — damaged or
(For lift arm) {23.8 kg} deformed,
replace it
(For lift arm) {21.2 kg}
18 Main valve spring of main 39.5 23.2 33.3 N — —

relief valve {3.4 kg}
19 Poppet spring of relief valve 49.3 41.9 259 N 47.8 208 N

{26.4 kg} {21.2 kg}
20 Check valve spring 32.6 24.5 44.1 N — —

{4.5 kg}
21 Suction valve spring 27.9 19.0 6.86 N — —

{0.7 kg}
10-142 WA380-5
3. Relief valve
• When the hydraulic pressure inside the port A

and the port B reaches the set pressure of the
pilot poppet spring (4), the pilot poppet (3)
opens to let the hydraulic pressure of the port B
flow from the port D to the port C and the pres-
sure of the port B drops.
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjusting screw
• When the pressure at the port B drops, pres-

Function sure difference occurs between the port A and
the port B by the orifice of the main valve (1)
• The relief valve is installed to the inlet of the and the main valve shall be pushed open to let
work equipment valve. When the oil pressure the oil of the port A to pass through the port C
rises above the specified level, this valve drains to flow into the drain circuit, to release the
the oil into the hydraulic tank to limit the maxi- abnormal pressure.
mum pressure of the work equipment circuit
• The preset pressure can be changed by increas-
and protect the circuit.
ing or decreasing the tension of the pilot pop-
pet spring (4).
Operation • To change the preset pressure, remove the cap
nut to loosen the lock nut. After that, screw-in
• The port A is connected to the pump circuit and the adjust screw (5) to raise the preset pressure
the port C is connected to the drain circuit. The and loosen the adjust screw to lower the preset
oil passes through the orifice of the main valve pressure.
(1) to fill the port B. The pilot poppet (3) is con-
tacting (seated) to the valve seat (2).
WA380-5 10-143
4. Safety-suction valve
1. Suction valve • When abnormal pressure is generated in port

2. Main valve A, suction valve (1) does not operate since d2 >
3. Main valve spring d1. Main valve (2) receives the oil pressure cor-
4. Pilot piston responding to the area difference between d3
5. Suction valve spring and d4 of ports A and C, however, since d3 >
6. Valve body d4.
• If the oil pressure applied to main valve (2)
reaches the set pressure of main valve spring
(3), main valve (2) operates and the oil flows
Function
from port A to port B.
• The safety-suction valve is in the bucket cylin-
der circuit in the work equipment valve. When
the work equipment valve is in neutral, if any
impact is applied to the cylinder and abnormal
pressure is generated, that pressure is released
through this valve to protect the cylinder.
• If negative pressure is generated in the cylinder
circuit, this valve works as a suction valve.
Operation
(1) Operation as safety valve

• Ports A and B are connected to the cylinder cir-
cuit and drain circuit respectively.
• The oil pressure in port A is applied through
the hole of pilot piston (4) to port D. It is also
applied through the orifice consisting of main
valve (2) and pilot piston (4) to port C.
• Pilot piston (4) is fixed to the safety valve and
the diameters (sectional areas) are set in the fol-
lowing order; d2 > d1 > d3 > d4.
10-144 WA380-5
(10)
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
• The suction valve prevents generation of nega-

tive pressure in the circuit.
Operation
• If negative pressure is generated in port A (lift

cylinder head) (If pressure lower than the pres-
sure in tank circuit port B is generated), main
poppet (1) opens because of the area difference
between d1 and d2, then the oil flows from
tank port B to cylinder port A.
WA380-5 10-145
(10)
6. Cut-off valve
Function
• The cut-off valve is installed between the

switching pump and work equipment valve. It
sends the oil from the switching pump to the
work equipment valve or drains it to control the
work equipment speed according to the work-
ing condition.
• The cut-off valve is operated with the hydraulic
system and the electronic governor controller.
• Operating condition of cut-off valve
c Cuts off (Drains oil)
± Does not operate (Sends oil to work
equipment valve)
Above Below When kick-
Mode 15.7 MPa 15.7 MPa down switch
{160 kg/cm²} {160 kg/cm²} is "ON"
Standard Hi c ± ±
specifica-
tion vehi- S c ± c
cle Lo c c c
Operation
(1) When work equipment valve is held

(When solenoid valve of hyper-specification
vehicle is turned OFF)
• The oil of the switching pump (The oil from the
steering valve) pushes up check valve (1) and
merges with the oil from the work equipment
pump and then flows into the work equipment
valve.
(2) When work equipment valve is operated
(When solenoid valve of hyper-specification
vehicle is turned OFF)
1) When work equipment pump pressure is lower

than cut-off pressure
• Similarly to the state where the work equip-
ment valve is held, the oil of the switching
pump (the oil from the steering valve) pushes
up check valve (1) and merges with the oil from
the work equipment pump and then flows into
the work equipment valve.
10-146 WA380-5
(10)
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)
7. Operation of the work equipment control valve

(1) Neutral position of the lift arm and bucket spools
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)
(2) RAISE position of the lift arm spool
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)
(3) LOWER position of the lift arm spool
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.
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)
(4) FLOAT position of the lift arm spool
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.
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)
(5) DUMP position of the bucket spool
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)
(6) TILT position of the bucket spool
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)
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT PPC VALVE
P : From HST charging pump

T : To hydraulic tank
P1 : To bucket TILT valve
P2 : To bucket DUMP valve
P3 : To lift arm RAISE valve
P4 : To lift arm LOWER (FLOAT) valve
10-154 WA380-5
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
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)
2. When in fine control

(NEUTRAL Fine control)
• If rod (7) and piston (12) are pushed by lever (8),

retainer (11) is pushed and spool (1) is also
pushed down through metering spring (2).
• Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil of the main pump flows
from port P1 to port PB.
• If the pressure in port P1 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simulta-
neously to release the pressure in port P1.
• As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port P1.
The positional relationship between spool (1)
and body (13) (where fine control hole f is
between drain chamber D and pump pressure
chamber PP) does not change until retainer
(11) comes in contact with spool (1).
• Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the
pressure in port P1 rises in proportion to the
stroke of the control lever.
• Accordingly, the control valve spool moves to a
position at which the pressure in the chamber
PB (equal to the pressure in port P1) is bal-
anced with the force of the control valve spool
return spring.
WA380-5 10-157
(10)
3. When in fine control 4. When lever is operated to stroke end

(When control lever is returned)
• 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)
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)
MAINTENANCE STANDARD PPC VALVE
PPC VALVE (FOR MULTI FUNCTION MONO LEVER)
P : From PPC accumulator

T : To hydraulic tank
P1 : To bucket TILT valve
P2 : To bucket DUMP valve
P3 : To lift arm RAISE valve
P4 : To lift arm LOWER (FLOAT) valve
10-159-1 WA380-5
1
(10)
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
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
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
3. At Fine Control 4. At Full Stroke

(When the control valve is returned)
• As the disc (8) begins to be returned, the spool (1) • When the disc (8) and the rod (7) push the pis-
is pushed upward by the force of the centering ton (11) down and the retainer (10) pushes the
spring (3) and by the pressure at the P4 port. spool (1) down, the fine control hole f is inter-
• Therefore, the fine control hole f leads to the rupted from the drain chamber D and leads to
drain chamber D and pressured oil is released the pump pressure chamber PP. Therefore, the
from the P4 port. pilot pressure oil from the main pump passes
• When pressure at the P4 port drops too much, through the fine control hole f and is led to the
the spool (1) is pushed downward with the PB chamber from the P4 port to push the con-
metering spring (2) and the fine control hole f is trol valve spool.
interrupted from the drain chamber D and leads • The return oil from the PA chamber flows to the
to the pump pressure chamber PP almost at the drain chamber D through the P3 port and the
same time. And the pump pressure is supplied fine control hole f.
through the fine control hole f until the pres-
sure at the P4 port rises to the pressure accord-
ing to the lever position.
• When the control valve spool returns, oil flows
in through the fine control hole f’ of the valve
on the non-moving side from the drain cham-
ber D and is led to the PA chamber through the
P3 port for replenishment.
10-159-5 WA380-5
b
5. At FLOAT 6. When FLOAT is released

• When the rod (7) and the piston (11) on the P4 • To return the disc from the FLOAT position,
port LOWER side are pushed downward with press it down with a force more than the
the disc (8), the ball (13) touches the rod (7) pro- adsorbing force between the solenoid (6) and
trusion a halfway in the stroke (the start of retainer (5).
detent operation). • Or demagnetize the solenoid (6), and the FLOAT
• When the rod (7) is pushed down more, the ball position is released and the lever returns to the
pushes the retainer (15) being held with the neutral position.
detent spring (14) upward and escapes outside • To raise the lift arm or to tilt the bucket, take the
and then rides over the piston protrusion a. same procedures.
• At this time, the rod (7') on the opposite side is
pushed up with the spring (4) through the
retainer (11').
• Also, the rod (7') is pushed up further, and
when the solenoid (6) is energized, the retainer
(5) is adsorbed to the solenoid (6).
• Therefore, the rod (7') remains pushed up and
keeps FLOAT even if the lever is no longer sup-
ported by hand.
• At the same time, the control valve also strokes
to the FLOAT position and comes to remain
floated.
WA380-5 10-159-6
b
MAINTENANCE STANDARD EPC
EPC SOLENOID
SOLENOID VALVE (IF(If
VALVE equipped)
EQUIPPED)
EPC SOLENOID VALVE (If equipped)
P : From control pump C2: Bucket DUMP

T : To tank C3: Lift arm RAISE
C1: Bucket TILT C4: Lift arm LOWER
1. Bucket TILT EPC 7. Spool

2. Bucket DUMP EPC 8. Spring
3. Lift arm RAISE EPC 9. Push pin
4. Lift arm LOWER EPC 10. Coil
5. Block 11. Plunger
6. Body 12. Connector
WA380-5
10-160 WA380-5
(10)
EPC SOLENOID
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)
EPC SOLENOID
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)
MAINTENANCE STANDARD SHUT
SHUT OFF
OFF VALVE (IF(If
VALVE equipped)
EQUIPPED)
SHUT OFF VALVE (If 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)
MAINTENANCE STANDARD ATTACHMENT
ATTACHMENT PPC
PPC VALVE
VALVE (IF(If equipped)
EQUIPPED)
ATTACHMENT PPC VALVE (If equipped)
T : To the tank P1: To the service valve

P : From the main pump P2: To the service valve
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
10-164 WA380-5
(10)
ATTACHMENT PPC
PPC VALVE
equipped)
Unit: mm

Free length Installed Installed Free Installed If spring is
10 Center ring spring x length load length load damaged or
Outside diameter
deformed,
38.0 N 30.4 N replace it
41.1 X 15.5 28.4 —
{3.88 kg} {3.1 kg}
16.7 N 13.3 N
11 Metering spring 22.7 X 8.10 22.0 —
{1.70 kg} {1.36 kg}
WA380-5 10-165
(10)
ATTACHMENT PPC
PPC VALVE
equipped)
Operation
1. At the neutral position

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

(Neutral fine control)
• When the piston (4) is pushed by the lever
(5), the retainer (7) is pushed and the spool
(1) also is pushed trough the metering
spring (2) to move to the lower side.
• When the fine control hole f is shut off from
the drain chamber D by the above, it con-
nects to the pressure chamber PP of the
pump almost simultaneously and the pilot
pressure oil of the main pump is led from
the P1 port to the A port through the fine
control hole f.
• When the pressure at the P1 port goes up,
the spool (1) is pushed back and, when the
fine control hole f is shut off from the pres-
sure chamber PP of the pump, it connects
to the drain chamber D almost simulta-
neously to release the pressure at the P1
port.
10-166 WA380-5
(10)
ATTACHMENT PPC
PPC VALVE
equipped)
3. At the fine control position (When the 4. At full stroke

control lever is returned) • When the lever (5) pushes down the piston (4)
• When the lever (5) is started to be returned, and when the retainer pushes down the spool
by the power of the centering spring (3) and (1), the fine control hole f is shut off from the
by the pressure of the P1 port, the spool (1) drain chamber D and, then, it connects to the
is pushed up. By the above, the fine con- pressure chamber PP of the pump.
trol hole f connects to the drain chamber D • Therefore, the pilot pressure oil coming from
to release the pressurized oil from the P1 the main pump passes through the fine control
port. hole f to be led to the A chamber through the
• In case the pressure of the P1 port drops P1 port to push the control valve spool.
excessively, the spool (1) is pushed down • The return oil from the B chamber passes
by the metering spring (2) and the fine con- through the P2 port and the fine control hole f'
trol hole f is shut off from the drain cham- to flow into the drain chamber D.
ber D, connecting to the drain chamber D
almost simultaneously to supply the pump
pressure PP until the pressure of the P1
port returns to the pressure corresponding
to the lever position.
• When the control valve spool returns, the
oil in the drain chamber D flows through
the fine control hole f' of the valve which is
not moving to be led to the B chamber
through the P2 port to refill the oil.
WA380-5 10-167
(10)
MAINTENANCE STANDARD COOLING FAN MOTOR
COOLING FAN MOTOR

Model: LMF28
P : From fan pump

T : From cooler to tank
TC: To tank
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)
1. Output shaft 8. End cover

2. Case 9. Center spring
3. Thrust plate 10. Check valve spring
4. Shoe 11. Check valve
5. Piston 12. Pilot valve
6. Cylinder block 13. Changeover spool
7. Valve plate 14. Changeover spool spring
Unit: mm

Free length Installed Installed Free Installed If spring is
10 Check valve spring x length load length load damaged or
Outside diameter deformed,
3.43 N 2.55 N replace it
13.0 x 6.5 7.0 {0.35 kg} — {0.26 kg}
WA380-5 10-169
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
• The oil sent from the hydraulic port flows

through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the Y-Y line
connecting the top dead center and bottom
dead center of the stroke of piston (4).
• The oil sent to one side of cylinder block (5)
presses pistons (4) (2 or 3 pieces) and generates
force F1 (F1 kg = P kg/cm² x π/4 D2 cm²).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of Eo
degrees to the output shaft (1), the force is
divided into components F2 and F3.
• The radial component F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = Σ(F3 x ri)]
rotates the cylinder block (5) through the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output
shaft revolves to transmit the torque.
10-170 WA380-5
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
(1) When pump is started
• If the hydraulic oil from the pump is supplied to

port P and the pressure on the MA side rises
and starting torque is generated in the motor,
the motor starts revolution. The oil on the out-
let MB side of the motor returns through port T
to the tank.
WA380-5 10-171
(10)
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)
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
COOLING FAN MOTOR DRIVE PUMP

Model: LPV30
P : EPC valve main pressure TO : Drain

PS: Suction port of pump PHO: Discharge port of pump
1. Bleeder
WA380-5 10-173
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
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
• Cylinder block (7) is supported on shaft (1)

through spline a. Shaft (1) is supported on the
front and rear bearings.
• The end of piston (6) has a concave sphere,
which holds shoe (5) as a spherical bearing.
• Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slide circularly.
Rocker cam (4) slides around ball (11).
• Piston (6) moves axially and relatively in each
cylinder of cylinder block (7).
• Cylinder block (7) revolves relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic pressure on the revolving surface of
the cylinder block is balanced properly.
WA380-5 10-175
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)
2. Control of discharge
• If swash plate angle α is increased, the differ-

ence between volumes E and F, or discharge Q,
is increased. Swash plate angle Eo is changed
with servo piston (10).
• Servo piston (10) is reciprocated linearly by the
signal pressure of the servo valve. This linear
motion is transmitted to rocker cam (4). Rocker
cam (4) supported on ball (11) rocks around ball
(11).
WA380-5 10-177
(10)
SERVO VALVE
P : EPC valve main pressure

T : Drain
PE: Control piston pressure
PH: Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
10-178 WA380-5
Function • Then, the cut of spool (5) connects the land of

the piston pressure path to the pump discharge
• The servo valve controls the relationship pressure path and then the discharge oil is sent
between the current input to the EPC valve and to the servo piston.
the swash plate angle as shown below. • The servo piston is pushed up by the rocker
cam. Then, position feedback is applied and the
lever moves in the direction to compress the
spring.
• If spool (5) is pushed back, the pump discharge
circuit is disconnected from the servo piston
circuit and the pressure in the servo piston
chamber lowers and then the rocker cam
returns toward the maximum swash plate
angle.
• These processes are repeated to fix the swash
plate to the position at which the EPC output
pressure is balanced with the spring force.
• Accordingly, as the EPC output pressure is
• The output oil of the EPC valve flows in the pis- increased or decreased, the swash plate angle
ton chamber to push piston (6). Piston (6) is narrowed or widened.
pushes spool (5) until it is balanced with the
spring.
WA380-5 10-179
SAFETY VALVE
Function
• The discharge pressure of the fan pump rises

when the engine is started and when the fan is
reversed to stop.
• The safety valve is installed to protect the fan
system circuit at these times.
• If the discharge pressure rises above the crack-
ing pressure of the safety valve, the seat of the
safety valve opens to release the oil into the
drain path to prevent generation of abnormally
high pressure in the discharge port.
10-180 WA380-5
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
WA380-5 10-181
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
Tolerance
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
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
11 and pin of joint of bucket cylin- 110 1.0
-0.090 +0.120 0.297
der rod and lever
12 and pin of joint of bell crank 120 1.0
-0.090 +0.145 0.335
and lift arm
13 and pin of joint of lift cylinder 95 1.0
-0.090 +0.120 0.297
rod and lift arm
14 and pin of joint of lift cylinder 95 1.0
-0.090 +0.120 0.297
bottom and frame
Width of boss Width of hinge

Standard
Joint of bucket cylinder and Standard Standard clearance
15 Tolerance Tolerance
frame size size
-0
110 114 ±1.5 2.5-6.0 Replace (Insert
-0.5
shims on both
+3 sides so that
16 Joint of lift arm and frame 122 — 129 7.0-10.0
+0 clearance will be
1.5 mm or less
+1.5 on each side)
17 Joint of lift arm and bucket 106 — 108 2.0-3.5
0
+2.8 +1.5
18 Joint of bucket link and bucket 112.5 116 0.7-5.5
-0.5 0
-0 +3
19 Joint of lift cylinder and frame 90 93.5 3.5-7.0
-0.5 +0
Joint of bell crank and bucket +2.8
20 112.5 117 ±1.5 1.7-6.5
link -0.5
Replace
+2
21 Joint of bell crank and lift arm 220 223 ±0.5 0.5-3.5
+0
Joint of bucket cylinder and -0 Adjust clearance

22 110 117 ±1.5 5.5-9.0 on each side to
bell crank -0.5 1.5 mm or less
Adjust clearance
23 Joint of lift arm and lift cylinder 100 — 106 ±1.5 4.5-7.5 on each side to
2.0 mm or less
10-182 WA380-5
(10)
MAINTENANCE STANDARD BUCKET
BUCKET
1. Bucket
2. Bolt-on cutting edge
3. Bucket tooth
Unit: mm

4 Wear of bucket tooth Replace
50 18.5
Clearance of fitting part of Adjust or

5 Max. 0.5 —
bucket tooth replace
Turn over or
6 Wear or cutting edge 93 — replace
WA380-5 10-183
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
BUCKET POSITIONER, BOOM KICK-OUT
1. Proximity switch
2. Bucket cylinder rod
3. Lever
4. Plate
Unit: mm
Clearance of bucket positioner

5 3-5
switch
Adjust
Clearance of boom kick-out
6 3-5
switch
10-184 WA380-5
(10)
Bucket positioner Boom kick-out

• The bucket positioner is operated electrically • The boom kick-out is operated electrically and
and used to return the bucket control lever from used to return the lift arm control lever to the
the TILT position to the HOLD position to obtain hold position to stop the lift arm when the lift
proper digging angle automatically when the arm moves to any position before the maxi-
bucket is moved from the DUMP position to any mum position.
bucket angle before the TILT position. • Plate (4) is fixed to the lift arm and proximity
• Lever (3) is bolted to bucket cylinder rod (2) and switch (1) is fixed to the frame.
proximity switch (1) is bolted to the cylinder. If the lift arm control lever is moved from the
• If the bucket control lever is moved from the lower position to the raise position, the lift arm
DUMP position toward the TILT position, the is raised. When the proximity switch and plate
bucket cylinder rod moves to the front side of come near each other at any point, the switch
the vehicle body and lever (3) moves forward, operates to return the lift arm control lever to
too. When proximity switch (1) leaves lever (3) the hold position.
at any point, the switch operates to return the
bucket control lever to the neutral position.
WA380-5 10-185
(10)
Operation of proximity switch

When lift arm is raised
• 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)
• If lift arm (3) is raised to the set position of the

kick-out, or if plate (2) reaches the detection
plane of proximity switch (1), proximity switch
(1) lights up and boom kick-out relay (4) is
turned on. As a result, the circuit of detent sole-
noid (6) of PPC valve (5) is turned off and the
coil is turned off. Accordingly, held lift arm
spool (8) receives the reaction force of spring
(9) and returns lift arm control lever (7) to the
neutral position.
When part to be detected is apart from detection

plane of proximity switch
Pilot lamp of proximity switch OFF
Boom kick-out relay switch circuit OFF
PPC valve detent solenoid circuit ON
PPC valve detent solenoid ON
When part to be detected is on detection plane of

proximity switch
Pilot lamp of proximity switch ON
Boom kick-out relay switch circuit ON
PPC valve detent solenoid circuit OFF
PPC valve detent solenoid OFF
WA380-5 10-187
(10)
When bucket is tilted
• 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)
• If the bucket is tilted to the set position of the

bucket leveler, or if lever (2) leaves the detec-
tion plane of proximity switch (1), the lamp of
proximity switch (1) goes off and lift arm kick-
out relay (4) is turned off. As a result, the circuit
of detent solenoid (6) of PPC valve (5) is turned
off and the coil is turned off.
Held dump spool (8) receives the reaction force
of spring (9) and returns bucket control lever (7)
to the NEUTRAL position.
When part to be detected is apart from detection

plane of proximity switch
Pilot lamp of proximity switch ON
Bucket positioner relay switch cir-

ON
cuit
PPC valve detent solenoid circuit ON
PPC valve detent solenoid ON
When part to be detected is on detection plane of

proximity switch
Pilot lamp of proximity switch OFF
Bucket positioner relay switch circuit OFF
PPC valve detent solenoid circuit OFF
PPC valve detent solenoid OFF
WA380-5 10-189
(10)
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

LIFT CYLINDER
BUCKET CYLINDER
Unit: mm
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
Tightening torque Lift 250±24.5 Nm {25.5±2.5 kgm}

4 of cylinder head Bucket 343±34.3 Nm {35±3.5 kgm}
Tightening torque Lift 294±29.4 Nm {30±3.0 kgm}

5 Retighten
of cylinder piston Bucket 294±29.4 Nm {30±3.0 kgm}
Tightening torque Lift 58.9–73.6 Nm {6.0–7.5 kgm}
6 of fixed screw of
cylinder piston Bucket 58.9–73.6 Nm {6.0–7.5 kgm}
10-190 WA380-5
(10)
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)
MAINTENANCE STANDARD AIR
AIR CONDITIONER
CONDITIONER (IF(If equipped)
EQUIPPED)
AIR CONDITIONER (If equipped)

AIR CONDITIONER PIPING
1. Air outlet duct 7. Air compressor

2. Fresh air suction duct 8. Hot water return piping
3. Inside air suction filter 9. Refrigerant piping
4. Inside-Fresh air changeover damper 10. Hot water take-off piping
5. Receiver tank 11. Air conditioner unit
6. Air conditioner condenser 12. Floor duct
10-192 WA380-5
(10)
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
MACHINE MONITORING SYSTEM

Outline
• The machine monitor system uses the sensors • Normal mode indications are those which are
and other devices installed to various parts of usually being made for ordinary use by the
the machine to observe the condition of the machine operators. The description below
machine. It processes this information swiftly applies to the contents of the main indications.
and displays it on the monitor panel to inform
the operator of the condition of the machine. 1. Items which are always indicated
• The machine monitor is available in two differ- • Meters (Travel speedometer or engine
ent specifications, the standard specification tachometer)
and the load meter specification. As to the load • Gauges (Engine coolant temperature gauge,
meter specification, machine monitor functions torque converter oil temperature gauge,
are being supplemented to carry out the neces- hydraulic oil temperature gauge and fuel
sary load meter calculations and relevant indi- level gauge)
cations, with an optional printer for printing out • Pilot indications
of the calculated data of the load meter. • Service meter
• The indications of the machine monitor will be
made under the normal mode and under the 1) Load meter specification items which are
always indicated
service mode.
(Items which are indicated in addition to the
• The machine monitor has ON/OFF output func- standard spec. indications)
tion of automatic preheating which assists with • Weight calculated by the load meter
the starting of the engine. • Time
2. Items which will be indicated only when some
abnormality occurs
• Cautions
• Action code indications (When the machine
monitor mode changeover switch (>) is
depressed and released while the action
code is being indicated, the failure code (6
digits) will be indicated.)
3. When the time comes to change the filter or oil,

necessary items for the filter change or oil
change will be indicated on the character dis-
play. (Maintenance monitoring functions)
4. In addition to the above, this system is

equipped with the functions to indicate the
travel distance integrating meter (odometer), to
reset the filter • oil changing time, to select the
telephone number inputting language and to
adjust the illuminance of the night time illumi-
nation for the machine monitor, by use of the
character display and its operation switch, the
machine monitor mode changeover switch.
1) Other functions under the load meter speci-
fication
With the load meter specification system,
functions necessary to make changeovers
of the load meter indication mode, to make
changeovers of the printer output mode, to
execute calibration of the load meter, and to
adjust the clock time are being supple-
mented in addition to the standard specifi-
cation functions.
WA380-5 10-193
(10)
• 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.
1. Electric fault history

This function will indicate the electric fault his-
tory data of respective controllers being memo-
rized by the machine monitor. Also, it can be
used to delete the aforementioned data.
2. Machine fault history

This function will indicate the machine fault his-
tory and machine fault history data of respec-
tive controllers being memorized by the
machine monitor.
3. Real time monitor

This function will make real time indications of
the inputting data and outputting data being
recognized by respective controllers on the net-
work.
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.
5. Revising the filter • oil changing time

This function is to be used for revisions of the
preset filter and oil changing time. (Revision of
the time for the maintenance monitor opera-
tion)
6. Controller initializing function

This function is being used to effect the settings
of this machine monitor before shipment from
our factory.
10-194 WA380-5
(9)
Individual circuit diagrams of the machine monitor

Starting and lighting functions
Load meter
WA380-5 10-195
(9)
Sensing functions
10-196 WA380-5
(9)
Power supply and network
WA380-5 10-197
(9)
Automatic preheating function
10-198 WA380-5
(9)
S-net input S-net signal using items

Work equipment
Machine monitor Transmission controller
S-net output controller
Hydraulic oil temperature Fan pump control
Coolant temperature Fan pump control
Torque converter temperature Fan pump control
Emergency steering self-
Emergency steering operation signal checks
Sensor adjusting mode signal Compensation Compensation
Machine monitor
Monitor mode switch

signal Compensation Compensation
Emergency steering self-

Automatic pre-heating start signal checks
Transmission trigger resetting signal Learning control
Machine model Machine model Machine model
selection selection selection
Tire selection Tire selection Tire selection
Tire compensation Tire compensation Tire compensation
Communication Communication
Controller specification
selection selection
Option specification Option selection Option selection
FNR lever or seesaw switch signal FNR indications
FNR solenoid output signal Actual speed stage indica-

tions
1, 2, 3 and 4 lever position signals 1 2 3 4 lever positions
1, 2, 3 and 4 solenoid output signal Actual speed stage indica-

tions
FNR seesaw switch selection signal Indicator
Transmission hold signal Indicator
Transmission controller
Auto-shifting selection signal Indicator

Lock up selection signal Indicator
E.C.S.S. signal Indicator
Fan reversing signal Indicator
Power mode signal Indicator
Trigger learned signal Hearing control
Transmission failure code Character inductance
Engine revolution signal Engine tachometer
Travel speed signal Travel speedometer
Kick down switch signal Semi-auto digging
Kick down mode signal Semi-auto digging
Buzzer signal Operation buzzer
I/O state signals Real time monitor
Semi-auto digging signal Indicator
equipment
controller
Work
Joystick neutral signal Neutral cut

Buzzer signal Operation buzzer
I/O status signal Real time monitor
WA380-5 10-199
(10)
MAINTENANCE STANDARD MACHINE MONITOR
MACHINE MONITOR
SPEEDMETER SPECIFICATIONS
1. Torque converter oil temperature gauge 22. Maintenance caution lamp

2. Torque converter oil temperature caution lamp 23. Battery electrolyte level caution lamp
3. Engine coolant temperature gauge 24. Battery charge circuit caution lamp
4. Engine coolant temperature caution lamp 25. Steering oil pressure caution lamp
5. Speedometer or engine tachometer 26. Emergency steering pilot lamp
6. Turn signal pilot lamp (left) 27. Character display
7. Headlamp high beam pilot lamp 28. Output mode pilot lamp
8. Turn signal pilot lamp (right) 29. Semi auto digging pilot lamp
9. Hydraulic oil temperature caution lamp 30. Preheating pilot lamp
10. Hydraulic oil temperature gauge 31. Auto greasing pilot lamp
11. Fuel level caution lamp 32. Joystick pilot lamp
12. Fuel gauge 33. Directional selector pilot lamp
13. Central warning lamp 34. Shift indicator
14. Brake oil pressure caution lamp 35. Auto-shift pilot lamp
15. Engine oil pressure caution lamp 36. Lockup pilot lamp
16. Engine oil level caution lamp 37. Shift hold pilot lamp
17. Radiator coolant level caution lamp 38. Shift lever position pilot lamp
18. Air cleaner clogging caution lamp 39. Brake oil level caution lamp
19. Parking brake pilot lamp 40. Transmission oil filter clogging caution lamp
20. Axle oil temperature caution lamp
21. Cooling fan reverse rotation pilot lamp
10-200 WA380-5
(10)
LOAD METER SPECIFICATION (If equipped)
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)
TABLE OF MONITOR INDICATION ITEMS

Determination conditions if the engine is in operation: c: Turns on.
The engine is to be deemed in operation when 2 of the : Flashes. (1.6sec 50% Duty)
following 3 conditions are being established.
1. Charge is normal. ✩: Intermittent (Cycle 240msec. ON 80msec. OFF
2. Engine oil pressure is normal. 160msec.)
3. History of occurrence of IGN_C = 24V when the starting U: According to separately set conditions.
key was turned is being registered.
Operation status
Engine in
Engine stopped operation
Indication color
Concentrated warning
Night time
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 — — — — — — —
When the small lamp is

Back light — Back light LED c turning ON — — — — — — Orange
The status will be main-

Engine revolution Pointer: tained until the starting
(Speedmeter — — — — — — — — key is turned OFF when
specification) Movement a communication error
is occurring.
5
(Can be
Travel speed switched over "0" will be indicated in
(Speedmeter between the — — — — — — — case of communication
specification) engine revo- error.
lution.)
Pointer: Other cases than below — — — — — — —

11
12
Fuel quantity Movement c
Indicator: LED 80 Ω or more — c — — c — Red
Other cases than below — — — — — — —

White range:
Pointer:
10 Hydraulic oil tem- Movement
c Warning: 110°C or more c c B@HANS c c B@HANS Red 50 - 110°C
9 perature Red range:
Gauge Indicator: LED
When abnormality is 110 - 135°C
Meter detected — — — DGH2KX — — — DGH2KX —

Warning: 102°C or more — c — — c — Red White range:
3 Pointer:
Engine coolant 50 - 102°C
Movement c
4 temperature Indicator: LED Warning: 105°C or more c c B@BCNS c c B@BCNS Red Red range:
102 - 135°C
When abnormality is
detected — — — DGE2KX — — — DGE2KX —

Warning: 120°C or more — c — — c — Red White range:
1 Pointer:
Torque converter Movement 50 - 120°C
c
2 oil temperature Indicator: LED Warning: 130°C or more c c B@BCNS c c B@BCNS Red Red range:
120 - 135°C
When an abnormality is
detected — — — DGE2KX — — — DGE2KX —
Turns on when the engine

revolution is selected
— Engine speed LED c under the service mode — — — — — — Green X r/min
optional select
Unit
To be set to by use of the
rotary switch on the moni-
— Travel speed LED c tor while engine revolu- — — — — — — Green km/h or MPH
tion is not being selected
10-202 WA380-5
(10)
Operation status
Engine in
Engine stopped
operation
Indication color
Night time
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
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.
"F" is being selected

F LED c (Neutral safety indication ✩ c c — c — Green
when engine is stopped)
N LED c "N" is being selected — c — — c — Orange
"R" is being selected

R LED c (Neutral safety indication ✩ c c — c — Green
when engine is stopped) Indication will be main-
tained until the starting
Shift lever
38 When the 4th speed is key is turned OFF when
positions 4 LED c being selected — c — — c — Green a combination error has
occurred.
When the 3rd speed is
3 LED c being selected — c — — c — Green
When the 2nd speed is

Speed 2 LED c being selected — c — — c — Green
shifting
When the 1st speed is
opera- 1 LED c being selected — c — — c — Green
tions
When auto-shift is being
selected — c — — c — Green Indication will be main-
tained until the starting
35 Auto-shift LED c key is turned OFF when
a combination error has
Other cases than above — — — — — — — occurred.
When auto-shift and shift Green Indication will be main-

hold is being selected — c — — c — tained until the starting
37 Shift hold LED c key is turned OFF when
Other cases than above — — — — — — — aoccurred.
combination error has
When the lock up function

— — — — c — Green The LED will not turn on
is in operation in case of machines
without lock up mecha-
Torque converter nism. Indication will be
36 lockup LED c maintained until the
(Optional) starting key is turned
OFF when a combina-
Other cases than above — — — — — — — tion error has occurred.
Interlocked with the

When blinker switch is blinker switch
6 being turned ON
Green ((Hazard lamp) will also
8
Turn signal LED c (including the time when — c — — c — be turned ON when the
the starting key is turned starting key is turned
OFF) OFF.)
When high beam is being

turned ON
(When the headlamp is
7 High beam LED c turned ON and, also, when — c — — c — Blue
the high beam is turned
ON)
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.
detected c c AB00L6 — — — Red
Normal oil level (CLOSE) — — — — — — — Low oil level alarm is

sounded when the start-
ing key is turned ON,
16 Engine oil level LED c and the alarm continues
B@BAZK after the engine is
Oil level is low (OPEN) — c — — — — Red started.
Normal coolant level

(CLOSE) — — — — — — —
Engine coolant
17 level LED c
Coolant level is low
(OPEN) — c — B@BCZK — c — B@BCZK Red
WA380-5 10-203
(10)
Operation status
Engine in
Engine stopped
operation
Indication color
Night time
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
c: Occurs.
—: Does
not occur.
Normal pressure (OPEN) — — — — — — —
Less than specified pres-

sure (CLOSE) When the abnormality
& when the engine revolu- was detected while the
Engine oil pres-
15 sure LED c tion is 500rpm or more — — — c c B@BAZG Red engine is stopped, the
& when 15 sec. or more alarm will continue after
has passed after starting starting the engine also.
the engine
detected — — — DHE4L6 — — — —
Normal pressure (CLOSE) — — — — — — —

sure (F) (OPEN)
& when the engine is
started (when detecting
time continues) & when 50 — — — c c 2G42ZG Red
sec. has passed after start-
ing the engine (without
detecting time)

sure (R) (OPEN)
time continues) & when 50 — — — c c 2G43ZG Red
Brake oil sec. has passed after start-
pressure ing the engine (without The alarm will be
14 Accumulator oil LED c detecting time) changed over, not being
pressure cancelled by the
Less than specified pres- changeover at 50 sec.
sure (F) (OPEN) after starting the engine.
time continues) & during — c — c c Red
50 sec. after starting the
engine (without detecting
time)

sure (F) (OPEN)
Other
time continues) & during — c — c c Red
symbols 50 sec. after starting the
engine (without detecting
time)
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 — — — —
When the steering oil

pressure is normal (OPEN) — — — — — — —
When emergency steer-

ing signal is being input
Emergency steer- while the engine is
ing function is in stopped, the system
operation determines that self-
25 (when the steer- LED c When the steering oil checking of emergency
ing oil pressure is
normal)
pressure dropped (CLOSE)
& when the engine revolu- — — c c DDS5L6 Red steering is in progress
and when the steering
(Optional) tion is 500rpm or more oil pressure is found too
low during self-check-
ing of emergency steer-
ing, the indicator will be
turned ON.
When the pump operates

(for 1 min. or more) c c DY30N1 c c DY30N1 Green
Emergency steer- (OPEN)
ing is normal
(Emergency When the pump operates
26 steering pump is LED c (for less than 1 min.) — c — — c — Green
in operation) (OPEN)
(Optional)
When the pump stops
(CLOSE) — — — — — — —
Normal — — — — — — —
2V or less — c — — c — D61AZK Red
Battery electro-
23 lyte level LED c When this option is not
(Optional) installed — — — — — — —
detected — — — DJBAKX — — — DJBAKX —
10-204 WA380-5
(10)
Operation status
Engine in
Engine stopped
operation
Indication color
Night time
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
c: Occurs.
—: Does
not occur.
When the parking brake is Turns ON as the contact

in operation — c — — c — Red goes OPEN when the
(OPEN) parking brake is oper-
ated.
19 Parking brake LED c This indicator will be
When the parking brake is commonly used with the
released — — — — — — — parking brake dragging
(CLOSE) prevention LED.
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
When pre-heating and

Other cases than below — — — — — — — after heating are not
made due to occurrence
of some abnormality,
When pre-heating is being the (including output
Preheating — c — — c — Red section failure) alarm
30 (Auto pre-heat- LED c made
will not turn on.
ing)
The indication will not
When a communication be made when a com-
error has occurred — — — — — — — munication error has
occurred.
When this option is not

installed — — — — — — —
When the wheel steering

is in operation — — — — — — —
When the Joystick is being

Joystick operated — c — — c — Green
32 changeover LED c
(Optional) "Priority to the FNR lever"
caution ✩ c ✩ c Green

Other occurred.
symbols When this option is not
installed — — — — — — —
When this function is not

in operation — — — — — — —
Semi auto dig-
29 ging LED c When the automatic dig-
— c — — c — Green
(Optional) ging is operation

occurred.
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.
When this option is not

installed — — — — — — —
When column shift is

being used — — — — — — —
When the R.H. FNR switch

is being used
When seasaw switch — c — — c — Green
Right directional mode
33 selector switch LED c
(Optional) As for the "priority to the
FNR lever" caution,
"Priority to the FNR lever"
caution ✩ c ✩ c Green when the optional Joy-
stick is being employed,
the Joystick indicator
will flash.

occurred.
WA380-5 10-205
(10)
Operation status
Engine in
Engine stopped
operation
Indication color
Night time
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
c: Occurs.
—: Does
not occur.
Power mode = P — c — — c — Green Will indicate the state

28 Power mode LED c where the power mode
Other cases than above — — — — — — — is being selected.
Cooling fan forward rota-
tion — — — — — — —
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)
Axle oil tempera-

20 ture LED c When the temperature
rises (Rear) c c B@C7NS c c B@C7NS Red
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)
SETTING OF THE MACHINE MONITOR
1. Machine model selecting rotary switch [SW1]

2. Spare rotary switch [SW2]
3. Speedometer/Tachometer indication changeover and tire size selecting rotary switch [SW3]
4. Engine controller installation setting dip switch [SW5-1]
5. Work equipment/joystick controller installation setting dip switch [SW5-2]
6. Spare dip switch [SW5-3]
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)
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.
Machine model SW1 Remarks

WA380-5 0
3. When making the setting of the rotary switch

[SW2]
Make the setting as follows and do not change
it.
Setting position of the SW2: "0"
10-208 WA380-5
(10)
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
Small diameter tire Usable in non-SI-unit

MPH indication 1 employing countries only
rpm indication 2 Small diameter tire
km/h indication 3 Large diameter tire
Large diameter tire Usable in non-SI-unit

MPH indication 4 employing countries only
rpm indication 5 Large diameter tire
Tire size WA380-5

20.5-25 small Standard
23.5-25 large If equipped
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"
7. When making the setting of the dip switch [SW5-3]

Setting position of the SW5-3: "OFF"
WA380-5 10-209
(10)
8. Serial No.: 60001 - 60219

When making the setting of the dip switch [SW5-4]
Serial No.: 60220 and up

When making the setting of a machine equipped with the joystick lever (When making the setting of the
dip switch [SW5-4]
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)
Service mode functions

1. Outline
1) Electric fault history
Use this function to check the electric fault history of respective controllers being memorized by the
machine monitor. Regarding the failure code being used in the electric fault history, refer to the
Chapter "Troubleshooting". When the fault is repaired and after checking and confirming that nor-
mal operation has been restored, delete the fault history.
The electric 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.
$$$: Indicates the number of times of occurrence of the subject failure code
%%%%%: Indicates the elapsed time from the initial occurrence of the same electric fault (the value
deducting the service meter value when the electric fault initially occurred from the current service
meter value).
@@@@@: Indicates the elapsed time from last occurrence of the same electric fault (the value
deducting the service meter value when the electric fault last occurred from the current service
meter value).
When the indication is showing the currently occurring electric fault, the failure code flashes. Up to
max. 20 failure codes can be memorized.
2) Machine fault history
Use this function to check the machine fault history of respective controllers being memorized by
the machine monitor. Regarding the failure code being used in the machine fault history, refer to
the Chapter "Troubleshooting".
The machine fault history indications on the character display are as follows.
***: Indicates which sequence number of fault history counting from the top.
######: Indicates the failure code.
$$$: 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)
3) Real time monitor

Use this function to check the inputting and outputting signals being recognized by respective con-
trollers on the network.
The real time monitor indications on the character display are as follows.
***: Indicates the item name.

#####: Indicates the ID number allocated to each item.
%%%* Indicates the data. When a unit is being used, the unit will be shown on the right-hand side
of the data.
By designating the ID number allocated to each item, it is also possible to have optional 2 items
indicated at the same time.
The indications on the character display when optional 2 items are indicated at the same time are as fol-
lows.
***: Indicates the designated ID numbers

%%%* Indicates the data. When a unit is being used, the unit will be shown on the right-hand side
of the data.
4) Tuning
Use this function to make initial adjustments of the sensors, etc. which are being installed to the
machine.
Use this function when sensors, EPC valves or controllers have been replaced or supplemented.
5) Changing the filter and oil changing time
This function is being explained in the section "Filter and oil changing time indication on the charac-
ter display" in the Chapter "Handling" in the Operation and Maintenance Manual. Use this function
when revising the changing time.
6) Settings of the optional equipment and functions
Use this function to indicate the installation status of the optional equipment and to change the set-
tings.
Use this function when optional equipment is installed or removed.
10-212 WA380-5
(8)
7) Settings of the serial number of the machine

Use this function to indicate the serial number of the machine and to make new settings.
Use this function for the purposes of machine controls, etc.
8) Controller initialization
Since this function is for factory use only, do not touch it.
WA380-5 10-213
(9)
2. Operation methods
10-214 WA380-5
Items Related to the Fault History of Electric System

1) Selection of displaying and clearing the fault history of electric system
The fault history is displayed in the order of occurrence with the new fault first.
A current fault is displayed prior to the restored ones.
Pressing the > 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.
2) Selection of displaying the fault history of electric system (first layer)

Pressing the > switch changes the screen to the [Select the initializing function] screen.
Pressing the < switch changes the screen to the [Select displaying the fault history of vehicle sys-
tem] screen.
Pressing the switch changes the screen to the ordinary or alert screen.
Pressing the switch changes the screen to the [Display abnormalities in electric system] screen.
WA380-5 10-215
(10)
3) Selection of displaying the fault history of electric system and clearing the entire fault history of
electric system (second layer)
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)
Items Related to the Fault History of Machine System

1) Display of the fault history of vehicle system
Pressing the switch changes the screen to the [Select displaying abnormalities in machine sys-
tem] screen on the first layer.
2) Selection of displaying the fault history of machine system (first layer)

Pressing the > switch changes the screen to the [Select the real-time monitor functions] screen.
Pressing the < switch changes the screen to the [Select displaying the fault history of machine sys-
tem] screen.
Pressing the switch changes the screen to the [Display abnormalities in electric system] screen.
WA380-5 10-217
(10)
3) Display of the fault history of vehicle system (second layer)

The fault history is displayed in the order of occurrence with the newest fault first.
The fault history is displayed in the order of occurrence with the newest fault first.
Pressing the > switch displays the next newer fault.
Pressing the < switch displays the next older fault.
Pressing the switch changes the screen to the [Select displaying abnormalities in vehicle system]
screen.
10-218 WA380-5
(10)
Items Related to Maintenance Monitor

1) Selection/display of the maintenance monitor items
Each time the > switch is pressed, an item is shown from No.1 in the ascending order.
Each time the < switch is pressed, an item is shown from No.13 in the descending order.
Pressing the switch changes the screen to the [Select the maintenance monitor functions] screen.
Pressing the switch changes the screen to the [Maintenance interval timer reset] screen.
2) Selection/display of the maintenance monitor (first layer)

Pressing the > switch changes the screen to the [Select the optional functions] screen.
Pressing the < switch changes the screen to the [Select the cylinder cut-out function] screen.
Pressing the switch changes the screen to the [Select the maintenance monitor items] screen.
WA380-5 10-219
(10)
3) Selection of the maintenance items (second layer)

The display is the same as that on the maintenance monitor which is included in the functions open
to operators, except that the maintenance caution lamp is turned off.
Pressing the switch changes the screen to the [Select the maintenance monitor functions] screen.
Pressing the switch changes the screen to the [Change the maintenance monitor interval time]
screen.
10-220 WA380-5
(10)
4) Changing the maintenance interval time (third layer)

The change of the maintenance interval time can be set to any value within a range 0-9999h.
Pressing the switch causes the change of the time skipped, and changes the screen to the [Select
the maintenance items] screen. In this case, a peep sounds for one second to notify that the opera-
tion is cancelled.
How to Enter Interval Time

1
b Enter a number from 0-9 in the cursor position.
2
c 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.
3
d If the desired number was entered, press the switch to apply it.
4
e The cursor moves to the second highest digit. Repeat the procedures mentioned in 2 and 3
until the last number is filled in the lowest digit.
5
f After the lowest digit was entered, press the switch.
6
g -1 If the entered value represents the time which can be set, the screen changes to the confir-
mation screen.
6 -2 Otherwise, the screen does not change to the confirmation screen but to the [Select the
maintenance items] screen. In this case, a peep sounds for one second to notify that the
7
h If a wrong number was entered, return to the [Maintenance items] screen with the switch, and do
the procedure from the beginning again.
WA380-5 10-221
(10)
5) Confirming the changed maintenance interval time (fourth layer)

Select YES or NO with the < or > SW.
Cursor (_) blinks on the selected item. Pressing the SW returns the display to the [Select the
maintenance items] screen, with the change applied if YES was selected, or not if NO was selected:
The default of the cursor is on NO (no change) 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
If the change of the time-setting was completed, peeps sound (on for 0.1 sec. off for 0.1 sec. on
for 0.1 sec.) to notify that the operation has been accepted.
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
Engine oil 500 ENG OIL 01

Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Corrosion resister 1,000 CORR RES 06
Transmission oil 1,000 TM OIL 12
Transmission oil filter 1,000 TM FILT 13
Hydraulic fluid filter 2,000 HYD FILT 04
Hydraulic oil tank breather element 2,000 HYD BREATH 05
Axle oil 2,000 AXLE OIL 15
Hydraulic fluid 2,000 HYD OIL 10
10-222 WA380-5
4
Real-time Monitoring Function

The real-time monitor shows real-time the information which the controller mounted on the vehicle has.
This function is used for checking and adjustment, diagnosis of faults of the vehicle and other purposes.
The real-time monitor shows the items and their data, classified by the controllers which have information.
It shows them in two ways: the ordinary display, and the 2-item display where two data items are shown
simultaneously.
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)
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.
***: Shows items.

%%%%%: Shows data and unit (SI system)
$$$$: Shows ID.
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)
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)
Real-time Monitoring Items

Displayed Component Terminal
Item ID Real-time monitoring item Item displayed Display unit Remarks
range detected No.
A value out
SI unit sys- of the range
All the items are shown even
if some of them are not Abridged due to tem so long displayed is
limitation of num- as the val- shown as the
equipped depending on mod- ber of letters. ues have lowest (high-
els and options.
units est) value in
the range.
Monitor panel controller
Shows the part
20200 Part No. of monitor’s ROM MONITOR ROM — — Monitor — No. of monitor-
panel’s ROM
01001 Engine speed ENG SPEED 1rpm 0-3000 Transmission L62-10
40000 Travel speed SPEED km/h 0-50 Transmission L62-20
04202 Fuel level FUEL SENSOR 1% 0-100 Monitor L55-1
Any temperature
04401 Hydraulic oil temperature HYD TEMP 1°C 24-131 Monitor L55-7 lower than 24°C is
displayed as 24°C
Any temperature
04103 Coolant temperature COOLANT TEMP 1°C 24-131 Monitor L55-8 lower than 24°C is
displayed as 24°C
Any temperature
lower than -31°C
04104 Coolant temperature (low) COOLANT Lo 1°C -31-91 Monitor L55-3
is displayed as
-31°C
Any temperature
40100 Torque converter oil temperature TC OIL TEMP 1°C 24-131 Monitor L55-2 lower than 24°C is
displayed as 24°C
04302 Charging level of alternator ALTERNATOR R 0.1V 0.0-30.0 Monitor L52-18
40200 Voltage of small lamps SMALL LAMP 0.1V 0.0-30.0 Monitor L53-12
40300 Battery electrolyte level A BATTERY A2V 0.1V 0.0-30.0 Monitor L55-5
40301 Battery electrolyte level B BATTERY B2V 0.1V 0.0-30.0 Monitor L55-12
06001 Lift arm angle BOOM ANG 1° -41-46 Monitor L55-10
40400 Lift arm bottom pressure BTM PRESS 0.01MPa 0.00-50.00 Monitor L55-9
40500 Lift arm rod pressure ROD PRESS 0.01MPa 0.00-50.00 Monitor L55-4
Calculated
40600 Calibration pressure CAL PRESS 0.01MPa 0.00-50.00 Monitor
value
Calculated
40700 Calculated pressure MES PRESS 0.01MPa 0.00-50.00 Monitor value
Calculated
40800 Calculated load weight MES LOAD 0.01t 0.00-50.00 Monitor
value
Switch on
30802 Rotary switch position SW1,SW2,SW3 — 0-F Monitor
the rear
Switch on
30904 Dip switch position SW5-1,SW5-2 — OFF.ON Monitor
the rear
Switch on
30905 Dip switch position SW5-3,SW5-4 OFF.ON Monitor
the rear
Switch on
the rear
Switch on
the rear
See separate
40900 Input signal D_IN_0-7 D-IN--0-----7 — 10101010 Monitor
sheet
See separate
40901 Input signal D_IN_8-15 D-IN--8-----15 — 10101010 Monitor
sheet
See separate
40902 Input signal D_IN_16-23 D-IN-16-----23 — 10101010 Monitor
sheet
See separate
sheet
See separate
sheet
Part No. of Transmission control- Shows part No. of
20201 TRANSM ROM — — Transmission —
ler’s ROM ROM
Calculated
41000 Target speed of fan pump FAN PUMP 1rpm 0-3000 Transmission
value
WA380-5 10-227
(10)

Item ID Real-time monitoring item Item displayed Display unit range detected No. Remarks
A value out
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.
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
31608 F ECMV current ECMV F 1mA 0-1000 Transmission L63-5
31606 R ECMV current ECMV R 1mA 0-1000 Transmission L63-15
31602 1st-clutch ECMV current ECMV 1 1mA 0-1000 Transmission L63-25
31603 2nd-clutch ECMV current ECMV 2 1mA 0-1000 Transmission L63-6
31604 3rd-clutch ECMV current ECMV 3 1mA 0-1000 Transmission L63-16
31605 4th-clutch ECMV current ECMV 4 1mA 0-1000 Transmission L63-26
31609 L/C ECMV current ECMV LU 1mA 0-1000 Transmission L63-35
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
41600 Selection of engine mode ENGINE MODE — P/N Transmission L61-6
Calculated
41700 Selection of shift mode SHIFT MODE — H/M/L Transmission
value
41808 F fill time FILL TIME F 10msec 0-2550 Transmission Calculated

value
Calculated
41806 R fill time FILL TIME R 10msec 0-2550 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
31508 F fill time FILL SW(F) — 0/1 (Normal/ Transmission Calculated

abnormal) value
0/1 (Normal/ Calculated
31506 R fill time FILL SW(R) — Transmission
abnormal) value
31502 1st-clutch fill time FILL SW(1) — abnormal) Transmission value
31503 2nd-clutch fill time FILL SW(2) — Transmission
abnormal) value
31504 3rd-clutch fill time FILL SW(3) — Transmission
abnormal) value
31505 4th-clutch fill time FILL SW(4) — Transmission
abnormal) value
40905 Input signal D_IN_0-7 D-IN--0------7 — 10101010 Transmission See separate

sheet
See separate
40906 Input signal D_IN_8-15 D-IN--8-----15 — 10101010 Transmission sheet
Transmission Seesheet
separate
40907 Input signal D_IN_16-23 D-IN-16-----23 — 10101010
40908 Input signal D_IN_24-31 D-IN-24-----31 — 10101010 Transmission See separate

sheet
30202 Rear brake oil temperature R BRAKE OIL 1°C 24-131 Transmission L61-20
40915 Output signal D_OUT_0-6 D-OUT-0------6 — 101010 Transmission See separate

sheet
40914 Output signal D_OUT_0-5 D-OUT-0------5 — 101010 Transmission See separate

sheet
10-228 WA380-5
(10)

Item ID Real-time monitoring item Item displayed Display unit range detected No. Remarks
A value out
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
Lever potentiometer-voltage Work

42003 BUCKET POT2 0.01V 0.00-5.00 L71-1
bucket 2 equipment
Lever potentiometer-voltage Joy- Work
42004 J/S POT1 0.01V 0.00-5.00 L71-9
stick 1 equipment
Lever potentiometer-voltage Joy- Work
42005 J/S POT2 0.01V 0.00-5.00 L71-3
stick 2 equipment
Lever potentiometer-voltage 3rd Work
42006 3RD POT1 0.01V 0.00-5.00 L71-20
valve 1 equipment
Lever potentiometer-voltage 3rd Work
42007 3RD POT2 0.01V 0.00-5.00 L71-14
valve 2 equipment
Work
06002 Lift arm angle BOOM ANG 1° -41-46 L71-8
equipment
Work
40401 Lift arm bottom pressure BTM PRESS 0.01MPa 0.00-50.00 — No function
equipment
0-256000
Number of times of lift arm lever Work Calculated
42100 BOOM LVR 1000 (incremental
operation equipment value
step=1000)
0-256000
Number of times of bucket lever Work Calculated
42101 BUCKET LVR 1000 (incremental
operation equipment value
step=1000)
0-256000
Number of times of 3rd lever oper- Work Calculated
42102 ation 3RD LVR 1000 (incremental equipment value
step=1000)
Work
01003 Engine speed ENG SPEED 1rpm 0-3000 L72-10
equipment
Work
40001 Travel speed SPEED 1km/h 0-50 equipment L72-20
Work See separate

40910 Input signal D_IN_0-7 D-IN--0------7 — 10101010
equipment sheet
Work See separate
40911 Input signal D_IN_8-15 D-IN--8-----15 — 10101010 equipment sheet
Work See separate
equipment sheet
Work See separate
equipment sheet
Work See separate
40917 Output signal D_IN_0-6 D-OUT-0------6 — 1010101
equipment sheet
40916 Output signal SOL/0-0-5 SOL/0-0------5 — 101010 Work See separate

equipment sheet
WA380-5 10-229
(10)
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:
***: Shows items. ***: Shows items.

%%%%%: Shows data and unit (SI system) %%%%%: Shows data and unit (SI system)
$$$$: Shows ID No. $$$$: Shows ID No.
If input status [0] or [1] is shown, Input OFF or ON is If output status [0] or [1] is shown, Output OFF or
displayed, respectively. ON is displayed, respectively.
10-230 WA380-5
4
Connector Pin No.

I/O signal Displayed item ON/OFF logic
No.
Machine Monitor
D-IN-0 Head lamp L52 1 Head lamp turned ON=(24V)/OFF (OPEN)
D-IN-1 No item L52 10 ON (24V)/OFF (OPEN)
D-IN-2 IGN_C L52 2 Starter activated=(24V)/OFF (OPEN)
D-IN-4 Auto-grease A (If equipped) L52 3 Tank empty or abnormal=(24V)/OFF (OPEN)
D-IN-5 Auto-grease B (If equipped) L52 12 Operating or abnormal=(24V)/OFF (OPEN)
D-IN-12 Blinker R L52 7 Right blinker=ON (24V)/OFF (OPEN)
D-IN-13 Blinker L L52 16 Left blinker=ON (24V)/OFF (OPEN)
D-IN-14 Input from the switch L52 8 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-15 Input from the switch L52 17 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) L53 1 Pressure normal=ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) L53 7 Pressure normal=ON (GND)/OFF (OPEN)
D-IN-18 No item L53 2 ON (GND)/OFF (OPEN)
D-IN-20 Clogged air cleaner L53 3 No clogging=ON (GND)/OFF (OPEN)
Parking brake in operation=ON (GND)/OFF
D-IN-26 Parking brake L54 1 (OPEN)
D-IN-27 Coolant level L54 10 Coolant level normal=ON (GND)/OFF (OPEN)
D-IN-28 Engine oil pressure L54 2 Dropped pressure=ON (GND)/OFF (OPEN)
D-IN-29 Engine oil level L54 11 Oil level normal=ON (GND)/OFF (OPEN)
(Emergency steering) motor (Emergency steering) motor activated=ON
D-IN-30 L54 3
normal (If equipped) (GND)/OFF (OPEN)
D-IN-31 No item — — —
Load meter subtotal switch (If
D-IN-32 L54 4 Switch pressed=ON (GND)/OFF (OPEN)
equipped)
Load meter cancel switch (If
equipped)
D-IN-34 High-beam switch L54 5 High-beam=ON (GND)/OFF (OPEN)
D-IN-36 Service function 2 L54 6 ON (GND)/OFF (OPEN)
D-IN-37 Input from the > switch L54 15 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-38 Input from the < switch L54 7 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-39 Dropped steering pressure L54 6 Oil pressure normal=ON (GND)/OFF (OPEN)
WA380-5 10-231
(10)
Connector Pin No.

No.
Transmission Controller
D-IN-0 Steering pressure switch (N.O.) L61 23 Pressure normal=ON (GND)/OFF (OPEN)
Abnormal pressure (drop down)=ON (GND)/
D-IN-1 Steering pressure switch (N.C.) L61 17 OFF (OPEN)
D-IN-2 Transmission cut-off switch L61 11 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-3 Transmission cut-off set switch L61 5 Switched pressed=ON (GND)/OFF (OPEN)
E.C.S.S. change-over switch (If
D-IN-4 L61 24 Switched pressed=ON (GND)/OFF (OPEN)
equipped)
Lock-up change-over switch (If
D-IN-5 L61 18 Switched pressed=ON (GND)/OFF (OPEN)
equipped)
D-IN-6 Kick-down switch L61 12 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-7 Engine power mode E L61 6 P mode=ON (GND)/OFF (OPEN)
D-IN-8 Shift range 1st L63 10 1st gear=ON (24V)/OFF (OPEN)
D-IN-9 Shift range 2nd L63 20 2nd gear=ON (24V)/OFF (OPEN)
D-IN-10 Shift range 3rd L63 30 3rd gear=ON (24V)/OFF (OPEN)
D-IN-11 Shift range 4th L63 40 4th gear=ON (24V)/OFF (OPEN)
D-IN-12 Joystick shift up (If equipped) L63 9 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-13 Joystick shift down (If equipped) L63 19 Switch pressed=ON (24V)/OFF (OPEN)
Electric (emergency steering) man-
ual switch (If equipped)
D-IN-15 IGN_C (AFTER N SAFETY) L63 39 Starter activated=ON (24V)/OFF (OPEN)
Right FNR (Joystick) change-over
D-IN-16 L62 35 Switch pressed=ON (24V)/OFF (OPEN)
switch (If equipped)
Right seesaw & Joystick F (If
D-IN-17 L62 25 Forward=ON (24V)/OFF (OPEN)
equipped)
Right seesaw & Joystick N (If
D-IN-18 L62 15 Neutral=ON (24V)/OFF (OPEN)
equipped)
Right seesaw & Joystick R (If
D-IN-19 L62 5 Reverse=ON (24V)/OFF (OPEN)
equipped)
D-IN-20 Direction lever F L62 36 Forward=ON (24V)/OFF (OPEN)
D-IN-21 Direction lever N L62 26 Neutral=ON (24V)/OFF (OPEN)
D-IN-22 Direction lever R L62 16 Reverse=ON (24V)/OFF (OPEN)
D-IN-23 Neutralizer (Parking brake) signal L62 6 Parking switch ON=(24V)/OFF (OPEN)
D-IN-24 E-POC FILL F L62 37 Fill switch ON=(GND)/OFF (OPEN)
D-IN-25 E-POC FILL R L62 27 Fill switch ON=(GND)/OFF (OPEN)
D-IN-26 E-POC FILL 1st L62 17 Fill switch ON=(GND)/OFF (OPEN)
D-IN-27 E-POC FILL 2nd L62 7 Fill switch ON=(GND)/OFF (OPEN)
D-IN-28 E-POC FILL 3rd L62 13 Fill switch ON=(GND)/OFF (OPEN)
D-IN-29 E-POC FILL 4th L62 3 Fill switch ON=(GND)/OFF (OPEN)
D-IN-30 E-POC FILL lock-up L62 2 Fill switch ON=(GND)/OFF (OPEN)
D-IN-31 Shift hold switch L62 38 Switch pressed=ON (GND)/OFF (OPEN)
SOL/0-0 Electric (emergency steering) relay L63 7 Output ON (24V)/OFF (OPEN)
(If equipped)
SOL/0-1 E.C.S.S. relay L63 17 Output ON (24V)/OFF (OPEN)
SOL/0-2 Switch pump cut-off L63 27 Output ON (24V)/OFF (OPEN)
SOL/0-3 Neutral output L63 37 Output ON (24V)/OFF (OPEN)
SOL/0-4 Fan pump reverse solenoid L63 28 Output ON (24V)/OFF (OPEN)
SOL/0-5 Fan pump neutral solenoid L63 38 Output ON (24V)/OFF (OPEN)
D-OUT-0 Back lamp relay L63 4 Output ON (24V)/OFF (OPEN)
D-OUT-1 Transmission cut-off indicator L63 8 Output ON (24V)/OFF (OPEN)
10-232 WA380-5
(10)
Connector Pin No.

No.
Work equipment controller (If equipped)
Joystick ON/OFF change-over Joystick (right FNR) selection=ON (24V)/OFF
D-IN-0 L71 23
switch (OPEN)
Operating position=ON(24V)/
D-IN-1 Work equipment lock lever switch L71 17 Obstruction position=OFF(OPEN)
Joystick speed Hi/Lo change-over Joystick Hi speed selection=ON (GND)/OFF
D-IN-8 L73 10
switch (OPEN)
D-IN-9 Bucket proximity switch (horizontal) L73 20 Horizontal position=ON (GND)/OFF (OPEN)
D-IN-10 Bucket full-stroke switch L73 30 Stroke end position=ON (GND)/OFF (OPEN)
D-IN-12 Semi-auto digging hard switch L73 9 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-13 Semi-auto digging soft switch L73 19 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-28 Remote positioner raise set switch L72 13 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-29 Remote positioner lower set switch L72 3 Switch pressed=ON (GND)/OFF (OPEN)
Remote positioner raise selection
switch
WA380-5 10-233
(10)
Connector Pin No.

No.
Remote positioner lower selection
switch
SOL/0-0 Joystick EPC cut relay L73 7 Output ON (24V)/OFF (GND)
SOL/0-1 Detent lift arm RAISE L73 17 Output ON (24V)/OFF (GND)
SOL/0-2 Detent lift arm FLOATING L73 27 Output ON (24V)/OFF (GND)
SOL/0-3 Detent TILT L73 37 Output ON (24V)/OFF (GND)
SOL/0-4 Work equipment lock solenoid L73 28 Output ON (24V)/OFF (GND)
SOL/0-5 No item L73 38 Output ON (24V)/OFF (GND)
D-OUT-1 Remote positioner raise lamp L73 8 Output ON (24V)/OFF (GND)
D-OUT-2 Remote positioner lower lamp L73 18 Output ON (24V)/OFF (GND)
10-234 WA380-5
(10)
(For Reference) Check Using the Real-Time Monitor
Example: Measurement of engine speed
Measure the engine speed under the following conditions:

Temperature of coolant: within operation range
Temperature of hydraulic oil: 45-55 °C
Temperature of power train oil: 70-90 °C
Use the real-time monitor first to check these conditions.

Conditions Real-time monitor item Component ID
Temperature of coolant COOLANT TEMP Machine monitor 04103
Temperature of hydraulic oil HYD TEMP Machine monitor 04401
Temperature of power train oil TC OIL TEMP Machine monitor 40100
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
(For Reference) Troubleshooting Using the Real-Time Monitor
Example: Cannot succeed in re-setting the Transmission cut-off position.
Possible causes of disabled cut-off of Transmission include the following:

Abnormal cut-off selection switch
Abnormal cut-off position set switch
Abnormal left brake pressure sensor
Abnormal Transmission controller
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.
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)
2. Check the cut-off set switch

D-IN-3 D-IN--0------7 L61-11 40905
40905:***0***
The fourth digit is [0] if the Transmission cut-off set switch has recognized itself as not ON.
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.
3. Check the left-hand brake pressure sensor

Check the left-hand brake pressure sensor with the engine kept operating.
Left brake pressure L.H. BRAKE L61-19 41100
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.
4. Check the cut-off pressure set value

Check the set value of the pressure at which Transmission is cut off.
1) Set the cut-off position at a desired pressure by stepping on the cut-off brake, with the left-hand
brake pressure sensor kept displaying.
Here, it is set at a pressure 1.5Mpa{15kg/cm²}.
Left brake pressure L.H. BRAKE L61-19 41100
41100: 1.50MPa
Set the cut-off position ([1.50] was selected arbitrarily).
Setting cut-off causes the pressure taken into memory when the set switch being pressed was
released.
2) Check the cut-off pressure just set on the real-time monitor.
Transmission cut-off pressure CUT OFF Calculated value 41200
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)
Load Meter Function (If equipped)
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)
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.
From the really measured value (D) in lift arm

lifting operation, value (B) is calculated accord-
ing to the calculation method below.
Weight is calculated from the differential pres- • The pressure fluctuates greatly and no fixed
sure (C) between the standard value (A) of lift value can be measured for 0.5 seconds after
arm pressure in unloaded state memorized the lift arm lifting start (E) due to the shift
(and corrected by calibration) and the calcu- from the static state to an dynamic state.
lated value (B) of lift arm pressure in the loaded So, the pressure cannot be used for calcula-
state. Also, it is designed for improving accu- tion.
racy that weights are detected and calculated
• Since the machine spring effect has peri-
while the boom is being lifted.
odic cycle of approximately one second, the
calculated value (B) is calculated as a mean
value of every second from the lift arm lift-
ing start to the stop.
10-236-2
10-237 WA380-5
(10)
Judgment of Lift Arm Lifting Start

When all the following conditions are satisfied, the lift arm is judged to have started moving, and weight
calculation starts.
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.)
Judgment of Stop of Lift Arm Lifting

When any of the following conditions is satisfied, the lift arm is judged to have stopped, and a weight calcu-
lation ends.
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.)
Condition 5 The calculation was carried out for 7 times.
Display of Calculated Weight

Calculated weight is displayed as the average value of each calculated values.
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)
4. Subtraction and Addition Modes

Addition Mode Subtraction Mode
At this mode, bucket load is added at each load- This mode is for reducing each bucket load
ing, and added value of loads is displayed, this from previously set target weight value, and is
mode is used to grasp total workloads. used for fixed total loading value works, etc.
• 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
Load Meter Cancel Switch

Total Load Display and Residual Quantity Display
Actual total load Total load Remarks

weight (t) display
To be displayed with
- -99.5 -99.9 decimal point
decimal point (round-
-99.4 - -0.1 -**.* ing off the second
fractions)
decimal point (round-
0 - 999.4 ***.* ing off the second
fractions)
To be displayed in • When this switch (1) is pressed during the
integers only (count- calculated weight display holding time (15
999.5 - 9999.4 **** ing factions of 0.5 and seconds after calculation), the bucket load
over as a unit and cut-
ting away the rest) is judged not to be loaded and the calcula-
tion is cancelled. The display of total load
To be displayed in
9999.5 - 9999 integers only. (or residual quantity) is also cancelled to be
increased (or decreased), and returns to the
previous value.
Unit of Calculated Weight
• All calculated weights are displayed in the SI
Load Meter Sub-total Switch
unit (metric ton). When "MPH" is selected to
display travel speed with the rotary switch
on the back of the monitor, however, it is
possible to change the unit to short ton by
setting the optional device in the service
mode. In this case, weights are printed out
in short ton as well.
k In countries where the SI unit is adopted,

the units of travel speed and load weight
should not be selected in any unit other
than the SI unit.
• To clear the total load display (in the addi-

tion mode), or to clear the residual quantity
display (in the subtraction mode), or to print
out displays, keep pressing this switch (1)
for more than 2 seconds.
Operation after the switch is

Specification pressed
The total load display (or residual
Without printer quantity display) is cleared.
The stored sub-total data are
With printer printed out. After being output, the
sub-total data are cleared.
WA380-5 10-236-5
10-241
(10)
Automatic sub-total Function

1) When a printer (If equipped) is connected
Subtotal Data When a weight is calculated at the 501st
• After calculating weight, the following data are time, the data will be stored in the RAM 15
stored as a set: seconds later, and at the same time, data up
• Kind of object materials to 500 times will be printed out. After
• Each load weight being printed out, the sub-total data will be
cleared. After the 500th data is stored, the
• Total number of loading times
following messages will be displayed on
• Total load weight the character display: "LOAD DATA FULL"
Memory capacity: More than 500 loading times and "CLEAR DATA" But the measurement
can be continued.
2) When a printer (If equipped) is not connected

When a weight is calculated at the 501st
time, the data will be stored in the RAM 15
seconds later, and at the same time, weight
data of each bucket load up to 500 times
will be cleared. After the 500th data is
stored, the following messages will be dis-
played on the character display: "LOAD
DATA FULL." , "CLEAR DATA". But the
measurement can be continued.
Display on the Character Display after the 500th

Data is Stored.
10-236-6
10-242 WA380-5
(10)
5. Cumulative Data Display Function
Data Display Data Reset

• Total load weight and total number of loading • Cumulative data of any of A to E or of all object
times are displayed in the addition mode or in materials are reset.
the subtraction mode. • "TOTAL DATA" is displayed on the character
• When "DATA" is selected on the load meter display. Press (>) or (<) on the monitor panel
function, then "TOTAL DATA" is displayed on mode selector switch 2, then, select any of A to
the character display. E or "turn on all" on the work object material
display, and press (<>) on the mode selector
switch.
• "RESET" and "YES <> NO" are displayed on the
character display for confirmation. Since the
cursor is located at the "NO" position right after
the screen changed, press (<) on the monitor
panel mode selector switch 2 to move it to the
"YES" position and press () on the mode
selector switch.
★ The time based on the hour meter in which the

data were integrated is displayed on the lower
line (*****-*****h).
Example) If 12300-12450h is displayed, the data
integrated in 150 h from 12300 h to 12450 h are
displayed on the character display.
• Press (>) or (<) on the monitor panel mode
selector switch 2 and select any or all of A to E.
When any of A to E is selected, the cumulative
weight (2) for each kind and the number of • When the monitor begins to operate, the buzzer
loading times (3) will be displayed. When turn will sound "Pipi", and the service meter display
on all is selected, the total cumulative weight appears.
(2) of all object materials from A to E and the
total number of loading times (3) will be dis-
★ When more than 6 hours has elapsed after the
played.
battery is disconnected, cumulative date of the
load will be deleted from the memory. Keep
this in mind when using battery disconnection
switch.
WA380-5 10-236-7
10-243
(8)
6. Printout (If equipped)

★ This function is available only when the printer (If equipped) is connected.
Output formats of the load meter can be selected from three (A, B and C) output modes. Output for-
mats of each mode are as follows:
★ For the output mode selection and output methods refer to the paragraph of "Operation of Load
Meter" in the Operation and Maintenance Manual.
Mode A (Total printout) Mode B (Sub-total printout) Mode C (Operation record printout)
• Machine Model, Serial number • Machine Model, Serial number • Machine Model, Serial number
• Printing time and date • Printing time and date • Record starting time and date, Service
• Sub-total data of loading (Kind, Num- • Loading data (Load weight) meter
ber of loading times, Load weight) • Loading sub-total data (Kind, Number • Record ending (printing) time and
• Total data of loading (Total number of of loading times, Load weight) data, Service meter
loading times, Total load weight) • Loading total data (Total number of • Subtotal data of loading (Kind, Num-
loading times, Total load weight) ber of loading times, Load weight)
• Total data of loading (Total number of
loading times, Total load weight)
• Maintenance time (Maintenance items,
remaining time)
Example of Printout in each Mode (In case of WA470-5)

Example of Printout in Mode A Example of Printout in Mode B Example of Printout in Mode C
WA470-5 #70001 WA470-5 #70001 WA470-5 #70001
25/OCT/2001 17:30 25/OCT/2001 17:30 Start time
25/OCT/2001 9:15
Material Times Total Load Material: A Service meter 00043.0h
A 1 2.62t 1: 2.62t End time
B 2 6.04t Total: 1 times 2.62t 25/OCT/2001 17:30
C 3 7.11t Service meter 00051.2h
D 4 9.04t Material: B
E 5 14.82t 1: 2.62t 2: 3.42t Material Times Total
Total 16 42.25t Total: 2 times 6.04t A 1 2.62t
B 2 6.04t
Material: C C 3 7.11t
1: 3.43t 2: 2.25t D 4 9.04t
3: 1.43t E 5 14.82t
Total: 3 times 7.11t Total 16 42.25t
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)
7. Calibration Load Calibration

• There are two kinds of calibrations, i.e., the no- • This calibration is for compensating the stan-
load calibration for measuring pressure when dard pressure in a loaded state and is intended
the bucket is empty and the load calibration for to carry out the compensation (B) of an error
measuring pressure when a known weight is from the standard value (A) in the vicinity of
loaded. When the lift arm is raised while the load calibration (C) conducted as shown in the
bucket is fully tilted, the lift arm operating pres- figure below.
sure without load (0kg) or with a known load
weight is memorized.
• In general, accuracy can be fully secured only in
calibration without load. When the center of
gravity of a load is quite different from our pre-
set position due to modification of the lift arm
or the bucket, it is necessary to calibrate at the
load.
★ The memory of calibration data is not deleted
even while the battery is removed for a certain
time.
No-load Calibration ★ For the calibrating method, see the paragraph

• This calibration is for canceling such weight of Inspection and Adjustment of Load Meter in
difference peculiar to machine as work equip- the Volume of Inspection and Adjustment.
ment weight, etc. and is intended to compen-
sate offset error (B) from standard value (A) as
shown in the figure below. 8. Calculation Stop
This function stops the calculating function of
the load meter. During the calculation stop,
the load meter display disappears, and the
travel speed display or the engine speed dis-
play appears and the data is not added to the
total data. To resume the calculation, select
the Addition Mode or the Subtraction Mode.
★ For how to stop calculation, refer to the
paragraph of "Operation of Load Meter" in
the Operation and Maintenance Manual.
WA380-5 10-236-9
10-244
4
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)
Setting necessary for option mounting

When one of the options below is added or replaced, initialize the sensors and solenoids using the machine
monitor.
Additional or changeable options Initial adjustment items
Transmission mainframe, Transmission controller, and ECMV Transmission initial learning
Lift arm angle sensor and work equipment controller Adjustment of work equipment lift arm angle
EPC lever, work equipment controller, and work equipment EPC Adjustment of work equipment EPC
valve
3 EPC levers, work equipment controller, and work equipment Adjustment of work machine EPC
EPC valve
Joystick lever, work equipment controller, Joystick EPC valve Adjustment of Joystick steering
Lift arm angle sensor and machine monitor Adjustment of load meter lift arm angle
10-240 WA380-5
(10)
Optional device setting for machine monitor

When one of the options below is added or removed, change the machine monitor setting. If the machine
monitor is replaced, set the option mounting state of the machine.
Option set items

Item No. Option item English Remarks
Monitor panel controller
1 Auto grease AUTO GREASE
2 Battery electrolyte reduction sensor BAT LIQUID *4
3 Transmission clogging sensor TRANSM CLOG *4
4 Printer PRINTER
5 Lift arm high lift specifications HI LIFT
6 Speed/engine tachometer switch ENGINE RPM *1
7 Short ton switch SHORT TON *2
1 Travel damper E.C.S.S
2 Torque converter lock-up LOCK UP
3 Emergency steering EMER STRG
4 Tire size TIRE SIZE *3
5 Spare switch AUTO RE FAN *4
6 Right FNR switch R.H. FNR SW
Work equipment controller
1 EPC lever EPC LEVER
2 Joystick lever JOY STICK
3 EPC 3rd levers EPC 3RD
* 1 : Setting of speed/engine tachometer indicator switch

When the rotary switch on the rear is km/h:the engine rotation is displayed at engine rotation option = ADD.
When the rotary switch on the rear is MPH:the engine rotation is displayed at engine rotation option = ADD.
When the rotary switch on the rear is rpm: the travel speed (km/h) is displayed engine rotation option = NO ADD.
* 2 : Setting of load meter short ton (US ton) indicator switch
When the DIP switches on the rear is MPH, the indicator is switched to short ton.
The MPH indicator is the domestic type using the non-SI unit (mile); so, do not change for SI unit countries.
* 3 : Adjustment of tire size
When the speed indicator does not match the actual value because an unspecified tire is used or a tire is abraded,
correct the tires so that the speed indicator matches the actual value.
When the normal tire size is changed, use the rotary switch 3 on the rear, not the adjustment function.
* 4 : No optional items are set for this machine.
WA380-5 10-241
(10)
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.
##: Displays an item number.

***: Displays an item name.
Upper row: Displayed when no option is set
2. Press and release the monitor panel mode
currently.
switch ( ).
Lower row: Displayed when option is set cur-
The screen changes to the monitor panel option
rently.
setting selectable display.
Pressing the switch changes ADD (set) or NO
ADD (not set), and the display is switched.
If the setting is changed, the operation accep-
tance completion sound (two short tones (0.1
sec. ON 0.1 sec. OFF 0.1 sec. ON)) is out-
put.
To adjust the tire size, the operation and display
sizes are as follows:
3. When the option setting controller is not the

monitor, use the monitor panel mode switch (<
or >) to switch to each controller.
Using the switches the 00% and @@%.

@@: Can be switched every 2% up to deflection
-12 to +12% for the setting of the DIP switches
on the rear.
+00+02+04+06+08+10+12-02-04
-06-08-10-12+00… .
When the value is changed, the operation
acceptance completion sound (two short tones
(0.1 sec. ON 0.1 sec. OFF 0.1 sec. ON)) is
output.
Adjust the tire size only when an unspecified
tire is mounted.
5. Press and release the monitor panel mode
switch ( ); the menu returns to the preceding
screen.
10-242 WA380-5
(10)
Transmission initial learning setting

Learning for correcting the solid difference of transmission
1. Learning data reset

Issue the learning data reset command to reset all learning data stored in the non-volatile memory.
Display of Transmission initial learning and procedure for resetting data
(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)
2. Initial learning procedure

Preparation for machine
1. Start the engine.

2. Display the transmission oil temperature (Item ID: 41500, ECMV OIL TEMP) on the real-time monitor.
3. Operate the gear shift lever and directional lever, and circulate the oil inside the transmission.
Gear range N2 F2 F1 F2 F3 F4 F3 F2 N2 R2 N2
Holding time 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 sec 2 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 transmission cut- off switch in the OFF
position (the lockup switch in the OFF position).
4. Increase the oil temperature of transmission to 55 - 70°C.

Set the oil temperature to the specified temperature while learning operation.
Check that the machine is in normal conditions (no fault is detected).
Initial learning method
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)
Adjustment of work equipment lift arm angle

(For electric work equipment lever) (If equipped)
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.
8. Confirm that the buzzer sounds (two short

tones) twice and the menu returns to the [Lift
Arm Angle Adjustment] screen. The setting is
then completed.
9. Pressing the switch ends the lift arm angle

correction even if it is performed currently.
WA380-5 10-245
(10)
Adjustment of work equipment EPC (If equipped)
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)
Adjustment for each EPC

Lift arm RAISE
1. Dump the bucket to lower the lift arm, and lift the front tires. Lift the lift arm (lower the machine) by
degrees in the engine high idling state.
2. Return the lever by fine operation to stop the lift arm (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 down 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. Press the switch; the work equipment EPC dispersion correction is ended even if it is in progress of
processing.
Lift arm LOWER
1. Adjust the lift arm to the horizontal level without load, and lower the lift arm 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.
5. When the switch is pressed as the lever stroke is 40% or more in the down direction, the buzzer
sounds for 1 second, and the adjustment is canceled as the [Work Equipment EPC Setting] screen
remains displayed.
Adjustment] screen.
WA380-5 10-247
(10)
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.
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.
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.
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.
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.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
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.
Adjustment] screen.
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.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
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.
Adjustment] screen.
10-248 WA380-5
(10)
Correction of position of work equipment EPC lever detent
Procedure for correcting position of work equipment EPC lever
Perform the following procedure with the engine stopped
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.
Screen for adjusting work equipment EPC

2. Input the ID with the < switch and > switch, then RAISE lift arm: No. 4
push the switch to go to the screen for the LOWER lift arm: No. 5
service person. Tilt bucket: No. 6
Set these items respectively.
Perform this correction procedure when the electric
work equipment control lever or work equipment
controller is replaced.
This correction procedure cannot be performed if
the ROM No. of the work equipment controller in
the real-time monitor is ****R200.
5. Push the switch and the screen for setting

the work equipment EPC appears.
3. Display the "Select initial setting of sensors"

screen with the < switch and > switch and enter
the setting.
Screen for setting work equipment EPC.
WA380-5 10-249
(10)
< 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.
The buzzer sounds twice and the screen for

adjusting work equipment EPC appears again.
6) Correction of the position of the work equipment

EPC lever detent can be stopped at any time by
pushing the switch.
5) -1. At this time, if the switch is pushed while

value (out of the design range), the buzzer sounds
for 1 second and the screen for setting work
equipment EPC does not change. The adjustment
is cancelled in this case.
EPC lever detent can be stopped at any time by
pushing the switch.
10-250 WA380-5
(10)
[Adjustment of the position of the bucket TILT

detent]
Perform the following procedure with the
engine stopped.
1) -3. Lower the lift arm to the ground.
2) -3. Stop and hold the bucket lever before the TILT
detent position.
3) -3. Push the switch at this time. The lever volt-
age is read and the standard value is changed
and saved.
4) -3. The buzzer sounds twice. The screen for
adjusting the work equipment EPC appears and
the adjustment is completed.
5) -3. At this time, if the switch is pushed while
value (out of the design range), the buzzer sounds
for 1 second. The screen for setting the work
equipment EPC does not change. The adjustment
is cancelled in this case.


EPC lever detent can be stopped at an time by
pushing the switch.
WA380-5 10-251
(10)
Adjustment of Joystick steering (If equipped)

1. Hold down the switch < switch for 5 seconds
or more at the same time, and change to the [ID
Entry] screen.
5. Press the switch here; the [Joystick Calibra-

tion Adjustment] screen appears. (Right or left)
2. Use the < and > switch to enter ID, and press
the switch to enter the service person screen.
Setting of starting point (Right or left)

6. Set the engine high idling state, and set the
switch speed High/Low switch to High.
(For this operation, use the stationary steering.)
3. Use the < and > switch to display the [Sensor
7. Start the steering by right or left steering fine-
Initialization Setting] screen, and press the
operation, and stop the steering. Then hold the
switch to decide the value.
lever at that position.
8. 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.
9. The buzzer sounds twice (two short tones), and
the [Joystick Steering Calibration Adjustment]
screen returns. The setting is then completed.
10. When the switch is pressed as the lever is in
the reverse state, the buzzer sounds for 1 sec-
ond, and the adjustment is canceled as the
[Joystick Calibration Setting] screen remains
4. Use the < and > switch to display the [Joystick displayed.
Calibration Adjustment] screen of set item 11 or 11. When the switch is pressed as the lever is at
12. (Right or left) the neutral position, the adjustment value is
cleared to the initial value, and the buzzer
sounds twice (two short tones). The menu then
returns to the [Joystick Steering Calibration
Adjustment] screen.
12. When the switch is pressed, the Joystick cali-
bration is ended even if it is in progress of pro-
cessing.
10-252 WA380-5
(10)
Adjustment of lift arm angle for load meter

(If equipped)
Adjustment of lift arm angle (upper position)

4. Press the < and > switch to display the [Work
1. Hold down the switch < switch for 5 seconds Equipment Lift Arm Angle Adjustment] screen
or more at the same time, and change to the [ID on set item 16.
Entry] 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-
offset value.
the menu returns to the [Lift Arm Angle Adjust-
9. Press the switch; the lift arm angle correction
is ended even if it is in progress of processing.
WA380-5 10-253
(10)
Adjustment of lift arm angle (Lower position)
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-
offset value.
the menu returns to the [Lift Arm Angle Adjust-
9. Press the switch; the lift arm angle correction
is ended even if it is in progress of processing.
• After the lift arm angle is adjusted, be sure to

perform calibration without load.
10-254 WA380-5
(10)
AMP070-20P [CN-L51]
Pin No. Specifications I/O Group Setting state Signal name WA380-5 Remarks
1 — — — — —
2 Small lamp power I — Power +24V — —
3 Small lamp power I — Power +24V — —
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)
6 SW power (+24V) I — Power +24V SW power (+24V) SW power (+24V)
7 SW power (+24V) I — Power +24V SW power (+24V) SW power (+24V)
8 — — — — —
9 GND I — GND GND GND
D_OUT_3 (+24V, sink

11 200mA) O A D/0 sink — —
12 D_OUT_2 (+24V, sink O A D/0 sink (Auto preheating —

200mA) relay)
D_OUT_1 (+24V, sink
13 O A D/0 sink Pre-lube relay —
200mA)
D_OUT_0 (+24V, sink Buzzer 1 Buzzer 1
14 200mA) O A D/0 sink (Machine monitor) (Machine monitor)
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)
AMP070-18P(1) [CN-L52]
1 D_IN_0(24V,5mA) I B D/I+24V High beam Head lamp
2 D_IN_2(24V,5mA) I B D/I+24V IGN C IGN C

Auto grease A
3 D_IN_4(24V,5mA) I B D/I+24V Auto grease A (If equipped) If equipped
4 D_IN_6(24V,5mA) I B D/I+24V (Direction F) — For compact type
5 D_IN_8(24V,5mA) I B D/I+24V (Direction R) — For compact type
6 D_IN_10(24V,5mA) I B D/I+24V (Diagnosis IN A) — Spare
7 D_IN_12(NSW24V,5mA) I C D/I+24V Blinker right Blinker right
8 D_IN_14(NSW24V,5mA) I C D/I+24V Service switch input switch input Machine monitor

operation switch
9 GND O — SIGNAL GND SIGNAL GND
10 D_IN_1(24V,5mA) I B D/I+24V IGN BR —
11 D_IN_3(24V,5mA) I B D/I+24V IGN R1 —
12 D_IN_5(24V,5mA) I B D/I+24V Auto grease B Auto grease B If equipped

(If equipped)
13 D_IN_7(24V,5mA) I B D/I+24V (Direction N) — For compact type
14 D_IN_9(24V,5mA) I B D/I+24V (HST: Hi/Lo switch) — For compact type
15 D_IN_11(24V,5mA) I B D/I+24V (Diagnosis IN B) — Spare
16 D_IN_13(NSW24V,5mA) I C D/I+24V Blinker left Blinker left

Machine monitor
17 D_IN_15(NSW24V,5mA) I C D/I+24V Service switch input switch input operation switch
18 A_IN_0(0-30V) I H A/I Alternator R Alternator R
AMP070-12P (1) [CN-L53]

1 D_IN_16(24V/GND,5mA) I D D/IGND Brake oil pressure Brake oil pressure

(Front) (Front)
Brake oil level
2 D_IN_18(24V/GND,5mA) I D D/IGND — Spare
(Front)
Air cleaner clog-
3 D_IN_20(24V/GND,5mA) I D D/IGND ging 1 Air cleaner clogging
4 D_IN_22(24V/GND,5mA) I D D/IGND (Spare) —

Transmission filter
5 D_IN_24(24V/GND,5mA) I E D/IGND —
clogging
6 GND O — GND Sensor GND Sensor GND
Brake oil pressure
7 D_IN_17(24V/GND,5mA) I D D/IGND —
(Rear)
Brake oil level
8 D_IN_19(24V/GND,5mA) I D D/IGND (Rear) — Spare
9 D_IN_21(24V/GND,5mA) I D D/IGND Air cleaner clog- — Spare

ging 2
10 D_IN_23(24V/GND,5mA) I D D/IGND (Spare) —
Seat belt mounting
11 D_IN_25(24V/GND,5mA) I E D/IGND alarm —
12 A_IN_0(0-30V) I H A/I Small lamp switch Small lamp switch
10-256 WA380-5
(10)
AMP070-18P(2) [CN-L54]
1 D_IN_26(24V/GND,5mA) I E D/IGND Parking brake Parking brake
2 D_IN_28(24V/GND,5mA) I E D/IGND Engine oil pressure Engine oil pressure Spare
3 D_IN_30(24V/GND,5mA) I E D/IGND E/G steering normal E/G steering normal

For load meter
Subtotal switch
4 D_IN_32(24V/GND,5mA) I F D/IGND Subtotal switch (If equipped) (Spare for
standard)
Printer output
5 D_IN_34(24V/GND,5mA) I F D/IGND High-beam switch
switch
Machine monitor
6 D_IN_36(24V/GND,5mA) I G D/IGND Service function 2
indicator switch
Machine monitor
7 D_IN_38(24V/GND,5mA) I G D/IGND Increment switch < switch input operation switch
8 P_IN_0(0.5Vp-p) I M P/I (travel speed sen- — For compact type

sor)
9 GND O — GND GND GND
10 D_IN_27(24V/GND,5mA) I E D/IGND Engine coolant level Engine coolant level
11 D_IN_29(24V/GND,5mA) I E D/IGND Engine oil level Engine oil level Spare
12 N.C. I E D/IGND N.C. —

For load meter
13 D_IN_33(24V/GND,5mA) I F D/IGND Cancel switch Cancel switch (Spare for
(If equipped)
standard)
Lift arm approach
14 D_IN_35(24V/GND,5mA) I F D/IGND switch —
15 D_IN_37(24V/GND,5mA) I G D/IGND Decrement switch > switch input

E/G steering opera- E/G steering opera-
16 D_IN_39(24V/GND,5mA) I G D/IGND
tion tion
17 P_IN_1(0.5Vp-p) I M P/I (Spare) — Pulse input
18 (NC) — — (NC) —
AMP070-12P(2) [CN-L55]
1 A_IM_2(High resistance I J A/I Fuel level sensor Fuel level sensor

input)
A_IM_4(High resistance Torque converter oil Torque converter oil
2 I J A/I
input) temperature sensor temperature sensor
Engine coolant tem- Engine coolant tem-
3 A_IM_6(High resistance I K A/I perature sensor (for perature sensor (for
input)
auto pre-heating) auto pre-heating)
Lift arm pressure Lift arm pressure
4 A_IM_8(0-5V) I L A/I sensor (rod) sensor (rod) For load meter
Battery electrolyte Battery electrolyte

5 A_IM_10(0-14V) — — level If equipped
level A (If equipped)
6 GND O — GND SIGNAL GND GND
A_IM_3(High resistance Hydraulic oil tem- Hydraulic oil temper-
7 input) I J A/I perature sensor ature sensor
8 A_IM_5(High resistance I J A/I Engine coolant tem- Engine coolant tem-

input) perature sensor perature sensor Hi
Lift arm pressure Lift arm pressure
9 A_IM_7(0-5V) I L A/I For load meter
sensor (bottom) sensor (bottom)
Lift arm angle sen-
10 A_IM_9(0-5V) I L A/I Lift arm angle sensor For load meter
sor
11 GND O — GND SIGNAL GND GND
Battery electrolyte
12 A_IM_11(0-14V) — — — Spare
level B
WA380-5 10-257
(10)
AMP070-12P(3) [CN-L56]
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-
5 S_NET(-) O N S-NET S_NET GND S_NET-
6 GND O — GND S_NET GND
7 GND O — GND CAN GND

Machine monitor-
Transmission, and
8 CAN- I/O P CAN CAN-
work equipment
controller
9 (NC)
10 (NC)
11 (NC)
12 (NC)
AMP070-14P(2) [CN-L57]
1 (NC) — — —
RS232_C serial
2 RS232C_1_RTS I/O Q communication —
3 RS232C_1_RD I Q RD RS232_C serial PC RX For monitoring PC

communication
4 RS232C_2_RD I R RD NC —
5 RS232C_2_RTS I/O R NC —
Load meter printer
6 — — Printer BUSY For load meter
busy input
7 (NC) — — —
8 RS232C_1_CTS I/O Q RS232_C serial — For load meter

communication For monitoring(PC)
RS232_C serial
9 RS232C_1_TX O Q TX Printer & PC TX
communication
RS232_C serial
10 RS232C_1_SG O Q communication —
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)
AMP040-8P [CN-L58]
Flash writing data Harness not con-

1 RS232C_0_TXD O S (sending) — nected in machine
2 FLASH_SW I S Flash writing switch — Harness not con-

nected in machine
3 RS232C_0_TXD O S —
(sending) nected in machine
Harness not con-
4 (NC) — — (NC) — nected in machine
5 RS232C_0_RXD I S Flash writing data — Harness not con-

(receiving) nected in machine
Harness not con-
6 (NC) — — (NC) —
nected in machine
7 RS232C_0_RXD I S (receiving) — nected in machine
8 GND O — GND — Harness not con-

nected in machine
Setting switches (on board)

1 16 Posi rotary SW1 I — Model selection Model selection
2 16 Posi rotary SW2 I — Specifications —

selection
Speed indicator
Speed indicator
3 16 Posi rotary SW3 I — switch and option switch
tire selection
Common rail Common rail
1 26 Posi dip SW1 I — engine controller engine controller
selection selection
Work equipment Work equipment
2 26 Posi dip SW2 I —
5 controller selection controller selection
3 26 Posi dip SW3 I — (Spare) —

6
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MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
TRANSMISSION CONTROL SYSTEM

SYSTEM DIAGRAM
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Control Function
1. Gear Speed Change Function

1) Electronic Modulation Function
In order to reduce shocks at gear speed changes (at engagement of the clutch), this function con-
trols the clutch oil pressure to the level suitable to the oil-pressure circuit depending on the engine
speed, oil temperature of the transmission, travel speed and gear speed change pattern. This con-
trol is performed through the whole range of gear speeds (including the lock-up clutch) according
to the data in the transmission modulation data table stored in the transmission controller memory.
The clutch to be turned off is also included in the target of the modulation control in order to reduce
running out of the torque. A learning function is also provided so that an abnormal time lag in the
gear speed change may be automatically modulation controlled.
2) Automatic Gear Speed Change
This function is consisted of the auto-shift and manual shift. The former decides the gear speed
automatically according the travel speed and the latter selects the gear speed according to the gear
speed specified by the gear shift lever.
In the auto-shift, the travel speed mode is switched between the auto-shift up and down depending
on the state of the engine-power mode and torque converter lockup control.
Shift mode change in case of the overseas spec.

In case of the overseas spec., depending on the status of the shift mode (NORMAL/H/M/L)
changeover switch, the status of the torque converter lock up (OFF/ON) switch and the status of the
power mode (POWER/NORMAL) changeover switch, automatic shift up or shift down is made to
become the following shift modes.
Power mode Lockup switch Shift mode switch position

switch position position Manual H M L
POWER Manual H-mode M-mode L-mode
OFF
NORMAL Manual M-mode M-mode L-mode
POWER Manual H-mode M-mode L-mode
ON
NORMAL Manual L-mode L-mode L-mode
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.
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2] Forward-reverse lever at “N” position

When the forward-reverse lever is at the neutral position, the number of speed of the transmis-
sion is fixed to the gear speed being set before the lever was shifted to “N”.
As long as the forward-reverse lever is at “N” position, operating the gearshift lever does not
change the gear speed.
3] Forward-reverse lever at “F” position
As the forward-reverse lever is shifted from N F, the transmission sends the modulation
instruction to the F-clutch and 2nd speed clutch’s ECMV (auto 2nd speed start).
a) Shift up (Gearshift lever at 4th speed and the auto-shift mode “H” is on)
If you increase travel speed up to 10.2km/h by increasing the engine speed from the acceler-
ator pedal, the gear speed will be shifted to the 3rd speed. If the travel speed is increased to
18.0km/h, the gear speed is shifted to the 4th speed.
b) Shift down (Gearshift lever at 4th speed and auto-shift mode “H” is on)
If you reduce the travel speed to 16.0km/h or less when 1,000 rpm or above engine speed is
turned on (when travelling up hills, for instance), the gear speed is shifted is to the 3rd speed.
If the travel speed is further reduced to 10.7km/h or less, it will be shifted to the 2nd speed.
c) Skip shift down (Gearshift lever at 3rd or 4th speed)
speed)
If you reduce the engine speed to less than 1,000 rpm by releasing the accelerator pedal
while the machine is traveling, the 3rd or 4th speed will be maintained until the travel speed
reaches 1km/h. As the travel speed reaches 1km/h, the gear speed will be shifted to the 2nd
speed.
If you run the accelerator pedal again when the travel speed is reduced to 5km/h or less and
the gearshift lever is positioned at 3rd or 4th speed, the gear speed will be shifted to the 2nd
speed as the engine speed reaches 1,000 rpm or above.
4] Forward-reverse lever at “R” position
In this case, just like when the forward-reverse lever is at “F” position, travel speed is changed
according to the position of the gearshift lever, auto-shift mode selected and given travel speed
as specified in the “Auto-Shift Point List”.
5] Gear speed change disabling time
It is a specified duration of time in which a selected gear speed is maintained in order to prevent
hunting after changing the speed. Duration of this time depends on the gear change pattern
(see the Auto-Shift Point List).
3) Shift Hold Function
This function is used to hold the gear speed being selected at when the hold switch is depressed.
Increasing a traveling speed does not cause the shift up as long as this function is turned on. Like-
wise, slowing down the traveling speed does not result in the shift down.
You can cancel the shift hold function by hitting the hold switch again.
This function is automatically cancelled if you operate the forward-reverse lever, gearshift lever or
kick down switch. This function does not hold ON status of the lockup.
4) Kick-Down Function
1] Kick down in the manual shift mode
The kick-down switch is operable only when the forward 2nd speed (F2) is selected. It is inoper-
able at any other speeds.
You can cancel the kick-down by shifting the forward-reverse lever to any position other than F
or by shifting the gearshift lever to any position other than F2.
You can select the 2nd speed by shifting the forward-reverse lever to R after selecting F1 from
the kick-down switch. If you move the gearshift lever to any speed other than the 2nd speed,
the speed will be changed to the one where the lever is positioned.
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2] Kick-down in the auto-shift mode

The kick-down switch is enabled irrespective of the position of the forward-reverse lever and
gearshift lever.
Following gear speed changes are available from the kick-down switch at respective travel
speeds.
Gear speed change from the kick-down switch is implemented after the predetermined gear
speed change disabling time is expired. When it is done from the forward-reverse lever, the
gear speed change is executed according to the Auto-Shift Point List.
Gear speed change dis-

Gear speed before change Travel speed Gear speed after change abling time
2nd speed Throughout whole speed 1st speed 5 seconds
ranges
Less than 12.5 km/h 1st speed 5 seconds
12.5 km/h to less than 25 km/h 2nd speed 4 seconds
3rd speed Gear speed change is not
More than 25 km/h available (remains at 3rd —
speed)
12.5 to less than 35 km/h 3rd speed 4 seconds
4th speed
Gear speed change is not
More than 35 km/h available (remains at 4th —
speed)
3rd speed (when lockup is
turned ON) More than 12.5 km/h 3rd speed (after lockup is *1
canceled)
4th speed (when lockup is
4th speed (after lockup is
turned ON) More than 12.5 km/h canceled) *1
*1: When the lockup is canceled from kick-down switch, it can be turned on only when:
zThe torque converter lockup switch is turned on once and then turned off again,
zTravel speed is increased from less than the lockup ON speed to above the ON speed (both indicated in the Auto-Shift
Point List).
5) Transmission Protection Function
In order to protect the transmission, several restrictions are laid down in F-R shift of the forward-
reverse lever during high-speed travel.
1] When the auto-shift is turned on
Zone I: F-R shift is enabled and the 2nd speed is selected (normal zone).
Zone II: F-R shift is enabled and the 2nd speed is selected, but alarm is warned.
Zone III: F-R shift is enabled though accompanied by alarm. Gear speed of the speed clutch is
selected from the Auto-Shift Point List and then the shift down to the 2nd speed maximum
results depending on the travel speed.
2] When the manual shift mode (3rd/4th speed) is turned on (speed of the speed clutch is not
changed because of the manual shift)
Zone I: F-R shift alone is enabled (normal alarm).
Zone II: F-R shift is enabled but accompanied by alarm.
Zone III: F-R shift is enabled but accompanied by alarm.
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6) Travel Speed Alarm Function

Alarm buzzer is sounded for travel speeds beyond 38km/h as over speeds. The alarm is turned off
as the travel speed is reduced to 36km/h or below.
Auto-Shift Point List
Forward (F) Reverse (R) Gear speed change

disabling time after
Shift lever position Solenoid signal the preceding
Speed (km/h) Speed (km/h) change (sec)
1T/C2T/C(L&M) 4.7 4.7 2

2, 3 or 4
1T/C2T/C(H) 5.3 5.3 2
2T/C3T/C(H) 10.2 10.2 2
3 or 4 2T/C3T/C(M) 9.0 9.0 2
2T/C3T/C(L) 7.0 7.0 2
3T/C3L/U(M&H) 13.9 16.0 0
Engine speed (1,000 rpm or above)
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
4 4T/C2T/C(L&M&H) 1.0 1.0 0

Engine
speed
3 or 4 3T/C2T/C(L&M&H) 1.0 1.0 0
Engine speed (Less than 1,000 4T/C2T/C(L&M&H) 5.0 5.0 2

rpm Above 1,000 rpm) 3T/C2T/C(L&M&H) 5.0 5.0 2
Through all speed Through all speed
2T/C1T/C(L&M&H) 5
ranges ranges
3T/C1T/C(L&M&H) Less than 12.5 Less than 12.5 5
3L/U3T/C(L&M&H) ranges ranges 0
Kick-down mode (When kick-
down switch OFF ON) 4T/C1T/C(L&M&H) Less than 12.5 Less than 12.5 5
4L/U4T/C(L&M&H) ranges ranges 0
4T/C3T/C(L&M&H) 12.5-35.0 12.5-35.0 4

3T/C2T/C(L&M&H) 12.5-35.0 12.5-35.0 4
1.
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Forward (F) Reverse (R) Gear speed change

disabling time after
Shift lever position Solenoid signal the preceding
Speed (km/h) Speed (km/h) change (sec)
4L/U2T/C(L&M&H) Zone I & II Zone I & II 2

4T/C2T/C(L&M&H) Zone I & II Zone I & II 2
2, 3 or 4 3L/U2T/C(L&M&H) Zone I & II Zone I & II 2

(R) NF
3T/C2T/C(L&M&H) Zone I & II Zone I & II 2

1T/C2T/C(L&M&H) ranges ranges 2
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
4L/U(H) 23.7 and up 25.2 and up —

4L/U(M) 22.2 and up 23.6 and up —
When direction switch is shifted (2) FNR RNF
4L/U(L) 20.7 and up 22.0 and up —

4T/C(H) 18.0-23.7 18.0-25.4 0
4 4T/C(M) 16.5-22.2 16.5-23.9 0
4T/C(L) 15.0-20.7 15.0-22.4 0
3T/C(H) 10.2-18.0 10.2-18.0 0
3T/C(M) 9.0-16.5 9.0-16.5 0
3T/C(L) 7.0-15.0 7.0-15.0 0
3L/U(M&H) 13.9 and up 16.0 and up —
3L/U(L) 11.0 and up 16.0 and up —
3 3T/C(H) 10.2-13.9 10.2-16.0 0
3T/C(M) 9.0-13.9 9.0-16.0 0
3T/C(L) 7.0-11.0 7.0-16.0 0
2T/C(H) up to 10.2 up to 10.2 0
3 or 4 2T/C(M) up to 9.0 up to 9.0 0
2T/C(L) up to 7.0 up to 7.0 0
2 2T/C(L&M&H) ranges ranges —
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2. Torque Converter Lockup Control Function (If equipped)

1) The torque converter lockup switch operation (ON/OFF) enables to implement the lockup automati-
cally.
When the lockup switch is turned on, the torque converter lockup can be automatically turned on or
off in the manual shift mode, too.
Following table shows the lockup specification-based gear speeds
Lockup specification-based gear speeds Lockup:
Travel mode F1 F2 F3 F4 R1 R2 R3 R4
Manual shift
Auto-shift (L, M, H) * *
* At the auto-shift mode, when the shift lever is on the 4th and actual range is 3rd, lockup
does not work. When the shift lever is on the 3rd and actual range is 3rd, lockup works.
2) Lockup travel speed

For the travel speed that turns ON/OFF the lockup, refer to the [Auto-Shift Point List].
In the manual shift mode, too, the lockup is turned on or off at the same travel as in the auto-shift
mode.
The lockup is cancelled as the travel speed reaches 40km/h or above. This arrangement is prepared
to ensure the driver safety. After the cancellation, if the travel speed is increased from below 38km/
h to 38km/h or above, the lockup is applied again.
3) Lockup protection function
The lockup is turned on only when the machine traveling direction matches the lever position.
Judgement of machine travel direction
b When the travel speed is ≥ 10km/h, the lever position decides the machine travel direction.
c As long as the travel speed ≥ 10km/h is kept, judgement of b above is maintained.
d When the travel speed < 10km/h is detected continuously for one second or more, the protec-
tion function judges that no speed data is available.
e When data on FR travel direction is not stored in the memory or when the travel direction does
not match the lever position, the lockup function is not turned on.
3. Transmission Cutoff Function

1) Function
If you step on the left brake pedal, this function causes the transmission to the neutral detecting oil
pressure in the brake circuit by use of the pressure sensor.
This function enables the cutoff at any position by storing position of the stepped-on brake where
the transmission is caused to the neutral as the brake circuit pressure.
2) Input and output
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3) Description of the control

This function causes the Transmission to neutral as a pressure greater than
(1) Transmission cutoff control the predetermined level is signaled by the left brake pressure sensor (when
Transmission cutoff switch is ON).
Enable condition Transmission cutoff switch ON (Transmission cutoff is enabled)
1) Step on the left brake pedal until it comes to the position desired
as the cutoff point.
2) Push and release the Transmission cutoff set switch.
3) The pressure at the time when the switch is released is tempo-
rarily stored. The setup complete buzzer is sounded twice
Setup procedure (beep).
4) At the same time, the indicator built in the Transmission cutoff
switch flashes for 2.5 seconds.
Set up of cutoff 5) After the flashing for 2.5 seconds, the brake position is stored on
(2) point memory (your setting is held after the key is turned off).
1) Push and release the Transmission cutoff set switch.
2) The indicator built in the Transmission cutoff switch will flash for
2.5 seconds.
3) While the flashing continued, push and release the Transmission
Reset procedure cutoff set switch again.
4) As the flashing is ended, the cutoff point is set as the default left
brake pressure. The setup cancel buzzer is sounded.
5) The setup (default) value is stored on memory (the set value is
held after the key is turned off).
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.
When Transmission is OFF Goes off Not available No control is provided
5) Transmission cutoff point settable range

Note: If you specify a value less than 0.49MPa (5kg/cm²), it will be set as 0.49MPa
Settable range (5kg/cm²).
Note: When a value larger than 4.41MPa (45kg/cm²), it will be set as 4.41MPa
0.49-4.41MPa {5-45kg/cm²} (45kg/cm²). The default value is 1.47MPa (15kg/cm²).
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)
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4. Right FNR Switch Selecting Function (If equipped)

The right FNR switch on the side of the work equipment lever can select forward/reverse travel without
operating forward-reverse lever on the steering column.
★ Right FNR switch is installed only for overseas specification.
System Diagram
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1) Turning on the right FNR switch functions

If you set the right FNR switch to the ON position, the signal enabling the right FNR to cause for-
ward-reverse travel is entered to the transmission controller.
When forward-reverse travel of the work equipment is handed over to the steering, both the steer-
ing column’s forward-reverse lever and the right FNR switch must be positioned at the neutral (N) in
order to ensure safety.
Right FNR switch Forward-reverse lever

Normal position N N
When switched from steer- Even resulting from abnor- Error is warned Error is warned
ing to right FNR mal position
Correcting approach Set to N Set to N
Normal position N N
When switched from right Even resulting from abnor- Error is warned Error is warned
FNR to steering mal position
Correcting approach Set to N Set to N
2) Switching between forward and reverse from the right FNR

If the forward-reverse lever on the steering column is positioned at the neutral in the state of 1)
above, switching between forward and reverse becomes available from the right FNR.
When the forward-reverse lever on the steering column is positioned at F or R, precedence is given
to the lever operation irrespective of the right FNR switch position.
3) Gear speed change from the right FNR switch
The same gear speed change functions as those from the steering column become available.
Operable switches when the right FNR switch function is installed

Operation on work Operation on steering column
equipment
Switching between
Switch selection auto-shift and Right FNR switch Forward-reverse lever Gearshift lever position
manual shift
Switching between for- When the lever is positioned at N,

operation from the work equipment Gear speed change becomes
Manual shift ward and reverse is is enabled. When the lever is at F available by changing the lever
available from the
or R, precedence is given to the position.
switch lever though an error is warned.
When right FNR
is selected
Switching between for- When the lever is positioned at N,
operation from the work equipment
Auto-shift (L,M,H) ward and reverse is is enabled. When the lever is at F Maximum gear speed (limiter)
available from the
switch or R, precedence is given to the
lever though an error is warned.
Normal operation is
available when fixed to Switching between forward and Gear speed change becomes
Manual shift N. Error is warned at reverse becomes available from the
any position other than lever. available from the lever.
When steering N.
column is
selected Normal operation is
available when fixed to Switching between forward and
Auto-shift (L,M,H) N. Error is warned at reverse becomes available from the Maximum gear speed (limiter)
any position other than lever.
N.
4) Safety function to be turned on at startup of engine

If the right FNR switch on the work equipment is not positioned at N, output of the neutral signal
from the transmission controller is disabled, and thus you can’t start up the engine. In this case,
too, the neutral caution is warned.
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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
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1) Turning on the joystick function

If you turn on Joystick FNR switch after turning on Joystick sprung switch by shifting the armrest
for the joystick to the lock position, the joystick function enable signal is entered to the transmission
controller.
When you switch the function between the joystick and steering, both the forward-reverse lever on
the steering column and Joystick FNR switch on the joystick must be positioned at neutral (N). It is
so required from the safety standpoint.
Joystick FNR switch Forward-reverse lever Gearshift lever
Normal position N N 1st to 3rd speeds
When switching is Even resulting from Error is warned Error is warned Error is warned
done from steering to abnormal position
joystick
Position at one of 1st
Correcting approach Position at N Position at N to 3rd speeds
Normal position N N Any position
When switching is Even resulting from
done from joystick to Error is warned Error is warned —
abnormal position
steering
Correcting approach Position at N Position at N —
2) Switching between forward and reverse from joystick

If the forward-reverse level on the joystick is at the neutral position in the state of 1) above, switch-
ing between forward and reverse becomes available from Joystick FNR switch.
When the forward-reverse level is positioned at F or R, precedence is given to the lever irrespective
of the Joystick FNR switch position.
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3) Switching of gear speed from joystick

• When the manual shift is selected
You can switch the gear speed from the shift up/down switches provided at the head of the joy-
stick. In this case, however, the gearshift lever on the steering column must be positioned at the
maximum gear speed (in the gear speed change range).
Example: When the gearshift lever is at the 3rd speed, switching from the shift up/down
switches is available in the range of the 1st and 3rd speeds. Pushing the shift up/down switches
from the 3rd speed does not turn on the 4th speed.
• When the auto-shift (L, M, H) is selected
The gearshift lever on the steering column is positioned at the maximum gear speed (gear
speed change range), thereby enabling the gear speed change. In this case, the shift up/down
switches provided at the head of the joystick is disabled for the speed change.
• Gear speed change from the hold switch or the kick down switch
The same function as that from the steering column becomes available.
Operable Switches (Levers) when Joystick Function is Installed

Operations on joystick Operations on steering column
Switching of Switching of Joystick FNR Shift down Gearshift lever posi-
joystick func- Shift up switch Forward-reverse lever
tion auto-shift switch switch tion
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.
4) Safety function to be turned on at start of engine

If the joystick is selected and Joystick FNR switch is not at N position at startup of the engine, out-
put of the neutral signal from the transmission controller is disabled and thus the engine can’t be
started.
When the joystick lever is operated (located at any position other than N), output of the neutral sig-
nal is disabled by the network signal from the work equipment controller. Thus, the engine can’t be
started.
The neutral caution will be warned for both of above cases.
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6. E.C.S.S. Function (If equipped)

This function automatically controls ON or OFF of the accumulator sealed with high-pressure gas as
well as relief of hydraulic oil of the work equipment taking into consideration of traveling state of the
machine. This system is intended at providing enhanced operator comfort by reducing rocking of the
machine body, preventing load shifts and improving work efficiency through the elasticity-based con-
trol of vertical motion of the work equipment.
Following table shows the operating conditions of the E.C.S.S.

E.C.S.S. switch Gear speed Travel speed E.C.S.S. output Operational status
Through all Not activated (in the pro-
OFF 0 - MAX OFF
gear speeds cess of charging)
Not activated (in the pro-
1st speed 0 - MAX OFF cess of charging)
ON Not activated (in the pro-
2nd - 4th Condition A OFF cess of charging)
speeds
Condition B ON Activated
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7. Electric Emergency Steering Function (If equipped)

1) Operation of electric emergency steering function
The transmission controller constantly monitors state of the steering oil pressure switch of the
steering circuit. If oil pressure of the steering goes low, thereby increasing the travel speed above
the emergency steering activation level, the transmission controller outputs the emergency steer-
ing ON signal to the relay to turn on the emergency steering.
This function can also be turned on from the emergency steering switch independent of the travel
speed or steering oil pressure.
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2) Self-check operation of emergency steering

3 seconds after the starting switch is turned on (after the monitor check is completed), the transmis-
sion controller implements the self-check in which the controller checks operation of the emergency
steering automatically.
In the following cases, however, the self-check is not implemented.
b When the engine starter is turned on from the starting switch.

c When the engine is already started (when engine speed of 500 rpm or above is detected).
d When the steering pressure is already present.
e When the automatic engine pre-heating function is turned on.
f When a emergency steering-related error is detected in the monitor check.
g When the engine has not been operated more than 10 seconds from the last self-check (when
the engine has not been operated at 500 rpm for 10 seconds or more).
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
8. Cooling Fan Control Function

1) Fan control
This system reduces loss of horsepower and noise at low temperature by employing the hydraulic
drive for the cooling fan and controlling the swash plate of the hydraulic pump swash.
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.
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2) Control of reverse fan rotation

You can reverse rotate the fan from the reverse fan rotation switch by activating the reverse rotation
solenoid for the hydraulically driven fan.
When the engine speed is 1,500 rpm or greater, this system increases the radiator cleaning capabil-
ity of the reverse rotated fan by setting both the fan pump swash plate and the fan revolution to the
maximum. When the engine revolution is less than 1,500 rpm, the fan pump swash plate is set to
the minimum in order to suppress generation of surge oil pressure due to reversing of the circuit at
engine stop.
Note that switching between the forward and reverse rotation is available only when the engine is
stopped.
Even if you may try to cause switching between the forward and reverse rotation while the engine
is in operation (when the engine speed is 500 rpm or above), operation signal is not output from the
reverse rotation solenoid.
Output from reverse Output from

rotation solenoid Reverse fan Output from fan Monitor indicator
Engine speed reverse rota-
(before switch oper- rotation switch pump EPC
tion solenoid
ation)
OFF OFFON ON MIN rotation OFFON
OFF ONOFF Stopped (less OFF Normal BlinkingOFF
ON OFFON than 500 rpm) ON MIN rotation BlinkingON
ON ONOFF OFF Normal ONOFF
OFF OFFON OFF Normal OFFBlinking
OFF ONOFF OFF Normal BlinkingOFF
Started (500 rpm
ON OFFON or above) ON * BlinkingON
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
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9. Switch Pump Cutoff Function

When digging operation at 1st speed is turned on from the kick down switch, this function is used to
reduce loss of horsepower due to driving for the switch pump by cutting the switch pump off.
The switch pump cutoff signal is output when digging operation is turned on from the kick down
switch.
10-278 WA380-5
10. Engine Overrun Protection Function

If you try to shift down while travelling downhill at a high-speed with the accelerator being stepped on,
engine overrun can result from driving force of the tires.
In order to prevent this engine overrun, the transmission controller restricts the shift down operation
depending on the given engine speed and revolution of the transmission output shaft (travel speed).
Following lists the conditions for turning on or off the protection:
1) Protect condition: If shift down is tried when the protect condition = A or (B & C) is met, an alarm is
output in stead of the shift down output.
2) Protect cancel condition: When the protect-cancel condition = D & (E or F) is met, the shift down
output is generated in stead of the alarm.
Protection condition [A or (B and C)] Cancel condition [D and (E or F)]
Targeted Condition A Condition B Condition C Condition D Condition E Condition F

shift down Transmission out- Transmission out- Transmission out- Transmission out-
gear speed Engine speed Engine speed
put speed put speed put speed put speed
3rd speed None 2,658 rpm or above 2,100 rpm or above None Less than 2,436 rpm Less than 1,900 rpm
2nd speed 2,658 rpm or above 1,846 rpm or above 2,100 rpm or above Less than 2,436 rpm Less than 1,698 rpm Less than 1,900 rpm
1st speed 1,846 rpm or above 1,107 rpm or above 2,100 rpm or above Less than 1,698 rpm Less than 997 rpm Less than 1,900 rpm
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
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tion mono lever (working equipment operation

12. Gear shift function by multi function mono lever), directional control and gear shift can be
lever carried out by other than the directional lever
If FNR switch, kick-down switch and holding and gear shift lever on the steering column.
switch are attached on the top of the multi func-
WA380-5
10-279-1 WA380-5
1
1) Operation of the FNR switch on the multi function mono lever

When the FNR shift switch is placed in the ON position, directional signal is input into the transmission
controller from the multi function mono lever.
When switching directional operation between multi function mono lever and steering column, both
FNR switch on multi function mono lever and steering columun should be on N position for safety.
FNR switch on multi Directional lever

function mono lever
Normal position N N
When switching directional
operation from the steering Symptoms in other than Generation of error warn- Generation of error warn-
column to the multi func- normal position ing ing
tion mono lever
Correcting method Place in the N position. Place in the N position.
Normal position N N
When switching directional
operation from the multi Symptoms in other than Generation of error warn- Generation of error warn-
function mono lever to the normal position ing ing
steering column
Correcting method Place in the N position. Place in the N position.
2) Directional operation on the multi function mono lever

When the directional lever installed on the steering column is in the neutral position in the above 1)
condition, directional operation can be carried out by the FNR switch on the multi function mono lever.
When the FNR lever on the steering column is set in the F or R position, regardless of the position of the
FNR switch on the multi function mono lever, priority is given to the lever operation.
3) When the FNR switch on the multi function mono lever is operated, the same function as gearshift
using the ordinary steering column is carried out.
Operable switch (lever) when multi function mono lever is equipped.
Operation on the multi Operation on the steering column
function mono lever
Auto/Manual Multi function mono lever

Selection Directional lever Gear shift lever
FNR switch
Work equipment is opera- Possible to shift speed by
Manual shift ble when fixed into the N lever operation
When multi Selectable between for- position.
function ward and reverse by switch Priority is given to the lever
mono lever is Maximum speed range
Auto-shift operation operation in other than N
selected (Limiter)
position, but error warning
is given.
Ordinary operation is Possible to shift speed by
Manual shift
When possible when FNR switch lever operation
Selectable between for-
steering is in N position.
Error warning is generated ward and reverse by lever
column is Maximum speed range
Auto-shift operation
selected when FNR switch is in (Limiter)
other than N position.
4) Safety function when starting the engine

When the FNR switch on multi function mono lever is selected at the time of starting the engine, a neu-
tral signal from the transmission controller is not output and the engine is not started if the FNR switch
on the multi function mono lever is not in the N position. In this case, neutral caution is given.
WA380-5 10-279-2
1
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) —
4th-speed Less than 12.5 - 35 km/h 3rd-speed 4 seconds
35 km/h or higher No shifting (4-speed) —
3rd-speed (at lockup)
12.5 km/h or higher 3rd-speed (lockup released) *1
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.
6) Shift hold function

The speed at the time when the hold switch was pressed is held and it will not be upshifted even when
the travel speed increases or it will not be downshifted even when the travel speed decreases.
When the directional lever, gear shift lever, FNR switch, or kickdown switch is operated, the shift hold
function is automatically released.
The condition of lockup ON/OFF will not be held.
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1
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STRUCTURE AND FUNCTION TRANSMISSION CONTROL SYSTEM
13. Torque Converter Charging Pump Bypass Function (If equipped)
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")
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MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
TRANSMISSION CONTROLSYSTEM
Electric Circuit Diagram (Standard)
★ Mark * indicates optional parts.
WA380-5
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1
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Electric Circuit Diagram (If equipped)
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WA380-5 10-283
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MAINTENANCE STANDARD TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
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1
MAINTENANCE STANDARD TRANSMISSION CONTROLLER
Input and output signals

DEUTSCH-24P [CN-L61]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 NC Input 13 NC Input
2 Shift mode H Input 14 Shift mode L Input
4 Signal GND — 16 Sensor supply source output (+24V) Output
5 Transmission cutoff set switch Input 17 Steering pressure switch (NC) Input
6 Engine power mode switch Input 18 Lockup selector switch Input
7 Reverse fan rotation switch Input 19 Left brake pressure sensor Input
8 Shift mode M Input 20 Rear brake oil temperature sensor Input
9 Transmission oil temperature sensor Input 21 Analog GND —
10 Signal GND — 22 Potentiometer power (+5V) Output
11 Transmission cutoff switch Input 23 Steering pressure switch (NO) Input
12 Kick down switch Input 24 E.C.S.S. switch Input
DEUTSCH-40P(1) [CN-L62]
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
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
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
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MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)
WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)

SYSTEM DIAGRAM
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1. Work equipment control

1) Electric lever control
Lift arm controlling function
• This function controls the EPC valve according to how much the lift arm lever was moved to allow
the control valve of the work equipment to operate, which, in turn allows the lift arm RAISE/LOWER
function to be performed.
Bucket controlling function
• This function controls the EPC valve according to how much the bucket lever was moved to allow
the control valve of the work equipment to operate, which, in turn allows the bucket TILT/DUMP
function to be performed.
3rd Lever controlling function
• This function controls the EPC valve according to how much the 3rd lever was moved to allow the
control valve of the work equipment to operate, which, in turn allows the 3rd valve cylinder
EXTEND/RETRACT function to be performed.
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Work equipment neutral cut

• When the work equipment lock lever for blocking the passage on the work equipment lever circuit
is in the LOCK position, the work equipment neutral cut solenoid is excited to unload the pilot pres-
sure on the work equipment valve. This mechanism prevents the work equipment from being acci-
dently operated by operation of the work equipment lever.
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)
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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.
Lift arm releasing function

• Lowering the lift arm lever to allow it to reach the detent range, a detent-on signal is output from
the work equipment controller to cause the lift arm lever to be maintained in the LOWER state. At
this time, the lift cylinder is released to allow the lift arm to be raised or lowered by external force.
Therefore, it this function starts when the lift arm is up in the air, it goes down due to its own
weight.
moved.
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Bucket leveling function

• If the bucket is below the horizontal position, operating the bucket lever to allow it to approach the
TILT detent range causes a detent-on signal to be output from the work equipment controller,
which, in turn allows the bucket lever to be maintained in the TILT state.
When the bucket is tilted and approaches the horizontal position, the bucket proximity switch
detects it, cancelling detent to stop the TILT operation.
At this time, the work equipment controller gradually slows down the bucket TILT EPC (referred to
as modulation control) to prevent excessive impact from arising upon stoppage of the bucket
motion.
moved.
If the bucket is tilted above the horizontal position, detent does not work even when the lever is
operated to approach the detent position.
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2. Remote positioner control

The remote positioner enables the operator to set the lift arm stop position as desired, smoothing lift
arm starting and stopping motions.
This enables safety and operability of backward digging operations as well as machine body operations
for approaching DUMP.
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.
Remote positioner mode selection and stop angle setting
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) : {
Applicable setting range for remote positioner stop position
Stop position
For RAISE For LOWER
Model
WA380 0° - +45.8° 0° - -40.8°
0°: Horizontal lift arm position
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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.)
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LOWER position setting
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.)
Output conditions for buzzers and indicator lamps

The same output conditions apply for both RAISE and LOWER operations.
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.
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3. Semi-auto digging control

Semi-auto digging control enables loads to be scooped in easily, simply by operating the lift arm lever
and the kickdown. With this function, even an amateur can achieve performance comparable with that
of a professional one.
1) Starting conditions for semi-auto digging

• Turn the auto-digging selection switch on (in the soft or hard mode).
• Set the lift arm angle of the work equipment to -35° or below (so that the bucket contacts the
ground).
• Operate the kickdown switch to shift down to the 1st speed gear with the transmission kept in
the forward mode.
• The engine speed increases and the travel speed drops (travel speed in km/h < 3.5 multiplied by
engine speed in rpm divided by 2,000).
• Semi-auto digging starts with lift arm RAISE operation.
2) Starting semi-auto digging
1] When the lift arm lever was replaced to the neutral position after semi-auto digging had started:
• Auto TILT starts on the bucket.
• The lift arm starts auto-lift after a travel speed of 1 km/h or below is maintained for 1 second.
• If lift arm RAISE is started at this time, AUTO-TILT stops during lift arm RAISE operation.
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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).
3) Termination of semi-auto digging

Semi-auto digging is terminated if one of the following conditions is satisfied:
• The shift lever is placed in a position other than forward.
• The lift arm is placed above the horizontal position.
• TILT operation reaches the stroke end.
• AUTO-TILT has been performed six times in the hard mode.
4) Semi-auto digging mode
• Soft mode
AUTO-TILT is continuously performed.
NOTE, however, TILT may temporarily stop due to manual interference
• Hard mode
AUTO-TILT operates intermittently in a cycle of 1 or 2 seconds.
The semi-auto digging mode is terminated when TILT has been performed six times in the hard
mode.
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4. Joystick steering control

Joystick steering control enables steering of the machine to be performed simply with the joystick,
without operating the steering wheel.
The steering wheel can be operated even during operation of the joystick. However, operation is artic-
ulated by either the joystick or the steering wheel, depending upon which is more powerful (in terms of
steering force) if the operating direction differs between the two.
The work equipment controller controls the steering system of the joystick.
The traveling system (forward/backward travel and gear shift) is controlled by the transmission control-
ler.
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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.
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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)
Electric Circuit Diagram (If equipped)
10-300 WA380-5
(10)
WA380-5 10-301
(10)
MAINTENANCE STANDARD WORK EQUIPMENT CONTROLLER (IF EQUIPPED)
WORK EQUIPMENT CONTROLLER (IF EQUIPPED)
10-302 WA380-5
(10)
MAINTENANCE STANDARD WORK EQUIPMENT CONTROLLER (IF EQUIPPED)
Input and output signals

DEUTSCH-24P [CN-L71]
1 Bucket lever potentiometer B Input 13 Lift arm lever potentiometer B Input
2 NC Input 14 Third EPC lever B Input
3 Joystick lever potentiometer B Input 15 NC Input
4 Signal GND — 16 Sensor power Output
5 NC Input 17 Lever prohibiting equipment operation switch Input
7 Bucket lever potentiometer A Input 19 Lift arm lever potentiometer A Input
8 Lift arm angle sensor Input 20 Third EPC lever A Input
9 Joystick lever potentiometer A Input 21 Analog GND —
10 Signal GND — 22 Potentiometer power Output
11 NC Input 23 Joystick ON/OFF switch Input
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
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 —
18 NC Output 38 Remote positioner lowering select switch Input
19 NC Output 39 Pulse GND —
20 Vehicle speed signal Input 40 NC Input
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
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)
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION CONTROL
10-304 WA380-5
1. Brake valve (left) 8. Gearshift lever

2. Transmission cutoff switch 9. Forward-reverse lever
3. Transmission cutoff set switch 10. Speed sensor
4. Relay box 11. Transmission control valve
5. Fuse box 12. Kick down switch
6. Transmission controller 13. Hold switch
7. Parking brake switch 14. Left brake pressure sensor
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
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
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)
MAINTENANCE STANDARD KICK DOWN, HOLD SWITCH
KICK DOWN, HOLD SWITCH
1. Switch A (white harness)

2. Spring
3. Harness
4. Switch B (yellow harness)
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)
MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
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)
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)
MAINTENANCE STANDARD ENGINE STOP CIRCUIT
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)
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)
MAINTENANCE STANDARD ENGINE POWER MODE SELECTOR CIRCUIT
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)
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
PARKING BRAKE CIRCUIT
Operation
1. When the starting switch is in the OFF position
• If you place the starting switch in the OFF posi-

tion, and then, the battery relay contact opens,
not allowing current to flow to the parking
brake circuit. For this reason, if the starting
switch is in the OFF position, the current does
not flow to the parking brake solenoid regard-
less of whether the parking brake switch is in
the ON or OFF position, operating the parking
brake.
10-314 WA380-5
(8)
2. When the starting switch is in the ON position

1) When the parking brake switch is in the ON (operation) position before placing the starting switch
in the ON position
• Since the parking brake selector switch is in the

ON (operate) position, current goes through the
battery relay, contact 1 of parking brake selec-
tor switch, contact 3, and parking brake safety
relay coil to the grounding. Consequently, the
terminals 3 and 5 of the parking brake safety
relay close. The current from the battery relay
continues to flow to the parking brake safety
relay coil and opens the battery relay contact
which is held open until the current stops flow-
ing to the parking brake circuit.
• At that time, the current does not flow to the
parking brake solenoid and the parking brake
remains in operation.
• In addition, this signal is input to the transmis-
sion controller to prevent dragging of the park-
ing brake by placing the transmission in the
neutral position during the operation of the
parking brake.
• If you place the parking brake selector switch in
the OFF (open) position after that, current goes
through the battery relay, parking brake safety
relay, contact 3 of parking brake selector
switch, contact 2, emergency brake switch, and
parking brake solenoid to the grounding, conse-
quently releasing the parking brake.
WA380-5 10-315
(10)
2) When the parking brake is in the OFF (release) position before placing the starting switch in the ON
position
• Since current does not flow to the parking brake

safety relay when the starting switch is in the
OFF position, the relay contact is open. Even if
you place the starting switch in the ON position,
the current does not flow to the parking brake
solenoid. Therefore, the parking brake will not
be released automatically.
10-316 WA380-5
(8)
3. When the main brake oil pressure lowers (emergency brake operates)
• When the main brake oil pressure lowers, the

contact of the emergency brake switch
mounted to the accumulator opens. This shuts
off current to the parking brake solenoid, conse-
quently draining the oil pressure out of the
parking brake cylinder to operate the parking
brake.
In this case, however, the parking brake release
signal is being issued to the transmission con-
troller unlike when you place the parking brake
switch in the ON position. Therefore, the trans-
mission is not switched to the N position.
By using this design and the engine brake when
the emergency brake functions, you can
shorten a braking distance. Even if the emer-
gency brake should function, it is possible to
move the machine.
WA380-5 10-317
(8)
MAINTENANCE STANDARD SENSORS
SENSORS
ENGINE SPEED SENSOR
SPEED SENSOR
1. Coil 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
• The engine speed sensor is mounted to the ring

gear of the flywheel housing. It generates pulse
voltage depending on the rotation of the gear
teeth to send a signal to the transmission con-
troller.
• The speed sensor is mounted to the transmis-
sion output gear. It generates pulse voltage
depending on the rotation of the gear teeth to
send a signal to the transmission controller.
The signal converted from the pulse to travel
speed in the transmission controller is sent to
the machine monitor for display through the
network.
10-318 WA380-5
(10)
ENGINE OIL PRESSURE SENSOR
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
• This sensor is mounted to the engine block.
The diaphragm detects oil pressure, and when
it reaches below the specified value, the switch
is turned ON.
ENGINE OIL LEVEL SENSOR
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)
COOLANT TEMPERATURE SENSOR (FOR MONITOR)

TORQUE CONVERTER OIL TEMPERATURE SENSOR
HYDRAULIC OIL TEMPERATURE SENSOR
TRANSMISSION OIL TEMPERATURE SENSOR
BRAKE OIL TEMPERATURE SENSOR
1. Connector 2. Plug 3. Thermistor

COOLANT TEMPERATURE SENSOR
(FOR PREHEATING)
1. Connector 2. Plug 3. Thermistor

Function • The transmission oil temperature sensor is
• The engine coolant temperature sensor is mounted to the transmission case. It handles a
mounted to the engine cylinder block, the temperature change as a resistance change of
torque converter oil temperature sensor is the thermistor and sends it as a signal to the
mounted to the transmission case, and the transmission controller.
hydraulic oil temperature sensor is mounted to The transmission controller is used for chang-
the hydraulic piping. ing over temperature tables for the electronic
Each sensor handles a temperature change as a modulation to use a gear shift pattern appropri-
resistance change of the thermistor and sends ate to oil temperature.
it as a signal to the machine monitor to display • The brake oil temperature sensor is mounted to
the temperature. the rear axle. It handles a temperature change
In addition, the temperature signal is sent to the as a resistance change of the thermistor and
transmission controller through the network sends a signal to the transmission controller.
and is used for cooling fan control. The transmission controller sends a signal to
the machine monitor through the network.
When it reaches the specified value, the lamp
lights and buzzer sounds as a warning.
10-320 WA380-5
(10)
TRANSMISSION CUT-OFF PRESSURE SENSOR
1. Sensor
2. Lead
3. Connector
Function
This sensor is mounted to the brake line block

under the floor. It detects brake operating pressure
to use it for position setting and operation of the
variable transmission cut-off function.
Relationship between pressure and voltage
WA380-5 10-321
(10)
COOLANT LEVEL SENSOR
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
• This sensor is mounted to the sub-tank in the

bulkhead. The float lowers to turn off the
switch when the coolant level reaches below
the specified level.
10-322 WA380-5
(8)
FUEL LEVEL SENSOR
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
• This sensor is mounted to the side surface of

the fuel tank. The float moves vertically
depending on the remaining quantity of the
fuel.
The movement of the float operates the vari-
able resistor through the arm and sends a sig-
nal to the machine monitor to indicate the
remaining quantity of the fuel.
WA380-5 10-323
(8)
LIFT ARM ANGLE SENSOR (IF EQUIPPED)
1. Shaft 4. Rotor
2. Housing 5. Connector
3. Bearing
Function
• This sensor is mounted to the front frame.

When the lift arm angle changes, the shaft
receives sliding resistance through the link on
the lift arm side to detect the lift arm angle.
You can mount it when mounting a load meter
or electric work equipment control lever.
10-324 WA380-5
(10)
AIR CLEANER CLOGGING SENSOR
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
• This sensor is mounted to the air cleaner outlet.

If the air cleaner is clogged to cause pressure to
rise to the specified pressure (negative pres-
sure), the warning lamp of the machine monitor
lights to issue a warning.
WA380-5 10-325
(8)
PRESSURE SENSOR FOR LOAD METER (IF EQUIPPED)
1. Sensor 3. Connector
2. Lead
Function
• This sensor is mounted to the bottom of the lift

cylinder and the both ends of the rod. It mea-
sures the pressure of the cylinder to use it for
calculation of load weight.
10-326 WA380-5
(10)
BATTERY ELECTROLYTE LEVEL SENSOR (IF EQUIPPED)
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
• This sensor is mounted to the battery. It sends

a signal to the machine monitor to indicate volt-
age change that occurs when the sensor end
comes out of the battery liquid into the air, giv-
ing a signal.
WA380-5 10-327
(10)
20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard value table for chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Testing and adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-201
★ 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
STANDARD VALUE TABLE FOR ENGINE
Machine Model WA380-5

Engine SAA6D114E-2
Standard Value For
Item Measurement Conditions Unit New Machine Service Limit Value
High idle (N mode) 1,900 ± 50 1,900 ± 50

High idle (P mode) 2,210 ± 50 2,210 ± 50
Low idle (N mode) 900 +50
0 900 +50
0
Revolving speed rpm
Low idle (P mode) 900 +50
0 900 +50
0
Rated revolving speed (N mode) 1,730 1,730

Rated revolving speed (P mode) 2,000 2,000
Exhaust tempera-
ture (Turbocharger All revolution ranges (Atmospheric tem- °C Max. 550 Max. 600
perature: 20 °C)
outlet temperature)
Max. 106.4
Intake air pressure kPa 113.1 - 126.4 {Max. 800}
At rated output
(Boost pressure) {mmHg} {850 - 950} Min. 133.3
{Min. 1,000}
At sudden acceleration Max. 4.5 Min. 6.5
Exhaust gas color Bosch index
At high idle Max. 1.0 Max. 1.5
Air intake valve
Valve clearance Exhaust valve mm 0.30 ± 0.05 0.30 ± 0.05
0.56 ± 0.05 0.56 ± 0.05
(Normal temperature)
Min. 2.0 {20.5}
Oil temperature: 40 - 60 °C MPa Min. 2.4 Difference between
Compression (SAE30 oil) {kg/cm2} {24.6}
pressure cylinders: Max. 0.7
{6.9}
(Engine speed) (rpm) (250 rpm) (250 rpm)
At rated output kPa Max. 0.98 Max. 1.96
Blow-by pressure (Operating range of coolant temperature)
(SAE30 oil) {mmH2O} {Max. 100} {Max. 200}
(Operating range of coolant temperature)

0.36 - 0.61 0.21
At high idle (15W-40) {3.5 - 6.0} {2.1}
At low idle (15W-40) MPa Min. 0.15 0.07

Oil pressure {1.5} {0.7}
{kg/cm2}
0.30 - 0.56 0.18
At high idle (SAE10W)
{3.0 - 5.5} {1.8}
Min. 0.10 0.07
At low idle (SAE10W) {1.0} {0.7}
Oil temperature All revolution ranges (Inside oil pan) °C 90 - 120 Min. 120
Fuel injection timing Before compression top dead center °(deg.) 8.5 ± 1 8.5 ± 1
Deflection made by
Above 10
finger pressure of Idler pulley - Crank 8 or
about 58.8 N {about pulley
6 kg} below 6
Belt tension mm
Deflection made by Air conditioner com-
finger pressure of
about 98 N {about pressor - Crank pul- 16 - 20 16 - 20
ley
10 kg}
20-2 WA380-5
(10)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

The * mark shows the value before the detent.
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}
FLOAT → HOLD Max. 14.7 {1.5} Max. 22.6 {2.3}

Working
equip-
ment con- HOLD → DUMP Max. 17.7 {1.8} Max. 26.5 {2.7}
trol lever
Bucket HOLD → TILT Max. 12.8 {1.3} * Max. 19.6 {2.0} *
TILT → HOLD Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD → RAISE • Engine speed: Low 43 ± 9 * 43 ± 18 *

Lift arm HOLD → RAISE idle 43 ± 9 * 43 ± 18 *
• Hydraulic oil tem-
Travel HOLD → RAISE
perature: mm 50 ± 9 50 ± 18
HOLD → RAISE 45 - 55 °C 50 ± 9 50 ± 18
Bucket
HOLD → RAISE 43 ± 9 * 43 ± 18 *
• Engine stopped
Play • Machine facing mm Max. 40 Max. 100
straight to front
• 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
• Engine speed: Max. 7.0

Low idling Low idling
4.5 ± 0.4
• Hydraulic oil
Operat- Max. 5.3
temperature: P mode Sec. 3.6 ± 0.3
ing time 45 - 55 °C
High idling • Left lock -
Right lock N mode 3.7 ± 0.3 Max. 5.7
• Engine speed: 1,200 rpm"

• Hydraulic oil temperature:
Clearance between front frame 45 - 55 °C
—
Frame and rear frame • Flat, level, straight, dry, mm 25 ± 2
and paved road
• At max. steering angle
WA380-5 20-3
(10)

Cate- Standard Value Service Limit
gory Item Measurement Condition Unit For New Machine Value
• Measure while engine is running.
Measure at 150 mm from fulcrum N 60.8 - 80.4 Max. 117.6
Pressing effort •
{kg} {6.2 - 8.2} {12.0}
of pedal.
Neutral (α1) • Measure while engine is 48 —

Acceler- stopped.
ator Pressing
pedal P-mode deg. 33 ± 1 —
angle
Neutral (α2)
N-mode 37 ± 1 —
Height of stopper (L) mm 60 ± 5 —
• Engine speed: Low idling N 294 ± 29.4 Max. 421.4

Operating effort
• Hydraulic oil temperature: 45 - 55°C {kg} {30 ± 3} {43}
Operating Neutral (α1) 45 —

angle deg. +1
Neutral (α2) 15 0 —
Brake
pedal
BWW10090
Play mm 5 ± 0.5 —
Fitting of wheel lock A • Tire inflation pressure: Specified Max. 2.5 —

ring B pressure Max. 4.0 —
Tire mm
Clearance of wheel TEW00003
lock ring C 2 - 10 —
20-4 WA380-5
(10)

Standard Value For
Category Item Measurement Conditions Unit New Machine Service Limit Value
• Engine coolant N mode 1,830 ± 50 1,830 ± 100

temperature:
Torque converter
Operating range
• Torque converter P mode 2,120 ± 50 2,120 ± 100
oil temperature:
Engine 60 - 80 °C N mode 1,810 ± 100 1,810 ± 200
speed Hydraulic stall • Hydraulic oil tem- rpm
perature: P mode 2,120 ± 100 2.120 ± 200
45 - 55 °C
N mode 1,715 ± 100 1,715 ± 200
Torque converter stall +
hydraulic stall
P mode 1,715 ± 100 1,715 ± 200
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
Lock-up 1.72 ± 0.15 1.72 ± 0.15

{17.5 ± 1.5} {17.5 ± 1.5}
Steering Steering relief pressure 45 - 55 °C MPa 15.7 ± 0.49 15.7
+0.49
{160 +5
}
{kg/cm2} {160 ± 5} -0.98 -10
• Engine speed: High idle
• Engine • Point where

speed: +0.5 +0.98
brake oil pres- 5.9 0 5.9 -0.5
Low idle
Charge cut-in pressure • Hydraulic sure warning {60 } {60 +10
-5 }
+5
oil tempera- 0
ture: 45 - 55
lamp goes out
Accumula- °C MPa
tor • Point where oil {kg/cm2}
pressure is 9.8 +0.98
9.8 +1.5
0 -0.5
Charge cut-out pressure going up and
then starts to {100 +100 } {100 +15
-5 }
go down
WA380-5 20-5
(9)

Cate- Standard Value For New
gory Item Measurement Conditions Unit Machine Service Limit Value
1st 6.8 ± 0.3 6.8 ± 0.5

2nd 12.3 ± 0.6 12.3 ± 0.9
P mode
3rd 21.4 ± 1.1 21.4 ± 1.6
4th 34.0 ± 1.7 34.0 ± 2.6
FORWARD
1st 5.3 ± 0.3 5.3 ± 0.4
2nd 9.3 ± 0.5 9.3 ± 0.7
N mode
3rd 16.7 ± 0.8 16.7 ± 1.3
Travel speed
Power 4th 27.0 ± 1.4 27.0 ± 2.0
train (Bucket
empty) km/h
1st 7.3 ± 0.4 7.3 ± 0.5
2nd 12.8 ± 0.6 12.8 ± 1.0
P mode
3rd 22.6 ± 1.1 22.6 ± 1.7
4th 35.0 ± 1.8 35.0 ± 2.6
REVERSE
1st 5.7 ± 0.3 5.7 ± 0.4
2nd 9.9 ± 0.5 9.9 ± 0.7
N mode
3rd 17.7 ± 0.9 17.7 ± 1.3
4th 27.9 ± 1.4 27.9 ± 2.1
Brake oil • Hydraulic oil temperature:

5.1 ± 0.49 {52 ± 5} 5.1 ± 0.98 {52 ± 10}
pressure 45 - 55 °C
• 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.
• Tire inflation pressure: Specified

pressure
Wheel • Flat, horizontal, straight, dry
brake
paved road surface
• Speed when applying brake:
Performance 20 km/h, braking delay: Within m Max. 5 Max. 5
0.1 sec.
• Brake pedal operating effort:
Specified operating effort (333 ±
33.3 N {34.0 ± 3.4kg})
• Measure braking distance
• Oil pressure: 4.9 MPa {50 kg/cm2} Shaft protrusion reaches

Disc wear mm Shaft protrusion 0 wear limit position (2.4
• Pedal depressed fully mm)
20-6 WA380-5
(10)

Cate- Standard Value For
gory Item Measurement Conditions Unit New Machine Service Limit Value
• Torque converter oil temperature:

Parking brake inlet 60 - 80 °C MPa Min. 2.27 Min. 2.27
pressure {kg/cm2} {Min. 23.1} {Min. 23.1}
• Engine speed: Low idling

pressure
• Flat paved road with 1/5 (11° 20’)
grade
• Dry, paved road surface
• Machine at operating condition
Parking
brake
Performance — Holds in position Holds in position
TEW01360
Disc thickness mm 3.2 ± 0.08 2.97

PPC valve basic pres-
sure
45 - 55 °C 3.72 +0.2
0 {38 +2
0 } 3.72 +0.2
-0.2 {38 +2
-2 }
• Engine speed: High idling
Lift arn • Hydraulic oil temperature:

PPC PPC RAISE, MPa
45 - 55 °C {kg/cm2}
valve FLOAT; 3.72 +0.1
-0.1 {38 +1
-1 } 3.72 +0.1
-0.2 {38 +1
-2 }
out- Bucket • Engine speed: High idling
put DUMP, TILT • Control lever operated fully
pres-
sure Lift arm 2.2 ± 0.25 2.2 ± 0.39
LOWER {22.5 ± 2.5} {22.5 ± 4}
WA380-5 20-7
(10)

Cate- Standard Value For
gory Item Measurement Conditions Unit New Machine Service Limit Value
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}
• Hydraulic oil temperature: 45 - 55 °C

• Run engine at high idling. N mode 6.2 ± 0.5 Max. 8.0
• Apply no load.
Lift arm RAISE
Raising time
P mode 5.3 ± 0.5 Max. 7.0
Lowering time
N mode 2.8 ± 0.5 Max. 4.0
Lift arm LOWER

Work equipment speed
P mode 2.7 ± 0.5 Max. 3.8
• Hydraulic oil temperature: 45 - 55 °C sec.

• Engine speed: High idling N mode 1.6 ± 0.3 Max. 2.3
Forward • No load
P mode 1.4 ± 0.3 Max. 2.0
Work equipment
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
Moving N mode 1.4 ± 0.3 Max. 2.0

bucket Backward
from level
position P mode 1.2 ± 0.3 Max. 1.8

• Stop engine and leave for 5 minutes, then mea-
sure for 15 minutes.
• Apply no load to bucket and set lift arm and
Retraction of lift
bucket in level position.l Max. 14 Max. 17
cylinder rod
Hydraulic drift
mm
Retraction of bucket
Max. 36 Max. 43
cylinder rod
20-8 WA380-5
(10)

Standard Value Service Limit
Category Item Measurement Conditions Unit For New Machine Value
• Engine speed: High idling
• Engine coolant temperature:
Min. 95 °C
Max. fan speed • Hydraulic oil temperature: 1,400 ± 100 1,400 ± 200
Min. 95 °C
• Torque converter oil tempera-
ture: Min. 105 °C
Oil pressure drive rpm
fan
• Engine coolant temperature:
Max. 40 °C
Min. fan speed • Hydraulic oil temperature: 240 ± 50 240 ± 100
Max. 40 °C
• Torque converter oil tempera-
ture: Max. 40 °C
WA380-5 20-9
(10)
TESTING AND ADJUSTING
Tools for testing, adjusting, and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-2

Measuring engine speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102
Measuring exhaust color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-104
Measuring exhaust temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
Adjusting valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
Measuring compression pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-108
Measuring blow-by pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-109
Measuring engine oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110
Measuring intake air pressure (boost pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
Testing and adjusting fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112
Adjusting engine speed sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-113
Bleeding air from fuel circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
Adjusting engine stop solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
Adjusting accelerator pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-117
Adjusting transmission speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
Testing and adjusting power train oil pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
Drawing of special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
Procedure for flushing torque converter, transmission hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . 20-125
Procedure for moving machine when transmission valve fails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-126
Testing and adjusting steering control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-128
Testing and adjusting steering oil pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-129
Testing hydraulic fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-131
Measuring brake oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-132
Testing wear of wheel brake disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-134
Bleeding air from brake circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-135
Testing wear of parking brake disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-136
Manual release method for parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-137
Testing and adjusting accumulator charge pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-138
Testing and adjusting working equipment ppc oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140
Testing and adjusting work equipment hydraulic pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-142
Testing and adjusting bucket positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-144
Testing and adjusting boom kick-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-145
Checking proximity switch actuation pilot lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-146
Adjusting machine monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-147
Testing and adjusting load meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150
Bleeding air. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-154
Releasing remaining pressure in hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-155
Releasing remaining pressure in E.C.S.S. circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-155
Pm clinic inspection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-156
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
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Check or
Symbol Part No. Part Name Q’ty Remarks
measurement item
Intake air pressure

(Boost pressure) A 799-201-2202 Boost gauge kit 1 –101 - 200 kPa (–760 - 1,500 mmHg)
Water temperature,
oil temperature, B 799-101-1502 Digital thermometer 1 –99.9 - 1,299 °C
exhaust temperature
799-101-5002 Oil pressure gauge kit (Analog) 1 Pressure gauge: {25,

2.5, 5.9, 39.2, 58.8 MPa
60, 400, 600 kg/cm2}
1
790-261-1204 Oil pressure gauge kit (Digital) 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Oil pressure C 2 799-401-2320 Oil pressure gauge 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
3 799-401-3300 Nipple 1
4 790T-301-1750 T-piece 1 Male, female: R1/8
1 795-790-3610 Compression gauge 1
Compression pressure D
2 795-790-3710 Adapter 1
1 799-201-1504 Blow-by checker 1
Blow-by pressure E
2 799-201-1590 Gauge 1 0 - 0.981 MPa {0 - 1,000 mmH2O}
795-799-1950 Lock pin 1
Valve clearance F Commercially
available Filler gauge 1
Fuel injection timing F 1 795-799-1950 Pin 1

1 799-201-9001 Handy smoke meter 1
Exhaust gas color G Commercially Bosch index: 0 - 9
2 Smoke meter 1
available
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Brake oil pressure H 4 799-301-1720 Adapter 1 M20 X 1.5 : Rc1/8
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 L=5m
7 790-261-1130 Coupling 1
Check of hydraulic drive
J 799-205-1100 Multitachometer 1 Digital indication : 6 - 99999.9 rpm
fan
Moving of machine
when transmission valve K 794-423-1190 Plug 1 20 X 1.5 mm
has failure
Check of parking brake disc Commercially
for wear M available Slide calipers 1 MITSUTOYO (Equivalent to N10)
Operating effort, 79A-264-0021 Push-pull scale 1 0 - 294 N {0 - 30 kg}

N
pressing force 79A-264-0091 Push-pull scale 1 0 - 490 N {0 - 50 kg}
Commercially
Stroke, hydraulic drift Q Scale 1
available
Commercially
Work equipment speed R available Stopwatch 1
Voltage, resistance S Commercially Tester 1

available
799-601-7400 T-adapter assembly 1
799-601-7330 Adapter 1 For S-16 (White)
1
799-601-7350 Adapter 1 For S-12 (White)
Check of sensors and T
wiring harnesses 799-601-7360 Adapter 1 For relay (5-pin type)
2 799-601-9000 T-adapter assembly 1 For DT type connector
For DT type connector
3 799-601-9300 T-adapter assembly 1 (For 24, 40-pin types)
WA380-5 20-101-2
(10)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
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
60 - 80 °C
BWW100101
1. Measuring engine speed (low idling and high

idling)
1) Switch to the monitoring function of Ser-
vice Mode 1 and display the engine
speed. For details, see SPECIAL FUNC-
TIONS OF MACHINE MONITOR in the
TROUBLESHOOTING section.
★ Monitoring item: ENG SPEED
2) Start the engine.
3) Turn the transmission cut-off selector
switch OFF and depress the left brake
securely.
4) Place the directional lever at F4 or R4.
• Operate the shift mode switch to
BWW10010 MANUAL and place the speed lever at
F4 or R4.
5) Release the parking brake.
6) Depress the accelerator pedal gradually
to raise the engine speed to full throttle,
and measure the engine speed when the
torque converter stalls.
★ Measure the stall speed 2 or 3 times.
★ Do not keep the stall condition for
2) Start the engine, set to the measurement more than 20 seconds. Make sure that
conditions, and measure the engine the torque converter oil temperature
speed. does not exceed 120 °C.
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
2) Start the engine and run at high idling.

3) Measure the engine speed when the
boom cylinder or bucket cylinder is
extended and the circuit is relieved.
4. Measuring torque converter stall + hydraulic

stall (full stall) speed:
1) The setting of the machine monitor is the
same as 2-1) Measuring torque converter
stall speed.
switch (2) OFF and depress the left brake
securely.
5) Release the parking brake.
WA380-5 20-103
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

Special tools required
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
WARNING! When installing or remov-

ing the measuring equipment, be care-
ful not to touch any high-temperature 2) Connect the probe hose, accelerator
parts. switch plug, and air hose to smoke meter
G2.
★ When measuring in the field where there is ★ The pressure of the air supply should
no air or power supply, use Handy Smoke be less than 1.5 MPa {15 kg/cm2}.
Checker G1; when recording official data, use 3) Connect the power cord to the AC 100 V
Smoke meter G2. outlet.
★ Before connecting the cord, check that
1. Measuring with Handy Smoke Checker G1 the power switch of the smoke meter
1) Fit filter paper in tool G1. is OFF.
2) Insert the exhaust gas intake port into the 4) Loosen the cap nut of the suction pump,
exhaust pipe. then fit the filter paper.
3) Start the engine and raise the engine ★ Fit the filter paper securely so that the
coolant temperature to the operating exhaust gas does not leak.
range. 5) Turn the power switch of smoke meter G2
4) Accelerate the engine suddenly run it at ON.
high idle, and at the same time operate 6) Accelerate the engine suddenly, and at
the handle of Handy Smoke Checker G1 to the same time, depress the accelerator
catch the exhaust gas on the filter paper. pedal and operate the relief valve to catch
the exhaust gas color on the filter paper.
7) Lay the filter paper used to catch the
exhaust gas color on top of unused filter
papers (10 sheets or more) inside the filter
paper holder, and read the indicated
BPW10340 value.
BPW10022
5) Remove the filter paper and compare it

with the scale provided to judge the con-
dition.
2. Measuring with Smoke Meter G2

1) Insert probe [1] of smoke meter G2 into
the outlet port of the exhaust pipe, then
secure it to the exhaust pipe with the clip.
20-104 WA380-5
(10)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

Special tool required
Sym Part
bol Name
Digital
tempera-
B 799-101-1502 1 -99.9 - 1,299 °C
ture
gauge
BPW10024
WARNING! Wait for the temperature

of the exhaust pipe to go down before
installing or removing the measuring
equipment.
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.
switch OFF and depress the left brake
securely.
• 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
WARNING! Do not keep the stall con-

dition for more than 20 seconds. Make
sure that the torque converter oil tem-
perature does not exceed 120 °C.
WA380-5 20-105
(10)
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
6) When the temperature becomes stable at ADJUSTING VALVE CLEARANCE

around the target temperature, cancel the
hydraulic relief, carry out only torque con- Special tool required
verter stall, and measure the exhaust tem-
perature. Part
★ The exhaust temperature at full stall Symbol Part No. Qty Remarks
Name
will start to go down, so measure the 795-799-
1 Pin 1 —
temperature when it becomes stable. 1950
F
★ If the exhaust temperature does not 2 Purchased Filler 1 —
gauge
go down and continues to go up,
make the temperature setting at full
stall higher. 1. Open the engine side cover.
2. Remove cover (1) and intake hose (2).
4. When measuring maximum value for exhaust
gas temperature, carry out actual work and
measure the maximum value when operat-
ing.
★ Use the PEAK mode function (the maxi-
mum value can be recorded) of the tem-
perature gauge.
★ The exhaust temperature differs greatly
according to the ambient temperature
(engine intake temperature), so if an
abnormal value is recorded, compensate
for the temperature.
★ Compensation temperature value = mea-
sured value + 2 x (converted ambient tem-
perature - ambient temperature). 3. Disconnect blow-by tube (3) from the head
• The converted ambient temperature is cover.
taken as 20 °C. 4. Disconnect clamps (4) (2 places).
5. Disconnect turbocharger waste gate tube (5)
from the turbocharger.
6. Remove head cover mounting bolts (6) and
head cover (7).
7. 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 tim-
ing pin (8) and set the No. 1 cylinder piston to
the compression top dead center (Insert the
timing pin in the gear hole)."
20-106 WA380-5
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
8. While the No. 1 cylinder piston is at the com-

pression top dead center, adjust the clear-
ances of the valves marked with z in the
valve arrangement table. Then, revolve the
crankshaft forward by 360 degrees and adjust
the clearances of the valves marked with c.
Valve arrangement table
Cylinder No.
Exhaust
valve
★ Pushing depth of timing pin (8): 8 mm
Air intake
valve
9. Insert filler gauge F2 in clearance b between

rocker lever (9) and valve stem (10) and adjust
the clearance with adjustment screw (11).
★ Turn the adjustment screw so that the
inserted filler gauge will move lightly.
★ When the No. 1 cylinder piston is at the

compression top dead center, the No. 1
cylinder rocker arm can be moved with
the hand by the valve clearance. If the
rocker arm does not move, the piston is
not at the compression top dead center.
In this case, revolve the crankshaft 1 more
turn."
★ After setting the No. 1 cylinder piston to
the compression top dead center, make a
match mark on the damper and install
pointer 2 to the front cover with a wire."
★ If checking with the timing pin installed to 10. Secure adjustment screw (11) and tighten
the engine is difficult, metallic pin assem- locknut (12).
bly F1 may be used."
Locknut : 24 ± 4.0 Nm {2.45 ± 0.41 kgm}
★ After setting to the compression top dead
center, be sure to pull out the timing pin."
★ After tightening the locknut, check the
valve clearance again."
WA380-5 20-107
5
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

Check tools
5. Install adapter D2 to the nozzle holder mount-
Sym- Part ing part of the cylinder to be measured and
bol Part No. Name Qty Remarks
tighten it to the specified torque.
Com-
1 795-790-3610 pres- 1 — Holder mounting bolt:
D sion
gauge 23.5 ± 3.9 Nm {2.4 ± 0.4 kgm}
2 795-790-3710 Adapter 1 —
6. Connect compression gauge D1 to the
adapter.
WARNING! When measuring the
compression pressure, take care not to
get burned with a hot part or caught in
a rotary part.
★ Measure the compression pressure after the

engine is warmed up.
(Engine oil temperature: 40 - 60 ° C).
1. Adjust the valve clearance correctly. For
details, see Adjusting valve clearance.
2. Remove engine hood assembly (1), exhaust
muffler assembly (2), air intake muffler
assembly (3), and air intake manifold (4). For
details, see DISASSEMBLY AND ASSEMBLY,
Removal and installation of nozzle holder
assembly. 7. Disconnect connector (10) (CN-E34) of fuel cut
solenoid (9) to prevent injection, then revolve
the engine with the starting motor and read
the pressure after the pressure gauge pointer
stops.
★ Apply some oil to the adapter mounting
part so that air will not leak.
★ When measuring the compression pres-
sure, check that the engine speed is in the
measuring range.
★ After measuring the compression pres-
sure, install the nozzle holder assembly.
3. Remove injection tube (5) of the cylinder to

be measured and disconnect spill tube (6).
4. Remove holder (7) and pull out nozzle assem-
bly (8).
★ Take care that foreign matter will not
enter the nozzle and cylinder.
20-108 WA380-5
5
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

6. Depress the accelerator pedal gradually to
Sym-
Part No.
Part
Qty Remarks
raise the engine speed to full throttle, and
bol Name measure the blow-by pressure when the
E 799-201-1504
Blow-by
1
0 - 4.9 kPa torque converter stalls.
checker {0 - 500 mmH2O}
WARNING! Do not keep the stall con-
1. Install nozzle 1 and hose 2 to blow-by hose dition for more than 20 seconds. Make
(1), and connect to blow-by checker E . sure that the torque converter oil tem-
perature does not exceed 120 °C.
★ Precautions when measuring blow-by

Blow-by varies greatly according to the
condition of the engine. Therefore, if the
blow-by value is considered abnormal,
check for problems connected with defec-
tive blow-by, such as excessive oil con-
sumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
2. Run the engine and raise the coolant temper-

ature to the operating range.
3. Turn the transmission cut-off selector switch BPW10026
OFF and depress the left brake securely.
4. Place the speed lever at F4 and R4.
• Turn the transmission manual switch ON
and place the speed lever at F4 and R4.
5. Release the parking brake.
WA380-5 20-109
(10)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

4. Run the engine and raise the coolant temper-
Sym- Part ature to the operating range.
bol Name 5. Measure the oil pressure with the engine at
Pressure gauge low idle and high idle.
Hydrau- 1.0 MPa
C2 799-401-2320 lic 1 {10 kg/cm2}
gauge (Use hose in C1
tool kit)
1. Open the engine right side cover.

2. Remove engine oil pressure switch (1) (width
across flats: 26mm). BPW10032
6. After completing the measurement, remove

the measuring equipment and return to the
original condition.
3. Install nipple 1 and hose 2, and connect oil

pressure gauge C2.
20-110 WA380-5
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

Check tool 5. Set the gear shift lever to F4 or R4.
• Turn on the transmission manual switch
Sym- Part No. Part Qty Remarks
and set the gear shift lever to F4 or R4.
bol Name
6. Release the parking brake.
Boost 7. Press the accelerator pedal gradually to full
pres- -101 - 199.9 kPa
A 799-201-2202 sure 1 {-760 - 1.500 throttle, then stall the torque converter and
gauge mmHg} measure the intake air pressure at that time.
kit
WARNING! When installing and

removing the measuring devices, take
care not to touch a hot part.
1. Remove intake air pressure pickup plug (1)

(NPTF 1/4) and install adapter (4) of oil pres-
sure gauge kit C1.
★ Remove mounting bolt (2) of the fuel tube
clamp and loosen the mounting bolt of
stay (3) and slide the stay backward.
2. Connect oil pressure measurement nipple (5)

and hose (6) to adapter (4) and pressure
gauge A.
3. Start the engine.

4. Turn OFF the transmission cut-off selector
switch and press the left brake securely.
WA380-5 20-111
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

Check tool 2) Remove plug (2) and reverse timing pin
(3) and check that timing pointer (4) on
Sym- Part the injection pump side is meshed with
bol Name pin (3).
F1 795-799-1950 Pin 1
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.
★ If checking with the timing pin installed to

the engine is difficult, metallic pin assem-
bly F1 may be used.
20-112 WA380-5
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

★ Adjust the engine speed sensor (CN-E27)
according to the following procedure.
1. Open the engine right side cover.

2. Screw in until the tip of sensor (1) contacts
the tip of the tooth of flywheel ring gear (2).
★ Check that there are no scratches or metal
particles stuck to the tip of the sensor.
Thread portion: Hydraulic sealant
3. Turn sensor (1) back 1/2 - 2/3 turns from that

position.
★ Adjust clearance a between so that the tip
of the sensor and the tip of the gear tooth
is 0.75 - 1.00 mm.
4. Secure sensor (1) with nut (3).
Nut: 69 - 74 Nm {7.0 - 7.5 kgm}
WA380-5 20-113
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT

★ If the fuel runs out or if any fuel circuit device 2. Remove air bleed plug (2) of the fuel filter and
is removed and installed, bleed air according operate priming pump (3).
to the following procedure. ★ Continue operating the priming pump
until flow out from the plug hole. When
1. Remove fuel filter (1) and fill it with fuel and fuel comes out, install the plug.
install it again.
Air bleed plug:
7.8 - 9.8 Nm {0.8 - 1.0 kgm}
3. Crank the engine (for 15 - 20 seconds) with

the starting motor 2 - 3 times.
★ When filling, use clean fuel and be careful

not to let dirt get in.
★ Add fuel through inlet port portion a (8
places) of the filter. Portion b is the outlet
port (clean side) after the fuel has been fil-
tered, so never add fuel from here.
★ If clean fuel is not available, do not

remove the filter. Operate the priming
pump to fill the filter with fuel.
20-114 WA380-5
(10)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ENGINE STOP SOLENOID
★ If the fuel injection pump or engine stop sole-

noid is replaced, adjust the engine stop sole-
noid according to the following procedure.
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
ADJUSTING ACCELERATOR PEDAL
Adjusting power mode
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
Adjusting normal mode
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
2. Projection a of stopper bolt (4):

20 mm (Temporary tightening.)
3. Operate the mode selector switch and check

that the cable moves smoothly.
• Position of stopper bolt
1: Power mode
2: Normal mode
20-118 WA380-5
(10)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
ADJUSTING TRANSMISSION SPEED SENSOR
• Adjust speed sensor (1) (CN-REV OUT)

1. Open the left cover of the rear frame.
2. Screw in sensor (1) until its tip comes in con-

tact with a tooth tip of gear (2).
★ Before installing the sensor, check that its

tip is free from a steel chip, a flaw, etc.
Threaded parts: Gasket sealant (LG-5)
3. Return sensor (1) by 1/2 - 1 turn.

★ Adjust clearance a between the sensor tip
and gear tooth tip to about 1.5 mm.
4. Lock sensor (1) with nut (3).
Nut: 69 - 74 Nm {7.0 - 7.5 kgm}
WA380-5 20-119
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE

Sym Part No. Part Qty Remarks

bol Name
Pressure
Analog gauge: 2.5,
1 5.9, 39.2,
799-101-5002 hydrau- Set 58.8 MPa
lic tester
{25, 60, 400,
C1 600 kg/cm2}
Pressure
Digital
790-261-1204 hydrau- 1 gauge:
Set 58.8 MPa
lic tester
{600 kg/cm2}
Pressure
Hydrau- gauge:
C2 799-401-2320 1
lic gauge 1.0 MPa
{10 kg/cm2}
Male/Female
C4 790T-301-1750 T-piece 1 R 1/8
See attached
drawing.
WARNING! Put block under the tires.
BWW10037
WARNING! Wait for the temperature
of the oil to go down before installing
or removing the measuring equip-
ment.
★ Measure the power train oil pressure under

the following conditions.
• Coolant temperature: Within operating range
• Power train oil temperature: 60 - 80 °C
• Remove the cover at the left side of the
rear frame.
★ Turn the transmission cut-off selector switch
OFF and use the left brake.
Oil pressure measuring position and measuring

gauges
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}
8 Transmission 1st clutch pressure 5.9 {60}

Transmission 3rd clutch pres-
9 sure 5.9 {60}
Transmission 2nd clutch pres-

10 sure 5.9 {60}
11 Parking brake pressure 5.9 {60}
20-120 WA380-5
(9)
1. Measuring main relief pressure 2. Adjusting the main relief valve

1) Install hose1 to oil pressure measure-
ment nipple (1).
WARNING! Adjust the main relief
valve with the engine stopped.
• If the main relief pressure is not within the

standard value, adjust as follows.
1) Remove plug (12).
2) Remove inner spring (13) and outer
spring (14).
3) Adjust by changing the thickness of shim
(15).
★ Standard shim thickness: 0.5 mm (0.5
x1)
★ Amount of adjustment for one shim:
0.04 MPa {0.4 kg/cm2}
2) Connect oil pressure gauge C1.
BWW10097
BPW10040
3) Start the engine, keep the gearshift lever

at the N position, and measure the oil
pressure with the engine at low idling and
rated speed.
4) After completing the measurement,
remove the measuring equipment and
return to the original condition.
WA380-5 20-121
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
3) Start the engine, keep the gearshift lever

3) Start the engine, keep the gearshift lever at the N position, and measure the oil
at the N position, and measure the oil pressure with the engine at rated speed.
pressure with the engine at rated speed. 4) After completing the measurement,
4) After completing the measurement, remove the measuring equipment and
remove the measuring equipment and return to the original condition.
return to the original condition.
20-122 WA380-5
5. Measuring transmission clutch pressure 2) F, R clutch (measurement plug: 4, 5)

• Remove measurement plug A of the i) Depress the brake.
ECMV valve, install the nipple and the ii) Start the engine and turn the parking
hose, then connect oil pressure gauge C1. brake switch OFF.
iii) Place the gearshift mode selector
switch at MANUAL.
iv) With the engine at low idling, keep the
directional lever at N, and operate the
speed lever to 4th speed.
v) With the engine at low idling, keep the
brake depressed, place the direc-
tional lever in F or R, then return the
directional lever to N.
WARNING! The machine

will move, so check care-
fully that the surrounding
area is safe.
1) 1st, 2nd, 3rd, 4th clutch
vi) Run the engine at rated speed and
• Plug 7: 4th clutch pressure measure the F and R clutch oil pres-
• Plug 8: 1st clutch pressure sure.
• Plug 9: 3rd clutch pressure vii) After completing the measurement,
• Plug 10: 2nd clutch pressure remove the measuring equipment
i) Depress the brake. and return to the original condition.
ii) Start the engine and turn the parking
brake switch OFF. 3) Torque converter lock-up clutch (mea-
iii) Run the engine at low idling, set the surement plug: 6)
directional lever at N, switch the shift
WARNING! The measurement is
mode selector switch to the MANUAL
made with the machine travelling, so
position, then place the speed lever in
check carefully that the surrounding
the speed range to be measured.
area is safe.
iv) With the engine at low idling, keep the
brake depressed, place the direc- i) Depress the brake.
tional lever on F or R, then return the ii) Place the gearshift mode selector
directional lever to N. switch at AUTO.
★ The above operation is carried out iii) Turn the parking brake switch OFF.
because when the directional iv) Place the speed lever at 3rd.
lever is at N, even if the speed v) Place the directional lever at F and
lever is operated, the speed range drive the machine.
is not shifted. vi) Travel with the engine running at
rated speed and measure the oil pres-
WARNING! The machine sure at the point where the lock-up
will move, so check care- pilot lamp lights up in F3.
fully that the surrounding vii) After completing the measurement,
area is safe. remove the measuring equipment
and return to the original condition.
v) Measure the oil pressure of the mea-
surement clutch oil with the engine at
4) Measuring parking brake pressure (mea-
rated speed.
surement plug: 11)
vi) After completing the measurement,
i) Turn the parking brake switch OFF.
remove the measuring equipment
ii) Start the engine and measure the
and return to the original condition.
pressure with the engine at low idling.
WA380-5 20-123
TESTING AND ADJUSTING DRAWING OF SPECIAL TOOL
DRAWING OF SPECIAL TOOL

Note) We will not liable for any result caused by a special tool made according to this drawing.
Tool C4
20-124 WA380-5
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION

HYDRAULIC CIRCUIT
★ Metal particles and other dirt in the torque 3) Repeat the procedure in step 4-1) and run
converter and transmission hydraulic circuit the engine at low idling for approx. 20
will reduce the life of the torque converter minutes.
and transmission, and will cause internal 5. Replace the filter cartridge.
damage. To prevent this, carry out flushing to 1) Using the procedure in Step, 2 replace the
remove the dirt in the hydraulic circuit. cartridge used for flushing with the new
cartridge (714-07-28711).
1. Flush the circuit if the following conditions
apply. WARNING! If the cartridge used for
1) If there has been any breakage of the flushing is used for a long time, there
torque converter, transmission, or will be premature clogging, so always
hydraulic equipment, and metal particles replace the flushing element with the
are circulating in the hydraulic circuit. standard element.
2) When the torque converter and transmis-
2) Add oil and check the level again.
sion have been overhauled or repaired.
2. Install a new filter cartridge.
1) Drain the oil from the filter piping.
2) remove the transmission oil filter car-
tridge, then install the cartridge
(714-07-28711).
3. Fill the transmission case with oil.
• Add fresh oil through the oil filter port to
the specified level, and run the engine to
circulate the oil through the system. Then
check the level again.
5 Transmission case: 54 l
4. Carry out flushing as follows.

1) After starting the engine, run the engine
for approx. 20 minutes at low idling with-
out operating the speed lever or direc-
tional lever.
★ From time to time, raise the engine
speed to approx. 1,500 rpm.
★ If the ambient temperature is low and
the engine coolant temperature gauge
does not enter the white range, con-
tinue the warming-up operation
longer.
2) Travel or carry out actual operations for
20 minutes.
★ Use all the speed ranges (FORWARD,
REVERSE, and 1st - 4th).
WA380-5 20-125
(10)
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE
TESTING AND ADJUSTING FAILS
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS

Special tool required 2. Disconnect wiring connector (2) of each
ECMV. (12 places, L/C specification: 14 places)
bol Name
K 794-423-1190 Plug 1 M20 x 1.5
★ If the machine cannot be moved because of a

failure in any parts of the transmission valve
system (electrical system, solenoid valves,
spools, etc.), it is possible to move the
machine by installing plug K.
WARNING! Plug K is only for emer-

gency use when the machine cannot
be moved in any speed range because
of a failure in the transmission control
valve. Install plug K to the ECMV only ECMV allocation diagram
when there has been a failure and it is
necessary to move the machine from a
dangerous working area to a safe
place for repairs.
BWW10100
WARNING! When carrying out this
operation, keep strictly to the proce-
dure and pay careful attention to
safety when moving the machine.
WARNING! To prevent the machine

from moving, lower the work equip-
ment completely to the ground, apply
the parking brake, and put blocks
under the tires.
WARNING! Carry out the operation

with the engine stopped.
WARNING! Be careful not to burn

yourself if the oil is hot.
1. Remove cover (1) at the left side of the rear

frame.
★ Wash the area around the ECMV clean
and remove all dirt and mud.
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.
WARNING! When the engine is

started, the transmission is also
engaged to start the machine. To
ensure safety when starting the
BWG10004 engine, check carefully that the direc-
tion of travel and area around the
machine are safe, and always keep the
brake pedal depressed.
WARNING! After moving the

machine, stop the engine, apply the
parking brake, and put blocks under
the tires.
BWG10005
WA380-5 20-127
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CONTROL
TESTING AND ADJUSTING STEERING CONTROL

★ Measurement conditions
• Engine speed: 1,200 rpm
• Road surface: Flat, horizontal, dry paved sur-
face
• Tire inflation pressure: Standard pressure
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
TESTING AND ADJUSTING STEERING OIL PRESSURE

Special tools required 2. Install oil pressure gauge C1 (39.2 MPa {400
kg/cm2}) to nipple (2) for measuring the left
Sym- Part No. Part Qty Remarks turn steering circuit.
bol Name
3. Run the engine at high idle, then turn the
Pressure steering wheel to the left and measure the
Analog gauge: 2.5,
type 1 5.9, 39.2, pressure when the relief valve is actuated.
799-101-5002 hydrau- Set 58.8 MPa
lic tester {25, 60, 400,
★ If the plug for the right turn steering cir-
C1 600 kg/cm2} cuit was removed, turn the steering wheel
Pressure to the right and measure the pressure.
Digital
type 1 gauge:
790-261-1204 58.8 MPa
hydrau- Set
lic tester {600 kg/
cm2}
Measuring
WARNING! Loosen the oil filler cap

slowly to release the pressure inside
the hydraulic tank, and operate the
steering wheel 2 or 3 times to release
the remaining pressure in the hydrau-
lic piping.
1. Fit frame lock bar (1) to the frame.
BPW10040
WA380-5 20-129
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Adjusting
WARNING! Always stop the engine

before adjusting the pressure.
1. Stop the engine.

2. Loosen locknut (3), then turn adjustment
screw (4) to adjust.
★ Turn the adjustment screw to adjust the
pressure as follows.
• To INCREASE pressure, turn CLOCK-
WISE
• To DECREASE pressure, turn COUN-
TERCLOCKWISE
★ Pressure adjustment for one turn of
adjustment screw: 14.8 MPa {151 kg/cm2}
★ If the relief pressure cannot be measured
correctly, do not try to adjust it.
BWW10066
20-130 WA380-5
TESTING AND ADJUSTING TESTING HYDRAULIC FAN
TESTING HYDRAULIC FAN

Check tool
Sym-
Part No. Part Name Qty Remarks
bol
Measurement
J 799-205-1100 Multi- 1 range:
tachometer
6 - 99999.9rpm
1. Open the radiator grill and remove covers (1),

(2), and (3).
2. Install stand [1] and probe [2] of multi-

tachometer J.
3. Stick reflector tape [3] to the fan.
4. Run the engine and measure the fan speed

with multitachometer [4] at the high idle and
low idle engine speeds.
WA380-5 20-131
(9)
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
MEASURING BRAKE OIL PRESSURE


bol Name
Brake
1 793-605-1001 1 —
test kit
2 790-101-1430 Coupler 1 —
BWW10073
3 790-101-1102 Pump 1 —
H 4 799-301-1720 Adapter 1 M20 x 1.5
(Rc1/8)
5 799-101-5160 Nipple 1 —
6 799-401-2220 Hose 1 L: 5 m
7 790-261-1130 Coupling 1 —
4. Loosen bleeder screw (3) and bleed the air.

WARNING! Apply the parking brake
and put blocks under the tires. ★ Operate pump H3 to bleed the air.
★ Use the same procedure to measure the front

brakes (left and right) and rear brakes (left
and right).
1. Stop the engine.

2. Remove brake tube (1) on the side to be mea-
sured.
3. Remove union (2), install adapter H4 and nip-
ple H5, then assemble brake test kit H1.
★ Use the O-ring assembled to the union.
5. Tighten bleeder screw (3), operate pump H3,

raise the pressure to 4.9 MPa {50 kg/cm2},
then tighten stop valve 1.
BEW00563
20-132 WA380-5
(10)
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
6. After applying the pressure, leave for 5 min-

utes and measure the drop in the pressure.
★ If the hose is moved while measuring the
pressure, the pressure will change, so do
not move the hose.
★ When removing brake test kit H1 after
testing, operate pump H3 to lower the
pressure of brake test kit H1, then remove
it.
★ After completing the operation, install the
brake tube, then bleed the air from the
brake circuit
• Brake test tool
WA380-5 20-133
(10)
TESTING AND ADJUSTING TESTING WEAR OF WHEEL BRAKE DISC
TESTING WEAR OF WHEEL BRAKE DISC
4. After completing the measurement, return to

WARNING! Stop the machine on hori- the original condition.
zontal ground and put blocks under the
tires. Cap (1): . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 29.4 - 39.2 Nm {3.0 - 4.0 kgm}
★ Brake oil pressure: 4.9 ± 0.49 MPa {50 ± 5 kg/cm2}
1. Remove cap (1).
2. Depress the brake pedal fully.

3. Push in shaft (2), then check protrusion x
(amount of wear) from guide (3).
★ Keep the pedal depressed while measur-
ing.
★ If the groove of shaft (2) is protruding
from the end face of guide (3), replace the
disc.
• Amount of wear: x
• Wear limit: y (2.4 mm)
BWW10076
20-134 WA380-5
(10)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
BLEEDING AIR FROM BRAKE CIRCUIT
5. When no more bubbles come out with the oil

WARNING! Stop the machine on hor- from the hose, tighten bleeder screw (2).
izontal ground and put block under the
tires. Bleeder screw: . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 10 - 20 Nm {1 - 2 kgm}
★ If equipment in the brake circuit has been
removed and installed, bleed the air from the
brake circuit as follows. 6. After completing the air bleeding, run the
★ Use the same procedure for both the front engine at low idling, check the oil level in the
brake circuit and rear brake circuit (2 places hydraulic tank, and more oil if necessary.
each).
• Raise the lift arm and put blocks under the lift
arm, and then remove front frame cover (1).
1. Connect air bleed hose 1 to bleeder screw

(2), then insert the other end in a container.
2. Start the engine and run at low idling.

3. Depress the brake pedal, and keep the brake
pedal depressed.
4. Loosen bleeder screw (2) approx. 1/2 turn,
and drain the air and oil.
WA380-5 20-135
(10)
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
TESTING WEAR OF PARKING BRAKE DISC

4. When the depth a is more than the standard
Sym- Part value, remove parking brake disc (4), and
bol Name measure disc width W. For details, see DISAS-
Commercially
(Mitsutoyo SEMBLY AND ASSEMBLY, Removal of park-
M available Calipers 1 N10 or ing brake disc.
equivalent)
• Judgement standard width W: 2.97 mm
★ If the parking brake does not work suffi- ★ When the depth of the parking brake disc
ciently, check the parking brake disc for wear is less than the standard value replace the
disc.

from moving, lower the bucket to the
ground and put blocks under the tires.
WARNING! Always stop the engine BDW00259

before carrying out this procedure.
1. Drain the oil from the transmission case.
Transmission case: . . . . . . . . . . . . 54 l
2. Remove 1 plug (1) (remove 1 of the 2 plugs).
BPW10045
3. Measure depth a with calipers M from the end

face of cage (2) to piston (3).
• Standard depth a: Max. 42.3 mm
20-136 WA380-5
TESTING AND ADJUSTING MANUAL RELEASE METHOD FOR PARKING BRAKE
MANUAL RELEASE METHOD FOR PARKING BRAKE

★ The parking brake is controlled by hydraulic 2. Remove 2 gauge mounting bolts (2), and
pressure, so if there should be any failure in tighten to plug mounting portion in turn.
the transmission or the emergency release ★ Remove bolts (2) on opposite sides.
solenoid and it becomes impossible to ★ When bolts (2) are screwed in, piston (3)
release the parking brake, it is possible to is pulled and the parking brake is
release it manually to move the machine. released.
★ Tighten the 2 bolts uniformly a little at a
time. (Tighten approx. 4 turns after the
WARNING! The manual release of the bolts contacts the seat.)
parking brake is designed only to
move the machine from a dangerous
working area to a safe place where
repairs can be carried out. This
method must not be used except in an
emergency.
BWW10079
from moving, lower the bucket to the
ground and put blocks under the tires.
WARNING! Always stop the engine

before carrying out this procedure.
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
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE

Special tools required 3. Fit nipple 1 and hose 2 for measuring oil
pressure to tool C3, then install oil pressure
Sym- Part No. Part Qty Remarks gauge C1(39.2 MPa {400 kg/cm2}).
bol Name
Pressure
Analog gauge: 2.5,
type 5.9, 39.2,
799-101-5002 hydrau- 1 58.8 MPa
lic tester {25, 60, 400,
1 600 kg/cm2}
C Pressure
Digital BPW10070
type gauge:
790-261-1203 1 58.8 MPa
hydrau-
lic tester {600 kg/
cm2}
3 799-401-3300 Nipple 1 —
Measuring
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}
Locknut : 9.8 - 11.8 Nm {1.0 - 1.2 kgm}
★ After completion of the adjustment, repeat

the above procedure for testing to check the
accumulator charge cut-in pressure and cut-
out pressure again.
WA380-5 20-139
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE

Special tools required 2) Install nipple 1 and hose 2 and connect
pressure gauge C1 (5.9 MPa {60 kg/cm2}).
Sym- Part No. Part Name Remarks 3) Start the engine, operate the work equip-
bol
ment control lever at high idling and mea-
Pressure sure the oil pressure.
Analog gauge: 2.5,
type 5.9, 39.2,
799-101-5002 hydraulic 58.8 MPa
tester {25, 60, 400,
C1 600 kg/cm2}
Digital Pressure
790-261-1203 type gauge:
hydraulic 58.8 MPa
tester {600 kg/cm2}

• Steer the vehicle to the right end.
WARNING! Loosen the oil filler cap

slowly to release the pressure inside
the hydraulic tank.
WARNING! Operate the control levers

several times to release the pressure in
the PPC accumulator circuit.
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. Measuring PPC valve output pressure Adjusting

1) Raise the lift arm and install a support to it 1. Adjusting PPC relief valve
and remove front frame inspection cover (1). Loosen locknut (3) of PPC relief valve (5), then
turn adjustment screw (4) to adjust.
★ Turn the adjustment screw to adjust as
follows.
CLOCKWISE.
• To DECREASE the pressure, turn
COUNTERCLOCKWISE.
★ Amount of adjustment for one turn of
adjustment screw: 1.79 MPa {18.3 kg/
cm2}.
Locknut : 9.8 - 11.8 Nm {1.0 - 1.2 kgm}
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
3) Start the engine, run the engine at high

idling, then operate the work equipment
control lever and measure the oil pressure.
WA380-5 20-141
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE

Special tools required 3) Connect hose 1 to nipple (1) for measur-
ing oil pressure and connect pressure
Sym- Part No. Part Remarks gauge C1 (39.2 MPa {400 kg/cm2}).
bol Name
Pressure 4) Start the engine, raise the lift arm approx.
Analog gauge: 2.5,
type 5.9, 39.2, 400 mm, run the engine at high idling, tilt
799-101-5002 hydraulic 58.8 MPa the bucket back, then measure the oil
tester {25, 60, 400,
C1 600 kg/cm2} pressure when the relief valve is actuated.
Digital Pressure
type gauge: WARNING! After measuring, repeat
790-261-1203
hydraulic 58.8 MPa the procedure used when installing the
tester {600 kg/cm2}
oil pressure gauge to release the pres-
sure inside the circuit, then remove the
★ Hydraulic oil temperature: 45 - 55 °C oil pressure gauge.
1. Measuring work equipment relief pressure
1) Raise bucket portion a approx. 30 - 50 mm
and set portion b in contact with the
ground.
2) Stop the engine, then operate the work
equipment control lever and check that
the bottom surface of the bucket (both
portion a and portion b is in contact with
the ground.
★ After lowering the bucket to the
ground, operate the work equipment
control lever several times to release
the remaining pressure in the piping.
BWW01193
20-142 WA380-5
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
Adjusting 3) Loosen locknut (3) and adjust with adjust-

1. Adjusting work equipment relief valve ment screw (4).
★ As the adjustment screw is
WARNING! When adjusting the oil
pressure, be sure to stop the engine.
CLOCKWISE.
1) Raise the lift arm and install a support to it • To DECREASE the pressure, turn
and remove front frame inspection cover COUNTERCLOCKWISE.
(1). ★ Quantity of adjustment per turn of adjust-
ment screw: 3.5 MPa {35.7 kg/cm2}
Locknut : 28 - 34 Nm {2.8 - 3.5 kgm}
★ After adjusting, measure the work

equipment relief pressure again
according to the procedure in "Mea-
suring" shown above.
2) Remove cap nut (2) of the relief valve.
WA380-5 20-143
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER
TESTING AND ADJUSTING BUCKET POSITIONER

★ Engine coolant temperature: White range of 2) Adjust and secure clearance a between
engine coolant thermometer the sensitive surface of proximity switch
★ Hydraulic oil temperature: 45 - 55 °C (1) and sensing bar (2) to the standard
range with the shim and mounting bolt of
Testing the proximity switch bracket.
1. Stop the engine and check that clearance a ★ Clearance a: 3 - 5 mm
between proximity switch (1) and sensing bar ★ Adjust sensing bar (2) with the shim
(2) is in the standard range. so that clearance a will be in the stan-
dard range through the stroke of the
sensing bar.
2. Adjusting installing position (stopping posi-
tion).
1) Lower the bucket to the ground and set it
to a desired digging angle, then return the
lever to the holding position and stop the
engine.
2) Secure switch protector (3) to the bucket
cylinder so that sensing bar (2) will be at
the center of the sensitive surface of prox-
imity switch (1).
• The installing position may be
checked by checking the operation of
2. Run the engine at a medium speed (1500 the pilot lamp of the proximity switch
rpm) and check the operating point. (Mea- with the starting switch at the ON
sure 3 times and obtain the average.) position. (When the pilot lamp goes
off, the bucket stops.)
Adjusting ★ After adjusting, start the engine and oper-
1. Adjusting clearance. ate the bucket control lever to check that
1) Adjust and secure clearance b between the bucket positioner operates at the
the tip of switch protector (3) and the sen- desired position.
sitive surface of the switch to the standard
range with switch nuts (4).
★ Standard clearance b: 0.5 - 1.0 mm
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
TESTING AND ADJUSTING BOOM KICK-OUT

★ Hydraulic oil temperature: 45 - 55 °C Adjusting
1. If dimension a is not within the standard
Testing value, move the plate to adjust.
1. Start the engine, operate the lift arm lever to 2. If dimension b is not within the standard
actuate proximity switch (1), then stop the value, adjust proximity switch mounting nut
engine. (3).
WARNING! Always be sure to apply

the safety lock to the work equipment Mounting nut: . . . . . . . . . . . . . . . . . . .
control lever. . . . . . . . 14.7 - 19.6 Nm {1.5 - 2.0 kgm}
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
3. Measure clearance b between the proximity

switch sensing surface and the plate.
★ Standard dimension b: 3 - 5 mm
BEW00236
WA380-5 20-145
(10)
TESTING AND ADJUSTING CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP

Proximity switch actuation pilot lamp (Red)
The proximity switch is equipped with a pilot
lamp which shows when it is being actuated, so
use this when adjusting.
TEW00245
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
ADJUSTING MACHINE MONITOR

Machine monitor rotary switches (SW1, SW2,
SW3) and dipswitches (SW5, SW6)
BWW10306
★ Be careful not to touch anything inside

• In the following cases, check the settings of the grommet except for the switch.
the rotary switches and dipswitches at the ★ When turning the rotary switch, use a pre-
rear face of the machine monitor, and change cision cross-head screwdriver and turn
the settings as necessary. slowly.
• When the machine monitor has been ★ The protruding triangular part of the
removed and installed again. rotary switch is the setting arrow.
• When the tire size has been changed ★ When changing the dipswitch, use a pre-
(travel speed compensation setting). cision flat-headed screwdriver and turn
• When an optional device has been slowly.
installed or removed.
• When the parts of the machine monitor
have been replaced with new parts (ser-
vice meter, odometer).
★ When carrying out these settings, it is
necessary to use the special operation
of the character display and mode
switch. For details, see STRUCTURE
AND FUNCTION, SPECIAL FUNC-
TIONS OF MACHINE MONITOR.
• The status of each switch can be checked
with the special function of the machine
monitor (monitoring function).
★ All setting operations are carried out with
the starting switch OFF and the monitor
panel removed.
★ Always set each switch as instructed.
WA380-5 20-147
• Setting function of switches

Switch Position Content Of Setting Position When Monitor Is Shipped
SW1 0-F Model selection 2
SW2 0-F Not used (Always set to 0) 0
SW3 0-F Speed/tachometer & tire size selection 0
OFF Common rail engine controller: Not installed
1 ON
ON Common rail engine controller: Installed
OFF Work equipment controller: Not installed
2 OFF
ON Work equipment controller: Installed
SW5
OFF
3 Not used (Always set to OFF) OFF
ON
OFF
ON
OFF
ON
OFF
ON
SW6
OFF
ON
OFF
ON
1. Setting rotary switch SW1 2. Setting rotary switch SW2

The machine monitor is designed to handle Rotary switch SW2 is set as follows. The set-
many models, so it must be set for the model ting must not be changed.
on which it is actually installed. • Set position of SW2: 0
When the machine monitor is replaced, use
rotary switch SW1 to select the correct model.
Model SW1 Remarks

WA380-5 0 —
20-148 WA380-5
(10)
3. Setting the rotary switch SW3 5. Setting dipswitch SW5-2

The machine monitor is set to calculate the When the joystick controller has been
travel speed for machines using standard installed or removed, set as follows.
tires. If the tire size has been changed, adjust • Controller removed
with rotary switch SW3 to compensate the Set position of dipswitch SW5-2: OFF
speed display.
• Controller installed
★ The settings for the tire sizes are as fol-
Set position of dipswitch SW5-2: ON
lows.
6. Setting dipswitch SW5-3
Meter Dipswitch SW5-3 is set as follows. The setting
SW3 Tire Size Remarks
Display
must not be changed.
km/h Standard
display 0 tire — • Set position of dipswitch SW5-3: OFF
MPH Standard Used only in countries
display 1 tire using non-SI units 7. Setting dipswitch SW5-4
rpm 2 Standard — Dipswitch SW5-4 is set as follows. The setting
display tire
km/h Large diam-
display
3
eter tire
— • Set position of dipswitch SW5-4: OFF
MPH Large diam- Used only in countries
4
display eter tire using non-SI units 8. Setting dipswitch SW6-1
rpm 5 Large diam- —
Dipswitch SW6-1 is set as follows. The setting
display eter tire must not be changed.
• Set position of dipswitch SW6-1: OFF
Tire size WA380-5
20.5-25 Standard 9. Setting dipswitch SW6-2
23.5-25 Large diameter Dipswitch SW6-2 is set as follows. The setting
When the meter display is changed, the con- • Set position of dipswitch SW6-2: OFF
tent of the speedometer display in the center
of the monitor changes. 10. Setting dipswitch SW6-3
• As an optional setting, it is possible to Dipswitch SW6-3 is set as follows. The setting
change from the speedometer display to must not be changed.
the tachometer display. • Set position of dipswitch SW6-3: OFF
• The units for the odometer on the charac-
ter displayed as set above. 11. Setting dipswitch SW6-4
★ If the tire size has been changed, adjust Dipswitch SW6-4 is set as follows. The setting
with rotary switch SW1 to compensate must not be changed.
the speed display. • Set position of dipswitch SW6-4: OFF
• If unlisted tires are used or if the tires
become worn and the speed display does
not match the actual speed, use and
optional setting to compensate for the
tires.
4. Setting dipswitch SW5-1

The setting when the common rail engine
controller is installed is as follows. The set-
ting must not be changed.
• Set position of dipswitch SW5-1: OFF
WA380-5 20-149
(10)
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
TESTING AND ADJUSTING LOAD METER

• Since the load meter is a simple measuring Performing Calibration for No Load (Zero Point
instrument, test it periodically (at any inter- Adjustment)
vals) according to the following procedure. (Supplemental Explanations)
Test it, too, when a bucket which is not stan- When carrying out calibration for no load, use the
dard is installed, when the pressure sensors following procedure to improve accuracy:
for the monitor and load meter or the boom
angle sensor is replaced, or when the load • Hydraulic oil temperature: The hydraulic
meter is used for the first time. oil temperature should be in approx 60 -
85 ° C: Perform calibration at around the
Testing center of the white range on the hydraulic
oil temperature gauge.
Test the load meter according to the following ( It is possible to compensate error of
procedure. pressure sensor due to the temperature ,
to perform calibration appropriate for the
1. Measure the weight without applying any machine.)
load on the bucket. • Engine speed : When carrying out calibra-
2. Put weights of about the normal load and tion, keep revolutions constant at the nor-
about 1/2 of the normal load, the weight of mal engine speed (about the rated speed).
which is known accurately, on the bucket and (The maximum effect of correction for the
measure their weight. engine speed can be achieved. When
3. Check that the error of the displayed weight is actually taking readings, accurate mea-
below the standard value. surements can be obtained even if the
Standard value: Error of measured value =< 1.5% engine speed varies.)
• Bucket posture: Perform calibration with
Allowable error
Model Normal Error at preci-
of displayed the bucket in the fully tilted position.
Load sion of 1.5%
load When taking readings of weight, the
WA380-5 5.1 t ± 0.077 t ± 0.1 t bucket should also be placed in the fully
tilted position.
In other than the fully tilted position, the
• When calculating the accuracy, note that the
center of gravity changes, which could
indicated weight is rounded off to the two
result in inaccurate measurement.
decimal places (Unit: 10 kg).
• Speed of work equipment: When per-
forming calibration, run the work equip-
Adjusting
ment at a slow speed. (Approx. 10
seconds from the travel postures to the
If the measurement accuracy of the load meter is
uppermost position of the lift arm.
out of the standard range, adjust load meter
(This operation is carried out to increase
measurement data when performing cali-
bration.)
1. Adjust the boom angle for the load meter (at
both upper limit and lower limit) in the moni- 1) Check that normal display of the service
tor service mode. meter and clock appears on the character
display.
★ See STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD, Machine
Monitor.
2. Calibrate the load meter for no load in the

operator mode.
★ See OPERATION AND MAINTENANCE
MANUAL, Handling Load Meter.
• Calibrate the load meter for no load
according to Performing Calibration for
No Load (Zero Point Adjustment) shown
below.
20-150 WA380-5
6
2) Press ( ) on monitor panel mode selector Performing Calibration for Load (Zero Point
switch 1 to display LOAD METER. Adjustment)
(Supplementary Explanations)
1) Check that the service meter and clock

appears normally on the character dis-
play.
3) Press ( ) on monitor panel mode selec-

tor switch 1, and then press (>) or (<) on
monitor panel mode selector switch 2 to
select CALIBRATION.
2) Press ( ) on monitor panel mode selector

switch 1 to display load meter.
3. After calibrating the load meter for no load,

perform TESTING again to check the mea-
surement accuracy of the load meter.
4. If the measurement accuracy of the load 3) Press ( ) on monitor panel mode selector
meter does not satisfy the standard, calibrate switch 1, and then press (>) or (<) on mon-
the load meter for load in the operator mode. itor panel mode selector switch 2 to select
★ Calibrate the load meter for load with CALIBRATION.
weights of the normal load and 1/2 of the
normal load.
In the calibration for load, the load meter
automatically judges the data of the nor-
mal load or the data of 1/2 of the normal
load and changes the standard data
according to the numeral data input when
calibration is started.
Set range of calibration Set range of calibration

Model of normal load data of 1/2 of normal load
data
WA380-5 5.0 t - 5.6 t 2.3 t - 2.8 t
★ When using the vehicle with loads

heavier than the normal load, do not cali-
brate with the normal load but calibrate
with the maximum hauling capacity for
higher accuracy. Note that a load larger
than twice the normal load is not calcu-
lated.
WA380-5 20-151
(7)
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.
5) Press (>) on the monitor panel mode

selector switch 2 to change the message
on the lower line to LOAD BUCKET and
then press ( ) on monitor panel mode
selector switch 1. 10) When the calibration for load setting has
been successfully completed, two short
beeps are sounded and the screen for
entering the target weight appears.
11) When calibration for load has not been
successfully completed, a beep sounds,
and the display goes back to CALIBRA-
TION on the upper line and LOAD
BUCKET on the lower line.
12) Repeat the steps from 6.
6) Press ( ) on monitor panel mode selector

switch 1. The display changes to STEP 1.
The display on the lower line changes
between FULLY ROLL BACK and Set to
AT CARRY POSI every three seconds.
7) Load the bucket with a load of which the
weight is known, tilt the bucket at the way
back by following the prompts, and lower
the lift arm to bring it to travel posture.
20-152 WA380-5
(7)
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.
14) Since the "10 ton" value is "0," leave it as

it is. Press ( ) on monitor panel mode
selector switch 1 once. Following confir-
mation of "0," the cursor moves to 1 ton.
15) It is not necessary to change the "1 ton"
value because it is the same "7" as the dis-
play, so press ( ) on monitor panel mode
selector switch 1. Following confirmation
of "7," the cursor moves to "0.1 ton."
16) For display of the "0.1 ton" value as "1,"
select 5 by pressing (>) or (<) on monitor
panel mode selector switch 2 and press
( ) on monitor panel mode selector
switch 1 once.
Now "5" has been confirmed and the tar-
get weight is set at 7.5 tons.
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.
3) Start the engine, and when oil comes out

from the air bleed hose, stop the engine
and remove the air bleed hose.
2. Bleeding air from work equipment PPC circuit
1) Operate each work equipment lever fully
and hold it in position to relieve the circuit
for approx. 1 minute. Carry out this opera-
tion once for each work equipment lever
stroke end.
20-154 WA380-5
(10)
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRES- RELEASING REMAINING PRESSURE

SURE IN HYDRAULIC CIRCUIT IN E.C.S.S. CIRCUIT
1. Releasing remaining pressure between each ★ When removing the piping of the E.C.S.S. cir-
hydraulic cylinder and control valve. cuit and E.C.S.S. valve, release the pressure
★ If the piping between the hydraulic cylin- in the accumulator as follows.
der and the control valve is to be discon- 1. Loosen locknut (2) of E.C.S.S. valve (1).
nected, release the remaining pressure 2. Loosen adjustment screw (3) 1/2 - 1 turn and
from the circuit as follows. release the pressure from the accumulator.
1) Stop the engine. • Locknut (2) and adjustment screw (3) are
2) Loosen the oil filler cap slowly to release painted red.
the pressure inside the hydraulic tank. 3. After releasing the remaining pressure, return
3) Operate the control levers. adjustment screw (3) to its original position
★ When the levers are operated 2 - 3 and tighten locknut (2) securely.
times, the pressure stored in the PPC
accumulator is removed. Start the Locknut : 12.7 ± 0.6 Nm {1.3 ± 0.06 kgm}
engine again, run at low idling for
approx. 5 minutes to charge the accu-
mulator, the stop the engine and
operate the control levers.
★ Repeat the above operation 2 - 3
times to release all the remaining
pressure.
BWW01405
2. Releasing remaining pressure in brake accu-
mulator circuit.
★ If the piping between the brake accumula-
tor and parking brake manual valve,
between the accumulator and the accu-
mulator check valve, or between the accu-
mulator and brake valve is to be
disconnected, release the remaining pres-
sure from the circuit as follows.
1) Stop the engine.
2) Depress the brake pedal at least 100 times
to release the pressure inside the brake
accumulator circuit.
3. Releasing remaining pressure in PPC accu- BWW01406
mulator circuit.
★ If the piping between the PPC accumula-
tor and PPC valve is to be disconnected,
release the remaining pressure from the
circuit as follows.
• Operate the control lever 2 - 3 times to
release the remaining pressure in the cir-
cuit.
WA380-5 20-155
(10)
TESTING AND ADJUSTING Pm
PM CLINIC INSPECTION TABLE
Pm CLINIC INSPECTION TABLE

WA380-5 #60001 and up
Machine serial No. #
Engine serial No.

HOUR INSPECTION SAA6D114E-2#
Work instruction No. Date of execution Service meter Inspector

Year: Month: Day: Hours
INTERVIEW WITH OPERATOR AND WALK-AROUND CHECK

Is there abnormality before starting inspection? Outside temperature
Max.: °C
Min.: °C
Altitude: m
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
Engine at low idle 900 – 950 900 – 950

2160 – 2260 2160 – 2260
Engine at high idle (2210 ± 50) (2210 ± 50)
Engine at high idle and torque con- 2070 – 2170 2020 – 2220
Engine speed verter stalled rpm
Engine at high idle and hydraulic
2020 – 2220 1920 – 2320
equipment stalled
Torque converter stalled + Hydraulic
equipment stalled 1615 – 1815 1515 – 1915
Blow-by pressure Engine at high idle and torque kPa Max. 0.98 Max. 1.96
converter stalled {Max. 1.00} {Max. 200}
Engine
0.36 – 0.61 Min. 0.21

Engine at high idle
{3.5 – 6.0} {Min. 2.1}
SAE30
Min. 0.15 Min. 0.07
Engine at low idle {Min. 1.5} {Min. 0.7}
Lubricating oil MPa
pressure {kg/cm2} 0.30 – 0.56 Min. 0.18
Engine at high idle {3.0 – 5.5} {Min. 1.8}
SAE10W
Engine at low idle Min. 0.10 Min. 0.07
{Min. 1.0} {Min. 0.7}
Engine at high idle and torque kPa 113.1 – 126.4 106.4 – 133.3
Boost pressure
converter stalled {mmHg} (850 – 950) (800 – 1000)
Engine at high idle and torque
Exhaust tempera- converter stalled Max. 650 Max. 700
°C
ture
Outside temperature — —
★ 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
Torque converter Engine at • Transmission neutral Max. 0.88 Max. 0.88

inlet oil pressure high idle {Max. 9.0} {Max. 9.0}
Torque converter Engine at MPa 0.39 – 0.49 0.39 – 0.49
outlet oil pressure high idle {kg/cm2} {4.0 – 5.0} {4.0 – 5.0}
1st, 2nd, 1.96 – 2.26 1.96 – 2.26
3rd, 4th • Torque converter oil {20.0 – 23.0} {20.0 – 23.0}
temperature: 60 - 80°C
ECMV output 1.76 – 2.06 1.76 – 2.06
(clutch) oil pressure F•R • Engine speed: {18.0 – 21.0} {18.0 – 21.0}
High idle
• Manual switch: ON 1.57 – 1.87 1.57 – 1.87
Lock-up
{16.0 – 19.0} {16.0 – 19.0}
20-156 WA380-5
(10)
TESTING AND ADJUSTING Pm
PM CLINIC INSPECTION TABLE
Pm CLINIC INSPECTION TABLE

WA380-5 #60001 and up
Standard value Service limit Measure-
Item Condition Unit for new machine value ment result Good Bad
Secure frame with frame lock bar.

Steering
Steering relief Engine at high idling MPa 15.2 – 16.2 14.7 – 16.2
pressure {kg/cm2} {155 – 165} {150 – 165 }
Parking brake inlet MPa Min. 2.27 Min.2.27
pressure 60 - 80°C {kg/cm2} {Min. 23.1} {Min. 23.1}
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
Charge cutout 9.8 – 10.8 9.3 – 11.3

pressure
pressure starts lower- {100 – 110} {95 – 115}
ing after rising.
• Engine at high idling 4.6 – 5.6 4.1 – 6.1
Brake oil pressure • Hydraulic oil temperature: 45 - 55°C {47 – 57} {42 – 62}
Lowering of brake • Engine: Stopped kPa

• Measure lowering of oil pressure from Max. 98{1.0} Max. 98{1.0}
oil pressure 4.9 MPa {50 kg/cm2} in 5 minutes {kg/cm2}

pressure
• Test on flat, level, straight, and dry
paved road.
Performance • Braking initial speed: 20 km/h, Delay m Max. 5 Max. 5
in pressing pedal: Max. 0.1 sec
• Brake pedal pressing force: Specified
force, 333 ± 33.3 N {34.0 ± 3.4 kg}
• Measure braking distance.
• Oil pressure: 4.9 MPa {50 kg/cm2} Projection of Projection of

Wear of disc mm shaft: Wear limit
• Pedal: Stroke end shaft: 0 (2.4 mm)
Work equipment 20.1 – 21.1 19.3 – 21.1
valve relief Bucket circuit relieved
pressure MPa {205 – 215} {197 – 215}
• P mode
{kg/cm2}
PPC valve relief • Engine at 3.7 – 3.9 3.5 – 3.9
pressure high {38 – 40} {36 – 40}
idling
Work equipment
• Hydraulic Rising time 4.8 – 5.8 Max. 7.0

Lift arm speed oil tem-
perature: Lowering time 2.2 – 3.2 Max. 3.8
45 - 55°C SEC
Dumping time 1.1 – 1.7 Max. 2.0
Bucket speed
Tilting time 1.6 – 2.2 Max. 2.6
• Hydraulic Bucket cylinder Max. 14 Max. 17
oil tem-
Hydraulic drift of perature: mm/15
work equipment 45 - 55°C Lift cylinder min. Max. 36 Max. 43
• Engine:
Stopped
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
Points to remember when troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

Sequence of events in troublshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
Precautions when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Equipment for troubleshooting electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
Special functions of machine monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
Categories, procedure, and method of using troubleshooting charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-249
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-254
T-adapter table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-275
Troubleshooting of transmission control system (TM mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
Troubleshooting of work equipment control system (WRK mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
Troubleshooting of monitor panel system (MON mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-701
Troubleshooting of hydraulic, mechanical system (H mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801
Troubleshooting of electrical system (E mode). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901
Troubleshooting of engine (S mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1001
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).
1. PRECAUTIONS WHEN HANDLING ELECTRIC

EQUIPMENT
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting one
component to another component, connectors
used for connecting and disconnecting one wire
from another wire, and protector or tubes used for
protecting the wiring.
Compared with other electrical components fitted
in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
coolant, heat, or vibration. Furthermore, during
inspection and repair operations they are fre-
quently removed and installed again, so they are
likely to suffer deformation or damage. For this
reason, it is necessary to be extremely careful
when handling wiring harnesses.
Main failures occurring in wiring harness

(1) Faulty contact of connectors
(faulty contact between male and female).
Problems with faulty contact are likely to occur
because the male connector is not properly
inserted into the female connector, or because
one or both of the connectors is deformed or
the position is not correctly aligned, or
because there is corrosion or oxidation of the
contact surfaces.
(2) Defective compression or soldering of con-

nectors
The pins of the male and female connectors
are in contact at the compressed terminal or
soldered portion, but there is excessive force
on the wiring, and the plating peels to cause
improper connection or breakage.
20-204 WA380-5
(10)
12 (3) Disconnections in wiring

If the wiring is held and tugged and the con-
nectors are pulled apart, or components are
lifted with a crane with the wiring still con-
nected, or a heavy object hits the wiring, the
crimping compression of the connectors to the
wire may be loosened, or the soldering may
be damaged, or the wiring may be broken.
(4) High pressure coolant entering a connector

The connector is designed to make it difficult
for coolant to enter (drip-proof structure), but if
high-pressure coolant is sprayed directly on
the connector, coolant may enter the connec-
tor depending on the direction of the coolant
jet. The connector is designed to prevent cool-
ant from entering, but if coolant does enter, it
is difficult for it to be drained. Therefore, if
coolant should get into the connector, the pins
will be short-circuited by the coolant, so if any
coolant gets in, immediately dry the connector
or take other appropriate action before pass-
ing electricity through it.
(5) Oil, grease or dirt stuck to connector

If oil or grease are stuck to the connector and
an oil film is formed on the mating surface
between the male and female pins, the oil will
not let the electricity pass, and this will cause
a defective contact. If there is oil or grease or
dirt stuck to the connector, wipe it off with a
dry cloth or blow dry with air, and spray it with
a contact restorer.
★ When wiping the mating portion of the
connector, be careful not to use excessive
force or deform the pins.
★ If there is coolant or oil present, it will
increase the contamination of the points,
so clean with air until all coolant and oil
has been removed.
WA380-5 20-205
(10)
2) Removing, installing, and drying connectors and

wiring harnesses
• Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors
held by a screw, loosen the screw fully, then
hold the male and female connectors in each
hand and pull apart. For connectors which
have a lock stopper, press down the stopper
with your thumb and pull the connectors apart.
★ Never try to pull apart with one hand.
(2) When removing the connectors from the clips,
pull the connector in a parallel direction to the
clip.
★ If the connector is twisted to the left and
right or up and down, the housing may
break.
(3) Action to take after removing connectors.

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or cool-
ant from getting in the connector portion.
★ If the machine is left for a long time, it is
particularly easy for improper contact to
occur, so always cover the connector.
20-206 WA380-5
(10)
• 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.
(2) Assemble the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with a lock stopper:
Push in the connector until the stopper clicks
into position.
(3) Correct any protrusion of the boot and any

misalignment of the wiring harness.
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the wiring
harness is misaligned, or the clamp is out of
position, adjust it to its correct position.
★ When blowing with dry air, there is danger
that the oil in the air may cause improper
contact, so clean with properly filtered air.
12 (4) When the wiring harness clamp of the connec-

tor has been removed, always return it to its
original condition and check that there is no
looseness of the clamp.
• Connecting connectors (DT type connector)
Since the DT 8-pole and 12-pole DT type connec-
tors have 2 latches respectively, push them in until
they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal) : a, b, d
• Incomplete locking state (Diagonal) : c
WA380-5 20-207
(10)
• Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe
it off with a dry cloth. Avoid washing it in coolant or
using steam. If the connector must be washed in
coolant, do not use high pressure coolant or
steam directly on the wiring harness.
If coolant gets directly on the connector, do as fol-

lows:
(1) Disconnect the connector and wipe off the
coolant with a dry cloth.
★ If the connector is blown dry with air, there
is the risk that oil in the air may cause a
faulty contact, so avoid blowing with air.
(2) Dry the inside of the connector with a dryer.

If coolant gets inside the connector, use a
dryer to dry the connector.
★ Hot air from the dryer can be used, but be
careful not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connector.
(3) Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to check
for any short circuits between pins caused by
coolant.
★ After completely drying the connector,
spray it with contact restorer and reas-
semble.
20-208 WA380-5
(10)
3) Handling control box

(1) The control box contains a microcomputer and
electronic control circuits.
This controls all of the electronic circuits on
the machine, so be extremely careful when
handling the control box.
(2) Do not open the cover of the control box
unless necessary.
(3) Do not place objects on top of the control box.

(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
(5) Do not leave the control box in a place where
it is exposed to rain.
(6) Do not place the control box on oil, coolant, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand)
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connecting connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in the circuit.
WA380-5 20-209
(10)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of hydrau-

lic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding
hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly
careful.
1) Be careful of the operating environment

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the field

If disassembly or maintenance work is carried out
on hydraulic equipment in the field, there is danger
of dust entering the equipment. It is also difficult to
confirm the performance after repairs, so it is
desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be
carried out in a specially prepared dust proof
workshop, and the performance should be con-
firmed with special test equipment.
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.
4) Do not let any dirt, or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil filler
and the area around it clean, and also use clean
pumps and oil containers. If an oil cleaning device
is used, it is possible to filter out the dirt that has
collected during storage, so this is an even more
effective method.
20-210 WA380-5
(10)
TROUBLESHOOTING
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil, so it
is best to change the oil when it is still warm.
When changing the oil, as much as possible of the
old hydraulic oil must be drained out. (Do not drain
the oil from the hydraulic tank; but drain the oil
from the filter and from the drain plug in the cir-
cuit.) If any old oil is left, the contaminants and
sludge in it will mix with the new oil and will
shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
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
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Action

Value
1. Check fuel level, type of fuel — Add fuel
Lubricating oil, coolant
2. Check for impurities in fuel — Clean, drain

3. Check hydraulic oil level — Add oil
4. Check filters (Hydraulic, Transmission, Engine) — Clean, drain
5. Check transmission oil level — Add oil
6. Check engine oil level — Add oil
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
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
14. Check for oil leakage

equipment
— Repair
Hydraulic,
15. Carry out air bleeding — Bleed air
16. Check brake Adjust or repair
17. Check battery voltage (Engine stopped) 24 - 26 V Replace

18. Check battery electrolyte level — Add or replace
19. Check for discolored, burnt, exposed wiring — Replace
Electrical equipment
20. Check for missing wiring clamps, hanging wire — Repair

21. Check for water leaking on wiring (Pay particular attention to water leak- Disconnect
ing on connectors or terminals) — connector and dry
22. Check for blown, corroded fuses — Replace
After running for
23. Check alternator voltage (Engine running at 1/2 throttle or above) several minutes: Replace
27.5 - 29.5 V
24. Sound of actuation of battery relay (When starting switch is turned ON,
OFF) — —
20-212 WA380-5
(10)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
SPECIAL FUNCTIONS OF MACHINE MONITOR

Normal functions and special functions of machine monitor
The machine monitor is equipped with normal functions and special functions.
Various items of data are displayed on the character display in the middle of the machine monitor. Depend-
ing on the internal setting of the machine monitor, the display items are divided into automatic display
items and items displayed when the machine monitor switches are operated.
1) Normal functions: Operator mode

Functions for which the content is normally displayed or which can be used displayed and operated by
the operator operating the switches.
2) Special functions 1: Service Mode 1
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
Operator mode ⇔ Service mode 1

Service meter, time display Electrical system trouble data
1 (Load meter specification) 11 display function
2 Load meter function 12 Mechanical system trouble

data display function
Machine data monitoring func-
3 Odometer display function 13
tion
Filter, oil replacement interval
4 display function 14 Reduced cylinder mode *1
5 Telephone number input func- 15 Adjustment function

tion
Filter, oil replacement time set-
6 Language selection function 16
ting function
Monitor brightness adjust-
7 ment function 17 Option selection function
8 (Time adjustment function) 18 Serial No. setting function

9 Action code display function 19 Initialize function
10 Failure code display function
• Items with ( ) are effective only for load meter specification.

• *1: Reduced cylinder mode is not effective because engine controller is not installed.
20-214 WA380-5
(9)
FLOW OF MODES AND FUNCTIONS
BWW10513
WA380-5 20-215
BWW10326
20-216 WA380-5
BJW11332
WA380-5 20-217
(8)
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.
Character display section

The character display consists of a top line and
bottom line with 16 characters each. A combina-
tion of the following characters (alphabet and
numerals) and symbols is displayed according to
the content.
1) Numerals: 1, 2, 3 . . .
2) Small letters: a, b, c . . .
3) Capital letters: A, B, C . . . BJH10092
4) Katakana: Japanese display only
5) Symbols: @, ¥, $ . . .
6) Special characters
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)
Operation and displays for operator mode

1. Service meter, time display function
When the starting switch is turned ON, the
top line shows the service meter and the bot-
tom line shows the time.
• The time display function is only on the
load meter specification machine. BWW10310
2. Load meter function
BWW10311
★ For details, see the "OPERATION AND MAINTENANCE MANUAL, Handling Load Meter".
WA380-5 20-219
(10)
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
4. Filter, oil replacement interval display func-

tion
1) Filter, oil replacement time display (auto-
matic display)
When the replacement interval for the fil- 6. Language selection function
ters or oil approaches, this information is The language used for the machine monitor
automatically displayed on the machine display can be selected by operating the
monitor to recommend the operator to switches.
carry out maintenance. ★ The functions of Service Mode 1 and Ser-
2) Resetting replacement time (selection vice Mode 2 are not included in the func-
menu) tions for display selection, so they are
When the maintenance operation for the always displayed in English.
filters and oil replacement has completed,
the switches on the machine monitor can
be used to reset the interval.
BWW10313
BWW10315

20-220 WA380-5
(10)
7. Monitor brightness adjustment function

The brightness of the machine monitor can
be adjusted by the switch to 7 levels.
BWW10316
8. Time adjustment function (load meter specifi-

cation)
The setting of the date and time on the
machine monitor can be selected by the
switch.
MAINTENANCE MANUAL, Handling Load BWW10317
Meter".
9. Action code display function

If any abnormality occurs on the machine, the
degree of the abnormality is automatically
displayed as a user code on the machine
monitor to recommend appropriate action to
the operator.
★ The diagram on the right shows an exam- BJH10100
ple of action code [E03] and [CALL + Tele-
phone number] being displayed in turn.
★ When action codes [E00], [E01], and [E02]
are displayed, [CALL + Telephone num-
ber] is not displayed.
★ Correspondence between action code and recommendation to operator

CALL + Telephone
Action Code Action Recommended to Operator
Number
E00 Not displayed • Returns mis-operated switch or lever to normal condition
• Carry out inspection and maintenance after completion of operations or when

E01 Not displayed changing shifts between operators
• When overrun related display is shown:

Reduce when engine speed and travel speed while continuing operations.
E02 Not displayed
• When overheat related display is shown:
Stop machine and keep engine running at mid-range speed under no load.
E03 Displayed • Stop engine and machine immediately and contact serviceman.
WA380-5 20-221
(10)
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.
★ For details of the displayed failure codes,

see "FAILURE CODE TABLE".
★ If no switch is operated on the failure
code display screen for more than 30 sec-
onds, the display automatically returns to
the action code display screen.
BWW10331
20-222 WA380-5
(10)
Failure code table
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
AA1ANX Engine air cleaner 1 Clogged (NX) MON E01

AA1BNX Engine air cleaner 2 Clogged (NX) MON E01
AB00L6 Alternator * See separate table (L6) MON E03
AB00MA Alternator Function impossible (MA) MON E03
B@BAZG Engine oil pressure Drop in oil pressure (ZG) MON E03
B@BAZK Engine oil Drop in level (ZK) MON E01
B@BCNS Engine Overheat (NS) MON E02
B@BCZK Radiator coolant level Drop in level (ZK) MON E01
B@C6ZK Brake oil (Front) Drop in level (ZK) MON E01
B@C7NS Brake oil temperature sensor Overheat (NS) TM E02
B@C7ZK Brake oil (Rear) Drop in level (ZK) MON E01
B@CENS Torque converter Overheat (NS) MON E02
B@GAZK Battery 1 Drop in level (ZK) MON E01
B@GBZK Battery 2 Drop in level (ZK) MON E01
B@HANS Hydraulic tank Overheat (NS) MON E02
D150KA Emergency steering relay Disconnection (KA) TM E03
D150KB Emergency steering relay Short Circuit (KB) TM E03
D160KA Back-up lamp relay Disconnection (KA) TM E01
D160KB Back-up lamp relay Short Circuit (KB) TM E01
D182KZ Preheating relay Disconnection or short circuit (KZ) MON E01
D191KA Neutral output relay Disconnection (KA) TM E03
D191KB Neutral output relay Short circuit (KB) TM E01
D192KA E.C.S.S. relay Disconnection (KA) TM E01
D192KB E.C.S.S. relay Short circuit (KB) TM E01
D193KA Joystick lever solenoid relay Disconnection (KA) WRK E03
D193KB Joystick lever solenoid relay Short circuit (KB) WRK E03
WA380-5 20-223
(10)
Failure Location of Failure (Location, component Con- Action

Code with failure) Nature of Failure (Problem, nature of failure) troller Code
D198KB Low - temperature bypass relay Short circuit (KB) TM E03
D198KY Low - temperature bypass relay Short circuit in power supply line (KY) TM E03
D5ZHL6 Monitor panel * See separate table (L6) MON E01
DAF0KK Monitor panel Drop in power source voltage, input (KK) MON E03
DAF0KT Monitor panel Abnormality inside controller (KT) MON E03
DAF3KK Monitor panel Drop in power source voltage, input (KK) MON E03
DAF5KP Load meter Drop in output voltage (KP) MON E01
DAF6KP Load meter Drop in output voltage (KP) MON E01
DAFAKM Monitor panel Mistaken operation or mistaken setting (KM) MON E03
DAFBKM Monitor panel Mistaken operation or mistaken setting (KM) MON E03
DAFSKQ Monitor panel Non match in model selection signal (KQ) MON E01
DAQ0KK Drop in power source voltage Drop in power source voltage, input (KK) TM —
DAQ2KK Solenoid power source circuit Drop in power source voltage, input (KK) TM —
DAQ9KQ Transmission Non match in model selection signal (KQ) TM E03
DAQSKR Monitor panel Defective communication, abnormality in MON E03

applicable component system (KR)
Work equipment controller power source
DB90KK Drop in power source voltage, input (KK) WRK E03
circuit
DB92KK Solenoid power source circuit Drop in power source voltage, input (KK) WRK E03
DB95KX Sensor power source circuit Input signal outside range (KX) WRK E03
DB9SKR Monitor panel Defective communication, abnormality in MON E03

applicable component system (KR)
DD15LD Monitor panel * See separate table (LD) MON E01
DD1ALD Remote positioner lamp * See separate table (LD) WRK E03
DD1BLD Remote positioner lamp * See separate table (LD) WRK E03
DD1CLD Load meter * See separate table (LD) MON E01
DDK3KA Shift switch Disconnection (KA) TM E03
DDK3KB Shift switch Disconnection (KB) TM E03
DDK6KA Shift lever Disconnection (KA) TM E03
DDK6KB Shift lever Short circuit (KB) TM E03
DDS5KA Steering circuit oil pressure Disconnection (KA) TM E03
DDS5KB Steering circuit oil pressure Short circuit (KB) TM E03
DDS5L6 Steering oil pressure Drop in oil pressure (ZG) MON E03
DDT0L4 Shift mode switch * See separate table (L4) TM —
DDT4LD Transmission cut-off switch * See separate table (LD) TM E01
DDW9LD Kick-down switch * See separate table (LD) TM E01
DDWLLD Hold switch * See separate table (LD) TM E01
DDY0LD Load meter * See separate table (LD) MON E01
DF10KA Shift lever Disconnection (KA) TM E01
DF10KB Shift lever Short circuit (KB) TM E01
Work equipment lever neutral position con-
(DFA0KM) Mistaken operation or mistaken setting (KM) WRK E00
firmation signal
Coolant temperature sensor (High tempera-
DGE2KX ture) Input signal outside range (KX) MON E01
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)

Nature of Failure (Problem, nature of failure)
DGR2KB Rear brake oil temperature sensor Short circuit (KB) TM E01
DGT1KX Torque converter Input signal outside range (KX) MON E01
DHA4KA Engine air cleaner 1 Disconnection (KA) MON E01
DHA5KA Engine air cleaner 2 Disconnection (KA) MON E01
DHE4L6 Engine oil pressure sensor See separate table (L6) MON E01
DHPCKX Cylinder bottom pressure sensor Input signal outside range (KX) MON E01
DHPDKX Cylinder rod pressure sensor Input signal outside range (KX) MON E01
DHT1KX Brake pressure sensor Input signal outside range (KX) TM E01
DHT2L6 Transmission filter See separate table (L6) MON E01
DJB1KX Battery electrolyte level 1 Input signal outside range (KX) MON E01
DJB3KX Battery electrolyte level 2 Input signal outside range (KX) MON E01
DK5FKA Joystick lever EPC potentiometer Disconnection (KA) WRK E03
DK5FKY Joystick lever EPC potentiometer Short circuit in power supply line (KY) WRK E03
DK5FL8 Joystick lever EPC potentiometer See separate table (L8) WRK E03
DK5GKA Joystick lever EPC potentiometer Disconnection (KA) WRK E03
DK5GKY Joystick lever EPC potentiometer Short circuit in power supply line (KY) WRK E03
DKA0KX Lift arm angle sensor Input signal outside range (KX) MON E01
DLE2KA Engine speed sensor Disconnection (KA) TM E03
DLE2LC Engine speed sensor See separate table (LC) TM E03
DLT3KA Speed sensor Disconnection (KA) TM E03
DLT3LC Speed sensor See separate table (LC) WRK E01
DT20KB Transmission cut-off indicator Short circuit (KB) TM —
DV00KB Alarm buzzer Short circuit (KB) MON E01
Reverse rotation solenoid valve for fan
DW7BKA Disconnection (KA) TM E01
pump
Reverse rotation solenoid valve for fan
DW7BKB pump Short circuit (KB) TM E01
DW7CKA Switch pump solenoid Disconnection (KA) TM E01

DW7CKB Switch pump solenoid Short circuit (KB) TM E01
DW7DKA EPC solenoid valve for fan pump Disconnection (KA) TM E01
DW7DKB EPC solenoid valve for fan pump Short circuit (KB) TM E01
DX16KA EPC valve for fan pump Disconnection (KA) TM E01
DX16KB EPC valve for fan pump Short circuit (KB) TM E01
DXH1KA ECMV for lock-up clutch Disconnection (KA) TM E01
DXH1KB ECMV for lock-up clutch Short circuit (KB) TM E01
DXH4KA ECMV for 1st clutch Disconnection (KA) TM E03
DXH4KB ECMV for 1st clutch Short circuit (KB) TM E03
DXH5KA ECMV for 2nd clutch Disconnection (KA) TM E03
DXH5KB ECMV for 2nd clutch Short circuit (KB) TM E03
DXH6KA ECMV for 3rd clutch Disconnection (KA) TM E03
DXH6KB ECMV for 3rd clutch Short circuit (KB) TM E03
DXH7KA ECMV for R clutch Disconnection (KA) TM E03
DXH7KB ECMV for R clutch Short circuit (KB) TM E03
DXH8KA ECMV for F clutch Disconnection (KA) TM E03
DXH8KB ECMV for F clutch Short circuit (KB) TM E03
DXHHKA ECMV for 4th clutch Disconnection (KA) TM E03
DXHHKB ECMV for 4th clutch Short circuit (KB) TM E03
DXHJKA 3rd lever EXTEND EPC solenoid Disconnection (KA) WRK E03
DXHJKB 3rd lever EXTEND EPC solenoid Short circuit (KB) WRK E03
DXHKKA 3rd lever RETRACT EPC solenoid Disconnection (KA) WRK E03
DXHKKB 3rd lever RETRACT EPC solenoid Short circuit (KB) WRK E03
WA380-5 20-225
5

Nature of Failure (Problem, nature of failure)
DXHLKA Joystick lever right EPC solenoid Disconnection (KA) WRK E03
DXHLKB Joystick lever right EPC solenoid Short circuit (KB) WRK E03
DXHMKA Joystick lever left EPC solenoid Disconnection (KA) WRK E03
DXHMKB Joystick lever left EPC solenoid Short circuit (KB) WRK E03
DY30MA Emergency steering pump Function impossible (MA) TM E03
DY30MC Emergency steering pump Operation impossible (MC) TM E03
DY30ME Emergency steering Cancel impossible (ME) MON E02
20-226 WA380-5
5
* Separate table: Detailed phenomena of problem codes (L*)
Problem Code Nature

L0 Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match
L5 Potentiometer signal and switch signal do not match
Engine speed signal, terminal C signal, signals for oil pressure switch, coolant temperature switch, etc. do
L6
not match operating condition or stopped condition of machine
L8 Analog signals for 2 systems do not match
LC Speed signals for 2 systems do not match
LD Switch has been kept pressed for abnormally long time
L.H. Fill signal is OFF when command current to ECMV is ON
★ Failure codes with ( )

These failure codes are not recorded as trouble data for either the electrical system or the mechanical
system.
★ Controller codes and troubleshooting mode names
The controller code name shown in the Controller column and the troubleshooting mode name in the
troubleshooting section are linked, so check the controller code for the failure code displayed, then go
to the applicable troubleshooting mode.
TM: Troubleshooting of transmission control system (TM MODE)
MON: Troubleshooting of machine monitor system (MON MODE)
WRK: Troubleshooting of work equipment control system (WRK MODE)
WA380-5 20-227
(10)
Procedure for switching to Service Mode 1 and

screen display
★ When using Service Mode 1, carry out the fol-
lowing special operation to switch the screen
display.
1) Checking screen display

With the machine monitor in the operator
mode, check that the screen is one of the fol-
lowing displays: Service meter, action code,
or failure code.
2) Initial screen display for ID input

Press the following 2 buttons at the same
time for at least 5 seconds to display the ini-
tial screen display for the ID input.
• [■] button and [<] button
★ If the buttons are held pressed for at least
BJH10103
5 seconds, the whole screen will give no
display, so check that the screen gives no
display, then release the buttons.
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.
4) Displaying menu initial screen

After all four digits of the ID are confirmed,
the menu initial screen of Service Mode 1 is
displayed.
★ Once the ID has been input and con-
firmed, it remains effective until the start-
ing switch is turned OFF.
20-228 WA380-5
5) Menu selection in Service Mode 1

Press the [>] or [<] buttons on the menu
screen and the menus of Service Mode 1 are
displayed endlessly in the following order.
★ The menu is displayed in the places
marked with [*].
• [>] button: Go on to the next menu
• [<] button: Go back to previous menu
1 ELECTRICAL FAULT: Trouble data dis-
play function for electrical system
2 MACHINE FAULT: Trouble data display
function for mechanical system
3 REAL-TIME MONITOR: Machine data
monitoring function
4 CYLINDER CUT-OUT: Reduced cylinder
mode
5 TUNING: Adjustment function
6 MAINTENANCE MONITOR: Filter, oil
replacement interval setting function
7 OPTION SELECT: Option installation
selection function
8 MACHINE No. SET: Serial No. setting
function
9 INITIALIZE: Initialize function (exclusive
function for factory)
6) Completion of mode, function

When operating at any point in any function,
it is possible to finish the mode or function by
using any of the following methods.
1 When continuing operations in another
mode or function: Press the [ ■] button
and return to the mode screen to be used
or menu screen to be used.
★ Note that if the [■] button is pressed
on the YES/NO screen, the function
will be executed.
★ If you return to the normal screen
(operator mode) by mistake, repeat
the procedure from Step 1) above
(there is no need to input the ID
again).
2 When completing all operations:
Turn the starting switch OFF.
WA380-5 20-229
11. Electrical system trouble data display func-

tion (ELECTRIC FAULT)
The monitor retains the data for problems
that occurred in the electrical system in the
past as failure codes. They can be displayed
as follows.
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)
2) Trouble data display

With the menu selected, press the [◊ ] but-
ton and display the trouble data recorded
in memory.
• [◊] button: Run menu
3) Displayed trouble data

With the display function for trouble data
of the electrical system, the following
data can be displayed.
A: Record number
B: Failure code (4-digit location code + 2
digit problem code
C: Number of occurrences (number of
occurrences of same code in past)
D: Elapsed time 1 (time elapsed on ser-
vice meter since first occurrence)
E: Elapsed time 2 (time elapsed on ser-
vice meter since last occurrence)
★ Failure codes for problems that are
still existing are shown on a flashing
display.
★ For details of the failure codes dis-
played, see FAILURE CODE TABLE in
the explanation for the failure code
display function.
★ Note that with the trouble data display
function and failure code display func-
tion for the electrical system, the dis-
played data are partially different.
★ If no trouble data are recorded, [-] is
displayed on the display portion.
20-230 WA380-5
4) Switching trouble data display

If the [>] button or [<] button is pressed
during the display of trouble data, the dis-
play switches to the other recorded trou-
ble data.
• [>] button: Go on to data for next
record number.
• [<] button: Go back to data for last
record number.
5) Deleting individual trouble data

i) Display the trouble data to be deleted,
then press the [◊] button once to dis-
play the individual item CLEAR screen
(Fig. 4).
• [◊ ] button: Display CLEAR screen
ii) Operate the buttons according to the
explanation on the screen (Fig. 4).
• [<] button: Select YES
• [>] button: Select NO
• [■] button: Run
★ The data for an existing problem
(flashing display) cannot be deleted.
6) Deleting all trouble data

i) Display the trouble data, then press
the [>] button or [<] button to display
the ALL CLEAR menu (Fig. 5).
ii) Press the [◊ ] button once to display
the ALL CLEAR screen (Fig. 6).
• [◊ ] button: Run ALL CLEAR menu
iii) Operate the buttons according to the
explanation on the screen (Fig. 6).
• [<] button: Select YES
• [>] button: Select NO
• [■] button: Run
★ The data for an existing problem
(flashing display) cannot be deleted.
WA380-5 20-231
12. Mechanical system trouble data display func-

tion (MACHINE FAULT)
The machine monitor retains the data for
problems that occurred in the mechanical
system in the past as failure codes. They can
be displayed as follows.
1) Menu selection
Select the display function for MACHINE
FAULT trouble data on the menu screen
of Service Mode 1 (Fig. 1).
★ The total number of trouble data
items recorded in memory is dis-
played in the [**] portion.
2) Trouble data display
With the menu selected, press the [◊ ] but-
ton and display the trouble data recorded
in memory (Fig. 2: example).
3) Display trouble data
With the display function for trouble data
of the mechanical system, the following
data can be displayed (Fig. 3).
A: Record number
B: Failure code (4-digit location code + 2-
digit problem code)
C: Number of occurrences (number of
occurrences of same code in past)
D: Elapsed time 1 (time elapsed on ser-
vice meter since first occurrence)
E: Elapsed time 2 (time elapsed on ser-
vice meter since last occurrence)
★ Failure codes for problems that are
still existing are shown on a flashing
display.
★ For details of the failure code dis-
played, see FAILURE CODE TALBLE in
the explanation for the failure code
display function.
★ Note that with the trouble data display
function and failure code display func-
tion for the mechanical system, the
displayed data are partially different.
★ If no trouble data are recorded, [-] is
displayed on the display portion.
20-232 WA380-5
4) Switching trouble data display

If the [>] button or [<] button is pressed
during the display of trouble data, the dis-
play switches to the other recorded trou-
ble data.
• [>] button: Go on to data for the next
record number
• [<] button: Go back to data for last
record number
5) Deleting trouble data (not permitted)
★ The trouble data for the mechanical
system cannot be deleted.
WA380-5 20-233
13. Machine data monitoring function (REAL-

TIME MONITOR)
The machine monitor can monitor the condi-
tion of the machine in real time through the
signals from the sensors installed to various
parts of the machine.
In the machine data monitoring function, the
following 2 types of display can be shown.
• 1st item independent display (for each
controller)
• 2nd item simultaneous display (code
input)
1) Menu selection
Select the machine data monitoring func-
tion on the menu screen of the Service
Mode 1 (Fig. 1).
2) Display sub menu
With the sub menu selected, press the [◊ ]
button and display the initial screen of the
sub menu (Fig. 2).
3) Select sub menu
If the [>] button or [<] button is pressed on
the sub menu screen, the sub menu dis-
plays endlessly in the following order
(Fig. 3).
★ The sub menu is displayed in the [*]
position.
• [>] button: Go on to next menu
• [<] button: Go back to last menu
1 MONITOR PANEL: Machine monitor
system
2 TRANSMISSION: Transmission con-
troller system
3 ENGINE: Engine controller system
4 BOOM: Work equipment controller
system
5 2 ITEM: 2-item display
20-234 WA380-5
4) Setting 1st item individual monitoring

i) Select the controller system for moni-
toring on the sub menu screen (Fig. 4:
Example).
ii) With the sub menu selected, press the
[◊ ] button and siplay the monitoring
data initial screen.
• [◊ ] button: Run sub menu
iii) Press the [>] button or [<] button to
select the item for monitoring (Fig. 5:
Example).
• [>] button: Go on to next item
• [<] button: Go back to last item
★ Scroll the monitoring items to dis-
play in the internally set order.
★ If the button is kept pressed, the
items will scroll at high speed.
★ To hold or cancel monitoring data:
If the [◊ ] button is pressed during
monitoring, the monitor data is held
and the [◊ ] mark flashes. If the [◊ ] but-
ton is pressed again, it becomes
active again.
5) Display data for 1st item individual moni-
toring
On the 1st item individual monitoring
screen, the following data are displayed
(Fig. 6).
A: Item display
B: Monitoring data (5-digit)
1: Monitoring data (including unit)
★ For details, see MONITORING CODE
TABLE.
WA380-5 20-235
6) Setting 2nd item simultaneous monitor-

ing
i) Select the 2nd item display on the sub
menu screen.
ii) With the sub menu selected, press the
[◊] button and display the monitoring
code input screen.
• [◊] button: Run sub menu
iii) Operate each button and input the
monitoring code for the 2nd monitor-
ing item directly.
• [>] button: Number at cursor goes
up
• [<] button: Number at cursor goes
down
• [◊] button: Number at cursor is
confirmed
• [■] button: Returns to code input
screen
iv) When both of the monitoring codes
have been confirmed, the screen
switches to the 2nd item display
screen.
★ To hold or cancel monitoring data:
If the [◊ ] button is pressed during
monitoring, the monitor data are held
and the [ ◊] mark flashes. If the [ ◊ ] but-
ton is pressed again, it becomes
active again.
7) Display data for 2nd item simultaneous
monitoring
On the 2nd item simultaneous monitoring
screen, the following data are displayed.
A: Monitoring code 1
1: Monitoring data 1 (including unit)
B: Monitoring code 2
2: Monitoring data 2 (including unit)
★ For details, see MONITORING CODE
TABLE.
20-236 WA380-5
Monitoring Code Table
MONITOR PANEL [Machine monitor system]

Monitoring Data Display
No. Monitoring Item Item Display Code Range Unit
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
24 Input signal D_IN_0-7 D-IN--0------7 40900 See separate table Status display
★ Note: The following monitoring items display

data for 2 or 3 systems at the same time.
• No. 19: Setting status of rotary switch
(displays 3 items at same time)
• No. 20: Setting status of dipswitch (dis-
plays 2 items at same time)
WA380-5 20-237
(10)
TRANSMISSION [Transmission controller system]

No. Monitoring Item Item Display Unit
Code Range
1 Transmission controller ROM part No. TRANSM ROM 20201 Arabic Numerals Status display
2 Fan pump speed FAN PUMP 41000 0 - 3000 rpm
3 Left brake pressure L.H. BRAKE 41100 0.00 - 50.00 MPa
4 Transmission cut-off pressure CUT OFF 41200 0.00 - 50.00 MPa
5 No. of times of kick down K/D TIMES 41300 — —
6 Average cycle time CYCLE TIME 41400 — sec.
7 F clutch solenoid circuit ECMV F 31608 0 - 1000 mA
8 R clutch solenoid circuit ECMV R 31606 0 - 1000 mA
9 1st clutch solenoid circuit ECMV 1 31602 0 - 1000 mA
10 2nd clutch solenoid circuit ECMV 2 31603 0 - 1000 mA
11 3rd clutch solenoid circuit ECMV 3 31604 0 - 1000 mA
12 4th clutch solenoid circuit ECMV 4 31605 0 - 1000 mA
13 Lock-up clutch solenoid current ECMV LU 31609 0 - 1000 mA
14 Fan pump solenoid valve current FAN EPC 41400 0 - 1000 mA
15 Transmission oil temperature ECMV OIL TEMP 41500 24 - 131 °C
16 (Not applied) — — — —
17 Shift mode selection SHIFT MODE 41700 H/M/L —
18 F clutch fill time FILL TIME F 41808 0 - 2550 msec
19 R clutch fill time FILL TIME R 41806 0 - 2550 msec
20 1st clutch fill time FILL TIME 1 41802 0 - 2550 msec
21 2nd clutch fill time FILL TIME 2 41803 0 - 2550 msec
22 3rd clutch fill time FILL TIME 3 41804 0 - 2550 msec
23 4th clutch fill time FILL TIME 4 41805 0 - 2550 msec
24 F clutch fill display FILL SW(F) 31508 0-1 Status display
25 R clutch fill display FILL SW(R) 31506 0-1 Status display
26 1st clutch fill display FILL SW(1) 31502 0-1 Status display
27 2nd clutch fill display FILL SW(2) 31503 0-1 Status display
28 3rd clutch fill display FILL SW(3) 31504 0-1 Status display
29 4th clutch fill display FILL SW(4) 31505 0-1 Status display
34 Output signal D_OUT_0-6 D-OUT-0------6 40915 See separate table Status display
35 Output signal SOL/0_0-5 SOL/O-0------5 40914 See separate table Status display
36 Rear brake oil temperature R BRAKE OIL 30202 24 - 131 °C
★ Content of display for monitoring items No. 24 - 29

0: Normal; 1: Delayed
20-238 WA380-5
(10)
WORK [Work equipment controller system]

No. Monitoring Item Item Display Unit
Code Range
1 Work equipment controller ROM part No. BOOM ROM 20202 — —
2 Boom RAISE solenoid valve current RAISE EPC 41900 0 - 1000 mA
3 Boom LOWER solenoid valve current LOWER EPC 41901 0 - 1000 mA
4 Bucket TILT solenoid valve current TILT EPC 41902 0 - 1000 mA
5 Bucket DUMP solenoid valve current DUMP EPC 41903 0 - 1000 mA
6 Joystick steering right solenoid valve current R.H. J/S EPC 41904 0 - 1000 mA
7 Joystick steering left solenoid current L.H. J/S EPC 41905 0 - 1000 mA
8 EPC solenoid valve of auxiliary valve 3RD EPC1 41906 0 - 1000 mA
9 EPC solenoid valve of auxiliary valve 3RD EPC2 41907 0f00 mA
10 Lever potentiometer voltage lift arm 1 BOOM POT1 42000 0.00 - 5.00 V
11 Lever potentiometer voltage lift arm 2 BOOM POT2 42001 0.00 - 5.00 V
12 Lever potentiometer voltage bucket 1 BUCKET POT1 42002 0.00 - 5.00 V
13 Lever potentiometer voltage bucket 2 BUCKET POT2 42003 0.00 - 5.00 V
14 Lever potentiometer voltage joystick steering 1 J/S POT1 42004 0.00 - 5.00 V
15 Lever potentiometer voltage joystick steering 2 J/S POT2 42005 0.00 - 5.00 V
16 Lever potentiometer voltage 3-tandem valve 1 3RD POT1 42006 0.00 - 5.00 V
17 Lever potentiometer voltage 3-tandem valve 1 3RD POT2 42007 0.00 - 5.00 V
18 Lift arm angle BOOM ANG 06002 -41 - 46 deg.
19 Lift arm bottom pressure BTM PRESS 40401 0.00 - 50.00 MPa
20 No. of times of lift arm lever operation BOOM LVR 42100 0 - 25600 x 1000
21 No. of times of bucket lever operation BUCKET LEVER 42101 0 - 25600 x 1000
22 No. of times of 3rd lever operation 3RD LVR 42102 0 - 25600 x 1000
23 Engine speed ENG SPEED 01003 0 - 3000 rpm
24 Travel speed SPEED 40001 0 - 50 km/h
29 Output signal D_OUT_0-6 D-OUT-0------6 40917 See separate table Status display
30 Output signal SOL/0_0-5 SOL/O-0------5 40916 See separate table Status display
WA380-5 20-239
(10)
★ ON/OFF switch signals input to controller

i) Method of reading input signal ii) Method of reading output signal
D-IN- -0- - - - - -7 D-OUT-0- - - - - -7
• Input status display 0: No input (OFF) • Output status display 0: No output
(OFF)
• Input status display 1: Input (ON)
• Output status display 1: Output (ON)
1 : Monitoring code 1 : Monitoring code

2 : Input status 2 : Output status
Starting from the left, the status is dis- Starting from the left, the status is dis-
played in turn from D-IN-0 to D-IN-7. played in turn from D-OUT-0 to D-
OUT-7.
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)
Input/
Monitoring
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)
Monitor Panel
Input/
Monitoring
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)
14. Reduced cylinder mode (CYLINDER CUT-OUT)

Reduced cylinder mode is not effective
because engine controller is not installed.
15. Adjustment function (default setting)
★ The machine monitor is used to carry out
the default setting when the transmission
has been overhauled or replaced, or the
sensors, EPC valve, controller have been
replaces or added, or when adjusting or
compensating for tolerance in installation
or individual differences in manufacture.
• 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)
16. Filter, oil replacement interval setting func-

tion
The machine monitor can set the mainte-
nance interval for filters and oil. This forms
the base for the filter and oil replacement
interval and display.
★ For details, see "STRUCTURE AND FUNC-
TION, Maintenance monitor items".
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)
17. Option selection function

• When adding or removing optional equip-
ment, change the setting on the machine
monitor.
• When the machine monitor has been
replaced, set the status of optional equip-
ment installed on the machine.
BWW10328
Option set items

Item No. Real-time Monitor Items English Display Remarks
Monitor Panel Controller
1 Auto grease AUTO GREASE
2 Battery electrolyte level drop sensor BAT LIQUID
3 Transmission clogging sensor TRANSM CLOG
4 Printer PRINTER
5 Lift arm Hi lift specification HI LIFT
6 Speedometer/tachometer display switch ENGINE RPM Use ADD screen to display engine speed
7 Short ton switch SHORT TON Can be switched only when MPH is displayed
Transmission Control
1 Travel damper E.C.S.S.
2 Torque converter lock-up LOCK UP
3 Emergency steering EMER STRG
4 Tire size TIRE SIZE Tire compensation for non-specified tires
5 Spare switch AUTO RE FAN
6 Right FNR switch R.H. FNR SW
Work Equipment Controller
1 EPC lever EPC LEVER
2 Joystick JOY STICK
3 EPC 3rd lever EPC 3RD
★ There is no set item for engine controller.
★ For details, see "STRUCTURE AND FUNCTION, Settings needed when installing optional equipment for
machine monitor".
20-246 WA380-5
(10)
18. Serial No. setting function

This is used to set the serial number of the machine.
★ For details, see "STRUCTURE AND FUNCTION,

Settings needed for the machine".
19. Initialize function

★ This function is a special function used only at
the factory, so it cannot be used when servicing
the machine.
WA380-5 20-247
(10)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS

SHOOTING CHARTS
Categories of troubleshooting
Mode Contents
TM mode Troubleshooting of transmission control system
WRK mode Troubleshooting of work equipment control system
MON mode Troubleshooting of monitor system
H mode Troubleshooting of hydraulic and mechanical system
E mode Troubleshooting of electrical system
S mode Troubleshooting of engine
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.
1. Procedure of troubleshooting to be taken when action code is displayed on monitor panel:

If an action code is displayed on the monitor panel, display the failure code in the failure code display
mode of the monitor panel (EMMS).
Carry out troubleshooting under the displayed failure code.
★ If the failure code is recorded, be sure to perform the operation for reproducing the failure to see if
the failure has been repaired or not (For the method of reproducing the failure, see the trouble-
shooting under the failure code).
2. Procedure of troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the monitor panel, check for a failure code in the failure code dis-
play mode of the monitor panel (EMMS).
If a failure code is recorded, carry out troubleshooting under it.
★ If the failure code is recorded, be sure to perform the operation for reproducing the failure to see if
the failure has been repaired or not (For the method of reproducing the failure, see the trouble-
shooting under the failure code).
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 TROUBLESHOOTING CHARTS

4. Phenomena considered to be failures and troubleshooting No.
★ With mark ● go to troubleshooting No. on failure code display
Troubleshooting
No. Phenomena considered to be failures Failure TM WRK MON H E
(Engine)
code mode mode mode mode mode
Failures related to failure code
Failure code is displayed on failure code display unit
1 ●
(LED display unit).
Failures related to engine
Starting performance is poor (starting always takes
2 S-1
time)
3 Engine does not turn E-1 S-2a)
Engine turns but no
4 S-2b)
exhaust smoke comes out
Engine does not start
Exhaust smoke comes out
5 but engine does not start S-2c)
(Fuel is being injected)
6 Engine does not pick up smoothly (follow-up is poor) S-3
7 Engine stops during operations S-4
8 Engine does not rotate smoothly (hunting) S-5
9 Engine lacks output (or lacks power) S-6
10 Exhaust smoke is black (incomplete combustion) S-7
Oil consumption is excessive (or exhaust smoke is
11 S-8
blue)
12 Oil becomes contaminated quickly S-9
13 Fuel consumption is excessive S-10
Oil is in coolant (or coolant spurts back, or coolant
14 S-11
level goes down)
Oil pressure caution lamp lights up (drop in oil pres-
15 S-12
sure)
16 Oil level rises (water, fuel in oil) S-13
17 Coolant temperature becomes too high (overheating) S-14
18 Abnormal noise is made S-15
19 Vibration is excessive S-16
20 Preheating is impossible or constant E-3
21 The engine does not stop E-2
Failures related to transmission controller (no failure code) (TM mode)
Defects for which failure code is not displayed on fail- TM-1 -
22
ure code display (character display unit) TM-29
Failures related to work equipment controller (WRK mode)
23 Defective lift arm lock switch system WRK-1
Defective remote positioner RAISE setting switch sys-
24 WRK-2
tem
Defective remote positioner LOWER setting switch
25 WRK-3
system
Defective remote positioner RAISE selection switch
26 system WRK-4
Defective remote positioner LOWER ON/OFF switch

27 WRK-5
system
28 Defective bucket cylinder proximity switch system WRK-6
Defective bucket cylinder full stroke detection switch
29 WRK-7
system
Defective semi-automatic digging HARD selection
30 WRK-8
switch system
20-249-1 WA380-5
(10)
5
Troubleshooting
(Engine)
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
Hot short-circuited bucket TILT magnet detent output

37 WRK-15
system
Hot short-circuited work equipment neutral lock sole-
38 WRK-16
noid output system
Hot short-circuited lift arm RAISE EPC solenoid sys-
39 tem WRK-17
Hot short-circuited lift arm LOWER EPC solenoid sys-

40 WRK-18
tem
41 Hot short-circuited bucket TILT EPC solenoid system WRK-19
Hot short-circuited bucket DUMP EPC solenoid sys-
42 WRK-20
tem
Hot short-circuited 3 valves extension EPC solenoid
43 WRK-21
system
Hot short-circuited 3 valves retraction EPC solenoid
44 WRK-22
system
Hot short-circuited joystick steering right EPC sole-
45 WRK-23
noid system
46 Hot short-circuited joystick steering left EPC solenoid WRK-24

system
Defective bucket positioner, boom kick-out and
47 WRK-25
FLOATING holding function
48 Defective boom kick-out function and cancellation WRK-26
49 Defective bucket leveler function and cancellation WRK-27
50 Defective lift arm FLOATING holding and cancellation WRK-28
Failures related to monitor panel (MON mode)
The parking brake indicator lamp does not light up
51 when the parking brake switch is turned ON (The MON-1
parking brake indicator switch circuit suffers a ground
fault)
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
The radiator coolant volume caution lamp does not

57 MON-8
light ON
The hydraulic oil temperature caution lamp does not
58 MON-9
light ON
The torque converter oil temperature caution lamp
59 does not light ON MON-10
60 The steering hydraulic caution lamp does not light ON MON-11
WA380-5 20-249-2
(10)
5
Troubleshooting
(Engine)
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
Input fault in monitor panel mode switch 2 [>] (Panel

64 MON-15
SW4)
65 Defective subtotal switch MON-16
66 Defective cancel switch MON-17
67 Defective bottom pressure sensor (Hot short fault) MON-18
68 Defective head sensor MON-19
The alarm buzzer does not sound or stop (disconnec-
69 tion or short circuit with chassis ground in buzzer out- MON-20
put system)
Failures related to hydraulic and mechanical system (H mode)
70 The machine does not start H-1
The lock-up clutch is not released (The engine stops)
71 H-2
(When the lock-up clutch is provided)
The travel speed is slow, the thrusting force is weak,
72 the uphill traveling power is weak, and the gear is not H-3a)
shifted
The torque converter lock-up clutch is not let in (If the
73 H-3b)
lock-up clutch is equipped)
Shocks are large at the times of starting and shifting
74 H-4
gear
75 Time lag is large at the times of starting and shifting H-5

gear
76 The torque converter oil temperature is high H-6
77 Steering wheel does not turn H-7
78 Steering does not work [machine with joystick] H-8
79 Turning, response of steering is poor H-9
80 Steering is heav H-10
81 Steering wheel shakes or jerks H-11
82 The brake does not work or does not work well H-12
83 The brake is not released or is dragged H-13
84 The brake is not released or dragged H-14
85 The lift arm does not rise H-15
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
Troubleshooting
(Engine)
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
When the control lever is switched from "HOLD" to

98 H-28
"TILT," the bucket falls temporarily
The control levers of lift arm and bucket do not move
99 H-29
smoothly and heavy
Failures related to electrical system (E mode)
100 The engine power modes cannot be selected E-4
101 The front wiper does not function E-5
102 The rear wiper does not function E-6
103 The side wiper does not function (If equipped) E-7
104 The wind washer does not function E-8
105 The headlamp (Lo beam) does not light on E-9
106 The headlamp (Hi beam) does not function E-10
107 The clearance lamp does not light on (Small lamp) E-11
108 The turn signal does not blink E-12
109 The horn does not sound E-13
110 The air conditioner does not work or does not stop E-14
WA380-5 20-249-4
5
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.
Related • Information related to troubleshooting or error that occurred.

Information
Causes Standard Value in Normal State and Remarks on Troubleshooting
<Data to fill in>

• Normal standard values used to judge probable cause
1 • Remarks regarding decision-making
<Condition when wiring harness is defective>

• Disconnection
There is defective connection of connector or disconnection in wiring har-
ness
2 • Short circuit with ground
Wiring harness not wired to ground (GND) circuit is in contact with ground
(GND) circuit
• Hot short
Wiring harness not wired to power supply (24 V) circuit is in contact with
Possible Probable cause when
Causes and trouble occurred power supply (24 V) circuit
Standard Val- 3 (the numbers are
ues index numbers and do <Points to remember when troubleshooting>
not indicate the order 1 Method of displaying connector No. and handling T-adapter
of priority) Unless there is special instruction, insert or connect the T-adapter as fol-
lows
•If there is no indication for the male or female terminal of the connector
No., disconnect the connector and insert the T-adapter in both the male
and female terminals
4 •If there is indication for the male or female terminal of the connector No.,
disconnect the connector and connect the T-adapter to only the termi-
nal indicated (either the male terminal or female terminal)
<Points to remember when troubleshooting>
2 Given order for pin numbers and handling tester lead
Unless there is a special instruction, connect tester (+) lead and (-) lead as
follows to carry out troubleshooting
5
•Connect the (+) lead to the wiring harness for the pin No. given first
•Connect the (-) lead to the wiring harness for the pin No. given last
20-250 WA380-5
(10)
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)
3) Operate the machine and carry out trou-

bleshooting of the items not checked in Cause
Step 1). a b c d e
Operate the machine in the same way as
Remedy ∆
in Step 1), and if any problem occurs, put X C A X
a check against the item. (In Trouble- Problems X
shooting item 5 in the diagram on the 1 ❍ ❍ ❍ ❍
right, the problem was re-enacted.) ✓ 2 ● ●
4) Find the matching cause in the cause col- 3 ❍ ❍
umn.
4 ❍ ❍
In the same way as in Step 2), if a prob-
lem is found, the ❍ marks on the same ✓ 5 ● ●
line for the troubleshooting item are the Applicable items found in Step 3)
causes. (In Troubleshooting item 5 in the Applicable items found in Step 1)
diagram on the right, the cause is b or e.)
Causes to eliminate Common causes
5) Narrow down the causes. Cause

Of the causes found in Step 2) and Step a b c d e
4), there are common items (❍ marks on ∆
Remedy
the line for each troubleshooting item and X C A X
in the same Cause column as each other) Problems X
that have causes common with the prob- 1 ❍ ❍ ❍ ❍
lem items found in the troubleshooting in ✓ 2 ● ●
Step 1) and Step 3). 3 ❍ ❍
★ The items that are not common (items 4 ❍ ❍
that do not have ❍ marks in the same
✓ 5 ● ●
cause common as each other) are
probably not the cause, so they can
be eliminated. Nature of remedy
(The causes for Troubleshooting item
2 in the diagram on the right are c or Cause
e, and the causes in Troubleshooting a b c d e
item 5 are b or e, so Cause e is the Remedy ∆
common cause.) X C A X
Problems X
6) Repeat the operation in Steps 3), 4), and
1 ❍ ❍ ❍ ❍
5) until the cause is narrowed down to 1
item (1 common item). ✓ 2 ● ●
★ If cause items are 2 or more, continue 3 ❍ ❍
until number of items becomes mini- 4 ❍ ❍
mum. ✓ 5 ❍ ●
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
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to
the mating portion of the housing.
★ Deuscht connector has marks of pin numbers on the wiring harness side.
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
Part number: 08055-00282 Part number: 08055-00292
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— —
• Grommet: red • Grommet: red
20-254 WA380-5
(7)
SWP Type Connector

Number
Male (Female housing) Female (Male housing) Number
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
SWP Type Connector

Number
Male (Female housing) Female (Male housing)
Number
BWP04715
16 BWP04716 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
20-256 WA380-5
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
4 BWP04721 BWP04722 799-601-7120
BWP04723 BWP04724
6 799-601-7130
8 BWP04725 BWP04726 799-601-7340
WA380-5 20-257
(7)
S Type Connector
Number
Number
BWP04728
8 BWP04727 799-601-7140
10 (white) BWP04729 BWP04730 799-601-7150
BWP04731 BWP04732
12 (white) 799-601-7350
BWP04733 BWP04734
16 (white) 799-601-7330
20-258 WA380-5
S Type Connector
Number
Number
BWP04736
BWP04735
10 (blue) —
— —
BWP04737 BWP04738
12 (blue) 799-601-7160
BWP04739 BWP04740
16 (blue) 799-601-7170
WA380-5 20-259
MIC Type Connector

Number
Number
Body part number: 79A-222-2640 Body part number: 79A-222-2630
7 (Quantity: 5 pieces) (Quantity: 5 pieces) —
11 Body part number: 79A-222-2680 Body part number: 79A-222-2670 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
BWP04742
BWP04741
5 799-601-2710

BWP04743 BWP04744
9 799-601-2950

BWP04745 BWP04746
13 799-601-2720

20-260 WA380-5
MIC Type Connector

Number
Number
BWP04748
BWP04747
17 799-601-2730

BWP04749 BWP04750
21 799-601-2740

— —
WA380-5 20-261
AMP040 Type Connector

Number
Number
BWP04752
BWP04751
8 799-601-7180
Housing part number: 79A-222-3430

—
(Quantity: 5 pieces)
BWP04753 BWP047544
12 799-601-7190
— Housing part number: 79A-222-3440

BWP04755 BWP04756
16 799-601-7210

BWP04757 BWP04758
20 799-601-7220

★ Terminal part number: 79A-222-3470 (for all numbers of pins).
20-262 WA380-5
AMP070 Type Connector

Number
Number
BWP04760
10 BWP04759 799-601-7510
— Part number: 7821-92-7330
12 BWP04761 BWP04762 799-601-7520
— Part number: 7821-92-7340
14 BWP04763 BWP04764 799-601-7530
— Part number: 7821-92-7350
18 BWP04765 BWP04766 799-601-7540
— Part number: 7821-92-7360
20 BWP04767 BWP04768 799-601-7550
— Part number: 7821-92-7370
WA380-5 20-263
(9)
L Type Connector
Number
Number
BWP04770
2 BWP04769 —
— —
PA Type Connector
Number
Number
BWP04772
9 BWP04771 —
— —
BENDIX (MS) Type Connector

Number
Number
BWP04774
10 BWP04773 799-601-3460
— —
20-264 WA380-5
KES1 Automobile Type Connector

Number
Number
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 —
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
08027-10620 (Black) 08027-10670 (Black)
WA380-5 20-265
KES1 Automobile Type Connector

Number
Number
BWP04784
BWP04783
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket)

Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
BWP04786
5 BWP04785 799-601-7360
— —
BWP04788
6 BWP04787 799-601-7370
— —
20-266 WA380-5
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell size T-adapter Part
code) Body (plug) Body (receptacle)
Number
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
WA380-5 20-267
5

Number
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
20-268 WA380-5
5

Number
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
WA380-5 20-269
5

Number
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
20-270 WA380-5
5

Number
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
WA380-5 20-271
5
DT Series connector
Number
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
4 799-601-9040
6 799-601-9050
20-272 WA380-5
5
DT Series connector
Number
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)
DTM Series connector
Number
Number
2 799-601-9010
DTHD Series connector

Number
Number
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
DRC26 Series connector
Number
Number
24 799-601-9360
— Part No.: 7821-93-3110
40
799-601-9350
(A)
— Part No.: 7821-93-3120
40
799-601-9350
(B)
— Part No.: 7821-93-3130
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.
799-601-2600 For measuring box Econo-21P c c c c c c

799-601-3100 For measuring box MS-37P c
799-601-3200 For measuring box MS-37P c
799-601-3300 For measuring box Econo-24P c
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P c c
799-601-3420 BENDIX(MS) 24P c c
799-601-3430 BENDIX(MS) 17P c c
799-601-3440 BENDIX(MS) 17P c c
799-601-3450 BENDIX(MS) 5P c c
799-601-3460 BENDIX(MS) 10P c c
799-601-3510 BENDIX(MS) 5P c c
799-601-3520 BENDIX(MS) 14P c c
799-601-3530 BENDIX(MS) 19P c c
799-601-2910 BENDIX(MS) 14P c c
799-601-3470 CASE c
799-601-2710 MIC 5P c c c c
799-601-2720 MIC 13P c c c c
799-601-2730 MIC 17P c c c c c c c
799-601-2740 MIC 21P c c c c c c c
799-601-2950 MIC 9P c c c c
799-601-2750 ECONO 2P c c
799-601-2760 ECONO 3P c c
799-601-2770 ECONO 4P c c
799-601-2780 ECONO 8P c c
799-601-2790 ECONO 12P c c
799-601-2810 DLI 8P c c
799-601-2820 DLI 12P c c
799-601-2830 DLI 16P c c
799-601-2840 Extension cable c c c
799-601-2850 CASE c
799-601-7010 X 1P c c
799-601-7020 X 2P c c c c
799-601-7030 X 3P c c c c
799-601-7040 X 4P c c c c
799-601-7050 SWP 6P c c c
799-601-7060 SWP 8P c c c
799-601-7310 SWP 12P c
799-601-7070 SWP 14P c c
WA380-5 20-275
5
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
—
799-601-7320 SWP 16P c

799-601-7080 M 1P c c
799-601-7090 M 2P c c c c
799-601-7110 M 3P c c c c
799-601-7120 M 4P c c c c
799-601-7130 M 6P c c c c
799-601-7340 M 8P c
799-601-7140 S 8P c c c c
799-601-7150 S 10P-White c c c c
799-601-7160 S 12P-Blue c c c
799-601-7170 S 16P-Blue c c c c
799-601-7330 S 16P-White c
799-601-7350 S 12P-White c
799-601-7180 AMP040 8P c
799-601-7190 AMP040 12P c c
799-601-7210 AMP040 16P c c c c
799-601-7220 AMP040 20P c c c c
799-601-7230 Short connector X-2 c c c c
799-601-7240 Case c c
799-601-7270 Cace c
799-601-7510 070 10P c
799-601-7520 070 12P c
799-601-7530 070 14P c
799-601-7540 070 18P c
799-601-7550 070 20P c
799-601-7360 Relay connector 5P c
799-601-7370 Relay connector 6P c
799-601-7380 JFC connector 2P c
799-601-9010 DTM 2P c c
799-601-9020 DT 2P c c
799-601-9030 DT 3P c c
799-601-9040 DT 4P c c
799-601-9050 DT 6P c c
799-601-9060 DT 8P-Gray c c
799-601-9070 DT 8P-Black c c
799-601-9080 DT 8P-Green c c
799-601-9090 DT 8P-Blown c c
799-601-9110 DT 12P-Gray c c
799-601-9120 DT 12P-Black c c
799-601-9130 DT 12P-Green c c
799-601-9140 DT 12P-Blown c c
799-601-9210 HD30 18-8 c c
799-601-9220 HD30 18-14 c c
20-276 WA380-5
5
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
—
799-601-9230 HD30 18-20 c c

799-601-9240 HD30 18-21 c c
799-601-9250 HD30 24-9 c c
799-601-9260 HD30 2-16 c c
799-601-9270 HD30 24-21 c c
799-601-9280 HD30 24-23 c c
799-601-9290 HD30 24-31 c c
799-601-9310 Plate For HD30 c c c
799-601-9320 For measuring box For DT, HD c c c
799-601-9330 Case c
799-601-9340 Case c
799-601-9350 DRC26 40P c
799-601-9360 DRC26 24P c
799-601-9410 For NE, G sensor 2P c
For boost pressure,
799-601-9420 3P c
fuel
799-601-9430 PVC socket 2P c
WA380-5 20-277
(9)
TROUBLESHOOTING OF TRANSMISSION
CONTROL SYSTEM
(TM MODE)
Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-303

Connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
Transmission control system diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-318
Failure Code [1500L1] (Double engagement detected) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . 20-321
Failure Code [15SAL1] (F_ECMV fill switch system short-circuited) is displayed . . . . . . . . . . . . . . . 20-322
Failure Code [15SALH] (F_ECMV fill switch system disconnected) is displayed . . . . . . . . . . . . . . . . 20-323
Failure Code [15SBL1] (R_ECMV fill switch system short-circuited) is displayed . . . . . . . . . . . . . . . 20-324
Failure Code [15SBLH] (R_ECMV fill switch system disconnected) is displayed . . . . . . . . . . . . . . . . 20-325
Failure Code [15SEL1] (1st_ECMV fill switch system short-circuited) is displayed . . . . . . . . . . . . . . 20-326
Failure Code [15SELH] (1st_ECMV fill switch system disconnected) is displayed . . . . . . . . . . . . . . . 20-327
Failure Code [15SFL1] (2nd_ECMV fill switch system short-circuited) is displayed . . . . . . . . . . . . . 20-328
Failure Code [15SFLH] (2nd_ECMV fill switch system disconnected) is displayed . . . . . . . . . . . . . . 20-329
Failure Code [15SGL1] (3rd_ECMV fill switch system short-circuited) is displayed . . . . . . . . . . . . . 20-330
Failure Code [15SGLH] (3rd_ECMV fill switch system disconnected) is displayed . . . . . . . . . . . . . . 20-331
Failure Code [15SHL1] (4th_ECMV fill switch system short-circuited) is displayed. . . . . . . . . . . . . . 20-332
Failure Code [15SHLH] (4th_ECMV fill switch system disconnected) is displayed. . . . . . . . . . . . . . . 20-333
Failure Code [15SJL1] (Lockup_ECMV fill switch system short-circuited) is displayed . . . . . . . . . . 20-334
Failure Code [15SJLH] (Lockup_ECMV fill switch system disconnected) is displayed . . . . . . . . . . . 20-335
Failure Code [989F00] (Transmission protection caution) is displayed . . . . . . . . . . . . . . . . . . . . . . . 20-336
Failure Code [B@C7NS] (Rear brake cooling oil overheat) is displayed . . . . . . . . . . . . . . . . . . . . . . . . 20-338
Failure Code [D150KA] (Emergency steering relay output system disconnected) is displayed . . . . 20-339
Failure Code [D150KB] (Emergency steering relay output system grounded) is displayed . . . . . . . 20-340
Failure Code [D160KA] (Backup lamp relay output system disconnected) is displayed . . . . . . . . . . 20-341
Failure Code [D160KB] (Backup lamp relay output system grounded) is displayed . . . . . . . . . . . . . 20-342
Failure Code [D191KA] (Neutral safety relay output system disconnected) is displayed . . . . . . . . . 20-344
Failure Code [D191KB] (Neutral safety relay output system grounded) is displayed . . . . . . . . . . . . 20-346
Failure Code [D192KA] (E.C.S.S. relay output system disconnected) is displayed [*] . . . . . . . . . . . . 20-348
Failure Code [D192KB] (E.C.S.S. relay output system grounded) is displayed [*] . . . . . . . . . . . . . . . 20-349
Failure Code [D198KB] (Ground fault in the low temperature bypass relay system)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-349-1
Failure Code [D198KY] (Hot-short in the low-temperature bypass relay system) is displayed. . . 20-349-2
Failure Code [DAQ0KK] (Controller power supply voltage lowered) is displayed. . . . . . . . . . . . . . . . 20-350
Failure Code [DAQ2KK] (Defective solenoid power supply system) is displayed . . . . . . . . . . . . . . . . 20-351
Failure Code [DAQ9KQ] (Model selection signal mismatch) is displayed . . . . . . . . . . . . . . . . . . . . . . 20-352
Failure Code [DDK3KA] (Right FNR switch signal not input) is displayed . . . . . . . . . . . . . . . . . . . . . . 20-354
Failure Code [DDK3KB] (Multiple right FNR switch signal input) is displayed . . . . . . . . . . . . . . . . . . 20-356
Failure Code [DDK4KA] (Joystick forward/reverse switch signal is not input) is displayed . . . . . . . . 20-357
Failure Code [DDK4KB] (Multiple joystick forward/reverse switch signals are input) is displayed . . 20-359
Failure Code [DDK5LD] (Hot short in joystick SHIFT_UP/SHIFT_DOWN switch)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-361
Failure Code [DDK6KA] (Forward-reverse lever signal not input) is displayed . . . . . . . . . . . . . . . . . . 20-362
Failure Code [DDK6KB] (Multiple forward-reverse lever signal input) is displayed . . . . . . . . . . . . . . 20-364
Failure Code [DDS5KA] (Steering pressure switch disconnected) is displayed . . . . . . . . . . . . . . . . . 20-366
Failure Code [DDS5KB] (Steering pressure switch grounded) is displayed . . . . . . . . . . . . . . . . . . . . 20-367
Failure Code [DDT0L4] (Manual/auto-shift selector switch selection failure) is displayed . . . . . . . . 20-368
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
CONNECTOR TYPES AND MOUNTING LOCATIONS

★ The address column of the table indicates each address of a connector placement diagram (diagram in
three dimensions) and an electrical circuit system diagram.
★ Symbols of the circuit diagram address column of the table:
TM: Transmission control system,WRK: Work equipment control system, MON: Monitoring system, E:
Electrical system.
★ The item enclosed by parentheses in the connector type column indicates the color of the connector
body. (B: Black, Br: Brown, G: Green, Gr: Gray, L: Blue, W: White.
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
1.PS DT-T 2 Transmission 1st clutch solenoid AJ-4 M-8

1.SW DT 2 Transmission 1st clutch fill switch AJ-4 O-8
2.PS DT-T 2 Transmission 2nd clutch solenoid AJ-3 M-8
2.SW DT 2 Transmission 2nd clutch fill switch AJ-3 O-8
3.PS DT-T 2 Transmission 3rd clutch solenoid AJ-4 M-8
3.SW DT 2 Transmission 3rd clutch fill switch AJ-4 O-8
4.PS DT-T 2 Transmission 4th clutch solenoid AJ-5 M-8
4.SW DT 2 Transmission 4th clutch fill switch AJ-5 O-8
A1 M 6 Air conditioner blower motor and resistor U-2
A2 SWP 6 Air conditioner air mixing servomotor U-2
A3 M 2 Air conditioner thermistor U-2
A4 X 2 Air conditioner air servomotor U-8
A5 X 2 Air conditioner condenser switch T-1
A6 Yazaki 2 Air conditioner Hi-Lo switch T-1
A7 Yazaki 4 Air conditioner blower relay (Main) W-6
A8 Yazaki 4 Air conditioner blower relay (Hi) W-6
A9 Yazaki 4 Air conditioner blower relay (M2) W-6
A11 Yazaki 4 Air conditioner condenser relay W-5
A12 Yazaki 4 Air conditioner condenser Hi (1) relay W-5
A14 Yazaki 4 Air conditioner MAG clutch relay W-4
A20 Terminal 1 Ground (Floor) T-2
Water temperature sensor (Vehicle with automatic air
A21 Yazaki 2 W-3
conditioner)
Inside temperature sensor (Vehicle with automatic air
A22 Yazaki 2 conditioner) U-2
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
AL1 M 6 Intermediate connector (Air conditioner relay) U-2

AL2 S (W) 12 Intermediate connector (Air conditioner relay) V-3
B01 DT-T 3 Air conditioner condenser motor A-7
B02 DT-T 3 Air conditioner condenser motor B-7
BR1 DT-T 6 Intermediate connector (Air conditioner condenser motor) J-2 W-6
WA380-5 20-303
(10)
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
C01 Yazaki 9 AM/FM radio C-9

C02 KES0 2 Speaker (Right) E-9
C03 KES0 2 Speaker (Left) G-9
C04 M 2 Front working lamp (Right) B-8 E-8
C05 M 2 Front working lamp (Left) B-8 E-8
C07 KES1 2 Room lamp C-8
C08 M 1 Door switch (Right) (Room Lamp) C-8
C09 M 1 Door switch (Left) (Room lamp) B-8
C10 — 2 Cigarette lighter A-7
C12 M 6 Front wiper motor A-7
C15 M 4 Rear wiper motor F-9
C17 Kyoritsu 4 Warning lamp switch D-9

ES
C18 Plug 1 Warning lamp (Beacon) C-8
C19 DT-T 6 Glass heater switch D-9
C29 M 1 Glass heater ON E-9
C33 H 1 Rear glass heater E-9
C35 H 1 Rear glass heater G-9
C38 M 1 Connector (Electric power take-off)
C39 Terminal 1 Ground (Radio) C-9 E-7
C40 Terminal 1 Ground (Cab) C-8
C41 M 1 Warning lamp F-9
C43 Yazaki 6 Side wiper switch E-9
C44 M 4 Right side wiper motor A-7
C45 M 4 Left side wiper motor A-7
C46 M 1 Intermediate connector (Power source) D-9
C47 Terminal 1 Ground (Cab) F-9
AMP1720
C47 21-2 16 A/C control AMP P-1
C47 AMP040 20 A/C control AMP (Vehicle with automatic air conditioner) D-9
AMP1722
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
CL5 S (W) 16 M-2
conditioner)
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)
Address
Number System
Connector Connector
No. Type
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
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)
Address
Number System
Connector Connector
No. Type
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
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
Address
Number System
Connector Connector
No. Type
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
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
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
L56 AMP070 12 Monitor panel controller M-5 B-2 O-2 B-3
L58 AMP040 8 Monitor panel controller M-2
WA380-5 20-307
(10)
Address
Number System
Connector Connector
No. Type
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
L146 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)
Address
Number System
Connector Connector
No. Type
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
PB.PS DT-T 2 Parking brake solenoid AJ-3 P-8

PB.SW DT-T 2 Parking brake indicate switch AJ-3 Q-8 P-8
R.PS DT-T 2 Transmission R clutch solenoid AJ-6 N-8
R.SW DT 2 Transmission R clutch fill switch AJ-5 O-8
R01 Terminal 1 Battery relay J-2 O-1 X-6 F-2
R02 Terminal 1 Slow-blow fuse L-2 P-1 F-4
R04 Terminal 1 Battery relay L-1 O-1 X-6 F-2
R05 Terminal 1 Slow-blow fuse K-3 P-1 X-7 F-3
R06 Terminal 1 Slow-blow fuse K-3 P-1 F-3
R09 Terminal 1 Slow-blow fuse K-2 F-3
R11 Terminal 1 Slow-blow fuse K-3 X-7 F-3
R13 L-1 O-1 X-6 F-2
R15 Terminal 1 Emergency steering relay J-1 O-1
R16 Terminal 1 Emergency steering relay J-1 N-1
R22 Terminal 1 Battery G-9 M-2 T-9 F-2
R24 DT-T 2 Diode (Battery relay) I-1 P-1 F-6
R25 DT-T 2 Diode (Battery relay) I-2 J-1 P-1 F-5
R26 DT-T 2 Diode (Starting motor) I-1 P-1 F-5
R27 DT-T 2 Diode (Starting motor) J-2 P-1 F-5
R29 DT-T 2 Fan pump EPC A-6 Q-3
R30 M 6 Rear combination lamp (Left) L-5 S-8
R31 M 6 Rear combination lamp (Right) H-9 S-8
R32 DT-T 2 Coolant level sensor B-8 X-8
R33 DT-T 2 Fuel level gauge sensor K-3 U-8
R34 M 2 License lamp L-6
R36 DT-T 3 Steering pump pressure switch E-1 Q-3 V-8
R37 DT-T 3 Emergency steering pressure switch D-1 Q-2 W-8
R38 DT-T 6 Auto grease controller N-1
WA380-5 20-309
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
R39 DT-T 2 Battery level sensor L-5 T-7

R43 KES1 2 Front windshield washer G-1
R44 DT-T 2 Diode (Washer) G-1
R45 KES1 2 Rear windshield washer H-1
R47 DT-T 2 Hydraulic oil temperature sensor A-6 W-1
R50 Terminal 1 Ground (Rear frame) I-9 M-1 T-1 D-1
R51 DT-T 2 Emergency brake switch 1 F-1 J-1
R53 DT-T 2 Front brake accumulator low pressure switch F-1 J-1 W-8
R54 DT-T 2 Rear brake accumulator low pressure switch F-1 J-2 W-8
R55 DT-T 2 Intermediate connector (Rear brake oil temperature) J-2 P-3
R56 DT-T 2 Rear brake oil temperature sensor H-1 Q-3
R63 Terminal 1 Slow-blow fuse L-2
R64 Terminal 1 Ground (Rear frame) L-5
R65 DT-T 6 Cooler automatic tilt motor switch (If equipped) L-4
R66 DT-T 2 Cooler automatic tilt motor H-9
R68 Terminal 1 Fuel solenoid relay I-9 F-1
R72 DT-T 2 Fuel solenoid relay K-9 F-1
REV OUT DT-T 2 Speed sensor AG-2 N-8
S01 DT-T 6 Front working lamp switch O-1 C-8
S02 DT-T 6 Rear working lamp switch O-1 C-8
S03 DT-T 6 Transmission cut-off ON/OFF switch M-4 B-5
S04 DT-T 6 Right FNR selector switch N-9 H-8 K-2 C-8
S05 DT-T 6 Transmission cut-off set switch M-9 H-8
S06 DT-T 6 Torque converter lockup ON/OFF switch O-8 I-8
S07 DT-T 6 Lift arm damper ON/OFF switch O-1 B-5
S12 DT-T 6 Remote positioner set switch (Vehicle with joystick) N-7 I-2
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
CONNECTOR LAYOUT DRAWING
20-312 WA380-5
WA380-5 20-313
5
20-314 WA380-5
5
WA380-5 20-315
5
20-316 WA380-5
5
WA380-5 20-317
5
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIAGRAM
TRANSMISSION CONTROL SYSTEM DIAGRAM
20-318 WA380-5
5
WA380-5 20-319
5
20-320 WA380-5
TROUBLESHOOTING FAILURE CODE [1500L1]
FAILURE CODE [1500L1]

Action Code Failure Code Controller Code Double engagement
Trouble
E03 1500L1 TM detected
Description of • A fill signal is input when double engagement is detected.

Trouble
Controller Reaction • No reaction.
Effect on Machine —
Related Information —
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.
Related Circuit Diagram

★ Refer to Failure codes 15SAL1, 15 SBL1, 15SEL1, 15SFL1, 15SGL1 and 15SHL1.
WA380-5 20-321
(10)
TROUBLESHOOTING FAILURE CODE [15SAL1]
FAILURE CODE [15SAL1]

Action Code Failure Code Controller Code
Trouble F_ECMV fill switch system short-circuited
E03 15SAL1 TM
Description of • An F_ECMV fill switch signal is input when F_ECMV is OFF.
Trouble
Controller Reac- • Assumes that the F_ECMV fill switch signal is on and turns output to “N”.
tion
Effect on Machine • No travel.
Related Informa- • Can be checked with the monitoring function (Code: 40908, D-IN-24).
tion
Causes Standard Values in Normal State and Remarks on Troubleshooting

1) Turn starting switch OFF.
2) Disconnect connector F.SW.
3) Connect T-adapter.
4) Start engine.
5) Turn transmission cut-off switch OFF.
1 Defective F_ECMV fill 6) Turn parking brake switch OFF.
switch 7) Do not apply parking brake while traveling.
Between Forward-reverse lever (Or Resistance 1 Ω and below

F.SW (Male) switch) = F
1 and body Other than above Resistance 1 MΩ and above
Possible Causes 2) Disconnect connectors L62 and F.SW.
and Standard Val- 2 Wiring harness 3) Connect T-adapter.
ues ground fault
Between L62 (Female) [/F.SW (Female) 1 - Resistance 1 MΩ and above
body
2) Disconnect connector L62.
3) Insert T-adapter.
4) Connect connector.
5) Start engine.
Defective transmis- 6) Turn transmission cut-off switch OFF.
3 sion and fan pump 7) Turn parking brake switch OFF.
motor controller 8) Do not apply parking brake while traveling.
Forward-reverse lever (Or
Between L62 switch) = F Voltage 1 V and below
[ - body
Other than above Voltage 20 - 30 V
Related circuit diagram
BWW10520
20-322 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SALH]
FAILURE CODE [15SALH]

Trouble F_ECMV fill switch system disconnected
E01 15SALH TM
Description of • An F_ECMV fill switch signal is input when F_ECMV is on.
Trouble
Controller Reac- • Assumes that the F_ECMV fill switch signal is OFF and uses fill-less modulation data.
tion
Effect on • May not travel.
Machine • Gear shifting shock or time lag may occur on forward-travel switchover.
tion

2) Disconnect connector F.SW.
4) Start engine.
Defective F_ECMV 6) Turn parking brake switch OFF.
1
fill switch 7) Do not apply parking brake while traveling.
Between F.SW Forward-reverse lever (Or Resistance 1 Ω and below

(Male) 1 - switch) = F
body Other than above Resistance 1 MΩ and above
Wiring harness 1) Turn starting switch OFF.

Possible Causes
and Standard Wiring harness dis- 2) Disconnect connectors L62 and F.SW.
Values 2 continuity (Discon- 3) Connect T-adapter.
nection or defective Wiring harness between L62 (Female) [ -
contact) Resistance 1 Ω and below
F.SW (Female) 1
4) Start engine.
Forward-reverse lever (Or
Between L62 Voltage 1 V and below
switch) = F
[ - body
BWW10520
WA380-5 20-323
(10)
TROUBLESHOOTING FAILURE CODE [15SBL1]
FAILURE CODE [15SBL1]

Trouble R_ECMV fill switch system short-circuited
E03 15SBL1 TM
Description of • An R_ECMV fill switch signal is input when R_ECMV is OFF.
Trouble
Controller Reaction • Assumes that the R_ECMV fill switch signal is on and turns output to “N”.
tion

2) Disconnect connector R.SW.
4) Start engine.
1 Defective R_ECMV fill 6) Turn parking brake switch OFF.

R.SW (Male) switch) = R
1 - body Other than above Resistance 1 MΩ and above
Possible Causes 1) Turn starting switch OFF.

2) Disconnect connectors L62 and R.SW.
and Standard Wiring harness 3) Connect T-adapter.
Values 2
ground fault
Between L62 (Female) Q/R.SW (Female) 1 Resistance 1 MΩ and above
- body
4) Start engine.
Forward-reverse lever (Or Voltage 1 V and below
Between L62 switch) = R
Q - body
BWW10520
20-324 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SBLH]
FAILURE CODE [15SBLH]

Trouble R_ECMV fill switch system disconnected
E01 15SBLH TM
Description of • An R_ECMV fill switch signal is input when R_ECMV is on.
Trouble
Controller Reac- • Assumes that the R_ECMV fill switch signal is OFF and uses fill-less modulation data.
tion
• May not travel.
Effect on Machine
• Gear shifting shock or time lag may occur on reverse-travel switchover.
tion

2) Disconnect connector R.SW.
4) Start engine.
1 Defective R_ECMV fill 6) Turn parking brake switch OFF.

R.SW (Male) switch) = R

Wiring harness dis- 2) Disconnect connectors L62 and R.SW.
and Standard Val- continuity (Disconnec- 3) Connect T-adapter.
ues 2
tion or defective
contact) Wiring harness between L62 (Female) Q - Resistance 1 Ω and below
R.SW (Female) 1
4) Start engine.
Forward-reverse lever (Or Voltage 1 V and below
Between L62 switch) = R
Q - body
BWW10520
WA380-5 20-325
(10)
TROUBLESHOOTING FAILURE CODE [15SEL1]
FAILURE CODE [15SEL1]

Trouble 1st_ECMV fill switch system short-circuited
E03 15SEL1 TM
Description of • A 1st_ECMV fill switch signal is input when 1st_ECMV is OFF.
Trouble
Controller Reaction • Assumes that the 1st_ECMV fill switch signal is on and turns speed clutch output OFF.
tion

2) Disconnect connector 1.SW.
4) Start engine.
Defective 1st_ECMV 5) Turn transmission cut-off switch OFF.
1 6) Turn parking brake switch OFF.
fill switch
7) Do not apply parking brake while traveling.
Between Gear shift lever = 1st speed Resistance 1 Ω and below
1.SW (Male)
2) Disconnect connectors L62 and 1.SW.
Possible Causes 2 Wiring harness 3) Connect T-adapter.
and Standard Val- ground fault
ues Between L62 (Female) G/1.SW (Female) 1 Resistance 1 MΩ and above
- body
5) Start engine.
9) Turn manual/auto shift selector switch to “Manual”.
10) Turn forward-reverse lever (Or switch) to “F” or “R”.
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]
FAILURE CODE [15SELH]

Action Code Failure Code Controller code
Trouble 1st_ECMV fill switch system disconnected
E01 15SELH TM
Description of • No 1st_ECMV fill switch signal is input when 1st_ECMV is on.
Trouble
Controller Reac- • Assumes that the 1st_ECMV fill switch signal is OFF and turns speed clutch output OFF.
tion
• May not travel at 1st speed.
Effect on Machine
• Gear shifting shock or time lag may occur on 1st-speed-travel switchover.
tion

4) Start engine.
Defective 1st_ECMV 5) Turn transmission cut-off switch OFF.
fill switch
Between Gear shift lever = 1st speed Resistance 1 Ω and below
1.SW (Male)
Wiring harness dis- 2) Disconnect connectors L62 and 1.SW.
Possible Causes
and Standard Val- 2 continuity (Disconnec- 3) Connect T-adapter.
tion or defective
ues contact) Wiring harness between L62 (Female) G - Resistance 1 Ω and below
1.SW (Female) 1
4) Start engine.
Defective transmis- 6) Turn parking brake switch OFF.
3 sion and fan pump 7) Do not apply parking brake while traveling.
motor controller 8) Turn manual/auto shift selector switch to “Manual”.
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]
FAILURE CODE [15SFL1]

Trouble 2nd_ECMV fill switch system short-circuited
E03 15SFL1 TM
Description of • A 2nd_ECMV fill switch signal is input when 2nd_ECMV is OFF.
Trouble
Controller Reac- • Assumes that the 2nd_ECMV fill switch signal is on and turns speed clutch output OFF.
tion
tion

4) Start engine.
Defective 2nd_ECMV 5) Turn transmission cut-off switch OFF.
1 fill switch 6) Turn parking brake switch OFF.
Between Gear shift lever = 2nd speed Resistance 1 Ω and below
2.SW (Male)
Possible Causes 2) Disconnect connectors L62 and 2.SW.
Wiring harness 3) Connect T-adapter.
and Standard Val- 2 ground fault
ues Between L62 (Female) 7/2.SW (Female) 1
- body Resistance 1 MΩ and above

4) Start engine.
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]
FAILURE CODE [15SFLH]

Trouble 2nd_ECMV fill switch system disconnected
E01 15SFLH TM
Description of • No 2nd_ECMV fill switch signal is input when 2nd_ECMV is ON.
Trouble
Controller Reaction • Assumes that the 2nd_ECMV fill switch signal is OFF and uses fill-less modulation data.
• May not travel at 2nd speed.
Effect on Machine • Gear shifting shock or time lag may occur on 2nd-speed-travel switchover.
tion

4) Start engine.
Defective 2nd_ECMV 5) Turn transmission cut-off switch OFF.
fill switch
Between Gear shift lever = 2nd speed Resistance 1 Ω and below
2.SW (Male)
Wiring harness dis- 2) Disconnect connectors L62 and 2.SW.
Possible Causes continuity (Disconnec- 3) Connect T-adapter.
and Standard Val- 2
ues tion or defective
contact) Wiring harness between L62 (Female) 7 -
Resistance 1 Ω and below
2.SW (Female) 1
4) Start engine.
Between L62 Gear shift lever = 2nd speed Voltage 1 V and below
WA380-5 20-329
(10)
TROUBLESHOOTING FAILURE CODE [15SGL1]
FAILURE CODE [15SGL1]

Trouble 3rd_ECMV fill switch system short-circuited
E03 15SGL1 TM
Description of • A 3rd_ECMV fill switch signal is input when 3rd_ECMV is OFF.
Trouble
Controller Reac- • Assumes that the 3rd_ECMV fill switch signal is on and turns speed clutch output OFF.
tion
tion

4) Start engine.
Defective 3rd_ECMV 5) Turn transmission cut-off switch OFF.
1 fill switch 6) Turn parking brake switch OFF.
Between Gear shift lever = 3rd speed Resistance 1 Ω and below
3.SW (Male)
Possible Causes Wiring harness dis- 2) Disconnect connectors L62 and 3.SW.
continuity (Disconnec- 3) Connect T-adapter.
and Standard Val- 2 tion or defective
ues Between L62 (Female) C/3.SW (Female) 1
contact) Resistance 1 MΩ and above
- body
4) Start engine.
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]
FAILURE CODE [15SGLH]

Trouble 3rd_ECMV fill switch system disconnected
E01 15SGLH TM
Description of • No 3rd_ECMV fill switch signal is input when 3rd_ECMV is ON.
Trouble
Controller Reaction • Assumes that the 3rd_ECMV fill switch signal is OFF and uses fill-less modulation data.
• May not travel at 3rd speed.
Effect on Machine • Gear shifting shock or time lag may occur on 3rd-speed-travel switchover.
tion

4) Start engine.
Defective 3rd_ECMV fill 6) Turn parking brake switch OFF.
1
Between Gear shift lever = 3rd

3.SW (Male) speed
Possible Causes Wiring harness disconti- 2) Disconnect connectors L62 and 3.SW.
and Standard Val- 2 nuity (Disconnection or 3) Connect T-adapter.
ues defective contact) Wiring harness between L62 (Female) C
- 3.SW (Female) 1
4) Start engine.
Defective transmission 6) Turn parking brake switch OFF.
3 and fan pump motor 7) Do not apply parking brake while traveling.
controller 8) Turn manual/auto shift selector switch to “Manual”.
Gear shift lever = 3rd
Between L62 speed Voltage 1 V and below
C - body
WA380-5 20-331
(10)
TROUBLESHOOTING FAILURE CODE [15SHL1]
FAILURE CODE [15SHL1]

Trouble 4th_ECMV fill switch system short-circuited
E03 15SHL1 TM
Description of • A 4th_ECMV fill switch signal is input when 4th_ECMV is OFF.
Trouble
Controller Reac- • Assumes that the 4th_ECMV fill switch signal is on and turns speed clutch output OFF.
tion
tion

4) Start engine.
Defective 4th_ECMV fill 5) Turn transmission cut-off switch OFF.
1 switch 6) Turn parking brake switch OFF.
Between Gear shift lever = 4th speed Resistance 1 Ω and below
4.SW (Male)
Possible Causes 2) Disconnect connectors L62 and 4.SW.
Wiring harness ground 3) Connect T-adapter.
and Standard Val- 2 fault
ues Between L62 (Female) 3/4.SW (Female)
1 - body Resistance 1 MΩ and above

4) Start engine.
3 and fan pump motor con- 7) Do not apply parking brake while traveling.
troller 8) Turn manual/auto shift selector switch to “Manual”.
Between L62 Gear shift lever = 4th speed Voltage 1 V and below
20-332 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SHLH]
FAILURE CODE [15SHLH]

Trouble 4th_ECMV fill switch system disconnected
E01 15SHLH TM
Description of • No 4th_ECMV fill switch signal is input when 4th_ECMV is on.
Trouble
Controller Reaction • Assumes that the 4th_ECMV fill switch signal is OFF and uses fill-less modulation data.
• May not travel at 4th speed.
Effect on Machine • Gear shifting shock or time lag may occur on 4th-speed-travel switchover.
tion

4) Start engine.
Defective 4th_ECMV fill 6) Turn parking brake switch OFF.
1
Between Gear shift lever = 4th

4.SW (Male) speed
Possible Causes Wiring harness disconti- 2) Disconnect connectors L62 and 4.SW.
and Standard Val- 2 nuity (Disconnection or 3) Connect T-adapter.
ues defective contact) Wiring harness between L62 (Female) 3
- 4.SW (Female) 1
4) Start engine.
3 and fan pump motor 7) Do not apply parking brake while traveling.
controller 8) Turn manual/auto shift selector switch to "Manual".
9) Turn forward-reverse lever (Or switch) to "F" or "R".
Gear shift lever = 4th
Between L62 speed Voltage 1 V and below
3 - body
WA380-5 20-333
(10)
TROUBLESHOOTING FAILURE CODE [15SJL1]
FAILURE CODE [15SJL1]

Trouble Lockup_ECMV fill switch system short-circuited
E03 15SJL1 TM
Description of • A Lockup_ECMV fill switch signal is input when Lockup_ECMV is OFF
Trouble
Controller Reac- • Assumes that the Lockup_ECMV fill switch signal is on and turns output OFF.
tion
tion

2) Disconnect connectors L62 and LC.SW.
1 Wiring harness ground 3) Connect T-adapter.
fault
Between L62 (Female) 2/LC.SW (Female) Resistance 1 MΩ and above
Possible Causes 1 - body
and Standard Val-
ues 1) Turn starting switch OFF.
Defective transmission 3) Insert T-adapter.
and fan pump motor con- 4) Start engine.
2 troller or lockup_ECMV
fill switch Between L62 Lockup = ON Voltage 1 V and below
20-334 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [15SJLH]
FAILURE CODE [15SJLH]

Trouble Lockup_ECMV fill switch system disconnected
E03 15SJLH TM
Description of • No Lockup_ECMV fill switch signal is input when Lockup_ECMV is ON.
Trouble
Controller Reaction • Assumes that the Lockup_ECMV fill switch signal is OFF and uses fill-less modulation data.
• May not be locked up.
Effect on Machine • Gear shifting shock or time lag may occur on lockup switchover.
tion

Wiring harness disconti- 2) Disconnect connectors L62 and LC.SW.
1 nuity (Disconnection or 3) Connect T-adapter.
defective contact) Wiring harness between L62 (Female) 2
Possible Causes - LC.SW (Female) 1 Resistance 1 Ω and below
and Standard Val-
Defective transmission 3) Insert T-adapter.
and fan pump motor 4) Start engine.
2
controller or
lockup_ECMV fill switch Between L62 Lockup = ON Voltage 1 V and below
WA380-5 20-335
(10)
TROUBLESHOOTING FAILURE CODE [989F00]
FAILURE CODE [989F00]

Trouble Transmission protection caution
E00 989F00 TM
• Not considered to be a failure.
Description of • The travel speed exceeds the allowable speed of the transmission on down shifting.
Trouble • The allowable speed of the transmission is exceeded on FR gear shifting.
• The travel speed exceeds 38km/h.
Controller Reac- • Issues a warning to attract operator's attention on FR gear shifting in auto shift mode.
tion
• May be started at 2nd speed during FR gear shifting in auto shift mode.
Effect on Machine • Down shifting may not be possible when the accelerator is fully pushed down.
Related Informa- • Refer to "Structure and Operation" (Transmission protection, travel speed warning, and engine overrun func-
tion tions).
Related circuit diagram (None)
20-336 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@C7NS]
FAILURE CODE [B@C7NS]

Trouble Rear brake cooling oil overheat
E02 B@C7NS TM
Description of • Rear brake overheat.
Trouble
Controller Reac- • No reaction.
tion
• Brake may be broken.
Effect on Machine
• A rear brake overheat warning is displayed.
Related Informa- • Can be checked with the monitoring function (Code: 30202 R BRAKE OIL).
tion

Defective rear 2) Disconnect connector R56.
brake oil tem- 3) Connect T-adapter.
1 perature sen-
Between R56 At normal temperature (25 °C) Resistance 35 - 50 k Ω
Possible Causes sor
and Standard Val- (Male) 1 - 2 At 100 °C Resistance 3.1 - 4.5 k Ω
ues
Defective 2) Disconnect connector L61.
transmission 3) Connect T-adapter.
2 and fan pump
motor con- Between L61 At normal temperature (25 °C) Resistance 35 - 50 k Ω
troller (Female) J - U At 100 °C Resistance 3.1 - 4.5 k Ω
20-338 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [D150KA]
FAILURE CODE [D150KA]

Action Code Failure Code Controller Code Emergency steering relay output system dis-
Trouble
E03 D150KA TM connected
Description of • No signal is output to the emergency steering relay due to disconnection.

Trouble
Effect on Machine • The electric emergency steering motor does not rotate.
Related Informa- —
tion

1) Turn starting switch OFF 10 or more seconds after starting engine.
2) Replace relay.
3) Turn starting switch ON (at self-check).
This Failure code (D150KA) issued Relay L126 is not defective
Defective emergency steer-
1 ing realy (L126) This Failure code (D150KA) not issued Relay L126 is defective
Possible Causes Between L105 (Male) 9 - 0 Resistance 200 - 400 Ω
and Standard Val-
2) Disconnect connectors L63 and L105.
Wiring harness discontinu-
2 ity (Disconnection or defec- Wiring harness between L63 (Female)
tive contact) 7 - L105 (Female) 9
Wiring harness between L105
(Female) 0 - body Resistance 1 Ω and below

Defective transmission and 2) Disconnect connector L63.
3 fan pump motor controller 3) Connect T-adapter.
Between L63 (Female) 7 - body Resistance 200 - 400 Ω
BWW10522
WA380-5 20-339
(10)
TROUBLESHOOTING FAILURE CODE [D150KB]
FAILURE CODE [D150KB]

Trouble Emergency steering relay output system grounded
E03 D150KB TM
Description of • No signal is output to the emergency steering relay due to disconnection.
Trouble
tion
Related Informa-
tion —

1) Turn starting switch OFF 10 or more seconds after starting engine.
2) Replace relay.
3) Turn starting switch ON (at self-check).
This Failure code (D150KB) issued Relay L126 is not defective
Defective emergency steer-
1 ing realy (L126)
This Failure code (D150KB) not issued Relay L126 is defective
Possible Causes 3) Connect T-adapter.
and Standard Between L105 (Male) 9 - 0 Resistance 200 - 400 Ω
Values
Wiring harness discontinuity 2) Disconnect connectors L63 and L105.
2 (Disconnection or defective 3) Connect T-adapter.
contact) Wiring harness between L63 (Female) Resistance 1 MΩ and above
7 - L105 (Female) 9
BWW10522
20-340 WA380-5
(10)

Trouble Backup lamp relay output system disconnected
E01 D160KA TM
Description of • Backup lamp relay output system disconnected.
Trouble
Related Informa- • No backup buzzer sounds or the backup lamp does not come on (Traveling is possible).
tion

2) Replace relay.
3) Turn starting switch ON.
4) Turn forward-reverse lever to “R”.
Defective backup lamp relay
1 (L117) This Failure code (D160KA) not issued Relay L117 is defective
Possible Causes Between L103 (Female) 1 - 2 Resistance 200 - 400 Ω
and Standard
Values 1) Turn starting switch OFF.
Wiring harness discontinu-
2 ity (Disconnection or defec- Wiring harness between L63 (Female) Resistance 1 Ω and below
tive contact) 4 - L103 (Male) 1
Wiring harness between L103 (Male)
2 - body
BWW10523
WA380-5 20-341
(10)

Trouble Backup lamp relay output system grounded
E03 D160KB TM
Description of • No signal is output to the backup lamp relay due to grounding.
Trouble
Controller Reac- • Turns output to the backup lamp relay OFF.
tion
Effect on Machine • No backup buzzer sounds or the backup lamp does not come on (Traveling is possible).
Related Informa-
tion —

2) Replace relay.
4) Turn forward-reverse lever to “R”.
This Failure code (D160KB) issued Relay L117 is not defective
Defective backup lamp relay
1 (L117) This Failure code (D160KB) not issued Relay L117 is defective
and Standard
Values Between L103 (Female) 1 - 2 Resistance 200 - 400 Ω
2 Wiring harness ground fault 3) Connect T-adapter.
Between L63 (Female) 4/L103 (Male)
1 - body Resistance 1 MΩ and above

BWW10523
20-342 WA380-5
(10)

Action Code Failure Code Controller Code Neutral safety relay output system discon-
Trouble
E03 D191KA TM nected
Description of • No signal is output to the neutral safety relay due to disconnection.

Trouble
Controller Reaction • Turns neutral output OFF.
• The engine cannot be started when the right FNR switch or joystick mode is on (Can be started in steering
Effect on Machine wheel mode).
Related Informa-
—
tion

2) Replace relay.
Defective exchange relay 4) Turn right or joystick F
1 (L115) 5) Turn FNR selector switch ON.
This Failure code (D191KA) not issued Relay L115 is defective
2) Replace relay.
4) Turn right or joystick FNR s
2 Defective neutral safety
relay (L116) 5) Turn FNR selector switch ON.
This Failure code (D191KA) not issued Relay L116 is defective
2) Disconnect connectors L62, L63, L101 and L102.
Wiring harness between L63 (Female) Resistance 1 Ω and below
[ - L101 (Female) D
Wiring harness disconti- Wiring harness between L101 (Female)

3 nuity (Disconnection or C - L102 (Female) A
Possible Causes defective contact) Wiring harness between L62 (Female)
and Standard Val- Y - L101 (Female) A Resistance 1 Ω and below
ues
Wiring harness between L102 (Female) Resistance 1 Ω and below
B - body
Wiring harness between L101 (Female)
B - body
5)urn 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 Other than above Voltage 1 V and below
4 and fan pump motor con-
troller When joystick mounted (arm rest lock and joystick switch = ON)
Joystick FNR
switch = “N” and Voltage 17 - 30 V
joystick lever =
Neutral
Between L63 [ -
body Joystick FNR Voltage 1 V and below
switch? N
Joystick lever
Voltage 1 V and below
being operated
20-344 WA380-5
(10)
WA380-5 20-345
(10)

Trouble Neutral safety relay output system grounded
E01 D191KB TM
Description of • No signal is output to the neutral safety relay due to grounding.
Trouble
Controller Reaction • Turns output to the neutral safety relay OFF when it is grounded.
• The engine cannot be started when the right FNR switch or joystick mode is on (Can be started in steering
Effect on Machine wheel mode).
Related Informa-
—
tion

2) Replace relay.
Defective exchange relay 4) Turn right or joystick FN
This Failure code (D191KB) issued Relay L115 is not defective.
This Failure code (D191KB) not issued Relay L115 is defective.
2) Replace relay.
Defective neutral safety relay 4) Turn right or joystick FNR switch
This Failure code (D191KB) issued Relay L116 is not defective.
This Failure code (D191KB) not issued Relay L116 is defective.
2) Disconnect connectors L63, L101 and L102.
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
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)
WA380-5 20-347
(10)

Trouble E.C.S.S. relay output system disconnected
E01 D192KA TM
Description of • No signal is output to the E.C.S.S. relay due to disconnection.
Trouble
Controller Reaction • Turns output OFF.
Effect on Machine • The boom damper does not operate.
• Referring to TESTING AND ADJUSTING, Adjusting machine monitor, check that the rotary switches (SW1,
Related Informa- SW2, and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set correctly.
tion • 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.

Defective boom damper 2) Disconnect connector L104.
1 relay (L125) 3) Connect T-adapter.
Between L104 (Female) (11) - (12) Resistance 200 - 400 Ω
and Standard Wiring harness discontinu-
Values 2 ity (Disconnection or defec- Wiring harness between L63 (Female) Resistance 1 Ω and below
tive contact) (17) - L104 (Female) (11)
Wiring harness between L104
(Female) (12) - body
Between L63 (Female) (17) - body Resistance 200 - 400 Ω
BJW11503
20-348 WA380-5
(10)

Trouble E.C.S.S. relay output system grounded
E01 D192KB TM
Description of • No signal is output to the E.C.S.S. relay due to grounding.
Trouble
Controller Reac- • Turns output to the boom damper relay OFF.
tion
Effect on Machine • The lift arm damper does not operate.
• Referring to TESTING AND ADJUSTING, Adjusting machine monitor, check that the rotary switches (SW1,
Related Informa- SW2, and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set correctly.
tion • Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of machine

Defective lift arm damper 2) Disconnect connector L104.
1 3) Connect T-adapter.
relay (L125)
Between L104 (Female) (11) - (12) Resistance 200 - 400 Ω
Possible Causes
and Standard Val- 2) Disconnect connectors L63 and L104.
ues 2
fault
Between L63 (Female) (17)/L104 (Female)
Resistance 1 M Ω and above
(11) - body
Defective transmission 2) Disconnect connector L63.
3 and fan pump motor con- 3) Connect T-adapter.
troller
BJW11503
WA380-5 20-349
(10)
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

1) Turn the starting switch off. 2) Disconnect the L63 and L93 connectors.
Ground fault in wiring har- 3) Connect the T-adapter.
1 ness Between L63 (female)(18), L93
Resistance 1 Ω or less
(female) (1) and machine body
1) Turn the starting switch off. 2) Disconnect the connector L93.
Possible Causes 3) Connect the t-adapter.
and Standard Between L93 (female) (1) and (2). Resistance 200 - 400 Ω
Values
1) Turn the starting switch off. 2) Disconnect the L93 connector.
Defective low temperature 3) Replace the low-temperature bypass relay (L93) with another one.
2 bypass relay 4) Turn the starting switch on.
Defective low-temperature bypass
Actuates normally. relay (L93).
Does not actuate normally (the error Normal temperature bypass relay
display stays on). (L93)
BWW10523
20-349-1 WA380-5
(10)
5
TROUBLESHOOTING FAILURE CODE [D198KY]
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

Possible Causes
1) Turn the starting switch off. 2) Disconnect the L63 connector.
and Standard 3) Connect the t-adapter.
Values 1 Hot-short in wiring harness
Between L63 (female) (18) and chaseis Voltage 1 V or less
BWW10523
WA380-5 20-349-2
(10)
5
TROUBLESHOOTING FAILURE CODE [DAQ0KK]
FAILURE CODE [DAQ0KK]

Trouble Controller power supply voltage lowered
— DAQ0KK TM
Description of • The controller power supply voltage is lowered.
Trouble
Controller Reaction • Cannot detect input signals properly.
Effect on Machine • Normal operation is disabled.
Related Informa- —
tion

Turn starting switch OFF.
2) Disconnect connectors L63 and FS3.
Wiring harness disconti- 3) Connect T-adapter.
1 nuity (Disconnection or Wiring harness between L63 (Female) 1/
defective contact) Resistance 1 Ω and below
A - FS3 (Female) 3
Between L63 (Female) K/U/V/W/ - body. Resistance 1 Ω and below
Possible Causes 2) Disconnect connector L63 and FS3.
and Standard Val- Wiring harness ground 3) Connect T-adapter.
2
ues fault
Between L63 (Female) 1/A/FS3
Resistance 1 MΩ and above
(Female) 3 - body
Defective transmission 4) Turn starting switch ON.
troller Constant
Between L63 1/A - body (NSW) Voltage 20 - 30 V
power sup-
ply
BWW10525
20-350 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DAQ2KK]
FAILURE CODE [DAQ2KK]

Trouble Defective solenoid power supply system
— DAQ2KK TM
Description of • The solenoid power supply system voltage is lowered.
Trouble
Controller Reac- • Disables solenoid output.
tion
Effect on Machine • Normal operation is disabled.
Related Informa-
tion —

1 nuity (Disconnection or
defective contact) Wiring harness between L63 (Female) 2/ Resistance 1 Ω and below
B/L - FS4 (Female) 2
Between L63 (Female) K/U/V/W - body Resistance 1 Ω and below
Possible Causes 2) Disconnect connectors L63 and FS4.
and Standard Val- Wiring harness ground
2 fault 3) Connect T-adapter.
ues
Between L63 (Female) 2/B/L - body Resistance 1 MΩ and above
troller Constant
Between L63 2/B/L - (NSW) Voltage 20 - 30 V
body power sup-
ply
BWW10525
WA380-5 20-351
(10)
TROUBLESHOOTING FAILURE CODE [DAQ9KQ]
FAILURE CODE [DAQ9KQ]

Trouble Model selection signal mismatch
E03 DAQ9KQ TM
Description of • The controller is recognized as another model.
Trouble
• Operates assuming the model operated before the Failure code was issued (Basically WA480) or default
Controller Reaction
model (WA470).
Effect on Machine • Gear shifting shock may occur.
Related Informa- • Set the model using the rotary switch (Refer to "Testing and Adjusting").
tion

Possible Causes and Stan-
dard Values 1 Controller model —
selection error
20-352 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK3KA]
FAILURE CODE [DDK3KA]

Trouble Right FNR switch signal not input
E03 DDK3KA TM
Description of • No signal is input due to disconnected or grounded right FNR switch input signal system.
Trouble
Controller Reac- • Cannot judge the faulty line input signal.
tion
Effect on Machine • Traveling is possible in steering wheel mode after the machine is stopped.
Related Informa- • Can be checked with the monitoring function (Code: 40907, D-IN-17, D-IN-18 or D-IN-19).
tion

2) Disconnect connectors FS4 and L12.
Wiring harness between FS4 (Female) 2 - L12
(Female) 1
Wiring harness discontinuity 2) Disconnect connectors FS4 and L12.
1 (Disconnection or defective 3) Connect T-adapter.
contact)
Wiring harness between L62 (Female) O - L12
(Female) 2 Resistance 1 Ω and below
Wiring harness between L62 (Female) E - L12 Resistance 1 Ω and below

(Female) 3
Wiring harness between L62 (Female) 5 - L12
(Female) 4
2 Wiring harness ground fault Between L62 (Female) O /L12 (Female) 2 - body Resistance 1 MΩ and above
Between L62 (Female) E /L12 (Female) 3 - body Resistance 1 MΩ and above
Between L62 (Female) 5 /L12 (Female) 4 - body Resistance 1 MΩ and above
Possible Causes
and Standard Val- 1) Turn starting switch OFF.
ues 2) Disconnect connector L12.
Between L12 (Male) Right FNR switch = F Resistance 1 Ω and below

2-1 Other than above Resistance 1 MΩ and above
3 Defective right FNR switch
Between L12 (Male) Right FNR switch = N Resistance 1 Ω and below
Between L12 (Male) Right FNR switch = R Resistance 1 Ω and below

When right FNR switch mounted (Right FNR switch = On)
Between L62 O and Right FNR switch = F Voltage 20 - 30 V

Defective transmission and
4 fan pump motor controller body Other than above Voltage 1 V and below
Between L62 E and Right FNR switch = N Voltage 20 - 30 V

body Other than above Voltage 1 V and below
Between L62 5 and Right FNR switch = R Voltage 20 - 30 V

body Voltage 1 V and below
20-354 WA380-5
(10)
BWW10526
WA380-5 20-355
(10)
TROUBLESHOOTING FAILURE CODE [DDK3KB]
FAILURE CODE [DDK3KB]

Trouble Multiple right FNR switch signal input
E03 DDK3KB TM
Description of • Multiple signals are input due to short-circuited right FNR switch input signal system.
Trouble
Controller Reac- • Cannot judge the FNR switch input signal.
tion
Effect on Machine • Traveling is possible in steering wheel mode after the machine is stopped.
tion

1) Turn starting switch OFF. 2) Disconnect connectors L62 and L12.
3) Connect T-adapter. 4) Turn starting switch ON.
1 V and
Wiring harness hot-shorted Between L62 (Female) O/L12 (Female) 2 - body Voltage below
1 incorrectly (Coming in con-
tact with 24 V wiring harness) Between L62 (Female) E/L12 (Female) 3 - body Voltage 1 V and
below
1 V and
Between L62 (Female) 5/L12 (Female) 4 - body Voltage below
1) Turn starting switch OFF. 2) Disconnect connector L12.
1 Ω and
Right FNR switch = F Resistance
Between L12 below
(Male) 2 - 1 1 MΩ and
Other than above Resistance above
1 Ω and
2 Defective right FNR switch Right FNR switch = N Resistance
below
Between L12
Possible Causes (Male) 3 - 1
and Standard Val- 1 MΩ and
Other than above Resistance
ues above
1 Ω and
Right FNR switch = R Resistance below
Between L12
Other than above Resistance
above
Right FNR switch = F Voltage 20 - 30 V
Between L62 O -
body Other than above Voltage 1 V and
Defective transmission and below
3 fan pump motor controller Right FNR switch = N Voltage 20 - 30 V
Between L62 E -
below
Right FNR switch = R Voltage 20 - 30 V
Between L62 5 -
below
20-356 WA380-5
(10)

When right FNR switch mounted
BWW10526
When multi function mono lever mounted
T2W02834
WA380-5 20-356-1
(10)

Trouble Joystick forward/reverse switch signal is not input
E03 DDK4KA TM
Description of • Signal is not input because of disconnection or short circuit with chassis ground in joystick forward/reverse
Trouble input signal system.
Controller Reac- • Cannot judge input signal in corresponding line.
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

1) Turn starting switch OFF. 2) Disconnect connectors FS4 and L37.
3) Connect T-adapter..
Wiring harness between FS4 (female) 2 - L37 Resistance 1 Ω and
(female) 1 below
Disconnection (or defective 3) Connect T-adapter.
1 contact) in wiring harness Wiring harness between L62 (female) O - L37 1 Ω and
(female) 2 Resistance below
Wiring harness between L62 (female) E - L37 Resistance 1 Ω and
(female) 3 below
Wiring harness between L62 (female) 5 - L37 1 Ω and
Resistance
(female) 4 below
Wiring harness between L62 (female) O - L37 Resistance 1 MΩ and
Short circuit with chassis (female) 2 above
2 ground in wiring harness Wiring harness between L62 (female) E - L37 1 MΩ and
Resistance
(female) 3 above
Wiring harness between L62 (female) 5 - L37 1 MΩ and
(female) 4 Resistance above
When joystick forward/ 1 Ω and
Possible Causes Resistance
Between L12 reverse switch is at "F" below
and Standard Val-
ues
(Male) 2 - 1 When joystick forward/ 1 MΩ and
reverse switch is not at "F" Resistance above
Defective joystick forward/ When joystick forward/ 1 Ω and
3 reverse switch reverse switch is at "N"
Resistance
below
Between L12
Resistance
reverse switch is not at "N" above
reverse switch is at "R" Resistance below
Between L12
(Male) 4 - 1 hen joystick forward/reverse Resistance 1 MΩ and
switch is not at "R" above
1) Turn starting switch OFF. 2) Disconnect connector L37. 3) Insert T-adapter.
4) Turn starting switch ON. 5) Turn joystick switch ON.
When joystick switch FNR
Voltage 20 - 30 V
Between L62 O - switch is at "F"
chassis ground When joystick switch FNR 1 V and
switch is not at "F" Voltage below
4 fan pump motor controller When joystick switch FNR Voltage 20 - 30 V
Between N62 E - switch is at "N"
Voltage
switch is not at "N" below
switch is at "R" Voltage 20 - 30 V
Between L62 5 -
switch is not at "R" Voltage below
WA380-5 20-357
(10)
Related electrical circuit diagram
20-358 WA380-5
(10)

Action Code Failure Code Controller Code Multiple joystick forward/reverse switch signals are
Trouble
E03 DDK4KB TM input
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

1) Turn starting switch OFF. 2) Disconnect L62 and L12. 3) Connect T-adapter.
Between L62 (female) O, L12 (female) 2 - chas- Voltage 1 V and
Hot short in wiring har- sis ground below
1 ness (Contact with 24-V
wiring harness) Between L62 (female) E, L12 (female) 3 - chas- 1 V and
Voltage
sis ground below
Between L62 (female) 5, L12 (female) 4 - chas- 1 V and
sis ground Voltage below
Resistance
Between L12 reverse switch is at "F" below
reverse switch is not at "F" Resistance above
Defective joystick forward/ When joystick forward/ 1 Ω and
2 reverse switch reverse switch is at "N"
Resistance
below
Between L12
Possible Causes (Male) 3 - 1 When joystick forward/ 1 MΩ and
Resistance
and Standard Val- reverse switch is not at "N" above
ues
reverse switch is at "R" Resistance below
Between L12
(Male) 4 - 1 hen joystick forward/reverse Resistance 1 MΩ and
switch is not at "R" above
4) Turn starting switch ON. 5) Turn joystick switch ON.
switch is at "F" Voltage 20 - 30 V
Between L62 O -
Voltage
switch is not at "F" below
Defective transmission and When joystick switch FNR
3 fan pump motor controller switch is at "N"
Voltage 20 - 30 V
Between N62 E -
switch is not at "N" Voltage below
When joystick switch FNR Voltage 20 - 30 V
Between L62 5 - switch is at "R"
Voltage
switch is not at "R" below
WA380-5 20-359
(10)
Related electrical circuit diagram
20-360 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDK5LD]
FAILURE CODE [DDK5LD]

Action Code Failure Code Controller Code Hot short in joystick SHIFT_UP/SHIFT_DOWN
Trouble
E03 DDK5LD TM switch
Description of • Joystick SHIFT_UP/SHIFT_DOWN switch signal is input for 30 seconds continuously.

Trouble
Controller Reac- • Ignores input signal.
tion
• Gear is shifted up or down once, then it cannot be shifted up or down with the joystick SHIFT_UP or
Effect on Machine SHIFT_DOWN switch.
• Operate can shift gear in auto shift mode or steering wheel mode.
Related Informa- • This failure can be checked with monitoring function (Code: 40906, D-IN-12, DIN-13).
tion

1) Turn starting switch OFF. 2) Disconnect L63 and L37. 3) Connect T-adapter.
Hot short in wiring har-
1 ness (Contact with 24-V Between L63 (female) 9, L37 (female) 8 - chas-
sis ground Voltage
1 V and
below
wiring harness)
Between L63 (female) I, L37 (female) 6 - chas- Voltage 1 V and
sis ground below
1 Ω and
When switch is at SHIFT_UP Resistance below
Between L37
Defective joystick SHIFT_UP/ (Male) 8 - 1 When switch is not at above Resistance 1 MΩ and
Possible Causes 2 SHIFT_DOWN switch position above
and Standard Val-
ues When switch is at 1 Ω and
Resistance
Between L37 SHIFT_DOWN below
(Male) 6 - 1 When switch is not at above 1 MΩ and
position Resistance above
When switch is at SHIFT_UP Voltage 20 - 30 V
Between L63 9 -
Defective transmission and chassis ground When switch is not at above Voltage 1 V and
position below
When switch is at
Voltage 20 - 30 V
Between N63 I - SHIFT_DOWN
chassis ground When switch is not at above 1 V and
position Voltage below
WA380-5 20-361
(10)

Trouble Forward-reverse lever signal not input
E03 DDK6KA TM
Description of • No signal is input due to disconnected or grounded forward-reverse input signal system.
Trouble
Controller Reac- • Cannot judge the faulty line (F, N or R) input signal.
tion
• Traveling is impossible with the lever positioned where an Error alarm is caused (Forward or reverse).
Effect on Machine
• Traveling is possible in right FNRSW mode when right FNRSW is mounted.
tion

Forward-reverse lever posi-
1 tioned incorrectly
Make sure that the lever is not positioned neutral.

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 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
and Standard Val- 4) Turn starting switch ON.
ues
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)
below
Between L04 (Male)
below
Between L62 Z -
body 1 V and
Other than above Voltage below
Right FNR switch = N Voltage 20 - 30 V
Between L62 P -
body 1 V and
Between L62 F -
body 1 V and
20-362 WA380-5
(10)
WA380-5 20-363
(10)

Trouble Multiple forward-reverse lever signal input
E03 DDK6KB TM
Description of • Multiple signals are input due to short-circuited forward-reverse lever input signal system.
Trouble
Controller Reac- • Stops traveling (Neutral state).
tion
• Traveling is impossible with the lever positioned where an error alarm is caused (Forward or reverse).
Effect on Machine
• Traveling is possible in right FNRSW mode when right FNRSW is mounted.
tion

Wiring harness hot-shorted 4) Turn starting switch ON.
1 incorrectly (Coming in con-
tact with 24 V wiring harness) Between L62 (Female) Z/L04 (Female) 2 - body Voltage 1 V and below
Between L62 (Female) P/L04 (Female) 3 - body Voltage 1 V and below
Between L62 (Female) F/L04 (Female) 4 - body Voltage 1 V and below
Defective forward-reverse Between L04 (Male) Forward-reverse lever = F Voltage 20 - 30 V

2 lever 2 - body
Possible Causes Other than above Voltage 1 V and below
and Standard
Values Between L04 (Male) Forward-reverse lever = N Voltage 20 - 30 V
3 - body Other than above Voltage 1 V and below
Between L04 (Male) Forward-reverse lever = R Voltage 20 - 30 V

Between L62 Z - Forward-reverse lever = F Voltage 20 - 30 V

Defective transmission and body Other than above Voltage 1 V and below
Between L62 P - Forward-reverse lever = N Voltage 20 - 30 V
Between L62 F - Forward-reverse lever = R Voltage 20 - 30 V

20-364 WA380-5
(10)
WA380-5 20-365
(10)
TROUBLESHOOTING FAILURE CODE [DDS5KA]
FAILURE CODE [DDS5KA]

Trouble Steering pressure switch disconnected
E03 DDS5KA TM
Description of • Both N.C and N.O signals of the steering pressure switch are open simultaneously.
Trouble
Controller Reac- • Turns electric emergency motor relay output OFF.
tion
• The auto emergency steering does not operate (However, the emergency steering can be operated manually).
Effect on Machine
• Self-check of the emergency steering does not work.
Related Informa- • Operate the emergency steering manually if the steering pressure is zero.
tion • Can be checked with the monitoring function (Code: 40905, D-IN-0 or D-IN-1).

2) Disconnect connector R36.
Engine stopped Resistance 1 Ω and below
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
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
Wiring harness between R36 (Female) A - body Resistance 1 Ω and below

Defective transmis-
3 sion and fan pump Engine stopped Voltage 1 V and below
motor controller Between L61 G - body
Engine started Voltage 20 - 30 V
Engine stopped Voltage 20 - 30 V
Between L61 M - body
Engine started Voltage 1 V and below
20-366 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDS5KB]
FAILURE CODE [DDS5KB]

Trouble Steering pressure switch grounded
E03 DDS5KB TM
Description of • Both N.C and N.O signals of the steering pressure switch is closed simultaneously.
Trouble
Controller Reaction • Turns electric emergency motor relay output OFF.
• The auto emergency steering does not operate (However, the emergency steering can be operated manually).
Effect on Machine • Self-check of the emergency steering does not work.
Related Informa- • Operate the emergency steering manually if the steering pressure is zero.
tion • Can be checked with the monitoring function (Code: 40905, D-IN-0 or D-IN-1).

Engine stopped Resistance 1 Ω and below
1 Ω and below
(Male) C - A
Between R36 Open to atmosphere (Reference) Resistance
Defective steering 1 MΩ and
1 pressure switch
Engine started Resistance
above
1 MΩ and
Engine stopped Resistance
above
(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.
Between L61 (Female) G/R36 (Female) C - body

Wiring harness ground
2 1 MΩ and
fault Resistance above
Between L61 (Female) M/R36 (Female) B - body Resistance 1 MΩ and

above
Defective transmission
3 and fan pump motor Between L61 G - Engine stopped Voltage 1 V and below
controller body Engine started Voltage 20 - 30 V
Between L61 M - Engine stopped Voltage 20 - 30 V

body Engine started Voltage 1 V and below
WA380-5 20-367
(10)
TROUBLESHOOTING FAILURE CODE [DDT0L4]
FAILURE CODE [DDT0L4]

Trouble Manual/auto-shift selector switch selection failure
— DDT0L4 TM
Description of • Signals of an incorrect combination were input from the manual/auto-shift selector switch.
Trouble
Controller Reac- • Switches to the manual shift mode.
tion
Effect on Machine • The position of the manual/auto-shift selector switch does not match the shift mode.
Related Informa- • The current shift mode selection can be checked with the monitoring function (Code: 41700) and the auto-shift
tion indicator.

2) Disconnect connectors L61 and S22.
1 discontinuity
connection or
(Dis-
Wiring harness between L61 (Female) D - S22 (Female) 2 Resistance 1 Ω and below
defective contact) Wiring harness between L61 (Female) 8 - S22 (Female) 3 Resistance 1 Ω and below
Wiring harness between L61 (Female) 2 - S22 (Female) 4 Resistance 1 Ω and below
1) Turn starting switch OFF. 2) Disconnect connectors L61 and S22. 3) Connect T-adapter.
2 Wiring harness
ground fault
Between connector L61 (Female) D/S22 (Female) 2 - body Resistance 1 MΩ and above
Between connector L61 (Female) 8/S22 (Female) 3 - body Resistance 1 MΩ and above
2) Disconnect connector S22.
Manual shift Resistance 1 MΩ and above
Between S22 Auto-shift L Resistance 1 Ω and below

(Male) 1 - 2 Auto-shift M Resistance 1 MΩ and above
Auto-shift H Resistance 1 MΩ and above
Defective manual/
Manual shift Resistance 1 MΩ and above
3 auto-shift selec-
tor switch (Over-
Between S22 Auto-shift L Resistance 1 MΩ and above
seas)
(Male) 1 - 3 Auto-shift M Resistance 1 Ω and below
Possible Causes
and Standard Auto-shift H Resistance 1 MΩ and above
Values Manual shift Resistance 1 MΩ and above
Between S22 Auto-shift L Resistance 1 MΩ and above

(Male) 1 - 4 Auto-shift M Resistance 1 MΩ and above
Auto-shift H Resistance 1 Ω and below
Manual shift Voltage 1 V or above
Between L61 D - Auto-shift L Voltage 1 V or below

body Auto-shift M Voltage 1 V or above
Auto-shift H Voltage 1 V or above
Defective trans-
4 mission and fan
pump motor con-
troller Between L61 8 - Auto-shift L Voltage 1 V or above
body Auto-shift M Voltage 1 V or below
Auto-shift H Voltage 1 V or above
Between L61 Auto-shift L Voltage 1 V or above

(Female) 2 - body Auto-shift M Voltage 1 V or above
Auto-shift H Voltage 1 V or below
20-368 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDT0L4]
WA380-5 20-369
(10)
TROUBLESHOOTING FAILURE CODE [DDT4LD]
FAILURE CODE [DDT4LD]

Action Code Failure Code Controller Code Ground fault of transmission cut-off setting
Trouble
E01 DDT4LD TM switch
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.
tion

1 and fan pump motor 1 Ω and
Cutoff setting switch = ON Resistance
controller Between S05 below
Cutoff setting switch = OFF Resistance above
and Standard 2) Disconnect connector L61 and S05.
Values Wiring harness ground 3) Connect T-adapter.
2 fault
Between L61 (Female) 5/S05 (Female) 4 - body Resistance 1 MΩ and
above
2) Disconnect connector L61 and S05.
3 and fan pump motor
controller 1 V and
Between L61 5 - Cutoff setting switch = ON Voltage
below
body
Cutoff setting switch = OFF Voltage 20 - 30 V
20-370 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDW9LD]
FAILURE CODE [DDW9LD]

Trouble Ground fault of kickdown switch system
E01 DDW9LD TM
Description of • Due to ground fault of the kickdown switch system, kickdown cannot be turned OFF.
Trouble
Controller Reac- • Cannot perform kickdown control after performing it once at ground fault.
tion
Effect on Machine • Cannot perform kickdown control after performing it once at ground fault.
tion

Defective kickdown
1 switch Kickdown switch = ON Resistance 1 Ω and
Between L14 below
Kickdown switch = OFF Resistance
above
and Standard 2) Disconnect connectors L61 and L14.
2 fault
1 MΩ and
Between L61 (Female) B/L14 (Female) 1 - body Resistance above
controller 1 V and
Between L61 B - Kickdown switch = ON Voltage below
body
Kickdown switch = OFF Voltage 20 - 30 V
WA380-5 20-371
(10)
TROUBLESHOOTING FAILURE CODE [DDW9LD]

For standard
WA380-5
20-371-1 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDWLLD]
FAILURE CODE [DDWLLD]

Trouble Ground fault of hold switch system
E01 DDWLLD TM
Description of • Due to ground fault of the hold switch system, the hold switch cannot be changed over.
Trouble
Controller Reaction • Cannot perform hold control after performing it once at ground fault.
Effect on Machine • Cannot perform hold control after performing it once at ground fault.
tion

1 Defective hold switch 1 Ω and
Hold switch = ON Resistance
Between L14 below
Hold switch = OFF Resistance above
Possible Causes
ues
2 Wiring harness
ground fault
Between L62 (Female) \/L14 (Female) 3 - body Resistance 1 MΩ and

above
Defective transmis- 3) Connect T-adapter.
3 sion and fan pump 4) Turn starting switch ON.
motor controller
Between L62 \ - Hold switch = ON Voltage 1 V and below
body Hold switch = OFF Voltage 20 - 30 V
20-372 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDWLLD]
12
For standard
WA380-5 20-373
(10)
TROUBLESHOOTING FAILURE CODE [DF10KA]
FAILURE CODE [DF10KA]

Trouble No input of gear shift lever signal
E01 DF10KA TM
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

1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Connect T-adapter.
Wiring harness between FS4 (Female) 2 - L04 (Female) 1 Resistance 1 Ω and below
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.
Between L04 5 - Shift range = 1 Voltage 20 - 30 V

Possible Causes
and Standard Val- body Other than above Voltage 1 V and below
ues
3 Defective gear
shift switch body Other than above Voltage 1 V and below


starting switch ON.

Defective trans- Shift range = 2 Voltage 20 - 30 V
and fan Between L63 J -
4 mission
pump motor con- body Other than above Voltage 1 V and below
troller
Between L63 T - Shift range = 3 Voltage 20 - 30 V
Between L63 _ - Shift range = 4 Voltage 20 - 30 V

20-374 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DF10KA]
BWW10528
WA380-5 20-375
(10)
TROUBLESHOOTING FAILURE CODE [DF10KB]
FAILURE CODE [DF10KB]

Action Code Failure Code Controller Code Input of multiple gear shift lever signals
Trouble
E01 DF10KB TM No input of gear shift lever signal
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

1) Turn starting switch OFF. 2) Disconnect connectors L63 and L04. 3) Connect T-adapter. 4)
Turn starting switch ON.
Wiring harness
hot short-circuit- Between L63 (Female) 0/L04 (Female) 5 - body Voltage 1 V or below
1 ing (Contacting Between L63 (Female) J/L04 (Female) 6 - body Voltage 1 V or below
24-V wiring har-
ness) Between L63 (Female) T/L04 (Female) 7 - body Voltage 1 V or below
Between L63 (Female) _/L04 (Female) 8 - body Voltage 1 V or below
1) Turn starting switch OFF. 2) Disconnect connectors L63 and L04. 3) Connect T-adapter. 4)
Turn starting switch ON.

body Other than above Voltage 1 V or below

2 Defective gear
shift switch body Other than above Voltage 1 V or below
Possible Causes
and Standard Val- Between L04 7 - Shift range = 3 Voltage 20 - 30 V
ues body Other than above Voltage 1 V or below

starting switch ON.

Defective trans- Shift range = 2 Voltage 20 - 30 V
and fan Between L63 J -
3 mission
pump motor con- body Other than above Voltage 1 V or below
troller
Between L63 T - Shift range = 3 Voltage 20 - 30 V
Between L63 _ - Shift range = 4 Voltage 20 - 30 V

20-376 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DF10KB]
BWW10528
WA380-5 20-377
(10)
TROUBLESHOOTING FAILURE CODE [DGF1KX]
FAILURE CODE [DGF1KX]

Trouble Transmission oil temperature sensor system failure
— DGF1KX TM
Description of • Due to Error of the transmission oil temperature sensor system, no transmission oil temperature signal can be
Trouble input.
Controller Reac- • Cannot determine the transmission oil temperature correctly.
tion
Effect on Machine • Gear shift shock occurs.
Related Informa- • Can be checked with the monitoring function (Code: 41500, ECMV OIL TEMP).
tion

2) Disconnect connector TM.T.
Defective transmission 3) Connect T-adapter.
1 oil temperature sensor
Between TM.T At normal temperature (25°C) Resistance 35 - 50 kΩ
(Male) 1 - 2 At 100 °C Resistance 3.1 - 4.5 kΩ
2) Disconnect connector L61 and TM.T.
2 fault
Possible Causes 1 MΩ and
and Standard Val- Between L61 (Female) 9/TM.T (Female) 1 - body Resistance
ues above
Wiring harness discon- 2) Disconnect connectors L61 and TM.T.
3 tinuity (Disconnection 3) Connect T-adapter.
or defective contact) Wiring harness between L61 (Female) 9 - TM.T
(Female) 1 Resistance 1 Ω or below

controller Between L61 At normal temperature (25°C) Resistance 35 - 50 kΩ
(Female) 9 - body At 100 °C Resistance 3.1 - 4.5 kΩ
20-378 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DGR2KA]
FAILURE CODE [DGR2KA]

Action Code Failure Code Controller Code Rear brake oil temperature sensor system dis-
Trouble
E01 DGR2KA TM connection
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

Defective rear brake oil 3) Connect T-adapter.
1 temperature sensor
Between R56 At normal temperature (25°C) Resistance 35 - 50 kΩ
2) Disconnect connectors L61, L63 and R56.
and Standard Val- Wiring harness discon- Wiring harness between L61 (Female) J - R56
ues 2 tinuity (Disconnection (Female) 1 Resistance 1 Ω or below
or defective contact)
Wiring harness between R56 (Female) 2 - L63 Resistance 1 Ω or below
(Female) KU
Wiring harness between R56 (Female) 2 - body Resistance 1 Ω or below
(Female) J - body At 100 °C Resistance 3.1 - 4.5 kΩ
WA380-5 20-379
(10)
TROUBLESHOOTING FAILURE CODE [DGR2KB]
FAILURE CODE [DGR2KB]

Action Code Failure Code Controller Code Ground fault of rear brake oil temperature sensor
Trouble
E01 DGR2KB TM system
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

Defective rear brake oil 3) Connect T-adapter.
1 temperature sensor
Between R56 At normal temperature (25°C) Resistance 35 - 50 kΩ
2 fault
1 MΩ or
Between L61 (Female) J/R56 (Female) 1 - body Resistance
above
Defective transmission 3) Connect T-adapter
(Female) J - body At 100 °C Resistance 3.1 - 4.5 kΩ
20-380 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DHT1KX]
FAILURE CODE [DHT1KX]

Action Code Failure Code Controller Code Transmission cut-off (Left brake pressure sen-
Trouble
E01 DHT1KX TM sor) signal discontinuity
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.

1) Turn starting switch OFF. 2) Disconnect connector L10. 3) Connect T-adapter. 4)
Start engine. 5) Step on the left brake.
Defective left brake Between 2 - 1 (Power supply) Voltage 20 - 30 V

1 pressure sensor Between 3 - 1 (Signal) Voltage 0.7 - 5.3 V
L10
Between 3 - 1 (Note: when open
Voltage 0.5 - 1.5 V
to atmosphere)
and Standard Val- Wiring harness discon- Wiring harness between L61 (Female) I - L10
ues 2 tinuity (Disconnection (Female) 3 Resistance 1 Ω or below
or defective contact)
Wiring harness between L61 (Female) F - L10 Resistance 1 Ω or below
(Female) 2
Wiring harness between L10 (Female) 1 - body Resistance 1 Ω or below
and fan pump motor 4) Turn starting switch ON.
3 controller 5) Step on the left brake.
Between F - body (Power supply) Voltage 20 - 30 V
L61
Between I - body (Signal) Voltage 0.7 - 5.3 V
WA380-5 20-381
(10)
TROUBLESHOOTING FAILURE CODE [DLE2KA]
FAILURE CODE [DLE2KA]

Trouble Engine revolution sensor system discontinuity
E03 DLE2KA TM
Description of • Due to discontinuity of the engine revolution sensor system, no engine speed signal can be input.
Trouble
Controller Reac- • Cannot detect engine speed. (Assumes that engine speed is 2,100 rpm.)
tion
Effect on Machine • Gear shift shock may occur.
Related Informa-
tion —

2) Disconnect connectors L62 and E27.
Wiring harness discon- 3) Connect T-adapter.
tinuity (Disconnection
1 or defective connector Wiring harness between L62 (Female) 0 - E27 Resistance 1 Ω or below
(Female) 1
contact)
Wiring harness between L62 (Female) ] - E27
Resistance 1 Ω or below
Possible Causes (Female) 2
ues 2) Disconnect connector E27.
Defective engine revo-
2 lution sensor 3) Connect T-adapter.
Between E27 (Male) 1 - 2 Resistance 500 - 1,000 Ω
3 and fan pump motor 4) Turn starting switch ON.
controller
Between L62 Voltage (Measured in AC range) 0.5 V or above
0-]
20-382 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DLE2LC]
FAILURE CODE [DLE2LC]

Trouble Engine revolution sensor failure
E03 DLE2LC TM
Description of • Due to ground fault of the engine revolution sensor system, no engine speed signal can be input.
Trouble
Controller Reac- • Cannot detect engine speed. (Assumes that engine speed is 2,100 rpm.)
tion
Effect on Machine • Gear shift shock may occur.
Related Informa-
tion —

1 fault or short-circuiting
Between L62 (Female) 0/E27 (Female) 1 - body Resistance 1 MΩ or
above
and Standard Defective engine revo- 2) Disconnect connector E27.
Values 2 lution sensor 3) Connect T-adapter.
Between E27 (Male) 1 - 2 Resistance 500 - 1,000 Ω
controller
Between L62
0-] Voltage (Measured in AS range) 0.5 V or above
WA380-5 20-383
(10)
TROUBLESHOOTING FAILURE CODE [DLT3KA]
FAILURE CODE [DLT3KA]

Action Code Failure Code Controller Code Speed sensor transmission output shaft revolution
Trouble
E03 DLT3KA TM system discontinuity
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

2) Disconnect connectors L62 and REV.OUT.
Wiring harness disconti-
1 nuity (Disconnection or Between wiring harnesses between L62 (Female) J -
defective contact) REV.OUT (Female) 1
Possible Causes Between wiring harnesses between L62 (Female) S - Resistance 1 Ω or below
and Standard REV.OUT (Female) 2
2) Disconnect connector REV.OUT.
2 Defective speed sensor 3) Connect T-adapter.
Between REV.OUT (Male) 1 - 2 Resistance 500 - 1,000 Ω
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]
FAILURE CODE [DT20KB]

Action Code Failure Code Controller Code Ground fault of built-in indicator lamp system of trans-
Trouble
— DT20KB TM mission cut-off switch
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

Wiring harness ground 2) Disconnect connectors L63 and S03.
Between L63 (Female) 8/S03 (Female) 5 - body Resistance 1 Ω or above
Possible Causes Defective built in indica- 3) Connect T-adapter.
and Standard 2 tor lamp of transmis- 4) Turn on starting switch.
Values sion cut-off switch
Between S03 Cutoff switch = ON Voltage 17 - 30 V
5-6 Cutoff switch = OFF Voltage 1 V or below
controller
Between L63 8 - Cutoff switch = ON Voltage 17 - 30 V
body Cutoff switch = OFF Voltage 1 V or below
WA380-5 20-385
(10)
TROUBLESHOOTING FAILURE CODE [DW7BKA]
FAILURE CODE [DW7BKA]

Trouble Fan pump reverse solenoid system discontinuity
E01 DW7BKA TM
Description of • Due to disconnection or hot short-circuiting of the fan pump reverse solenoid system, no output goes to the fan
Trouble reverse solenoid.
Controller Reac- • Turns OFF output to the fan reverse solenoid.
tion
Effect on • Cannot reverse rotation of the fan.
Machine
Related Infor-
—
mation

Defective fan reverse 2) Disconnect connector GR2.
1 solenoid 3) Connect T-adapter
Between GR2 (Male) 1 - 2 Resistance 35 - 45 Ω
and Standard Wiring harness disconti- 2) Disconnect connectors L63 and GR2.
Values 2 nuity (Disconnection or 3) Connect T-adapter.
defective contact) Wiring harness between L63 (Female) R - GR2
(Female) 1
controller
Between L63 (Female) R - body Resistance 35 - 45 Ω
BWW10533
20-386 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW7BKB]
FAILURE CODE [DW7BKB]

Trouble Fan pump reverse solenoid system short-circuiting
E01 DW7BKB TM
Description of • Due to short-circuiting of the fan pump reverse solenoid system, no output goes to the fan reverse solenoid.
Trouble
Controller Reac- • Turns OFF output to the fan reverse solenoid.
tion
Effect on • Cannot reverse rotation of the fan.
Machine
Related Infor-
—
mation

Defective fan reverse 2) Disconnect connector GR2.
1 solenoid 3) Connect T-adapter.
Between GR2 (Male) 1 - 2 Resistance 35 - 45 Ω
and Standard 2) Disconnect connectors L63 and GR2.
2 fault
Wiring harness between L63 (Female) R - GR2
Resistance 1 Ω or above
(Female) 1
controller
Between L63 (Female) R - body. Resistance 35 - 45 Ω
BWW10533
WA380-5 20-387
(10)
TROUBLESHOOTING FAILURE CODE [DW7CKA]
FAILURE CODE [DW7CKA]

Trouble Switch pump cut-off relay discontinuity
E01 DW7CKA TM
Description of • Due to discontinuity of the transmission pump cut-off relay system, no output goes to the transmission pump
Trouble cut-off relay.
Controller Reac- • Does not output to the transmission pump cut-off relay.
tion
Effect on • Cannot turn transmission pump cut-off relay on.
Machine
Related Infor-
—
mation

1 pump cut-off relay 3) Connect T-adapter.
(L130)
Between L106 (Female) C - D Resistance 200 - 400 Ω
Possible Causes 2) Disconnect connectors L63 and L106.
and Standard Wiring harness disconti- 3) Connect T-adapter.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) Q - L106 (Male)
defective contact) Resistance 1 Ω or below
C
Wiring harness between L130 (Male) D and body Resistance 1 Ω or below
controller
Between L63 (Female) Q - body. Resistance 200 - 400 Ω
BWW10533
20-388 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW7CKB]
FAILURE CODE [DW7CKB]

Trouble Switch pump cut-off relay ground fault
E01 DW7CKB TM
Description of • Due to ground fault of the switch pump cut-off relay system, no output goes to the switch pump cut-off relay.
Trouble
Controller Reac- • Turns output to the transmission pump cut-off relay OFF.
tion
Effect on • Cannot turn transmission pump cut-off relay on.
Machine
Related Infor-
—
mation

1 pump cut-off relay 3) Connect T-adapter.
(L106)
Between L106 (Female) C - D Resistance 200 - 400 Ω
2 fault
1 MΩ and
Between L63 (Female) Q/ L106 (Male) C - body. Resistance
above
controller
Between L63 (Female) Q - body. Resistance 200 - 400 Ω
BWW10532
WA380-5 20-389
(10)
TROUBLESHOOTING FAILURE CODE [DX16KA]
FAILURE CODE [DX16KA]

Trouble Fan pump EPC solenoid system discontinuity
E01 DX16KA TM
Description of • Due to mdiscontinuity of the fan pump EPC solenoid system, no output goes to the fan pump EPC solenoid.
Trouble
tion
Effect on • Fan revolution reaches the limit.
Machine
Related Infor-
—
mation

Defective fan pump EPC 2) Disconnect connector R29.
1 solenoid system 3) Connect T-adapter.
Between R29 (Male) 1 - 2 Resistance 5 - 10 Ω
Possible Causes 2) Disconnect connectors L63 and R29.
and Standard 3) Connect T-adapter
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) Z - R29 (Female)
defective contact) 1
Wiring harness between L63 (Female) M - R29 (Female)
2 Resistance 1 Ω or below

controller
Between L63 (Female) Z - M Resistance 5 - 10 Ω
BWW10132
20-390 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DX16KB]
FAILURE CODE [DX16KB]

Trouble Fan pump EPC solenoid system ground fault
E01 DX16KB TM
Description of • Due to ground fault of the fan pump EPC solenoid system, no output goes to the fan pump EPC solenoid.
Trouble
Controller Reac- • Turns output to the fan pump EPC solenoid OFF.
tion
Effect on • Fan revolution reaches the limit.
Machine
Related Infor-
—
mation

Defective fan pump EPC 2) Disconnect connector R29.
Between R29 (Male) 1 - 2 Resistance 5 - 10 Ω
Values Wiring harness ground 3) Connect T-adapter
2 fault
Wiring harness between L63 (Female) Z/R29 (Female)
Resistance 1 MΩ or above
1 - body
controller
BWW10531
WA380-5 20-391
(10)
TROUBLESHOOTING FAILURE CODE [DXH1KA]
FAILURE CODE [DXH1KA]

Trouble Lock-up clutch _ECMV solenoid system discontinuity
E01 DXH1KA TM
Description of • Due to discontinuity of the lock-up clutch ECMV solenoid system, no output goes to the lock-up clutch _ECMV.
Trouble
Controller Reac- • No action
tion
Effect on • The lock-up clutch cannot be engaged.
Machine
Related Infor-
—
mation

Defective lock-up clutch 2) Disconnect connector LC.PS.
1 _ECMV 3) Connect T-adapter.
Between LC.PS (Male) 1 - 2 Resistance 5 - 15 Ω
Possible Causes 2) Disconnect connectors L63 and LC.PS.
and Standard 3) Connect T-adapter.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) Y - LC.RS
defective contact) (Female) 1
Wiring harness between L63 (Female) M - LC.RS

controller
Between L63 (Female) Y - M Resistance 5 - 15 Ω
20-392 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXH1KB]
FAILURE CODE [DXH1KB]

Trouble Lock-up clutch _ECMV solenoid system short-circuiting
E01 DXH1KB TM
Description of • Due to short-circuiting of the lock-up clutch ECMV solenoid system, no output goes to the lock-up clutch _ECMV.
Trouble
Controller Reac- • Turns output to the lock-up clutch ECMV solenoid OFF.
tion
Effect on • The lock-up clutch cannot be engaged.
Machine
Related Infor-
—
mation

Defective lock-up clutch 2) Disconnect connector LC.PS.
1 _ECMV 3) Connect T-adapter.
Between LC.PS (Male) 1 - 2 Resistance 5 - 15 Ω
and Standard 2) Disconnect connectors L63 and LC.PS.
2 fault
Wiring harness between L63 (Female) Y/LC.PS 1 MΩ or
Resistance
(Female) 1 - body above
controller
Between L63 (Female) Y - C Resistance 5 - 15 Ω
WA380-5 20-393
(10)

Action Code Failure Code Controller code
Trouble 1st_ECMV solenoid system discontinuity
E03 DXH4KA TM
Description of • Due to discontinuity of the 1st_ECMV solenoid system, no output goes to the 1st_ECMV.
Trouble
tion
Effect on • "1st" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

2) Disconnect connector 1.PS.
1 Defective 1st_ECMV 3) Connect T-adapter.
Between 1.PS (Male) 1 - 2 Resistance 5 - 15 Ω
Possible Causes 2) Disconnect connectors L63 and 1.PS.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) O - 1.PS
Wiring harness between L63 (Female) C - 1.PS

controller
Between L63 (Female) O - C Resistance 5 - 15 Ω
20-394 WA380-5
(10)

Trouble 1st_ECMV solenoid system short-circuiting
E03 DXH4KB TM
Description of • Due to ground fault of the 1st_ECMV solenoid system, no output goes to the 1st_ECMV.
Trouble
Controller Reac- • Turns output to the 1st_ECMV solenoid OFF.
tion
Effect on • "1st" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

1 Defective 1st_ECMV 3) Connect T-adapter.
and Standard 2) Disconnect connectors L63 and 1.PS.
2 fault
Wiring harness between L63 (Female) O/1.PS (Female)
1 - body
controller
WA380-5 20-395
(10)

Trouble 2nd_ECMV solenoid system discontinuity
E03 DXH5KA TM
Description of • Due to discontinuity of the 2nd_ECMV solenoid system, no output goes to the 2nd_ECMV.
Trouble
tion
Effect on • "2nd" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

1 Defective 2nd_ECMV 3) Connect T-adapter.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) 6 - 2.PS
Wiring harness between L63 (Female) 3 - 2.PS

controller
Between L63 (Female) 6 - 3 Resistance 5 - 15 Ω
20-396 WA380-5
(10)

Trouble 2nd_ECMV solenoid system short-circuiting
E03 DXH5KB TM
Description of • Due to ground fault of the 2nd_ECMV solenoid system, no output goes to the 2nd_ECMV.
Trouble
Controller Reac- • Turns output to the 2nd_ECMV solenoid OFF.
tion
Effect on • "2nd" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

1 Defective 2nd_ECMV 3) Connect T-adapter.
2 fault
Wiring harness between L63 (Female) 6/2.PS (Female)
1 - body
controller
WA380-5 20-397
(10)

Trouble 3rd_ECMV solenoid system discontinuity
E03 DXH6KA TM
Description of • Due to discontinuity of the 3rd_ECMV solenoid system, no output goes to the 3rd_ECMV.
Trouble
tion
Effect on • "3rd" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

1 Defective 3rd_ECMV 3) Connect T-adapter.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) F - 3.PS
Wiring harness between L63 (Female) 3 - 3.PS

controller
Between L63 (Female) F - 3 Resistance 5 - 15 Ω
20-398 WA380-5
(10)

Trouble 3rd_ECMV solenoid system short-circuiting
E03 DXH6KB TM
Description of • Due to ground fault of the 3rd_ECMV solenoid system, no output goes to the 3rd_ECMV.
Trouble
Controller Reac- • Turns output to the 3rd_ECMV solenoid OFF.
tion
Effect on • "3rd" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

1 Defective 3rd_ECMV 3) Connect T-adapter.
2 fault
Wiring harness between L63 (Female) F/3.PS (Female)
1 - body
controller
WA380-5 20-399
(10)

Trouble R_ECMV solenoid system discontinuity
E03 DXH7KA TM
Description of • Due to discontinuity of the R_ECMV solenoid system, no output goes to the R_ECMV.
Trouble
tion
Effect on • “R” cannot be engaged. (Traveling in “F” is possible.)
Machine
Related Infor-
—
mation

2) Disconnect connector R.PS.
1 Defective R_ECMV 3) Connect T-adapter.
Between R.PS (Male) 1 - 2 Resistance 5 - 15 Ω
Possible Causes 2) Disconnect connectors L63 and R.PS.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) E - R.PS
Wiring harness between L63 (Female) C - R.PS

controller
Between L63 (Female) E - C Resistance 5 - 15 Ω
20-400 WA380-5
(10)

Trouble R_ECMV solenoid system ground fault
E03 DXH7KB TM
Description of • Due to ground fault of the R_ECMV solenoid system, no output goes to the R_ECMV.
Trouble
Controller Reac- • Turns output to the R_ECMV solenoid OFF.
tion
Effect on • “R” cannot be engaged. (Traveling in “F” is possible.)
Machine
Related Infor-
—
mation

2) Disconnect connector R.PS.
Between R.PS (Male) 1 - 2 Resistance 5 - 15 Ω
and Standard 2) Disconnect connectors L63 and R.PS.
2 fault
Wiring harness between L63 (Female) E/R.PS (Female)
Resistance 1 Ω or above
1 - body
controller
WA380-5 20-401
(10)

Trouble F_ECMV solenoid system discontinuity
E03 DXH8KA TM
Description of • Due to discontinuity of the F_ECMV solenoid system, no output goes to the F_ECMV.
Trouble
tion
Effect on • “F” cannot be engaged. (Traveling in “R” is possible.)
Machine
Related Infor-
—
mation

2) Disconnect connector F.PS.
Between F.PS (Male) 1 - 2 Resistance 5 - 15 Ω
Possible Causes 2) Disconnect connectors L63 and F.PS.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) 5 - R.PS
Wiring harness between L63 (Female) 3 - R.PS

controller
20-402 WA380-5
(10)

Trouble F_ECMV solenoid system ground fault
E03 DXH8KB TM
Description of • Due to ground fault of the F_ECMV solenoid system, no output goes to the F_ECMV.
Trouble
Controller Reac- • Turns output to the F_ECMV solenoid OFF.
tion
Effect on • “F” cannot be engaged. (Traveling in “R” is possible.)
Machine
Related Infor-
—
mation

2) Disconnect connector F.PS.
1 Defective F_ECMV 3) Connect T-adapter.
Between F.PS (Male) 1 - 2 Resistance 5 - 15 Ω
and Standard 2) Disconnect connectors L63 and F.PS.
2 fault
Wiring harness between L63 (Female) 5/F.PS (Female)
1 - body
controller
WA380-5 20-403
(10)
TROUBLESHOOTING FAILURE CODE [DXHHKA]
FAILURE CODE [DXHHKA]

Trouble 4th_ECMV solenoid system discontinuity
E03 DXHHKA TM
Description of • Due to discontinuity of the 4th_ECMV solenoid system, no output goes to the 4th_ECMV.
Trouble
tion
Effect on • "4th" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

2) Disconnect connector 4th.PS.
Possible Causes 2) Disconnect connectors L63 and F.PS.
Values 2 nuity (Disconnection or Wiring harness between L63 (Female) P - 4.PS Resistance 1 Ω or below
Wiring harness between L63 (Female) C - 4.PS

controller
Between L63 (Female) P - C Resistance 5 - 15 Ω
20-404 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXHHKB]
FAILURE CODE [DXHHKB]

Trouble 4th ECMV solenoid system short-circuiting
E03 DXHHKB TM
Description of • Due to ground fault of the 4th_ECMV solenoid system, no output goes to the 4th_ECMV
Trouble
Controller Reac- • Turns output to the 4th_ECMV solenoid OFF.
tion
Effect on • "4th" cannot be engaged. (Traveling in other passes is possible.)
Machine
Related Infor-
—
mation

1 Defective F_ECMV 3) Connect T-adapter.
and Standard 2) Disconnect connectors L63 and 4th.PS.
2 fault
Wiring harness between L63 (Female) P/4.PS (Female)
1 - body
controller
WA380-5 20-405
(10)
TROUBLESHOOTING FAILURE CODE [DY30MA]
FAILURE CODE [DY30MA]

Action Code Failure Code Controller Code Motor-driven emergency steering pump failure (malfunc-
Trouble
E03 DY30MA TM tion in manual mode)
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.

3) Connect T-adapter (Single-unit check).
Defective emer-
gency steering relay Between L105
(Male) A - B Relay =OFF Resistance 1 MΩ or above
1 (L126) (Power and
signal lines short-cir- 1) Turn starting switch OFF.
cuited) 2) Disconnect connector L105.
3) Connect T-adapter (Single-unit check).
Between L105 (Male) 9 - 0 Resistance 200 - 400 Ω
Defective emer- 1) Turn starting switch OFF.
gency steering relay 2) Disconnect two harnesses at 100B at both ends of emergency steering motor.
(For driving emer- 3) Connect T-adapter.
2 gency steering
motor) (Power and
signal lines short-cir- Between disconnected relay terminals Resistance 1 MΩ or above
cuited)
2) Disconnect connectors L63, L105 and R15, and line 396 (between emergency steering
relay and emergency steering motor).
Possible Causes 3 Hot short-circuiting
between harnesses
and Standard Between L63 (Female) 7/L105 (Female) 9 - body Voltage 1 V or below
Values
Between L105 (Female) B, R15 terminal, - body Voltage 1 V or below
Between line 396 (Emergency steering relay, emergency Voltage 1 V or below
steering motor, and body)
Wiring harness dis- 2) Disconnect connectors L54 and R37.
continuity (Discon- 3) Connect T-adapter.
4 nection or defective
c
contact) Wiring harness between L54 (Female) 3 - R37 (Female)

Defective emer- Emergency steering = Stopped Resistance 1 Ω or below

5 gency steering pres- At open to atmosphere (for refer-
sure switch Resistance 1 Ω or below
c-A
Between R37 (Male) ence)
Emergency steering = Operating
(High pressure) (Operate in manual Resistance 1 Ω or below
mode.)
Defective transmis- 2) Disconnect connector L63.
6 sion and fan pump 3) Connect T-adapter.
motor controller
20-406 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DY30MA]
BWW10527
WA380-5 20-407
(10)
TROUBLESHOOTING FAILURE CODE [DY30MC]
FAILURE CODE [DY30MC]

Action Code Failure Code Controller Code Motor-driven emergency steering pump failure (Malfunc-
Trouble
E03 DY30MC TM tion in manual mode)
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.

1) Keep engine on for 10 seconds or longer and turn starting switch OFF.
2) Replace L126 relay with another relay of the same type.
3) Turn starting switch ON (for self-check).
Defective emer- Issues this Failure code (DY30MC). Relay (L126) = Normal
gency steering relay
1 (L126) (Internal dis- Does not issue this Failure code (DY30MC). Relay (L126) = Defective
continuity or defec-
tive contact) 1) Turn starting switch OFF.
2) Disconnect connectors L105, R15, R16, line 396 (between emergency steering relay
and terminals at both ends of emergency steering motor), and line 030 (battery relay and
emergency steering relay).
Wiring harness dis-
2 continuity (Discon-
nection or defective
Wiring harness between L105 (Female) B - R15 terminal Resistance 1 Ω or below
contact) Wiring harness between R16 terminal - body Resistance 1 Ω or below
Line 030 (Battery relay and emergency steering relay) Resistance 1 Ω or below
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
Defective emer- Emergency steering = Stopped Resistance 1 Ω or below

4 gency steering pres- At open to atmosphere (For refer-
sure switch Resistance 1 Ω or below
c-A
Between R37 (Male) ence)
(High pressure) (Operate in manual Resistance 1 MΩ or above
mode.)
Defective emer- Between emer- Emergency steering = Stopped Voltage 1 V or below
5 gency steering motor gency motor (+) ter-
minal and body (Operate in manual mode.) Voltage 20 - 30 V

Defective transmis- 2) Disconnect connectors L63.
6 sion and fan pump 3) Connect T-adapter.
motor controller
Between L63 (Female) 7 and body Resistance 200 - 400 Ω
20-408 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DY30MC]
BWW10527
WA380-5 20-409
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-1]
TROUBLESHOOTING CODE [TM-1]

Troubleshoot- Failure Code Controller Code
ing code Discontinuity or hot short-circuiting of kickdown switch
Trouble
system
TM-1 — (TM)
Description of • Due to discontinuity or hot short-circuiting of the kickdown switch system, kickdown cannot be performed.
Trouble
tion
Effect on • Cannot perform kickdown control by turning the kickdown switch ON.
Machine
Related Infor- • Can be checked with the monitoring function (Code: 40905, D-IN-6).
mation

Defective kickdown 3) Connect T-adapter.
1 switch
Between L14 Kickdown switch = ON Resistance 1 Ω or below
(Male) 1 - 2 Kickdown switch = OFF Resistance 1 MΩ or above
Possible Causes defective contact) Wiring harness between L61 (Female) B - L14 (Female) 1 Resistance 1 Ω or below
and Standard Between L14 (Female) 2 - body Resistance 1 Ω or below
Values
Wiring harness hot 1) Turn starting switch OFF.
short-circuiting 2) Disconnect connectors L61 and L14.
★ In this case, fuse A-2 3) Connect T-adapter.
3 burns out when the 4) Turn starting switch ON.
switch is operated.
Between L61 (Female) B/L14 (Female) 1 - body Voltage 1 V or below

2) Disconnect connectors L61.
controller Between L61 B - Kickdown switch = ON Voltage 1 V or below
body Kickdown switch = OFF Voltage 20 - 30 V
20-410 WA380-5
(10)

For standard
WA380-5 20-410-1
5

ing code Hold switch system discontinuity or hot short-circuiting
Trouble
(No hold control performed by pressing hold switch)
TM-2 — (TM)
Description of • Due to discontinuity or hot short-circuiting of the hold switch system, the hold switch cannot be changed over.
Trouble
tion
Effect on • Hold control cannot be performed by pressing the hold switch.
Machine
Related Infor- • Can be checked with the monitoring function (Code: 40908, D-IN-31)
mation

1 Defective hold switch
Between L14 Hold switch = ON Resistance 1 Ω or below
(Male) 3 - 4 Hold switch = OFF Resistance 1 MΩ or above
2 nuity (Disconnection or Wiring harness between L62 (Female) \ - L14 (Female)
Possible Causes defective contact) Resistance 1 Ω or below
3
and Standard
Values Between L14 (Female) 4 - body Resistance 1 Ω or below
short-circuiting 2) Disconnect connectors L62 and L14.
3 ★ In this case, fuse A-2 3) Connect T-adapter.
blows out when the 4) Turn starting switch ON.
switch is operated. Between L62 (Female) \/L14 (Female) 3 - body Voltage 1 V or below
controller Hold switch = ON Voltage 1 V or below
Between L62 \ -
body Hold switch = OFF Voltage 20 - 30 V
20-410-2 WA380-5
(10)
5

For standard
WA380-5 20-411
5

ing code Torque converter lock-up switch system failure (No lock-
Trouble
up performed or no lock-up cancellation performed)
TM-3 — (TM)
Description of • Due to failure of the torque converter lock-up switch system, lock-up cannot be performed (Failure associated
Trouble with discontinuity) or lock-up cannot be cancelled normally (Failure associated with ground fault).
tion
Effect on • Lock-up or lock-up cancellation cannot be performed.
Machine
Related Infor- • Torque converter lock-up switch input signal can be checked with the monitoring function (Code: 40905, D-IN-5).
mation • The service mode of the monitor can be used to check if the lock-up option is implemented or not.

Defective torque con-
1 verter lock-up switch Torque converter lock-up switch =
Between S06 Resistance 1 Ω or below
ON
(Male) 4- 3
Other than above Resistance 1 MΩ or more
2 nuity (Disconnection or Wiring harness between L61 (Female) H - S06 (Female)
4
Between S06 (Female) 3 - body Resistance 1 Ω or below
Possible Causes Wiring harness hot 1) Turn starting switch OFF.
and Standard
Values short-circuiting (Con- 2) Disconnect connectors L61 and S06.
tacting 24-V harness) 3) Connect T-adapter.
3 ★ In this case, fuse A-2 4) Turn starting switch ON.
blows out when the
switch is operated. Between L61 (Female) H/S06 (Female) 4 - body Voltage 1 V or below

Between L61 (Female) H/S06 (Female) 4 - body Resistance 1 MΩ or above
controller Torque converter lock-up switch = Voltage 1 V or below
Between L61 H - ON
body
BWW10534
20-412 WA380-5
(10)

ing code Neutralizer signal (Parking brake switch signal) system
Trouble
failure
TM-4 — (TM)
• Due to failure of the neutralizer signal (Parking brake switch signal) system, always the neutral state is ON (Fail-
Description of ure associated with hot short-circuiting) or FR operation is performed while the parking brake is operated and
Trouble
traveling occurs with the brake engaged (Failure associated with discontinuity).
tion
Effect on • The neutralizer cannot be controlled, or it is always operating.
Machine
Related Infor- • Parking brake input switch signal can be checked with the monitoring function (Code: 40907, D-IN-23).
mation

Between L01 Parking brake switch = ON Resistance 1 Ω or below

Defective parking brake (Male) 1 - 3 Parking brake switch = OFF Resistance 1 MΩ or above
1 switch
Between L01 Parking brake switch = ON Resistance 1 MΩ or above
(Male) 2 - 3 Parking brake switch = OFF Resistance 1 Ω or below
Between L01 Always Resistance 1 MΩ or above
(Male) 1 - 2
2) Disconnect connectors PB and PS.
Defective parking brake
2 solenoid Between PB.PS (Male) 1 - 2 Resistance 10 - 40 Ω
Between PB.PS (Female) 2 - body Resistance 1 Ω or below
Between PB.PS (Male) 1/2 - body Resistance 1 Ω or below
Possible Causes Wiring harness disconti- 2) Disconnect connectors L62 and L01.
and Standard 3 nuity (Disconnection or 3) Connect T-adapter.
Values defective contact) Wiring harness between L62 (Female) 6 - L01 (Female)
2
2) Disconnect connectors L62, L01, and PB.PS.
Wiring harness hot 3) Connect T-adapter.
4 short-circuiting (Con- 4) Turn starting switch ON.
tacting 24-V harness)
Between L62 (Female) 6/L01 (Female) 2 {PB.PS
Voltage 1 V or below
(Female) 1} - body
2) Disconnect connector DIODE.
To be measured from 2 side in
5 Defective diode (DIODE) diode range. Continuity Positive
Between DIODE
(Male) 2 - 1 To be measured from 1 side in Continuity None
diode range.
★ Replacing DIODE can also correct this failure.
Wiring harness ground 1) Turn starting switch OFF.

fault 2) Disconnect connectors L62, L01 and PB.PS.
6 - In this case, the fuse 3) Connect T-adapter.
blows out when the Between L62 (Female) 6/L01 (Female) 2 {PB.PS
switch is operated. Resistance 1 MΩ or above
(Female) 1} - body
20-414 WA380-5
(10)
Troubleshooting Failure Code Controller

code Code Trouble Neutralizer signal (parking brake switch signal) system failure
TM-4 — (TM)
When parking brake switch is
Possible Causes switched from OFF to ON (Not Voltage 1 V or below
and Standard Defective transmission released)
Values 7 and fan pump motor con- Parking brake switch = OFF
troller Voltage 1 V or below
Between L62 6 - (Retained OFF) (Not released)
body When parking brake switch is
switched from ON to OFF Voltage 20 - 30 V
(Released)
Parking brake switch = ON
(Retained on) (Not released)
WA380-5 20-415
(10)

ing code Emergency steering switch (motor-driven emergency
Trouble
steering operation switch) signal system failure
TM-5 — (TM)
Description of • Due to failure of the emergency steering switch (motor-driven emergency steering operation switch) signal sys-
Trouble tem, emergency steering does not function. Or, emergency steering always functions.
tion
Effect on • Emergency steering does not function. Or, emergency steering always functions.
Machine
Related Infor- • Emergency steering switch input signal can be checked with the monitoring function (Code: 40906, DN-IN-14).
mation

Defective emergency 3) Connect T-adapter.
1 steering manual switch
Between S19 Emergency steering switch = ON Resistance 1 Ω or below
(Male) 4 - 3 Emergency steering switch = OFF Resistance 1 MΩ or above
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
Defective emergency 2) Disconnect connectors R15, R16 and both power lines (100sq).
3 steering operation relay
Between relay contacts. Resistance 1 MΩ or above
Wiring harness disconti- 2) Disconnect connectors L63 and S19.
defective contact) Wiring harness between L63 (Female) S - S19 (Female) Resistance 1 Ω or below
1
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
Wiring harness ground 2) Disconnect connectors L63, L105, L126 and S19.
Between L63 (Female) S/S19 (Female) 1 - body Resistance 1 MΩ or above
2) Disconnect connectors L63, L126 and S19.
Between L63 (Female) S/L126 (Female) 1/S19 Resistance 1 MΩ or above
Wiring harness short- (Female) 4 - body
7 circuiting
2) Disconnect connectors L126 and R15.
Between L126 5/R15 - body Resistance 1 MΩ or above
controller Emergency steering switch = ON Voltage 20 - 30 V
Between L63 S -
20-416 WA380-5
(10)
BWW10527
WA380-5 20-417
5

ing code Transmission cut-off switch system discontinuity or
Trouble
ground fault
TM-6 — (TM)
• Due to discontinuity or ground fault of the transmission cut-off switch system, the transmission cut-off mode
Description of cannot be enabled (Failure associated with discontinuity).
Trouble
• Or the transmission cut-off mode cannot be cancelled (Failure associated with ground fault).
tion
Effect on • The transmission cut-off mode cannot be enabled or cancelled.
Machine
mation

1 cut-off switch
Between S03 Transmission cut-off switch = ON Resistance 1 Ω or below
(Male) 4 - 3 Transmission cut-off switch = OFF Resistance 1 MΩ or above
Wiring harness between L61 (Female) A - S03 (Female)
defective contact) 4 Resistance 1 Ω or below

Possible Causes Hot short-circuiting 1) Turn starting switch OFF.
and Standard between harnesses 2) Disconnect connectors L61 and S03.
Values (Contacting 24-V har- 3) Connect T-adapter.
3 ness) 4) Turn starting switch ON.
★ In this case, fuse A-2
blows out when the Between L61 (Female) (11)/S03 (Female) 4 - body Voltage 1 V or below
switch is operated.
Between L61 (Female) A/S03 (Female) 4 - body Resistance 1 MΩ or above
controller
Between L61 A - Transmission cut-off switch = ON Voltage 1 V or below
body Transmission cut-off switch = OFF Voltage 20 - 30 V
20-418 WA380-5
(10)

ing code Transmission cut-off setting switch system discontinuity
Trouble
or hot short-circuiting
TM-7 — (TM)
Description of • Due to discontinuity or hot short-circuiting of the transmission cut-off setting switch system, the cut-off setting
Trouble signal is left as input.
tion
Effect on • The transmission cut-off point cannot be reset.
Machine
mation

1 cut-off setting switch
Between S05 Cut-off setting switch = ON Resistance 1 Ω or below
(Male) 4 - 3 Cut-off setting switch = OFF Resistance 1 MΩ or above
Possible Causes defective contact) Wiring harness between L61 (Female) 5 - S05 (Female)
and Standard 4 Resistance 1 MΩ or above
Values
Hot short-circuiting 2) Disconnect connectors L61 and S03.
3 between harnesses 3) Connect T-adapter.
Between L61 (Female) 5/S05 (Female) 4 - body Voltage 1 V or below
2) Disconnect connector L61 and S05.
controller Cut-off setting switch = ON Voltage 1 V or below
Between L61 5 -
body Cut-off setting switch = OFF Voltage 20 - 30 V
WA380-5 20-419
(10)

ing code Transmission cut-off (left brake sensor) signal short-cir-
Trouble
cuiting
TM-8 — (TM)
Description of • Due to short-circuiting of the left brake pressure sensor signal system, no signal for the left brake oil pressure
Trouble sensor can be input.
tion
Effect on • Even when the left brake is not stepped ON, traveling in the neutral mode is not possible when transmission cut-
Machine off is ON (When the transmission cut-off function is used).
Related Infor- • Left brake oil pressure can be checked with the monitoring function (Code: 41100, L.H. BRAKE).
mation • Can be checked by stepping ON the left brake while the transmission cut-off function is ON.

4) Start engine.
Defective left brake 5) Step ON the left brake.
1 pressure sensor
Between L10 2 - 1 (Power supply) Voltage 20 - 30 V
Between L10 3 - 1 (Signal) Voltage 0.7 - 5.3 V
Between L10 3 - 1 (Note: when open to atmosphere) Voltage 0.5 - 1.5 V
Possible Causes
Values Wiring harness short- 2) Disconnect connectors L61 and L10.
2 circuiting 3) Connect T-adapter.
Between L61 (Female) I/L10 (Female) 3 - body Voltage 1 V or below
Defective transmission 4) Start engine.
3 and fan pump motor 5) Step ON the left brake.
controller
Between L61 F - body (Power supply) Voltage 20 - 30 V
Between L61 I - body (Signal) Voltage 0.7 - 5.3 V
20-420 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE
TROUBLESHOOTING CODE [TM-9A]
[TM-9a]
TROUBLESHOOTING CODE [TM-9a]

ing code Joystick SHIFT_UP/SHIFT_DOWN siwtch system failure
Trouble
(discontinuity or ground fault)
TM-9a — (TM)
Description of • When operating the joystick, SHIFT_UP or SHIFT_DOWN action cannot be enabled (due to discontinuity or
Trouble ground fault).
tion
• When operating the joystick, SHIFT_UP or SHIFT_DOWN action cannot be enabled (due to discontinuity or
Effect on ground fault).
Machine
• The gear can be shifted in the auto-shift or handle mode.
Related Infor- • Can be check with the monitoring function (Code: 40906, D-IN-12, D-IN-13).
mation Note: The up/down switch (SHIFT_UP/SHIFT_DOWN) cannot be used in the auto-shift mode.

Wiring harness discontinuity Resistance 1 Ω or below
(Female ) 8
1 (Disconnetion or defective
contact) Wiring harness between L63 (Female) I - L37
(Female ) 6 Resistance 1 Ω or below
Wiring harness between fuse A-2 - L37

(Female ) 1 (In this case, FNR does not work Resistance 1 Ω or below
either.)
Wiring harness ground fault 3) Connect T-adapter.
★ In this case, fuse A-2
2 blows out when the Between L63 (Female) 9/L37 (Female) 8 - Resistance 1 MΩ or above
body
switch is operated
Possible Causes Between L63 (Female) I/L37 (Female) 6 -
and Standard body
Values
Defective joystick SHIFT_UP/ Between L37 (Male) 1 SHIFT_UP Resistance 1 Ω or below
3 SHIFT_DOWN switch -2 Other than above Resistance 1 MΩ or above
Between L37 (Male) 6 SHIFT_DOWN Resistance 1 Ω or below

-1 Other than above Resistance 1 MΩ or above
Defective transmission and SHIFT_UP Voltage 20 - 30 V
4 fan pump motor controller Between L63 9 - body
Other than above Voltage 1 V or below
SHIFT_DOWN Voltage 20 - 30 V
Between L63 I - body
WA380-5 20-421
(10)
TROUBLESHOOTING TROUBLESHOOTINGCODE
TROUBLESHOOTING CODE[TM-9B]
[TM-9b]
TROUBLESHOOTING CODE [TM-9b]

ing code Trouble Joystick ON/OFF change over switch system failure
TM-9b — (TM)
Description of • Due to failure of the joystick ON/OFF change over switch system, the joystick cannot be switched ON/OFF.
Trouble • The FNR mode cannot be enabled (Due to ground fault), or in the handle mode (Due to discontinuity).
tion
• The joystick mode cannot be enabled or cancelled.
Effect on • The FNR switch mode cannot be enabled.
Machine
• The handle mode cannot be enabled.
Related Infor- • The joystick ON/OFF switch input signal can be checked with the monitoring funtion (Code: 40907, D-IN-16).
mation • The service mode of the monitor can be used to check if the joystick (If equipped) is implemented or not.

Defective joystick ON/ 3) Connect T-adapter.
1 OFF switch
Between L39 Joystick ON/OFF switch = ON Resistance 1 Ω or below
(Female) 4 - 3 Other than above Resistance 1 MΩ or above
Defective joystick N lock 3) Connect T-adapter.
2 switch
Left arm rest = Locked Resistance 1 Ω or below
(Female) A - c
Between L38
Other than above Resistance 1 MΩ or above
Wiring harness between L62 (Female) Y - L39 (Female) Resistance 1 Ω or below
3
Wiring harness disconti- 2) Disconnect connectors L38 and L39.
Possible Causes defective contact) Wiring harness between L38 (Female) A - L39 (Female)
and Standard Resistance 1 Ω or below
Values 4
Between S38 (Female) c - body Voltage 20 - 30 V
Wiring harness hot 2) Disconnect connectors L62 and S04.
4 short-circuiting (Con- 3) Connect T-adapter.
tacting 24 V harness) 4) Turn starting switch ON.
Between L62 (Female) Y/S04 (Female) 4 - body Voltage 1 V or below
fault 2) Disconnect connectors L62,S04, L71, L39, and L40.
5 ★ In this case, fuse A-2 3) Connect T-adapter.
blows out when the
switch is operated. Between L62 (Female) Y/S04 (Female) 4 - body Resistance 1 MΩ or above

controller
Between L62 Y - Joystick ON/OFF switch = ON Voltage 20 - 30 V
20-422 WA380-5
(10)
TROUBLESHOOTING [TM-9b]
TROUBLESHOOTING CODE [TM-9B]
Related diagram circuit
WA380-5 20-423
(7)
TROUBLESHOOTING TROUBLESHOOTINGCODE
TROUBLESHOOTING CODE[TM-10]
[TM-10]

ing code Trouble FNR switch mode change over switch system failure
TM-10 — (TM)
• Due to failure of the FNR switch mode change over switch system, the FNR switch mode cannot be changed
Description of over.
Trouble • - The FNR switch mode cannot be enabled (Due to ground fault). Or the handle mode cannot be enabled (Due to
discontinuity).
tion
Effect on • The FNR switch mode cannot be enabled or cancelled.
Machine
Related Infor- • The FNR switch mode change over signal can be checked with the monitoring function (Code: 40907, D-IN-16).
mation • The service mode of the monitor can be used to check if the right FNR switch is installed or not.

1) Turn starting switch OFF. 2) Disconnect connector S04. 3) Connect T-adapter.
Defective FNR switch FNR switch mode change over
1 mode change over Between S04 Resistance 1 Ω or below
switch switch = ON
(Male) 4 - 3
Other than above Resistance 1 MΩ or above
1) Turn starting switch OFF. 2) Disconnect connectors L62 and S04.
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.
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.
5 and fan pump motor FNR switch mode change over Voltage 20 - 30 V
controller Between L62 Y - switch = ON
body
20-424 WA380-5
(10)

ing code Trouble Starting switch "C" (IGN_C) signal system failure
TM-11 — (TM)
Description of • After the engine started, discontinuity or ground fault occurred in the "C" terminal signal input circuit of the
Trouble starting switch.
tion
Effect on • The engine cannot be started. (Ground fault causes fuse B-1 to blow out, resulting in disabling the starting
Machine switch.)
Related Infor- • Terminal input signal (0/1) of the starting switch "C" (IGN "C") can be checked with the monitoring function
mation (Code: 40906,D-IN-15).

Defective starting (Igni- 3) Connect T-adapter.
1 tion key) switch
Between S31 Starting switch = "C" (at starting) Resistance 1 Ω or below
(Male) 1 - 3 Other than above Resistance 1 MΩ or above
2 Defective diode R26
Between R26 (Male) 1 - 2
★ To be measured from 2 side in diode range. Continuity Positive
★ Replacing R26 can also correct this failure.
3 Defective diode R27
Between R27 (Male) 1 - 2
★ To be measured from 2 side in diode range. Continuity Positive
★ Replacing R27 can also correct this failure.
Defective neutral safety 3) Connect T-adapter.
4 relay (L116)
Between L116 Relay = ON Resistance 1 Ω or below
Possible Causes (Male) 3 - 5 Relay = OFF Resistance 1 MΩ or above
and Standard
Values 5 Defective starting motor ★ Perform separate inspection.
Wiring harness between L63 (Female) ] - L102
(Female) D
Between L102 (Female) C - S31 (Female) 3 Resistance 1 Ω or below
7 short-circuiting (Con-
tacting 24-V harness) Between L63 (Female) ]/L102 (Female) D - body Voltage 1 V or below
Between L102 (Female) C/S31 (Female) 3 - body Voltage 1 V or below
Wiring harness ground 2) Disconnect connectors L63, S31, E01, L81 and L52.
fault 3) Connect T-adapter.
8 *In this case, fuse A-2
blows out when the Between L63 (Female) ]/L102 (Female) D - body Resistance 1 MΩ or above
switch is operated.
Between L102 (Female) C/S31 (Female) 3 - body Resistance 1 MΩ or above
controller Starting switch = "C" (at starting) Voltage 20 - 30 V
Between L63 ]
and body Other than above Voltage 1 V or below
20-426 WA380-5
(10)
bww10515.eps
WA380-5 20-427
(10)

ing code Trouble Engine power mode switch discontinuity or ground fault
TM-12 — —
• Due to discontinuity or ground fault of the engine power mode switch, the engine power mode cannot be
Description of changed over.
Trouble • Power mode selection is disabled (Due to discontinuity), or the economy mode cannot be selected (Due to
ground fault).
tion
Effect on • As the engine mode cannot be changed over, the engine is fixed either to the power or economy mode.
Machine
Related Infor- • Can be checked with the monitoring function (Code: 41600 ENGINE MODE).
mation

Defective engine mode
1 selection switch Engine = Power mode Resistance 1 Ω or below
Between S04
(Male) 4 - 1 1 MΩ or
Engine = Economy mode Resistance
above
Wiring harness between L61 (Female) 6 - S21
defective contact) (Female) 4 Resistance 1 Ω or below

Possible Causes Wiring harness hot 1) Turn starting switch OFF.
and Standard short-circuiting (Con- 2) Disconnect connectors L61 and S21.
Values tacting 24-V harness) 3) Connect T-adapter.
blows out when the
switch is operated. Between L61 (Female) 6/S21 (Female) 4 - body Voltage 1 V or below

4 fault
1 MΩ or
Between L61 (Female) 6/S21 (Female) 4 - body Resistance
above
controller Engine = Power mode Voltage 1 V or below
Between L61 6 -
body Engine = Economy mode Voltage 20 - 30 V
bww10166.eps
20-428 WA380-5
(10)

ing code Trouble E.C.S.S. ON/OFF switch discontinuity or ground fault
TM-13 — —
Description of • Due to discontinuity or ground fault of the E.C.S.S. ON/OFF switch, the E.C.S.S. function cannot be enabled (Due
Trouble to discontinuity) or cancelled (Due to ground fault).
tion
Effect on • The E.C.S.S. function cannot be enabled.
Machine • The E.C.S.S. function cannot be cancelled.
• 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.
Related Infor- • Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of machine
mation
• Can be checked with the monitoring function (Code: 40905, D-IN-4).

Defective E.C.S.S. ON/
1 OFF switch Boom damper ON/OFF switch = ON Resistance 1 Ω or below
Between S07
(Male) (4) - (3) Boom damper ON/OFF switch = Resistance 1 MΩ or
OFF above
2 nuity (Disconnection or Wiring harness between L61 (Female) (24) - S07
(Female) (4)
Between S07 (Female) (3) and body Resistance 1 Ω or below
Possible Causes short-circuiting (Con- 2) Disconnect connectors L61 and S07.
and Standard tacting 24-V harness) 3) Connect T-adapter.
Values 3 ★ In this case, fuse A-2 4) Turn starting switch ON.
blows out when the
switch is operated. Between L61 (Female) (24)/S07 (Female) (4) - body Voltage 1 V or below

4 fault
Between L61 (Female) (24)/S07 (Female) (4) - body Resistance 1 MΩ or
above
controller Boom damper ON/OFF switch = ON Voltage 1 V or below
Between L61 (24) -
body Boom damper ON/OFF switch =
OFF Voltage 20 - 30 V
BJW11504
WA380-5 20-429
(10)

ing code Hydraulic fan reverse switch signal system hot short-cir-
Trouble
cuiting or discontinuity
TM-14 — —
Description of • Due to ground fault or discontinuity of the fan reverse switch signal system, the fan reverse switch cannot be
Trouble turned OFF (Due to hot short circuiting) or ON (Due to discontinuity).
tion
Effect on • The fan reverse switch cannot be turned ON or OFF.
Machine
Related Infor- —
mation

Defective fan reverse 3) Connect T-adapter.
1 switch
Between S16 Fan reverse switch = ON Resistance 1 Ω or below
(Male) 4 - 3 Fan reverse switch = OFF Resistance 1 MΩ or above
2) Disconnect connectors L61 and L16..
Wiring harness between L61 (Female) 7 - S16
Wiring harness disconti- (Female) 4 Resistance 1 Ω or below
defective contact) 1) Turn starting switch OFF.
Possible Causes
and Standard Between S16 (Female) 3 and body Voltage 20 - 30 V
Values
short-circuiting (Con- 2) Disconnect connectors L61 and S16.
tacting 24-V harness) 3) Connect T-adapter.
blows out when the
switch is operated. Between L61 (Female) 7/S16 (Female) 4 - body Voltage 1 V or below

Between L61 (Female) 7/S16 (Female) 4 - body Resistance 1 MΩ or above
controller
Between L61 7 - Fan reverse switch = ON Voltage 20 - 30 V
body Fan reverse switch = OFF Voltage 1 V or below
20-430 WA380-5
(10)

ing code Motor-driven emergency steering relay output system
Trouble
hot short-circuiting
TM-15 — —
Description of • Due to hot short-circuiting of the motor-driven emergency steering relay output system, the emergency steering
Trouble motor keeps operating.
tion
Effect on • The emergency steering motor keeps operating.
Machine
Related Infor- —
mation

1 short-circuiting
and Standard
Values Between L63 (Female) 7/S105 (Female) 9 - body Voltage 1 V or below
controller
WA380-5 20-431
(10)

ing code Trouble E.C.S.S. relay output system hot short-circuiting
TM-16 — —
Description of • Due to hot short-circuiting of the E.C.S.S. relay output system, the E.C.S.S. keeps operating.
Trouble
tion
Effect on • The E.C.S.S. keeps operating.
Machine
Related Infor- and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set correctly.
mation • Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of machine

Wiring harness hot Between L63 (Female) (17)/L104 (Female) (11) - body Voltage 1 V or below
1 short-circuiting
and Standard 2) Disconnect connectors F13 and L125.
Values 3) Connect T-adapter.
Between F13 (Female) (1)/L125 (Female) (5) - body Voltage Max. 1V
controller
BJW11505
20-432 WA380-5
(10)

ing code Switch pump cut-off relay output system hot short-cir-
Trouble
cuiting
TM-17 — —
Description of • Due to hot short-circuiting of the switch pump cut-off relay output system, the switch pump cut-off relay is
Trouble always ON.
tion
Effect on • The switch pump cut-off relay is always ON.
Machine
Related Infor- —
mation

1 short-circuiting
and Standard
Values Between L63 (Female) Q/L106 (Female) C - body Voltage 1 V or below
controller
Between L63 (Female) Q - body Resistance 200 - 400 Ω
WA380-5 20-433
(10)

ing code Trouble Back lamp relay output system hot short-circuiting
TM-18 — —
Description of • Due to hot short-circuiting of the back lamp relay output system, the back lamp buzzer keeps beeping.
Trouble
tion
Effect on • The back lamp buzzer keeps beeping.
Machine
Related Infor- —
mation

Possible Causes 1 short-circuiting 4) Turn starting switch ON.
and Standard
Values Between L63 (Female) 4/L103 (Female) 1 - body Voltage 1 V or below
controller
20-434 WA380-5
(10)

ing code Trouble Neutral output system hot short-circuiting
TM-19 — —
Description of • Due to hot short-circuiting of the neutral output system, engine can be started when the FNR lever or FNR see-
Trouble saw switch is not in the "N" position in the seesaw switch mode (Joystick mode).
tion
Effect on • The engine can be started when the FNR lever or FNR seesaw switch is not in the "N" position in the seesaw
Machine switch mode (Joystick mode).
Related Infor- —
mation

and Standard
Values Between L63 (Female) [/L101 (Female) D - body Voltage 1 V or below
controller
Between L63 (Female) [ - body Resistance 200 - 400 Ω
WA380-5 20-435
(10)

ing code Trouble FECMV solenoid system hot short-circuiting
TM-20 — —
Description of • Due to a failure of the FECMV solenoid system, FECMV is turned ON without DIR is turned to "F."
Trouble
tion
Effect on • The transmission may be damaged.
Machine • Traveling may be disabled.
Related Infor- —
mation

2) Disconnect connectors L63 and F.PS.
1 short-circuiting
and Standard
Values Between L63 (Female) 5/F.PS (Female) 1 - body Voltage 1 V or below
controller
20-436 WA380-5
(10)

ing code Trouble RECMV solenoid system hot short-circuiting
TM-21 — —
Description of • Due to a failure of the RECMV solenoid system, RECMV is turned ON without DIR is turned to "R."
Trouble
tion
Related Infor- —
mation

2) Disconnect connectors L63 and R.PS.
and Standard
Values Between L63 (Female) E R.PS (Female) 1 - body Voltage 1 V or below
controller
WA380-5 20-437
(10)

ing code Trouble 1st ECMV solenoid system hot short-circuiting
TM-22 — —
Description of • Due to hot short-circuiting of the 1st ECMV solenoid system, 1st ECMV is turned ON without shifting the gear to
Trouble "1st."
tion
Related Infor- —
mation

2) Disconnect connectors L63 and 1.PS.
and Standard
Values Between L63 (Female) O/1.PS (Female) 1 - body Voltage 1 V or below
controller
20-438 WA380-5
(10)

ing code Trouble 2nd ECMV solenoid system hot short-circuiting
TM-23 — —
Description of • Due to hot short-circuiting of the 2nd ECMV solenoid system, 2nd ECMV is turned ON without shifting the gear
Trouble to "2nd."
tion
Related Infor- —
mation

and Standard
Values Between L63 (Female) 6/2.PS (Female) 1 - body Voltage 1 V or below
controller
WA380-5 20-439
(10)

ing code Trouble 3rd ECMV solenoid system hot short-circuiting
TM-24 — —
Description of • Due to hot short-circuiting of the 3rd ECMV solenoid system, 3rd ECMV is turned ON without shifting the gear to
Trouble "3rd."
tion
Related Infor- —
mation

1 short-circuiting
and Standard
Values Between L63 (Female) F/3.PS (Female) 1 - body Voltage 1 V or below
controller
20-440 WA380-5
(10)

ing code Trouble 4th ECMV solenoid system hot short-circuiting
TM-25 — —
Description of • Due to hot short-circuiting of the 4th ECMV solenoid system, 4th ECMV is turned ON without shifting the gear to
Trouble "4th."
tion
Related Infor- —
mation

and Standard
Values Between L63 (Female) P/4.PS (Female) 1 - body Voltage 1 V or below
controller
WA380-5 20-441
(10)

ing code Trouble Lock-up ECMV solenoid system hot short-circuiting
TM-26 — —
Description of • Due to hot short-circuiting of the lock-up ECMV solenoid system, lock-up suddenly turns ON.
Trouble
tion
Effect on • Lock-up suddenly turns ON.
Machine
Related Infor- —
mation

2) Disconnect connectors L63 and LC.PS.
and Standard
Values Between L63 (Female) Y/LC.PS (Female) 1 - body Voltage 1 V or below
controller
Between L63 (Female) Y - M Resistance 5 - 15 Ω
20-442 WA380-5
(10)

ing code Trouble Fan pump EPC solenoid system hot short-circuiting
TM-27 — —
Description of • Due to hot short-circuiting of the fan pump EPC solenoid system, the fan operates with minimum revolution.
Trouble
tion
Effect on • The fan operates with minimum revolution.
Machine
Related Infor- —
mation

1 short-circuiting
and Standard
Values Between L63 (Female) Z/R29 (Female) 1 - body Voltage 1 V or below
controller
WA380-5 20-443
(10)

ing code Trouble Fan reverse solenoid system hot short-circuiting
TM-28 — —
Description of • Due to hot short-circuiting of the fan reverse solenoid system, the fan keeps operating in reverse revolution.
Trouble
tion
Effect on • The fan keeps operating in reverse revolution.
Machine
Related Infor- —
mation

2) Disconnect connectors L63 and GR2.
and Standard
Values Between L63 (Female) R/GR2 (Female) 1 - body Voltage 1 V or below
controller
BWW10533
20-444 WA380-5
(10)

ing code Speed sensor (transmission output shaft revolution) sys-
Trouble
tem failure
TM-29 — —
Description of • Due to ground fault of the speed sensor system, speed sensor signal cannot be input.
Trouble
tion
• Gear shift shock occurs.
Effect on • Shift up cannot be performed in the auto-shift mode. (Traveling in the manual mode is possible.)
Machine
• Engine overrun may occur.
Related Infor- —
mation

Defective installation of Check the clearance between the sensor and the gear.
1 speed sensor ★ See the checking/adjusting manual.
2) Disconnect connector REV.OUT.
2 Defective speed sensor 3) Connect T-adapter.
Between REV.OUT (Male) 1 - 2 Resistance 500 - 1000 Ω
Possible Causes
Values 2) Disconnect connectors L62 and REV.OUT.
3 fault Between L62 (Female) J/REV.OUT (Female) 1 - body Resistance 1 MΩ or above
Between L62 (Female) S/REV.OUT (Female) 2 - body Resistance 1 MΩ or above
controller
Between L63 (Female) J - S Resistance 500 - 1000 Ω
WA380-5 20-445
(10)

ing code Trouble E.C.S.S. solenoid system discontinuity or ground fault
TM-30 — —
Description of • Since the E.C.S.S. solenoid is defective or its circuit is discontinued or has a ground fault, the E.C.S.S. system
trouble does not operate.
Controller reac- • No reaction.
tion
Effect on • The E.C.S.S. system does not operate.
machine
Check the following items in advance.
and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set correctly.
Related infor-
• Check that the E.C.S.S. switch is turned ON.
mation
• Referring to TROUBLESHOOTING, Special functions of machine monitor, check that the optional selection of the
E.C.S.S. is effective.
• Check that failure codes [D192KA] and [D192KB] are not displayed.
Cause Standard value in normal state and remarks on troubleshooting

Between L125 (female) (3) - body Voltage 20- 30 V
Wiring harness disconti- 2) Disconnect connector F13.
Possible Causes 1 nuity (Disconnection or 3) Connect T-adapter.
and Standard defective contact) 4) Turn starting switch ON.
Values 5) Turn E.C.S.S. switch ON.
Between F13 (female) (1) - body Voltage 20- 30 V
2) Disconnect connector F13.
Between F13 (female) (2) - body Resistance Max. 1 Ω
Defective E.C.S.S. sole- 2) Disconnect connector F13.
2 noid
Between F13 (male) (1) - (2) Resistance 21 - 24 Ω
Related circuit diagrams
20-446 WA380-5
(10)
TROUBLESHOOTING OF WORK EQUIPMENT
CONTROL SYSTEM
(WRK MODE)

Connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
Work equipment control system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
Failure Code [D193KA] (Defective joystick steering cut relay system (main system disconnected))
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521
Failure Code [D193KB] (The joystick solenoid cut relay output system is grounded properly) is
displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
Failure Code [DB90KK] (Lowering work equipment controller power supply) is displayed . . . . . . . 20-523
Failure Code [DB92KK] (Defective solenoid electric power supply system) is displayed . . . . . . . . . 20-524
Failure Code [DB95KX] (Defective 5 V electric power supply system) is displayed . . . . . . . . . . . . . . 20-526
Failure Code [DD1ALD] (Defective remote positioner UP set switch (ground fault)) is displayed. . . 20-528
Failure Code [DD1BLD] (Defective remote positioner DOWN set switch (ground fault))
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-529
Failure Code [DFA0KM] (Defective neutral caution for joystick work equipment lever) is displayed . . . . 20-530
Failure Code [DK59KA] (Defective lift arm EPC lever potentiometer system (main circuit
discontinuity or ground fault)) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . 20-531
Failure Code [DK59KY] (Defective lift arm EPC lever potentiometer system (main short circuit))
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-532
Failure Code [DK59L8] (Defective lift arm EPC potentiometer system (displacement of main and
sub-circuit) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-533
Failure Code [DK5AKA] (Defective lift arm EPC lever potentiometer system (disconnection of main)
(disconnection, ground of sub)) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . 20-534
Failure Code [DK5AKY] (Defective lift arm EPC lever potentiometer system (short sub-circuit))
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-535
Failure Code [DK5BKA] (Defective bucket EPC lever potentiometer system (main circuit
Failure Code [DK5BKY] (Defective bucket EPC lever potentiometer system (main shorted))
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-537
Failure Code [DK5BL8] (Defective input signal for bucket EPC lever potentiometer system
(displacement of main and sub-circuit)) is displayed . . . . . . . . . . . . . . . . . . 20-538
Failure Code [DK5CKA] (Defective bucket EPC lever potentiometer system (sub-circuit
Failure Code [DK5CKY] (Defective bucket EPC lever potentiometer system (short sub-circuit))
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-540
Failure Code [KD5DKA] (Defective 3rd valve lever potentiometer system (main circuit
Failure Code [DK5DKY] (Defective 3rd valve lever potentiometer system (main circuit
short circuit)) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-542
Failure Code [DK5DL8] (Defective 3rd valve EPC lever potentiometer system input signal
(displacement of main and sub-circuit)) is displayed . . . . . . . . . . . . . . . . . . 20-543
Failure Code [DK5EKA] (Defective 3rd valve EPC lever potentiometer system (sub-circuit
Failure Code [DK5EKY] (Defective 3rd valve EPC lever potentiometer system (short sub-circuit))
is displayed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-545
Failure Code [DK5FKA] (Defective joystick steering EPC lever potentiometer system (main
circuit discontinuity or ground fault)) is displayed . . . . . . . . . . . . . . . . . . . . 20-546
Failure Code [DK5FKY] (Defective joystick steering EPC lever potentiometer system (main
circuit shorted)) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-547
WA380-5 20-501
(10)
TROUBLESHOOTING
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

Electrical system.
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

A21 Yazaki 2 Water temperature sensor (Vehicle with automatic air W-3
conditioner)
Outside temperature sensor (Vehicle with automatic air

A23 Yazaki 2 W-4
conditioner)
A26 DT-T 2 conditioner)
W-3

WA380-5 20-503
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

Kyoritsu
C17 4 Warning lamp switch D-9
ES
C47 AMP1720 16 A/C control AMP P-1

21-2
AMP1722
CL5 S (W) 16 M-2
conditioner)
CL6 M 6 Intermediate connector (Vehicle with automatic air M-3 B-3 C-5
conditioner)
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
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
WA380-5 20-505
(10)
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
lamp)
20-506 WA380-5
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
WA380-5 20-507
(10)
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
20-508 WA380-5
(10)
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
switch)
W-3,

R13 L-1 O-1 X-6 F-2
WA380-5 20-509
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

stick)
S14 DT-T 6 N-8 I-2
stick)
20-510 WA380-5
(10)
20-512 WA380-5
WA380-5 20-513
5
Serial No.: 60001 - 60207
20-514 WA380-5
(9)
WA380-5 20-515
5
Serial No.: 60208 and up
20-515-1 WA380-5
(9)
WA380-5 20-515-2
(9)
20-516 WA380-5
5
WA380-5 20-517
5
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
20-518 WA380-5
WA380-5 20-519
20-520 WA380-5

Action Code Failure Code Controller Code Defective joystick steering cut relay system (Main
Trouble
E03 D193KA WRK circuit disconnected)
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 —

1 Defective relay (L41) 3) Connect T-adapter.
Possible Causes Wiring harness dis- 2) Disconnect connectors L73 and L41.
and Standard Val- continuity (Discon-
ues 2 3) Connect T-adapter.
nection or defective
contact) Wiring harness between L73 (Female) 7 -
L41 (Female) 5 Resistance 1 Ω and below

Defective work equip- 2) Disconnect connector L73.
3 ment controller 3) Connect T-adapter.
WA380-5 20-521
(10)

Action Code Failure Code Controller Code The joystick solenoid cut relay output system is
Trouble
E03 D193KB WRK grounded properly
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 —

1 Defective relay (L41) 3) Connect T-adapter.
Possible Causes Wiring harness 2) Disconnect connectors L73 and L41.
and Standard Val- ground fault (Discon- 3) Connect T-adapter.
ues 2 nection or defective
contact) Wiring harness between L73 (Female) 7/
L41 (Female) 5 - body Resistance 1 MΩ and above

20-522 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB90KK]
FAILURE CODE [DB90KK]

Trouble Lowering work equipment controller power supply.
E03 DB90KK WRK
Description Of • Controller power supply voltage is lowered.
Trouble
Controller • The input signal cannot be detected normally.
Reaction
Effect on Machine • Normal operation is impossible.
Related
Information —

Wiring harness dis- 3) Connect T-adapter.
continuity (Discon-
1
nection or defective Wiring harness between L73 (Female) 1/A - Resistance 1 Ω and below
connector contact) FS3 (Female) 1
Possible Causes Wiring harness 2) Disconnect connectors L73 and FS4.
and Standard Val- ground fault 3) Connect T-adapter.
ues 2 ★ In this case, FS B-
d is broken. Between L73 (Female) 1/A/FS3 (Female) 3 Resistance 1 MΩ and above
- body
3 Defective work equip- 4) Turn starting switch ON.
ment controller
Constant
Between L73 1/A - body (NSW) electric Voltage 20 - 30 V
power supply
WA380-5 20-523
(10)
TROUBLESHOOTING FAILURE CODE [DB92KK]
FAILURE CODE [DB92KK]

Action Code Failure Code Controller Code Defective solenoid electric power supply sys-
Trouble
E03 DB92KK WRK tem
Description of • The solenoid power supply voltage is lowered.

Trouble
Controller Reac- • No output to solenoid (Stops all the electric power supply voltage at 18 V and below).
tion
Effect on Machine • The work equipment cannot be operated.
Related
Information —

Wiring harness dis- 3) Connect T-adapter.
continuity (Disconnec-
1
tion of defective Wiring harness between L73 (Female) 2/B/ Resistance 1 Ω and below
contact) L - FS4 (Female) f
Possible Causes Wiring harness 2) Disconnect connectors FS2 and battery relay M terminal.
and Standard ground fault 3) Connect T-adapter to F32.
Values 2 ★ In this case, FS A-f
is broken. Between L73 (Female) 2/B/L/FS4 Resistance 1 MΩ and above
(Female) 5 - body
3 Defective work equip- 4) Connect connector L73.
ment controller 5) Turn starting switch ON.
(SLU) electric
Between L73 2/B/L - body power supply Voltage 20 - 30 V
20-524 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB95KX]
FAILURE CODE [DB95KX]

Trouble Defective 5 V electric power supply system
E03 DB95KX WRK
Description of • 5 V sensor electric power supply system is grounded improperly.
Trouble
Controller • Turns off the output to all EPC.
Reaction
Effect on Machine • The work equipment and the joystick cannot be operated.
Related
Information —

Wiring harness 2) Disconnect connectors L71, L28, L29, L34, and L30. Disconnect F18.
1 ground fault 3) Connect T-adapter.
Between L71 (Female) L - body Resistance 1 MΩ and above
2 Defective boom EPC Between L28 (Male) 4 - 1 Resistance 2.5 - 3.9 kΩ
lever potentiometer
Between L28 (Male) e - body Resistance 1 MΩ and above
3 Defective bucket EPC Between L29 (Male) 4 - 1 Resistance 2.5 - 3.9 kΩ
lever potentiometer
Between L29 (Male) 4 - body Resistance 1 MΩ and above
Possible Causes
and Standard Val- 1) Turn starting switch OFF. 2) Disconnect connector L34. 3) Connect T-adapter.
Defective joystick
ues 4 steering EPC lever Between L34 (Male) 4 - 1 Resistance 2.5 - 3.9 kΩ
potentiometer
5 Defective 3rd EPC Between L30 (Male) 4 - 1 Resistance 2.5 - 3.9 kΩ
lever potentiometer
1) Turn starting switch OFF. 2) Disconnect connector F18. 3) Connect T-adapter.
6 Defective boom EPC Between F18 (Male) 3 - 1 Resistance 4 - 6 kΩ
lever potentiometer
Between F18 (Male) 3 - body Resistance 1 MΩ and above
ment controller
Between L71 L - K Voltage 4.75 - 5.25 V
20-526 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB95KX]
BWW10245
WA380-5 20-527
(10)
TROUBLESHOOTING FAILURE CODE [DD1ALD]
FAILURE CODE [DD1ALD]

Action Code Failure Code Controller Code Defective remote positioner UP set switch
Trouble
E03 DD1ALD WRK (Ground fault)
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

1 Wiring harness 3) Connect T-adapter.
ground fault
Between L72 (Female) C/S12 (Female) 1 - Resistance 1 MΩ and above
body
Remote posi-
Defective remote positioner set Resistance 1 Ω and below
2 switch = Up
tioner set switch
Possible Causes Between S12 (Male) 1 - 2 Remote posi-
and Standard Val- tioner set
ues switch = Resistance 1 MΩ and above
Other than
above
Remote posi-
3 Defective work equip- tioner set Voltage 1 V and below
ment controller switch = Up
Between L72 (Male) C - Remote posi-
body tioner set
switch = Voltage 17 - 30 V
Other than
above
20-528 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DD1BLD]
FAILURE CODE [DD1BLD]

Action Code Failure Code Controller Code Defective remote positioner DOWN set switch
Trouble
E03 DD1BLD WRK (Ground fault)
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.
Information

1 Wiring harness 3) Connect T-adapter.
ground fault
Between L72 (Female) C/S12 (Female) 1 - Resistance 1 MΩ and above
body
Remote posi-
Defective remote positioner set Resistance 1 Ω and below
2 switch = Up
tioner set switch
Possible Causes Between S12 (Male) 3 - 2 Remote posi-
and Standard Val- tioner set
ues switch = Resistance 1 MΩ and above
Other than
above
Remote posi-
3 Defective work equip- tioner set Voltage 1 V and below
ment controller switch = Up
Between L72 (Male) 3 - Remote posi-
body tioner set
switch = Voltage 20 - 30 V
Other than
above
WA380-5 20-529
(10)
TROUBLESHOOTING FAILURE CODE [DFAOKM]
FAILURE CODE [DFAOKM]

Action Code Failure Code Controller Code Defective neutral caution for joystick work equip-
Trouble
E00 DFAOKM WRK ment lever
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.
Information

Defective lift arm neu- 4) Turn starting switch ON. 5) Set lock lever to lock position.
1
tral lock switch
Between L71 G - body Voltage 1 V and below
Defective lift arm EPC 4) Turn starting switch ON. 5) Set lock lever to neutral position.
Possible Causes 2
lever potentiometer
And Standard Val- Between L71 I - K Voltage 2.4 - 3.9 V
ues
Defective bucket EPC 4) Turn starting switch ON. 5) Set lock lever to neutral position.
3
lever potentiometer
Between L71 7 - K Voltage 2.4 - 3.9 V
Defective 3rd EPC 4) Turn starting switch ON. 5) Set lock lever to neutral position.
4
lever position
Between L71 J - K Voltage 2.4 - 3.9 V
20-530 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK59KA]
FAILURE CODE [DK59KA]

Action Code Failure Code Controller Code Defective lift arm EPC lever potentiometer sys-
Trouble
E03 DK59KA WRK tem (Main circuit discontinuity or ground fault)
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.
Information

Wiring harness dis- 2) Disconnect connector L71 and L28.
continuity (Disconnec- 3) Connect T-adapter.
1
tion or defective
contact) Wiring harness between L71 (Female) I -
L28 (Female) 3
Wiring harness 2) Disconnect connector L71 and L28.
ground fault
Between L71 (Female) I - Body Resistance 1 MΩ and above
Possible Causes
And Standard Val- 1) Turn starting switch OFF.
Defective potentiome- 3) Connect T-adapter.
3 ter 4) Turn starting switch ON.
5) Set lock lever to neutral position.
Between L28 3 - 1 Voltage 2.4 - 2.6 V
Defective work equip- 3) Connect T-adapter.
4 ment controller 4) Turn starting switch ON.
Between L71 I - K (Set lever to neutral Voltage 2.4 - 2.6 V
position)
WA380-5 20-531
(10)
TROUBLESHOOTING FAILURE CODE [DK59KY]
FAILURE CODE [DK59KY]

Action Code Failure Code Controller Code Defective lift arm EPC lever potentiometer system
Trouble
E03 DK59KY WRK (Main short circuit)
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
Information

2) Disconnect connector L71 and L28.
Harness shorted to 3) Connect T-adapter.
electric power supply
1
(Contacted to electric Between L71 (Female) I/L28 (Female) 3 - Voltage 1 V and below
Possible Causes power supply harness) body
and Standard Val- Between L71 (Female) I - K Voltage 1 V and below
ues
2 4) Turn starting switch ON.
ment controller
5) Set lever to neutral position.
Between L71 (Female) I - K Voltage 2.4 to 2.6 V
20-532 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK59L8]
FAILURE CODE [DK59L8]

Action Code Failure Code Controller Code Defective lift arm EPC potentiometer system
Trouble
E03 DK59L8 WRK (Displacement of main and sub circuit)
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.
Related • Can be checked with the monitoring function (Code: 42000 and 42001).
Information

1) Turn starting switch OFF. 2) Disconnect connector L71 and L28.
Lever = Neutral Voltage 2.4 - 2.6 V
Between L28 Lever = Full stroke at the up side Voltage 3.9 - 4.4 V
3-1
Defective potentiometer Lever = Full stroke at the up side Voltage 0.6 - 1.1 V
1 ★ Defective installa-
tion (Loose and play) Lever = Neutral Voltage 2.4 - 2.6 V
Between L28 Lever = Full stroke at the up side Voltage 0.6 - 1.1 V
2-1
Lever = Full stroke at the up side Voltage 3.9 - 4.4 V
Between L28
4-1 Lever = Neutral Voltage 4.75 - 5.25 V
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
Wiring harness between L71 (Female) C - L28

3) Insert T-adapter. 4) Turn starting switch ON.
Between L71
I-K Lever = Full stroke at the up side Voltage 3.9 - 4.4 V
3 Defective work equip-
ment controller Lever = Full stroke at the up side Voltage 0.6 - 1.1 V
Between L71
C-K Lever = Full stroke at the up side Voltage 0.6 - 1.1 V
Lever = Full stroke at the up side Voltage 3.9 - 4.4 V
WA380-5 20-533
(10)
TROUBLESHOOTING FAILURE CODE [DK5AKA]
FAILURE CODE [DK5AKA]

Action Code Failure Code Controller Code Defective lift arm EPC lever potentiometer system
Trouble (Disconnection of main) (Disconnection, ground of
E03 DK5AKA WRK sub)
Description Of • Defective lift arm EPC lever potentiometer system (Main circuit discontinuity) (Sub circuit discontinuity or
Controller Reac- • Stops the lift arm EPC solenoid output.
tion
Related Informa- • Can be checked with the monitoring function (Code: 42001).
tion

defective contact) Wiring harness between L71 (Female) C -

fault
Between L71 (Female) C/L28 (Female) 2 Resistance 1 MΩ and above
Possible Causes - body
and Standard Val-
3 Defective potentiometer 4) Turn starting switch ON.
Defective work equip- 3) Insert T-adapter.
Between L71 C - K Voltage 2.4 - 2.6 V
20-534 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5AKY]
FAILURE CODE [DK5AKY]

Action Code Failure Code Controller Code Defective lift arm EPC lever potentiometer sys-
Trouble
E03 DK5AKY WRK tem (Short sub circuit)
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.
Information

Defective harness hot 2) Disconnect connector L71 and L28.
short (Contacted to elec- 3) Connect T-adapter.
1
tric power supply har-
ness) Between L71 (Female) C/L28 (Female) 2
Possible Causes Voltage 1 V and below
and Standard Val- - body
ment controller
Between L71 C - K Voltage 2.4 - 2.6 V
WA380-5 20-535
(10)
TROUBLESHOOTING FAILURE CODE [DK5BKA]
FAILURE CODE [DK5BKA]

Action Code Failure Code Controller Code Defective bucket EPC lever potentiometer system
Trouble
E03 DK5BKA WRK (Main circuit discontinuity or ground fault)
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.
tion

defective contact) Wiring harness between L71 (Female) 7 -
L29 (Female) 3
Possible Causes fault
and Standard Val- Between L71 (Female) 7 - body Resistance 1 MΩ and above
ues 1) Turn starting switch OFF. 2) Disconnect connector L29.
3 Defective potentiometer 5) Set lever to neutral position.
1) Turn starting switch OFF. 2) Disconnect connectors L71.
Defective work equip- 3) Connect T-adapter. 4) Turn starting switch ON.
4 5) Set lever to neutral position.
ment controller
20-536 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5BKY]
FAILURE CODE [DK5BKY]

Action Code Failure Code Controller Code Defective bucket EPC lever potentiometer sys-
Trouble
E03 DK5BKY WRK tem (Main circuit shorted)
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.
tion

Wiring harness ground 4) Turn starting switch ON.
1
fault
Between L71 (Female) 7/L29 (Female) 3 Voltage 1 V and below
and Standard Val-
ues Between L71 (Female) 7 - K Voltage 1 V and below
ment controller
WA380-5 20-537
(10)
TROUBLESHOOTING FAILURE CODE [DK5BL8]
FAILURE CODE [DK5BL8]

Action Code Failure Code Controller Code Defective input signal for bucket EPC lever potentiometer
Trouble system (Displacement of main and sub circuit).
E03 DK5BL8 WRK
Description of • The input signal for the bucket EPC lever potentiometer system (main and sub circuit) is not coincided.
Trouble
Controller • Turns off the bucket EPC solenoid output and the bucket EPC lever magnet detent output.
Reaction
Related • Can be checked with the monitoring function (Codes: 42002 and 42003).
Information

Between L29
3-1 Lever = Full stroke at the tilt side Voltage 3.9 - 4.4 V
Defective potentiometer
1 ★ Defective installation Lever = Full stroke at the dump side Voltage 0.6 - 1.1 V
(Loose and play) Lever = Neutral Voltage 2.4 - 2.6 V
Between L29
2-1 Lever = Full stroke at the tilt side Voltage 0.6 - 1.1 V
Lever = Full stroke at the dump side Voltage 3.9 - 4.4 V
1) Turn starting switch ON. 2) Disconnect connectors L71 and L29.
Possible Causes and 3) Connect T-adapter.
Standard Values Wiring harness discontinuity Wiring harness between L71 (Female) 7 - L29
2 (Disconnection or defective Resistance 1 Ω and below
(Female) 3
contact)

Between L71
7-K Lever = Full stroke at the tilt side Voltage 3.9 - 4.4 V
3 Defective work equipment
controller Lever = Full stroke at the dump side Voltage 0.6 - 1.1 V
Between L71 Lever = Full stroke at the tilt side Voltage 0.6 - 1.1 V
1-K
Lever = Full stroke at the dump side Voltage 3.9 - 4.4 V
20-538 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5CKA]
FAILURE CODE [DK5CKA]

Action Code Failure Code Controller Code Defective bucket EPC lever potentiometer sys-
Trouble
E03 DK5CKA WRK tem (Sub circuit discontinuity or ground fault)
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.
tion

defective contact) Wiring harness between L71 (Female) 1 -
L29 (Female) 2
Wiring harness ground 2) Disconnect connectors L71 and L29.
fault
Between L71 (Female) 1 - body Resistance 1 MΩ and above
Possible Causes
WA380-5 20-539
(10)
TROUBLESHOOTING FAILURE CODE [DK5CKY]
FAILURE CODE [DK5CKY]

Action Code Failure Code Controller Code Defective bucket EPC lever potentiometer system
Trouble
E03 DK5CKY WRK (Short sub circuit)
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
Information

Electric power supply 3) Connect T-adapter.
shorted to harness
Possible Causes Between L71 (Female) 1/L29 (Female) 2
ues
ment controller
Between L71 1 - K (Lever neutral) Voltage 2.4 - 2.6 V
20-540 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5DKA]
FAILURE CODE [DK5DKA]

Action Code Failure Code Controller Code Defective 3rd valve lever potentiometer system
Trouble
E03 DK5DKA WRK (Main circuit discontinuity or ground fault)
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.
Information

defective contact) Wiring harness between L71 (Female) J-

Possible Causes Between L71 (Female) J - body Resistance 1 MΩ and above

ment controller
Between L30 J - K (Lever neutral) Voltage 2.4 - 2.6 V
WA380-5 20-541
(10)
TROUBLESHOOTING FAILURE CODE [DK5DKY]
FAILURE CODE [DK5DKY]

Action Code Failure Code Controller Code Defective 3rd valve lever potentiometer system
Trouble
E03 DK5DKY WRK (Main circuit short circuit)
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
Information

Defective harness hot 2) Disconnect connectors L71 and L30.
tric power supply har-
Possible Causes ness) Between L71 (Female) J/L30 (Female) 3
and Standard Val- - body Voltage 1 V and below
ues
ment controller
Between L71 J - K Voltage 2.4 - 2.6 V
20-542 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5DL8]
FAILURE CODE [DK5DL8]

Action Code Failure Code Controller Code Defective 3rd valve EPC lever potentiometer
Trouble system input signal (Displacement of main and
E03 DK5DL8 WRK sub circuit)
Description Of • The input signal for the 3rd EPC lever potentiometer 2 systems (Main and sub circuit) is not coincided.
Trouble
Controller Reaction • Turns off the 3rd valve EPC solenoid output and the 3rd EPC lever magnet detent output.
Related • Can be checked with the monitoring function (Codes: 42006 and 42007).
Information

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
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

Possible Causes 3) Connect T-adapter. 4) Turn starting switch ON.
and Standard Val-
ues Wiring harness disconti-
2 nuity (Disconnection or Wiring harness between L71 (Female) J - L30 Resistance 1 Ω and below
(Female) 3
defective contact)
Wiring harness between L71 (Female) D - L30
(Female) 2
Lever = Full stroke at the exten-
L71 J - K sion 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 = 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]
FAILURE CODE [DK5EKA]

Action Code Failure Code Controller Code Defective 3rd valve EPC lever potentiometer system
Trouble
E03 DK5EKA WRK (Sub circuit discontinuity or ground fault)
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
Information

defective contact) Wiring harness between L71 (Female) D -

Possible Causes Between L71 (Female) D - body Resistance 1 MΩ and above

ment controller
Between L71 D - K Voltage 2.4 - 2.6 V
20-544 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5EKY]
FAILURE CODE [DK5EKY]

Action Code Failure Code Controller Code Defective 3rd valve EPC lever potentiometer
Trouble
E03 DK5EKY WRK system (Short sub circuit)
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.
Information

Defective harness hot 2) Disconnect connectors L71 and L30.
1 tric power supply har- 4) Turn starting switch ON.
Possible Causes ness) Between L71 (Female) D/L30 (Female) 2 Voltage 1 V and below
ues
Between L71 D - K Voltage 2.4 - 2.6 V
WA380-5 20-545
(10)
TROUBLESHOOTING FAILURE CODE [DK5FKA]
FAILURE CODE [DK5FKA]

Action Code Failure Code Controller Code Defective joystick steering EPC lever potenti-
Trouble ometer system (Main circuit discontinuity or
E03 DK5FKA WRK ground fault)
Description Of • The joystick steering EPC lever potentiometer signal system is disconnected (Main circuit discontinuity or
• Turns off the joystick steering EPC solenoid output.
Controller Reaction • Stops the joystick steering EPC lever magnet detent output.
Effect on Machine • The joystick lever steering cannot be operated.
Information

defective contact) Wiring harness between L71 (Female) 9 - Resistance 1 Ω and below
L34 (Female) 3
2
fault
Between L71 (Female) 9, L34 (Female) 3
and Standard Val-
ment controller
20-546 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5FKY]
FAILURE CODE [DK5FKY]

Trouble
E03 DK5FKY WRK ometer system (Main circuit shorted)
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

Wiring harness discontinu- 2) Disconnect connectors L71 and L34.
1 ity (Disconnection or defec- 3) Connect T-adapter.
tive contact) Wiring harness between L71 (Female)
9 - L34 (Female) 3
Possible Causes Wiring harness hot short cir- 3) Connect T-adapter.
and Standard 2 cuit (Electric power supply 4) Turn starting switch ON.
Values harness is contacted)
9/L34 (Female) 3 - body
Defective work equipment 3) Connect T-adapter.
3 controller 4) Turn starting switch ON.
WA380-5 20-547
(10)
TROUBLESHOOTING FAILURE CODE [DK5FKM]
FAILURE CODE [DK5FKM]

Trouble Joystick steering EPC lever neutral system caution
E00 DK5FKM WRK
Description Of • The joystick steering EPC lever neutral operation is abnormal.
Trouble
Controller • Turns off the joystick steering EPC solenoid output.
Reaction
Effect on Machine • The steering cannot be operated by the joystick lever.
Related
Information —
20-548 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5FL8]
FAILURE CODE [DK5FL8]

Trouble ometer system input signal (Deviation of posi-
E03 DK5FL8 WRK tional signals of main and sub circuits)
Description Of • Input signals of the joystick steering EPC lever potentiometer 2 systems (Main and sub circuits) are not identi-
Trouble cal.
Controller Reaction • Stops joystick steering EPC solenoid output.
• The steering cannot be operated by joystick.
Effect on Machine
• It is operable by using the handle in the handle mode.
Related • Can be checked with the monitoring function (Code: 42004 and 42005).
Information

Between L34
3-1 Lever = left (Full stroke) Voltage 1.1 - 1.5 V
Defective potentiometer
1 ★ Defective installa- Lever = right (Full stroke) Voltage 3.5 - 4.0 V
Between L34
2-1 Lever = left (Full stroke) Voltage 3.5 - 4.0 V
Lever = right (Full stroke) Voltage 1.1 - 1.5 V
Possible Causes 1) Turn starting switch ON. 2) Disconnect connectors L71 and L34.
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

Between L71
9-K Lever = left (Full stroke) Voltage 1.1 - 1.5 V
ment controller Lever = right (Full stroke) Voltage 3.5 - 4.0 V
Between L71
3-K Lever = left (Full stroke) Voltage 3.5 - 4.0 V
Lever = right (Full stroke) Voltage 1.1 - 1.5 V
WA380-5 20-549
(10)
TROUBLESHOOTING FAILURE CODE [DK5GKA]
FAILURE CODE [DK5GKA]

Action Code Failure Code Controller Code Defective joystick steering EPC lever potentiometer
Trouble system (Disconnection or ground fault of sub cir-
E03 DK5GKA WRK cuit)
Description Of • The joystick steering EPC lever potentiometer (Sub) signal system is disconnected (Disconnection or ground
Trouble fault of sub circuit).
Controller • Stops joystick steering EPC solenoid output.
Reaction
Effect on Machine • Steering cannot be operated by using the joystick.
Related • Can be checked with the monitoring function (Code 42005).
Information

defective contact) Between L71 (Female) 3, L34 (Female) 2
- body
2 fault
Between L71 (Female) 3, L34 (Female) 2
Possible Causes - body Resistance 1 Ω and below
and Standard Val-
ment controller
20-550 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DK5GKY]
FAILURE CODE [DK5GKY]

Trouble
E03 DK5GKY WRK ometer system (Sub circuit short circuit)
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

Wiring harness discontinu- 2) Disconnect connectors L71 and L34.
1 ity (Disconnection or defec- 3) Connect T-adapter.
tive contact) Wiring harness between L71 (Female)
3 - L34 (Female) 2
Possible Causes
2 Wiring harness hot-short 4) Turn starting switch ON.
Values
3/L34 (Female) 2 - body
Defective work equipment 3) Connect T-adapter.
3 controller 4) Turn starting switch ON.
WA380-5 20-551
(10)
TROUBLESHOOTING FAILURE CODE [DKAOKA]
FAILURE CODE [DKAOKA]

Action Code Failure Code Controller Code Defective lift arm angle sensor system (Disconnection or
Trouble ground fault)
E01 DKAOKA WRK
Description Of • Disconnection or ground fault of lift arm angle signal system and power supply system disconnection.
Trouble
• Controls the voltage value of the lift arm EPC potentiometer signal as input voltage.
Controller Reaction • Cancels the remote positioner function.
• Cancels semi-auto excavation function.
Effect on Machine • The remote positioner and the semi-auto excavation function cannot operate.
Related Information • Can be checked with the monitoring function (Code: 06002).

1) Turn starting switch OFF. 2) Disconnect connectors L71 and F18. 3) Connect T-adapter.
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)
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)

Possible Causes and 4) Turn starting switch ON.
Between F18 C - A
Standard Values
Voltage 4.75 - 5.25 V
3 Defective boom 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
Between F18 C - A Resistance 4 - 6 kΩ
Between L71 L - body The whole gamut Voltage 4.75 - 5.25 V
Defective work equipment con-
4 At the time of the boom maxi-
troller 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
20-552 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DKAOKY]
FAILURE CODE [DKAOKY]

Trouble Defective lift arm angle sensor system (Short circuit)
E01 DKAOKY WRK
Description Of • Short circuit of the lift arm angle signal system and the GND system disconnection.
Trouble
• Controls the voltage value of the lift arm EPC potentiometer signal as input voltage.
Controller • Cancels the remote positioner function.
Reaction • Cancels the semi-auto excavation function.
Effect on Machine • The remote positioner and the semi-auto excavation function cannot operate.

Information

Defective wiring harness short 4) Turn starting switch ON.
1 circuit (The signal harness con-
B - body
tacts the power supply harness) Wiring harness between L71 (Female) 8, F18 (Female)
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
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
Between F18 C - A Resistance 4 - 6 kΩ
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
At the time of the boom maxi- Voltage
1.0 - 2.0 V
mum lowering
WA380-5 20-553
(10)
TROUBLESHOOTING FAILURE CODE [DLE2LC]
FAILURE CODE [DLE2LC]

Trouble Defective engine speed sensor system
E01 DLE2LC WRK
Description Of • The engine speed sensor system ground fault prevents the engine speed signal input.
Trouble
Controller • Cannot detect engine speed (Recognizes engine speed as 2000 rpm).
Reaction
Effect on Machine • Work equipment feeling decreases.
Information

2) Disconnect connectors L72 and F62.
and Standard Val- Wiring harness discontinuity
ues 1 (Disconnection or defective Wiring harness between L72 (Female) 0 - L62
Resistance 1 Ω and
contact) (Female) 9 below
★ When the transmission controller does not detect "Defective engine speed
sensor" (Failure code: DLE2KA and DLE2LC)
20-554 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DLT3LC]
FAILURE CODE [DLT3LC]

Action Code Failure Code Controller Code Defective transmission output axis speed sensor
Trouble
E03 DLT3LC WRK system (Disconnected)
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.
Information

and Standard Val- Wiring harness discontinuity
ues 1 (Disconnection or defective Wiring harness between L72 (Female) J - L62
Resistance
1 Ω and
contact) (Female) I below
★ When the transmission controller does not detect "Defective engine speed
sensor" (Failure code: DLT3KA)
WA380-5 20-555
(10)
TROUBLESHOOTING FAILURE CODE [DUM1KB]
FAILURE CODE [DUM1KB]

Trouble Remote positioner RAISE lamp system ground fault
E03 DUM1KB WRK
Description Of • The remote positioner RAISE lamp system ground fault prevents output to the indicator lamp.
Trouble
Controller • No reaction.
Reaction
Effect on Machine • The remote positioner RAISE indicator lamp cannot be turned on.
Information

Defective remote 2) Disconnect connector S13.
1 positioner RAISE 3) Connect T-adapter.
indicator lamp
Between S13 (Male) 5 - 6 Resistance Approx. 20 Ω
Possible Causes 2 ground fault
and Standard Wiring harness between L73 (Female) 8, S13 (Female) 5 -
body Resistance 1 MΩ and above
Values
Defective work 4) Turn starting switch ON.
3 equipment control-
When the remote positioner
ler RAISE lamp is ON. Voltage 17 - 30 V
When the remote positioner Voltage 1 V and below
RAISE lamp is OFF.
20-556 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DUM2KB]
FAILURE CODE [DUM2KB]

Action Code Failure Code Controller Code Remote positioner LOWER lamp system ground
Trouble
E03 DUM2KB WRK fault
Description Of • The remote positioner LOWER lamp system ground fault prevents output to the indicator lamp.
Trouble
Reaction
Effect on Machine • The remote positioner LOWER indicator lamp cannot be turned on.
Information

Defective remote 2) Disconnect connector S14.
1 positioner LOWER 3) Connect T-adapter.
indicator lamp
Between S14 (Male) 5 - 6 Resistance Approx. 20 Ω
Possible Causes 2 ground fault
and Standard Wiring harness between L73 (Female) H, S14 (Female) 5 -
Values
2) Disconnect connector SL73.
Defective work 4) Turn starting switch ON.
3 equipment control-
When the remote positioner
ler LOWER lamp is ON. Voltage 17 - 30 V
When the remote positioner Voltage 1 V and below
LOWER lamp is OFF.
WA380-5 20-557
(10)
TROUBLESHOOTING FAILURE CODE [DW4PKA]
FAILURE CODE [DW4PKA]

Trouble Disconnected lift arm RAISE EPC solenoid system
E03 DW4PKA WRK
Description Of • The lift arm RAISE EPC solenoid system disconnection 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.
Information

Defective lift arm 3) Connect T-adapter.
1 RAISE EPC sole-
noid Between F20 (Male) 1 - 2 Resistance 9 - 10.2 Ω
Possible Causes
and Standard Wiring harness dis- 2) Disconnect connectors L73 and F20.
Values continuity (Discon- 3) Connect T-adapter.
2 nection or Wiring harness between L73 (Female) 6 - F20 (Female) 1 Resistance 1 Ω and below
defective contact)
Wiring harness between L73 (Female) 3 - F20 (Female) 2 Resistance 1 Ω and below
Defective work 2) Disconnect connector L73.
3 equipment control- 3) Connect T-adapter.
ler 4) Turn starting switch ON.
Between L73 6 - 3 Resistance 9 - 10.2 Ω
20-558 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4PKB]
FAILURE CODE [DW4PKB]

Action Code Failure Code Controller Code Lift arm RAISE EPC solenoid system ground
Trouble
E03 DW4PKB WRK fault
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.
Information

Defective lift arm 2) Disconnect connector F20.
1 RAISE EPC sole- 3) Connect T-adapter.
noid
Between F20 (Male) 1 - 2 Resistance 9 - 10.2 Ω

Possible Causes 2) Disconnect connectors L73 and F20.
and Standard ground fault or
2 defective short cir- 3) Connect T-adapter.
Values
cuit Wiring harness between L73 (Female) 6 - body Resistance 1 MΩ and above
Between L73 6 - 3 Resistance 9 - 10.2 Ω
WA380-5 20-559
(10)
TROUBLESHOOTING FAILURE CODE [DW4QKA]
FAILURE CODE [DW4QKA]

Trouble Disconnected lift arm LOWER EPC solenoid system
E03 DW4QKA WRK
Description Of • The lift arm LOWER EPC solenoid system disconnection 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.
Information

1 LOWER EPC sole-
Possible Causes
2 nection or Wiring harness between L73 (Female) F - F21 (Female) 1 Resistance 1 Ω and below
defective contact)
Between L73 F - 3 Resistance 9 - 10.2 Ω
20-560 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4QKB]
FAILURE CODE [DW4QKB]

Action Code Failure Code Controller Code Lift arm LOWER EPC solenoid system ground
Trouble
E03 DW4QKB WRK fault
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.
Information

Defective lift arm 2) Disconnect connector F21.
1 LOWER EPC sole- 3) Connect T-adapter.
noid

and Standard ground fault or
2 defective short cir- 3) Connect T-adapter.
Values
cuit Wiring harness between L73 (Female) F - body Resistance 1 MΩ and above
Between L73 F - 3 Resistance 9 - 10.2 Ω
WA380-5 20-561
(10)
TROUBLESHOOTING FAILURE CODE [DW4RKA]
FAILURE CODE [DW4RKA]

Trouble Disconnected bucket TILT EPC solenoid system
E03 DW4RKA WRK
Description Of • The bucket TILT EPC solenoid system disconnection prevents output to the lift arm bucket TILT EPC solenoid.
Trouble
Controller • Stops the output to the bucket TILT EPC solenoid.
Reaction • Stops the output to the bucket TILT detent.
Effect on Machine • The bucket TILT cannot move.
Information

Defective bucket 3) Insert and connect T-adapter.
1 TILT EPC solenoid
2 nection or Wiring harness between L73 (Female) 5 - F22 (Female) 1 Resistance 1 Ω and below
defective contact)
ler
Between L73 (Female) 5 - 3 Resistance 9 - 10.2 Ω
20-562 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4RKB]
FAILURE CODE [DW4RKB]

Trouble Bucket TILT EPC solenoid system ground fault
E03 DW4RKB WRK
Description Of • The bucket TILT EPC solenoid system ground fault prevents output to the bucket TILT EPC solenoid.
Trouble
Controller • Stops the output to the bucket TILT EPC solenoid.
Reaction • Stops the output to the bucket TILT detent.
Effect on Machine • The bucket TILT cannot move.
Information

Defective bucket 2) Disconnect connector F22.
1 TILT EPC solenoid 3) Insert and connect T-adapter.
Possible Causes Wiring harness 1) Turn starting switch OFF.
and Standard ground fault and 2) Disconnect connector L73 and F22.
Values 2 defective short cir- 3) Connect T-adapter.
cuit Wiring harness between L73 (Female) 5 - body Resistance 1 MΩ and above
ler
Between L73 (Female) 5 - 3 Resistance 9 - 10.2 Ω
WA380-5 20-563
(10)
TROUBLESHOOTING FAILURE CODE [DW4SKA]
FAILURE CODE [DW4SKA]

Trouble Bucket DUMP EPC solenoid system disconnection
E03 DW4SKA WRK
Description Of • The bucket DUMP EPC solenoid system disconnection prevents output to the bucket DUMP EPC solenoid.
Trouble
Controller • Stops the output to the bucket DUMP EPC solenoid.
Reaction
Effect on Machine • The bucket DUMP cannot move.
Information

Defective bucket 3) Connect T-adapter.
1 DUMP EPC sole-
and Standard Wiring harness dis- 3) Connect T-adapter.
Values continuity (Discon-
2 nection or Wiring harness between L73 (Female) E - F23 (Female) 1 Resistance 1 Ω and below
defective contact) Wiring harness between L73 (Female) E - body Resistance 1 MΩ and above
ler
Between L73 (Female) E - 3 Resistance 9 - 10.2 Ω
20-564 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DW4SKB]
FAILURE CODE [DW4SKB]

Action Code Failure Code Controller Code Bucket DUMP EPC solenoid system ground
Trouble
E03 DW4SKB WRK fault
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.
Information

Defective bucket 2) Disconnect connector F23.
1 DUMP EPC sole- 3) Connect T-adapter.
noid
cuit Wiring harness between L73 (Female) E - body Resistance 1 MΩ and above
ler
Between L73 (Female) E - 3 Resistance 9 - 10.2 Ω
WA380-5 20-565
(10)
TROUBLESHOOTING FAILURE CODE [DWM1KA]
FAILURE CODE [DWM1KA]

Action Code Failure Code Controller Code Work equipment neutral lock solenoid system dis-
Trouble
E01 DWM1KA WRK connection
Description Of • Work equipment neutral lock solenoid power supply system is disconnected.
Trouble
Reaction
Effect on Machine • Normal operation is possible (Does not affect the lock lever).
Related
Information —

Defective neutral lock 2) Disconnect connector F26.
Between F26 (Male) 1 - 2 Resistance 35 - 45 Ω
And Standard Wiring harness discon- 3) Connect T-adapter.
Values 2 tinuity (Disconnection
Wiring harness between L73 (Female) R - F26
or defective contact) (Female) 1 Resistance 1 Ω or below
Wiring harness between F26 (Female) 2 - body Resistance 1 Ω or below

3 ment controller 3) Connect T-adapter
Between L73 (Female) R - body Resistance 1 MΩ and above
20-566 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DWM1KB]
FAILURE CODE [DWM1KB]

Action Code Failure Code Controller Code Work equipment neutral lock solenoid system
Trouble
E01 DWM1KB WRK ground fault
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

Defective neutral 4) Connect the connector.
1 lock solenoid 5) Turn starting switch ON.
(Ground fault)
Between F26 (Male) 1 - 2 Resistance 35 - 45 Ω
Possible Causes Between F26 (Male) 1 - body Resistance 1 MΩ and above

Values Wiring harness 2) Disconnect connectors L73 and F26.
ground fault or 3) Connect T-adapter.
2 defective short cir-
cuit Wiring harness between L73 (Female) R,F26 (Female) 1 - Resistance 1 MΩ and above
body
ler
Between L73 (Female) R - body Resistance 1 MΩ and above
WA380-5 20-567
(10)
TROUBLESHOOTING FAILURE CODE [DWN6KA]
FAILURE CODE [DWN6KA]

Trouble Lift arm RAISE magnet detent system disconnection
E01 DWN6KA WRK
Description Of • The detent cannot be controlled due to the lift arm RAISE magnet detent system disconnection.
Trouble
• Stops output to the magnet detent solenoid.
Controller • Stops the remote RAISE function.
Reaction
• Stops the output of the remote positioner RAISE lamp.
Effect on Machine • The detent does not work but normal operation is possible.
Information

2) Disconnect connector L26E.
1 RAISE magnet
detent Between L26E (Male) 1 - 2 Resistance 35 - 45 Ω
Between L26E - body Resistance 1 MΩ and above
Wiring harness dis- 2) Disconnect connectors L73 and L26E.
continuity (Discon- 3) Connect T-adapter.
2 nection or
Possible Causes defective contact) Wiring harness between L73 (Female) G - L26E (Female) Resistance 1 MΩ and below
and Standard 1
Wiring harness between L73 (Female) G - L26E (Female)
1 Resistance 1 Ω and below
Defective work
3 equipment control- 1) Turn starting switch OFF.
ler 2) Disconnect connector L73.
Lever neutral Voltage 1 V and below
Between L73 G - body
Lever maximum raise position Voltage 17 - 30 V
20-568 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DWN6KB]
FAILURE CODE [DWN6KB]

Trouble Lift arm RAISE magnet detent system ground fault
E01 DWN6KB WRK
Description Of • The detent cannot be controlled due to the lift arm RAISE magnet detent system ground fault.
Trouble
Controller • Stops the remote RAISE function.
Reaction
• Stops the output of the remote positioner RAISE lamp.
Effect on Machine • The detent does not work but normal operation is possible.
Information

1 RAISE magnet
detent Between L26E (Male) 1 - 2 Resistance 35 - 45 Ω
Wiring harness between L26E (Male) 1 - body Resistance 1 MΩ and above
and Standard Wiring harness 2) Disconnect connectors L73 and L26E.
Values ground fault (Dis- 3) Connect T-adapter.
2 connection or
defective contact) Wiring harness between L73 (Female) G,L26E (Female) 1
- body
ler
Between L73 (Female) G - body Resistance 35 - 45 Ω
WA380-5 20-569
(10)

Trouble Lift arm FLOATING magnet detent system disconnection
E01 DWN7KA WRK
Description Of • The detent cannot be controlled due to the lift arm FLOATING magnet detent system disconnection.
Trouble
Controller • Stops the remote FLOATING function.
Reaction
• Stops the output of the remote positioner FLOATING lamp.
Effect on • The detent does not work but normal operation is possible.
Machine
Information

1 FLOATING magnet
detent Between L27 (Male) 1 - 2 Resistance 35 - 45 Ω
Between L27 - body Resistance 1 MΩ and above
Possible Causes Wiring harness dis- 1) Turn starting switch OFF.

and Standard continuity (Discon- 2) Disconnect connectors L73 and L27.
2 nection or 3) Connect T-adapter.
Values
defective contact) Wiring harness between L73 (Female) Q - L27 (Female) 1 Resistance 1 Ω and below

Defective work 3) Connect T-adapter.
3 equipment control- 4) Turn starting switch ON.
ler Lever neutral Voltage 1 V and below
Between L73 Q - body
Lever floating position Voltage 17 - 30 V
20-570 WA380-5
(10)

Trouble Lift arm FLOATING magnet detent system ground fault
E01 DWN7KB WRK
Description of • The detent cannot be controlled due to the lift arm FLOATING magnet system ground fault.
Trouble
Controller • Stops the remote FLOATING function.
Reaction
• Stops the output of the remote positioner FLOATING lamp.
Machine
Information

1 FLOATING magnet
detent Between L27 (Male) 1 - 2 Resistance 35 - 45 Ω
Wiring harness between L27 (Male) 1 - body Resistance 1 MΩ and above
and Standard Wiring harness 2) Disconnect connectors L73 and L27.
2 connection or
defective contact) Wiring harness between L73 (Female) Q,L27 (Female) 1 - Resistance 1 Ω and above
body
WA380-5 20-571
(10)

Trouble Bucket TILT magnet detent system disconnection
E01 DWN8KA WRK
Description of • The detent cannot be controlled due to the bucket TILT magnet detent system disconnection.
Trouble
Controller • Stops the remote bucket TILT function.
Reaction
• Stops the output of the remote positioner bucket TILT lamp.
Machine
Information

1 TILT magnet detent
Between L25E (Male) 1 - 2 Resistance 35 - 45 Ω
Between L25E - body Resistance 1 MΩ and above
Possible Causes Wiring harness dis- 2) Disconnect connectors L73 and L25E.
and Standard continuity (Discon- 3) Connect T-adapter.
2 nection or
Values
defective contact) Wiring harness between L73 (Female) [ - L25E (Female) Resistance 1 Ω and below
1
Defective work 3) Connect T-adapter.
3 equipment control- 4) Turn starting switch ON.
ler
Lever neutral Voltage 1 V and below
Between L73 [ - body
Lever tilt position Voltage 17 - 30 V
20-572 WA380-5
(10)

Action Code Failure Code Controller Code Bucket TILT magnet detent system failure (Power supply
Trouble
E01 DWN8KB WRK system ground fault)
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.
Controller • Stops the remote bucket TILT function.
Reaction
• Stops the output of the remote positioner bucket TILT lamp.
Machine
Information

1 TILT magnet detent
Between L25E (Male) 1 - 2 Resistance 35 - 45 Ω
Wiring harness between L25E (Male) 1 - body Resistance 1 MΩ and above
and Standard Wiring harness 2) Disconnect connectors L73 and L25E.
2 connection or
defective contact) Wiring harness between L73 (Female) [,L25E (Female) 1 Resistance 1 Ω and above
- body
Defective work 2) Disconnect connector L25E.
ler
WA380-5 20-573
(10)
TROUBLESHOOTING FAILURE CODE [DXHJKA]
FAILURE CODE [DXHJKA]

Trouble 3rd valve extension EPC solenoid system disconnection
E03 DXHJKA WRK
Description Of • 3rd valve extension EPC solenoid system disconnection prevents output to the 3rd valve EPC solenoid.
Trouble
Controller Reac- • Stops output to the 3rd valve extension EPC solenoid.
tion
Effect on • The 3rd valve cannot extend.
Machine
Related Infor- • Can be checked with the monitoring function (Code: 41906).
mation

Defective 3rd valve 3) Connect T-adapter.
1 extension EPC
solenoid Between F24 (Male) 1 - 2 Resistance 9 - 10.2 Ω
and Standard Wiring harness dis- 2) Disconnect connector L73 and F24.
2 nection or
defective contact) Wiring harness between L73 (Female) O - F24 (Female) 1 Resistance 1 Ω and below
Wiring harness between L73 (Female) C - F24 (Female) 2 Resistance 1 Ω and below
ler
Between L73 (Female) O - C Resistance 9 - 10.2 Ω
20-574 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXHJKB]
FAILURE CODE [DXHJKB]

Trouble 3rd valve extension EPC solenoid system ground fault
E03 DXHJKB WRK
Description Of • 3rd valve extension EPC solenoid system ground fault prevents output to the 3rd valve EPC solenoid.
Trouble
Controller • Stops output to the 3rd valve extension EPC solenoid.
Reaction
Effect on • The 3rd valve cannot extend.
Machine
Information

Defective 3rd valve 2) Disconnect connector F24.
1 extension EPC 3) Connect T-adapter.
solenoid
cuit Wiring harness between L73 (Female) O - body Resistance 1 MΩ and above
ler
Between L73 (Female) O - C Resistance 9 - 10.2 Ω
WA380-5 20-575
(10)
TROUBLESHOOTING FAILURE CODE [DXHKKA]
FAILURE CODE [DXHKKA]

Trouble 3rd valve retraction EPC solenoid system disconnection
E03 DXHKKA WRK
Description Of • 3rd valve retraction EPC solenoid system disconnection prevents output to the 3rd valve EPC solenoid.
Trouble
Controller • Stops output to the 3rd valve retraction EPC solenoid.
Reaction
Effect on • The 3rd valve cannot retract.
Machine
Information

Defective 3rd valve 3) Connect T-adapter.
1 retraction EPC
solenoid Between F25 (Male) 1 - 2 Resistance 9 - 10.2 Ω
and Standard Wiring harness dis- 2) Disconnect connector L73 and F25.
2 nection or
defective contact) Wiring harness between L73 (Female) Y - F20 (Female) 1 Resistance 1 Ω and below
Wiring harness between L73 (Female) C - F25 (Female) 2 Resistance 1 Ω and below
ler
Between L73 (Female) Y - C Resistance 9 - 10.2 Ω
20-576 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DXHKKB]
FAILURE CODE [DXHKKB]

Trouble 3rd valve retraction EPC solenoid system ground fault
E03 DXHKKB WRK
Description Of • 3rd valve retraction EPC solenoid system ground fault prevents output to the 3rd valve EPC solenoid.
Trouble
Controller • Stops output to the 3rd valve retraction EPC solenoid.
Reaction
Effect on • The 3rd valve cannot retracted.
Machine
Information

Defective 3rd valve 2) Disconnect connector F25.
1 retraction EPC 3) Connect T-adapter.
solenoid
cuit Wiring harness between L73 (Female) Y - body Resistance 1 MΩ and above
ler
Between L73 (Female) Y - 3 Resistance 9 - 10.2 Ω
WA380-5 20-577
(10)
TROUBLESHOOTING FAILURE CODE: [DXHLKA]
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.

Defective joystick steer- 3) Connect T-adapter.
1 ing right-hand EPC sole-
noid Between L36 (Male) 1 - 2 Resistance 10 - 15 Ω
Between L36 (Male) 1 - body Resistance 1 MΩ or more
Possible Causes
and Standard Wiring harness between L73 (Female) P - L36 (Female)
Values Wiring harness disconti- 1
defective contact) Wiring harness between L36 (Female) 2 - L41 (Female) Resistance 1 Ω or below
1
Wiring harness between L73 (Female) M - L41 (Female) Resistance 1 Ω or below
2
Defective work equip-
Between L73 (Female) P - L41 (Female) 1 Resistance 10 - 15 Ω
20-578 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE: [DXHLKB]
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
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.

Defective joystick steer- 2) Disconnect connector L36.
1 ing right-hand EPC sole- 3) Connect T-adapter.
noid
and Standard Wiring harness ground 3) Connect T-adapter.
Values 2
fault
Wiring harness between L73 (Female) P, L36 (Female)
1 - body Resistance 1 MΩ or more
ment controller
Between L73 (Female) P - L41 (Female) 1 Resistance 10 - 15 Ω
WA380-5 20-579
(10)
TROUBLESHOOTING FAILURE CODE: [DXHMKA]
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
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

Defective joystick steer- 3) Connect T-adapter.
1 ing left-hand EPC sole-
noid Between L35 (Male) 1 - 2 Resistance 10 - 15 Ω
Between L35 (Male) 1 - body Resistance 1 MΩ or more
and Standard
Values Wiring harness disconti- Wiring harness between L73 (Female) Z - L35 (Female) 1 Resistance 1 Ω or below
defective contact) Wiring harness between L35 (Female) 2 - L41 (Female) 3 Resistance 1 Ω or below
Wiring harness between L73 (Female) M - L41 (Female) 4 Resistance 1 Ω or below
Between L73 (Female) Z - L41 (Female) 3 Resistance 10 - 15 Ω
20-580 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE: [DXHMKB]
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-
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

Defective joystick 2) Disconnect connector L3.
1 steering left-hand EPC 3) Connect T-adapter.
solenoid
and Standard Wiring harness
Values 2 ground fault 3) Connect T-adapter.
Wiring harness between L73 (Female) Z, L35 (Female) 1 - Resistance 1 MΩ or more
body
Between L73 (Female) Z - L41 (Female) 3 Resistance 10 - 15 Ω
WA380-5 20-581
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [WRK-1]
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-
cuited or grounded lift arm lock (Work equipment lock lever) switch system or cannot be locked.
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).

Defective lift arm lock
1 switch Boom lock switch = ON Resistance 1 Ω and below
Between L13
(Male) 1 - 2 Boom lock switch = OFF 1 MΩ and
Resistance
above
2) Disconnect connectors L71, L13, and FS4.
defective contact) Between FS4 (Female) 5 - L13 (Male) 2 Resistance 1 Ω and below
Wiring harness between L13 (Female) 1 - L71 (Female)
G
Wiring harness
Values grounded or short-cir-
cuited incorrectly 3) Connect T-adapter.
★ Fuse A-5 blows in
Between L13 (Female) 1, L71 (Female) G - body Resistance 1 MΩ and
this case above
Wiring harness hot-
4 shorted incorrectly 3) Connect T-adapter.
Between L13 (Female) 1, L71 (Female) G - body Voltage 1 V and below
ment controller
Between L71 Boom lock switch = ON Voltage 1 V and below
G - body Boom lock switch = OFF Voltage 20 - 30 V
20-582 WA380-5
(10)

Troubleshooting Code Failure Code Controller Code Defective remote positioner
Trouble
WRK-2 — (WRK) RAISE setting switch system.
• The RAISE stopping position of the remote positioner cannot be set due to incorrectly disconnected
remote positioner RAISE setting switch system and hot-short.
Effect on Machine • The stopping position of the remote positioner RAISE setting cannot be set.
Related Information • Can be checked with the monitoring function (Code: 40913_D-IN-28).

Defective remote posi-
1 tioner RAISE setting Remote positioner setting switch =
switch Resistance 1 Ω and below
Between S12 RAISE
(Male) 1 - 2 Remote positioner setting switch = 1 MΩ and
Resistance
Other than above above
defective contact) Wiring harness between L72 (Female) C - S12 (Female)
Possible Causes 1 Resistance 1 Ω and below
and Standard
Wiring harness ground 3) Insert T-adapter.
3 fault or hot-shorted 4) Turn starting switch ON.
Between L72 (Female) C, S12 (Female) 1 - body Voltage 1 V and below
ment controller Remote positioner setting switch =
RAISE
(Male) C -
body Remote positioner setting switch =
Voltage 20 - 30 V
Other than above
WA380-5 20-583
(10)

Trouble
WRK-3 — (WRK) LOWER setting switch system
• The LOWER stopping position of the remote positioner cannot be set due to incorrectly disconnected
remote positioner LOWER setting switch system and hot-short.
Effect on Machine • The remote positioner LOWER stopping position cannot be set.

1 tioner LOWER setting Remote positioner setting switch =
Between S12 LOWER
(Male) 3 - 2 Remote positioner setting switch = 1 MΩ and
Resistance
Other than above above
defective contact) Wiring harness between L72 (Female) 3 - S12 (Female)
and Standard
3 Hot-shorted wiring har- 3) Insert T-adapter.
ness 4) Turn starting switch ON.
Between L72 (Female) 3 - S12 (Female) 3 Voltage 1 V and below
ment controller Remote positioner setting switch =
LOWER
(Male) 3 -
body Remote positioner setting switch =
20-584 WA380-5
(10)
WA380-5 20-585
5

Trouble RAISE selection switch system.
WRK-4 — (WRK)
• The remote positioner cannot select RAISE or cancel RAISE selection due to incorrectly disconnected,
grounded or hot-shorted remote positioner RAISE selection switch system.
Effect on Machine • The remote positioner cannot select RAISE or cancel RAISE selection.

1 tioner RAISE selection Remote positioner RAISE selection
Between S13 switch = ON
(Male) 4 - 3 Remote positioner RAISE selection 1 MΩ and
Resistance
switch = OFF above
2) Disconnect connectors L72, S13, S12, and FS3.
2 nuity (Disconnection or Wiring harness between L72 (Female) 2, S13 (Female)
defective contact) Resistance 1 Ω and below
4 - S12 (Female) 6
Wiring harness between FS3 (Female) A - S12 (Female)
Possible Causes
and Standard 2) Disconnect connectors L72, S13, and S12.
fault
Between L72 (Female) 2, S13 (Female) 4, S12 1 MΩ and
Resistance
2) Disconnect connectors L72, S13, and S12.
Hot-shorted wiring har- 3) Connect T-adapter.
ness
Between L72 (Female) 2, S13 (Female) 4, S12 Voltage 1 V and below
(Female) 6 - body
Defective work equip- 4) Turn starting switch ON.
5 ment controller
Between L72 Remote positioner ON/OFF switch = ON Voltage 1 V and below
(Female) 2 -
body Remote positioner ON/OFF switch = OFF Voltage 20 - 30 V
20-586 WA380-5
(10)
WA380-5 20-587
5

Trouble LOWER ON/OFF switch system
WRK-5 — (WRK)
• The remote positioner cannot select LOWER or cancel LOWER selection due to incorrectly disconnected,
grounded or hot-shorted remote positioner LOWER ON/OFF switch system.
Effect on Machine • The remote positioner cannot select LOWER or cancel LOWER selection.

Defective remote posi- 3) Connect T-adapter.
1 tioner LOWER ON/OFF
switch Remote positioner ON/OFF switch = ON Resistance 1 Ω and below
Between S14
(Male) 4 - 3 Remote positioner ON/OFF switch = OFF Resistance 1 MΩ and
above
2) Disconnect connectors L72, S13, S12, and FS3.
2 nuity (Disconnection or Wiring harness between L72 (Female) \ - S14 (Female)
defective contact) 4 - S12 (Female) 4 Resistance 1 Ω and below
Wiring harness between FS3 (Female) A - S12 Resistance 1 Ω and below

(Female) 5
and Standard 2) Disconnect connector L72, S13, and L72.
Values 3 Wiring harness ground 3) Connect T-adapter.
fault
Between L72 (Female) \, S14 (Female) 4, S12 1 MΩ and
Resistance
2) Disconnect connectors L72, S14, and S12.
ness
Between L72 (Female) \, S14 (Female) 4, S12 Voltage 1 V and below
(Female) 4 - body
Defective work equip- 4) Turn starting switch ON.
5 ment controller
Between L72 Remote positioner ON/OFF switch = ON Voltage 1 V and below
(Female) \ -
body Remote positioner ON/OFF switch = OFF Voltage 20 - 30 V
20-588 WA380-5
(10)
WA380-5 20-589
5
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
cylinder proximity switch system.
Effect on Machine • The bucket leveler does not function.

2) Disconnect connectors L73, F09, and L104.
Wiring harness disconti- Wiring harness between FS4 (Female) 5 - F09 (Female)
1 nuity (Disconnection or A Resistance 1 Ω and below
defective contact)
B
Wiring harness between L73 (Female) J - F09 (Female) Resistance 1 Ω and below
Wiring harness between F09 (Female) C - body Resistance 1 Ω and below

2
Wiring harness ground Between L73 (Female) J, F09 (Female) B, L104 7 - Resistance 1 MΩ and
fault body above
FS4 (Female) 5, F09 (Female) A - body 1 MΩ and
Resistance
★ Fuse A-5 blows in this case above
and Standard
Values 2) Disconnect connectors L73, F09, and L104.
ness
Between L73 (Female) J, F09 (Female) B, L104 7 - Voltage 1 V and below
body
Defective bucket cylinder
4 proximity switch 4) Turn starting switch ON.
Between F09 Bucket under level Voltage 1 V and below

B-C Bucket above level Voltage 20 - 30 V
ment controller
Between L72 Bucket under level Voltage 1 V and below
J - body Bucket above level Voltage 20 - 30 V
20-590 WA380-5
(10)
WA380-5 20-591
5
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,
grounded or short-circuited bucket cylinder full stroke detection switch system.
Effect on Machine • Semi-automatic general operation mode is not available or cannot be cancelled.

Wiring harness disconti- Wiring harness between FS4 (Female) 5 - F19 (Female)
1 nuity (Disconnection or A Resistance 1 Ω and below
defective contact)
B
Wiring harness between L73 (Female) T - F19 (Female) Resistance 1 Ω and below
Wiring harness between F19 (Female) C - body Resistance 1 Ω and below

Between L73 (Female) T, F19 (Female) B - body

Wiring harness ground 1 MΩ and
2 Resistance
fault above
FS4 (Female) 5, F19 (Female) A - body 1 MΩ and
Resistance
Possible Causes
Values 2) Disconnect connectors L73 and F19.
3 ness 4) Turn starting switch ON.
Between L73 (Female) T, F19 (Female) B - body Voltage 1 V and below
Defective bucket cylinder 3) Insert T-adapter.
4 full stroke detection 4) Turn starting switch ON.
switch
Between F19 Other than tilt stroke end Voltage 1 V and below
B-C Tilt stroke end Voltage 20 - 30 V
ment controller
Between L72 Other than tilt stroke end Voltage 1 V and below
T - body Tilt stroke end Voltage 20 - 30 V
20-592 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code Defective semi-automatic digging

Trouble HARD selection switch system
WRK-8 — (WRK)
• The semi-automatic digging HARD control is not available or the semi-automatic digging HARD mode
Description of Trouble cannot be cancelled due to incorrectly disconnected, grounded or short-circuited semi-automatic digging
HARD selection switch system.
• Semi-automatic digging HARD control is not available or the semi-automatic digging HARD mode cannot
Effect on Machine
be cancelled.

2) Disconnect connectors L73, and S15.
defective contact) Wiring harness between L73 (Female) 9 - S15 (Female)
Wiring harness between S15 (Female) 2 - body Resistance 1 Ω and below

2 Wiring harness ground 1 MΩ and
fault Between L73 (Female) 9, S15 (Female) 1 - body Resistance above
FS3 (Female) A, S15 (Female) 5 - body 1 MΩ and
Resistance
Possible Causes Hot-shorted wiring har- 3) Connect T-adapter.
3
and Standard ness 4) Turn starting switch ON.
Values
Between L73 (Female) 9, S15 (Female) 1 - body Voltage 1 V and below
Defective semi-auto- 4) Turn starting switch ON.
4
matic digging (HARD) Semi-automatic digging switch (Hard-
Between S15 ware) = ON
1-2 Semi-automatic digging switch (Hard- Voltage 20 - 30 V
ware) = Other than ON
ment controller Semi-automatic digging switch (Hard) =
Between L72 ON
9 - body Semi-automatic digging switch (Hard) = Voltage 20 - 30 V
Other than ON
WA380-5 20-593
(10)
Troubleshooting Code Failure Code Controller Code Defective semi-automatic digging

Trouble SOFT selection switch system
WRK-9 — (WRK)
• The semi-automatic digging SOFT control is not available or the semi-automatic digging HARD mode can-
Description of Trouble not be cancelled due to incorrectly disconnected, grounded or short-circuited semi-automatic digging
SOFT selection switch system.
• Semi-automatic digging SOFT control is not available or the semi-automatic digging SOFT mode cannot
Effect on Machine
be cancelled.

defective contact) Wiring harness between L73 (Female) I - S15 (Female)
Wiring harness between S15 (Female) 2 - body Resistance 1 Ω and below

2 Wiring harness ground 1 MΩ and
fault Between L73 (Female) I, S15 (Female) 3 - body Resistance above
FS3 (Female) A, S15 (Female) 5 - body 1 MΩ and
Resistance
Possible Causes Hot-shorted wiring har- 3) Connect T-adapter.
3
and Standard ness 4) Turn starting switch ON.
Values
Between L73 (Female) I, S15 (Female) 3 - body Voltage 1 V and below
Defective semi-auto- 4) Turn starting switch ON.
4 matic digging switch
(SOFT) Semi-automatic digging switch (Soft-
Between S15 ware) = ON
3-2 Semi-automatic digging switch (Soft- Voltage 20 - 30 V
ment controller Semi-automatic digging switch (Soft-
Between L72 ware) = ON
I - body Semi-automatic digging switch (Soft- Voltage 20 - 30 V
20-594 WA380-5
(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.
Effect on Machine • The joystick mode cannot be used or cancelled.

1 Defective joystick ON/
OFF switch Between L39 Joystick ON/OFF switch = ON Resistance 1 Ω and below
(Female) 4 - 1 MΩ and
3 Other than above = OFF Resistance above
2 Defective joystick N lock
switch Between L38 Left arm rest = Lock Resistance 1 Ω and below
(Female) A -
C
1 MΩ and
Other than above = OFF Resistance above
2) Disconnect connectors L71, L39, and L38.
Wiring harness between L71 (Female) M - L39 (Female) Resistance 1 Ω and below
4
Wiring harness disconti- Wiring harness between L38 (Female) A - L39 (Female)
3 nuity (Disconnection or 3 Resistance 1 Ω and below
Possible Causes defective contact)
Values 2) Disconnect connectors L71 and L38.
Between L38 (Female) A - body Voltage 20 - 30 V
Hot-shorted wiring har-
4 ness (Contacting 24 V 3) Connect T-adapter.
harness) 4) Turn starting switch ON.
Between L71 (Female) M, S04 (Female) 4 - body Voltage 1 V and below
fault 2) Disconnect connectors L71, S04, L71, L39, and L40.
5 ★ Fuse A-2 blows at
1 MΩ and
switch operation in Between L71 (Female) M, S04 (Female) 4 - body Resistance
above
this case
ment controller
Between L71 Joystick ON/OFF switch = ON Voltage 20 - 30 V
M - body Other than above Voltage 1 V and below
20-596 WA380-5
(10)
WA380-5 20-597
5
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-
stick steering speed HI/LO switch system.
Effect on Machine • The joystick steering speed slows or accelerates (Cannot be switched between HI/LO).

Defective joystick HI/LO
1 switch Between L40 Joystick ON/OFF switch = ON Resistance 1 Ω and below
(Female) 4 - 1 MΩ and
3 Other than above = OFF Resistance
above
defective contact) Wiring harness between L73 0 - L40 (Female) 4 Resistance 1 Ω and below
Between L40 (Female) 3 - body Resistance 1 Ω and below
Possible Causes 2) Disconnect connectors L73, and L40.
and Standard Hot-shorted wiring har-
Values
harness) 4) Turn starting switch ON.
Between L73 0, L40 (Female) 4 - body Voltage 1 V and below
fault 2) Disconnect connector L73, S04, L71, L40 and L40.
Between L73 0, L40 (Female) 4 - body Resistance 1 MΩ and
switch operation in above
this case
Between L73 Joystick ON/OFF switch = ON Voltage 20 - 30 V

20-598 WA380-5
(10)
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.
Effect on Machine • The joystick steering solenoid cannot be turned OFF.

Hot-shorted wiring har-
Possible Causes harness) 4) Turn starting switch ON.
and Standard
Values Between L73 (Female) 7, L41 (Female) 5 - body Voltage 1 V and below
ment controller
WA380-5 20-599
(10)
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.
• RAISE detent left turned ON.
Effect on Machine
• Normal operation is possible excluding automatic cancel of detent.

2) Disconnect connectors L73 and L26E.
Short-circuited wiring 3) Connect T-adapter.
1 harness
and Standard
Values Between L73 (Female) G, L26E (Female) 1 - body Voltage 1 V and below
ment controller 3) Connect T-adapter.
Between L73 (Female) G - body Resistance 35 - 45 Ω
20-600 WA380-5
(10)
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.
• RAISE detent left turned ON.
Effect on Machine • Normal operation is possible excluding automatic cancel of detent.

1 Short-circuited wiring 3) Connect T-adapter.
Possible Causes harness 4) Turn starting switch ON.
and Standard
Values Between L73 (Female) Q, L27 (Female) 1 - body Voltage 1 V and below
ment controller
WA380-5 20-601
(10)
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.
• TILT detent left turned ON.
Effect on Machine
• Normal operation is possible excluding automatic cancel of detent.

2) Disconnect connectors L73 and L25E.
1 harness
and Standard
Values Between L73 (Female) [, L25E (Female) 1 - body Voltage 1 V and below
20-602 WA380-5
(10)
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.
Effect on Machine • Working equipment locked even when the lock lever is free.

1
and Standard
Values Between L73 (Female) R, F26 (Female) 1 - body Voltage 1 V and below
WA380-5 20-603
(10)
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.
Effect on Machine • Lift arm raises in full speed.

and Standard
Values Between L73 (Female) 6, F20 (Female) 1 - body Voltage 1 V and below
ment controller
Between L73 (Female) 6 - body Resistance 9 - 10.2 Ω
20-604 WA380-5
(10)
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-
tem.
Effect on Machine • Lift arm lowers in full speed.

1 harness
and Standard
Values Between L73 (Female) F, F21 (Female) 1 - body Voltage 1 V and below
Between L73 (Female) F - body Resistance 9 - 10.2 Ω
WA380-5 20-605
(10)
Troubleshooting Code Failure Code Controller Code Hot short-circuited bucket TILT
WRK-19 — (WRK)
Description of Trouble • Bucket TILT EPC solenoid gets turned on due to hot short-circuited bucket TILTEPC solenoid system.
Effect on Machine • Lift arm tilts in full speed.

and Standard
Values Between L73 (Female) 5, F22 (Female) 1 - body Voltage 1 V and below
ment controller
Between L73 (Female) 5 - body Resistance 9 - 10.2 Ω
20-606 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code Hot short-circuited bucket DUMP
WRK-20 — (WRK)
Description of Trouble • Bucket DUMP EPC solenoid gets turned on due to hot short-circuited bucket DUMP EPC solenoid system.
Effect on Machine • Bucket dumps in full speed.

and Standard
Values Between L73 (Female) E, F23 (Female) 1 - body Voltage 1 V and below
ment controller
Between L73 (Female) E - body Resistance 9 - 10.2 Ω
WA380-5 20-607
(10)
Troubleshooting Code Failure Code Controller Code Hot short-circuited 3 valves

Trouble extension EPC solenoid system
WRK-21 — (WRK)
• 3 valves extension EPC solenoid gets turned on due to hot short-circuited 3 valves extension EPC solenoid
system.
Effect on Machine • 3 valves extend in full speed.

1 harness
and Standard
Values Between L73 (Female) O, F24 (Female) 1 - body Voltage 1 V and below
Between L73 (Female) O - body Resistance 9 - 10.2 Ω
20-608 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code Hot short-circuited 3 valves

Trouble retraction EPC solenoid system
WRK-22 — (WRK)
• 3 valves retraction EPC solenoid gets turned on due to hot short-circuited 3 valves retraction EPC solenoid
system.
Effect on Machine • 3 valves retract in full speed.

1 harness
and Standard
Values Between L73 (Female) Y, F25 (Female) 1 - body Voltage 1 V and below
Between L73 (Female) Y - body Resistance 9 - 10.2 Ω
WA380-5 20-609
(10)
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
right EPC solenoid system.
Effect on Machine • Steering all the way to the right is possible.

1 harness
and Standard
Values Between L73 (Female) P, L36 (Female) 1 - body Voltage 1 V and below
Between L73 (Female) P - body Resistance 10 - 15 Ω
20-610 WA380-5
(10)
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
EPC solenoid system.
Effect on Machine • Steering all the way to the left is possible.

1 harness
and Standard
Values Between L73 (Female) Z, L35 (Female) 1 - body Voltage 1 V and below
Between L73 (Female) Z - body Resistance 10 - 15 Ω
WA380-5 20-611
(10)
Troubleshooting Code Failure Code Controller Code Defective bucket positioner,

Trouble boom kick-out and FLOATING
WRK-25 — — holding function
• Bucket positioner, boom kick-out and lift arm FLOATING holding functions do not function due to proxim-
Description of Trouble ity switch and PPC detent circuit power supply system ground fault.
Effect on Machine • Bucket positioner, boom kick-out and FLOATING holding do not function.

Wiring harness ground
fault 2) Disconnect connector FS4, L104, L27S, (LL5), F9 and F10.
★ Fuse A-5 blows in
1 MΩ and
this case Between FS4 (Female) 5 - body Resistance
above
3) Disconnect relays L123, L124.
4) Connect T-adapter
Relay sub-wiring har-
Between L104 (Male) 1 - 2, 7, B - body Resistance 1 MΩ and
ness ground fault above
2
★ Fuse A-5 blows in 1 MΩ and
Between L104 (Male) 3 - 2, 7, B - body Resistance
this case above
1 MΩ and
Between L104 (Male) 6 - 2, 7, B - body Resistance above
Possible Causes
and Standard 1 MΩ and
Values Between L104 (Male) 8 - 2, 7, B - body Resistance
above
Relay ground fault
★ In case 2 items are normal
3 ★ Fuse A-5 blows in 1 MΩ and
this case Between L104 (Male) 1 - 2 Resistance above
Between L104 (Male) 6 - 7 Resistance 1 MΩ and

above
Proximity switch ground 2) Disconnect connectors F9 and F10.
fault 1. Connect T-adapter.
Between F09 (Male) A - B, C - body

4 ★ Fuse A-5 blows at 1 MΩ and
Resistance
switch operation in above
Between F10 (Male) A - B, C - body

this case 1 MΩ and
Resistance above
20-612 WA380-5
(10)
WA380-5 20-613
5

Troubleshooting Code Failure Code Controller Code Defective boom kick-out function
Trouble
WRK-26 — — and cancellation
• Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity switch
Description of Trouble system, lift arm PPC detent system and lift arm detent relay system.
Effect on Machine • Boom kick-out does not function or cannot be cancelled.

Defective lift arm detent 1) Turn starting switch OFF. 2) Disconnect connector L123. 3) Replace boom
1 relay detent relay (L123) with other relay. 4) Boom kick-out operation.
Boom kick-out functions Boom detent relay (L123) is abnormal
Boom kick-out does not function Boom detent relay (L123) is abnormal
1) Turn starting switch OFF. 2) Disconnect connector L26S. 3) Connect T-
Defective lift arm PPC adapter.
2 detent
Between L26S (Male) 1 - 2 Resistance 30 - 50 Ω
1) Turn starting switch OFF. 2) Disconnect connectors L123. 3) Replace boom
positioner proximity switch (F10) with bucket leveler proximity switch (F9).
Defective lift arm posi-4) Boom kick-out operation.
3
tioner proximity switch Boom kick-out functions Boom kick-out proximity switch (F10) is abnormal
Boom kick-out does not function Boom kick-out proximity switch (F10) is normal
1) Turn starting switch OFF. 2) Disconnect connectors FS4, L104, L26S, and F10.
Wiring harness between FS4 (Female) 5 - F10 (Female) A Resistance 1 Ω and below
B
Wiring harness between L104 (Female) 2 - F10 (Female)
Wiring harness between F10 (Female) C - body
4 nuity
Wiring harness between L104 (Female) 5 - L26S (Female)
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.
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
returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connectors L104 and F10. 3) Connect
T-adapter. 4) Turn starting switch ON.
★ 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)
WA380-5 20-615
5

Troubleshooting Code Failure Code Controller Code Defective bucket leveler function
Trouble
WRK-27 — — and cancellation
• Bucket kick-out does not function or cannot be cancelled due to defective bucket leveler proximity switch
Description of Trouble system, bucket PPC detent system and bucket detent relay system.
Effect on Machine • Bucket leveler does not function or cannot be cancelled.

Defective bucket detent 1) Turn starting switch OFF. 2) Disconnect connector L124. 3) Replace bucket
1 relay detent relay (L124) with other relay. 4) Bucket leveler operation.
Bucket leveler functions Bucket detent relay (L124) is abnormal
Bucket leveler does not function Bucket detent relay (L124) is abnormal
1) Turn starting switch OFF. 2) Disconnect connector L25S. 3) Connect T-
Defective bucket PPC adapter.
2 detent
Between L25S (Male) 1 - 2 Resistance 30 - 50 Ω
1) Turn starting switch OFF. 2) Disconnect connectors L124. 3) Replace bucket
leveler proximity switch (F9) with boom kick-out proximity switch (F09).
Defective bucket leveler 4) Bucket leveler operation.
3 positioner proximity
switch Bucket leveler functions Bucket leveler proximity switch (F09) is abnormal
Bucket leveler does not function Bucket leveler proximity switch (F09) is normal
1) Turn starting switch OFF. 2) Disconnect connectors FS4, L104, L25S, and F9.
Wiring harness between FS4 (Female) 5 - F09 (Female) A Resistance 1 Ω and below
Wiring harness disconti- B

Wiring harness between L104 (Female) 7 - F09 (Female)
and defective contact) Wiring harness between F09 (Female) C - body

4 nuity (Disconnection
Wiring harness between L104 (Female) 9 - L25S (Female)
and Standard
Values Wiring harness between L25S (Female) 2 - body Resistance 1 Ω and below
★ Bucket positioner does not function in all items
1) Turn starting switch OFF. 2) Disconnect connectors L104, F09, and FS4.
1 MΩ and
★ Bucket leveler does not function in this case (Lever Resistance above
returns to neutral)
Wiring harness ground Between L104 (Female) 9, L25S (Female) 1 and body
5 fault
1 MΩ and
returns to neutral)
Between FS4 (Female) 5, F09 (Female) A - body
1 MΩ and
returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connectors L104 and F09. 3) Connect
T-adapter. 4) Turn starting switch ON.
★ Fuse of hot-shorted circuit blows in this case
6 Hot-shorted wiring har- 1) Turn starting switch OFF. 2) Disconnect connectors L104 and L25S. 3) Con-
ness
nect T-adapter. 4) Turn starting switch ON.
Between L104 (Female) 9, L25S (Female) 1 - body
★ Bucket leveler does not function in this case (Lever Voltage 1 V and below
does not return to neutral).
20-616 WA380-5
(10)
Related cicuit diagram
WA380-5 20-617
5
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
PPC detent system.
Effect on Machine • Lift arm FLOATING holding does not function or cannot be cancelled.

Defective bucket PPC 2) Disconnect connector L27S.
detent
Possible Causes Between L27S (Male) 1 - 2 Resistance 30 - 50 Ω
Values 2) Disconnect connectors FS4 and L27S.
2 nuity (Disconnection or Wiring harness between FS4 (Female) 5 and L27S
defective contact) (Female) 1 Resistance 1 Ω and below
Wiring harness between L27S (Female) 2 and body Resistance 1 Ω and below
20-618 WA380-5
(10)
TROUBLESHOOTING OF MONITOR SYSTEM
(MON MODE)

Connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
Monitor system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
Failure code [2F00MA] Dragging of parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-722
Failure code [2G42ZG] Accumulator oil pressure (Front circuit) low . . . . . . . . . . . . . . . . . . . . . . . . . 20-724
Failure code [2G43ZG] Accumulator oil pressure (Rear brake circuit) low. . . . . . . . . . . . . . . . . . . . . 20-725
Failure code [AA1ANX] Air cleaner 1 clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-726
Failure code [AB00L6] Defective battery charging circuit (alternator terminal R signal detected
when engine stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-728
Failure code [AB00MA] Defective battery charging circuit (No alternator terminal R signal
detected, detection failure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-729
Failure code [B@BAZG] Engine oil pressure low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-730
Failure code [B@BAZK] Engine oil level low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-731
Failure code [B@BCNS] Engine coolant temperature overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-732
Failure code [B@BCZK] Alarm indicating low coolant level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-733
Failure code [B@HANS] Hydraulic oil temperature overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-734
Failure code [B@CENS] Torque converter oil temperature overheating . . . . . . . . . . . . . . . . . . . . . . . 20-735
Failure code [D182KZ] The preheater relay coil is disconnected or shirt-circuited. . . . . . . . . . . . . . 20-736
Failure code [D5ZHL6] Starting switch C (IGN "C") input failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-738
Failure code [DA80L4] Auto grease input failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-739
Failure code [DAF3KK] SW power supply (for operation) = On and NSW power supply
(For memory) is off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-740
Failure code [DAF5KP] 5V power supply output failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-742
Failure code [DAF6KP] 24V power supply output failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-744
Failure code [DAFBKM] Wrong information on model selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-746
Failure code [DAFSKQ] Wrong information on meter display selection . . . . . . . . . . . . . . . . . . . . . . . 20-747
Failure code [DAQSKR] S-NET communication failure (between monitor panel and transmission
controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-748
Failure code [DB2SKR] S-NET communication failure (between monitor panel and engine
controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-749
Failure code [DBQSKR] S-NET communication failure (Between monitor panel
and work equipment controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-750
Failure code [DB9SKR] S-NET communication failure (between monitor panel and work equipment
controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-751
Failure code [DD15LD] Monitor panel mode selector switch 1 [■] (panel SW1) input error . . . . . . 20-752
Failure code [DD16LD] Monitor panel mode selector switch 1 [◊ ] (panel SW2) input error . . . . . . 20-753
Failure code [DD17LD] The monitor panel mode selector switch 2 [<] (panel SW3) input circuit
remains closed for more than one minute . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-754
Failure code [DD18LD] Monitor panel mode selector switch 2 [>] (panel SW4) input error . . . . . . . 20-755
Failure code [DD1CLD] Sub-total switch failure [*] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-756
Failure code [DDS5L6] Decreased steering oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-758
Failure code [DDY0LD] Cancel switch failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-760
Failure code [DGE2KX] Engine coolant temperature sensor system failure . . . . . . . . . . . . . . . . . . . . 20-762
Failure code [DGE3L6] Abnormal connection of engine coolant temperature (low temperature)
sensor system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-763
Failure code [DGH2KX] Hydraulic oil temperature sensor system failure . . . . . . . . . . . . . . . . . . . . . . 20-764
Failure code [DGT1KX] Torque converter oil temperature sensor system failure . . . . . . . . . . . . . . . 20-765
Failure code [DHE4L6] Engine oil pressure sensor system failure . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-766
Failure code [DHPCKX] Bottom pressure sensor failure [*] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-768
WA380-5 20-701
(10)
TROUBLESHOOTING
Failure code [DHPDKX] Head pressure sensor failure [*] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-770

Failure code [DKA0KX] Lift arm angle sensor failure [*] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-772
Failure code [DV00KB] Short-circuited alarm buzzer output system . . . . . . . . . . . . . . . . . . . . . . . . . 20-773
Failure code [DY30ME] The emergency steering remains actuated for more than one minute . . . . 20-775
Troubleshooting Code [MON-1] The parking brake indicator lamp does not light up
when the parking brake switch is turned ON (The parking brake
indicator switch circuit suffers a ground fault). . . . . . . . . . . . . . . 20-776
Troubleshooting Code [MON-2] The brake oil pressure caution lamp does not light up
when the emergency brake is applied (Front circuit) . . . . . . . . . 20-778
Troubleshooting Code [MON-3] The brake oil pressure caution lamp does not light up
when the emergency brake is applied (Rear circuit) . . . . . . . . . . 20-779
Troubleshooting Code [MON-4] The air cleaner clogging indicator lamp does not light ON . . . . 20-780
Troubleshooting Code [MON-5] The engine hydraulic caution lamp does not light ON . . . . . . . . 20-782
Troubleshooting Code [MON-6] The engine oil level caution lamp does not light ON . . . . . . . . . 20-783
Troubleshooting Code [MON-7] The engine coolant temperature caution lamp does not
light ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-784
Troubleshooting Code [MON-8] The radiator coolant volume caution lamp does not light ON . . 20-785
Troubleshooting Code [MON-9] The hydraulic oil temperature caution lamp does not light ON . 20-786
Troubleshooting Code [MON-10] The torque converter oil temperature caution lamp does not
light ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-787
Troubleshooting Code [MON-11] The steering hydraulic caution lamp does not light ON . . . . . . . 20-788
Troubleshooting Code [MON-12] Input fault in monitor panel mode switch 1 [■] (Panel SW1) . . . 20-789
Troubleshooting Code [MON-13] Input fault in monitor panel mode switch 1 [◊ ] (Panel SW2) . . . 20-790
Troubleshooting Code [MON-14] Input fault in monitor panel mode switch 2 [<] (Panel SW3) . . . 20-791
Troubleshooting Code [MON-15] Input fault in monitor panel mode switch 2 [>] (Panel SW4) . . . 20-792
Troubleshooting Code [MON-16] Defective subtotal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-793
Troubleshooting Code [MON-17] Defective cancel switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-794
Troubleshooting Code [MON-18] Defective bottom pressure sensor (Hot short fault). . . . . . . . . . . 20-795
Troubleshooting Code [MON-19] Defective head sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-796
Troubleshooting Code [MON-20] The alarm buzzer does not sound or stop (disconnection or
short circuit with chassis ground in buzzer output system) . . . . 20-797
★ 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)

Electrical system.
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

conditioner)

A23 Yazaki 2 W-4
conditioner)
W-3

WA380-5 20-703
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

Kyoritsu
ES

21-2
AMP1722
CL5 S (W) 16 M-2
conditioner)
conditioner)
20-704 WA380-5
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
WA380-5 20-705
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
lamp)
20-706 WA380-5
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
WA380-5 20-707
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
20-708 WA380-5
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
switch)
W-3,

R13 L-1 O-1 X-6 F-2
WA380-5 20-709
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

stick)
S14 DT-T 6 N-8 I-2
stick)
20-710 WA380-5
(10)
5
20-712 WA380-5
WA380-5 20-713
5
20-714 WA380-5
5
WA380-5 20-715
5
20-716 WA380-5
5
WA380-5 20-717
5
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
MONITOR SYSTEM DIAGRAM
20-718 WA380-5
WA380-5 20-719
20-720 WA380-5
WA380-5 20-721
TROUBLESHOOTING FAILURE CODE [2F00MA]
FAILURE CODE [2F00MA]

Trouble Defective parking brake system
E00 2F00MA MON
Description of • The parking brake operating detection circuit is opened when the F or R clutch is operating (the neutralization
Trouble function does not work).
Controller • Triggers an alarm.
Reaction
Effect on • Dragging of parking brake (The parking brake remains operating).
Machine
• The monitoring function (code: 40903, D-IN-26) allows the input state (ON/OFF) of the parking brake pressure
switch to be checked.
Related • The transmission gear shift lever input signal can be checked with the monitoring function (code: 40907, D-IN-
Information 20, 21 or 22).
• The monitoring function (code: 40907, D-IN-23) allows the input state (ON/OFF) of the parking brake switch to
be checked.

2) Disconnect connector PB.SW.
3) Connect t-adapter.
Defective parking
1 brake indicator Parking brake oil pressure = 0.6 MPa Resistance 1 Ω and below
switch Between PB.SW (6.1 kg/cm2) and above
(Male) 1 - 2 Parking brake oil pressure = 0.34 MPa
(3.5 kg/cm2) and below
discontinuity 2) Disconnect connectors L54 and PB.SW.
2 (Disconnection 3) Connect t-adapter.
or defective
contact) Wiring harness between L54 (Female) 1 - PB.SW (Female) 1 Resistance 1 Ω and below
4) Start engine.
3 Defective
monitor panel Parking brake oil pressure = 0.6 MPa
Possible Causes (6.1 kg/cm2) and above Voltage 1 V and below
Between L54
and
Standard (Female) 1 - body Parking brake oil pressure = 0.34 MPa Voltage 20 - 30 V
Values (3.5 kg/cm2) and below
Between L01 Parking brake switch = ON Resistance 1 Ω and below

Defective parking (Male) 1 - 3 Parking brake switch = OFF Resistance 1 MΩ and above
4 brake switch
Between L01 Parking brake switch = ON Resistance 1 MΩ and above
(Male) 2 - 3 Parking brake switch = OFF Resistance 1 Ω and below
Between L01 At any time Resistance 1 MΩ and above
(Male) 1 - 2
2) Disconnect connector PB.PS.
Defective parking
5 brake solenoid Between PB.PS (Male) 1 - 2 Resistance 10 - 40 Ω
Between PB.PS (Female) 2 - body Resistance 1 Ω and below
Between PB.PS (Male) 1/2 - body Resistance 1 MΩ and above
20-722 WA380-5
(10)
5
TROUBLESHOOTING FAILURE CODE [2F00MA]

Parking brake oil pressure = 4.41 MPa
(45 kg/cm2) and above Resistance 1 Ω and below
Between R51
(Male) 1 -2 Parking brake oil pressure = 4.41 MPa Resistance 1 MΩ and above
Defective (45 kg/cm2) and below
6 emergency brake
Possible Causes pressure switch 1) Turn starting switch OFF.
and 2) Disconnect connector R52.
Standard 3) Connect t-adapter.
Values Parking brake oil pressure = 4.41 MPa
Between R52 (45 kg/cm2) and above
(Male) 1 - 2 Parking brake oil pressure = 4.41 MPa
(45 kg/cm2) and below Resistance 1 MΩ and above

Wiring harness 2) Disconnect connectors L01 ,L62 and PB.SW.
discontinuity 3) Connect t-adapter.
7 (Disconnection
or defective Wiring harness between L01 (Female) 2 and PB.PS (Female) 1 Resistance 1 Ω and below
contact)
Wiring harness between L01 (Female) 2 and L62 (Female) 6 Resistance 1 Ω and below
WA380-5 20-723
(10)
5
TROUBLESHOOTING FAILURE CODE [2G42ZG]
FAILURE CODE [2G42ZG]

Trouble Accumulator oil pressure (Front circuit) low
E03 2G42ZG MON
Description of • The accumulator pressure sensor (Front) circuit is opened 50 seconds after the engine started.
Trouble
Reaction
• The accumulator oil pressure (Front brake circuit) is low.
Effect on ★The front brake may be disabled.
Machine
★The parking brake may remain ON.
Related • Can be checked with the monitoring function (Code: 40902_D-IN-16).
Information

Low accumulator
oil pressure
1 —
(Front brake
circuit)
Defective brake 4) Start engine.
oil pressure
2
sensor (Front Front brake oil pressure = 5.88 MPa Resistance 1 Ω and below
brake circuit) Between R53 (Male) (60 kg/cm2) and above
Possible Causes 1-2 Front brake oil pressure = 5.88 MPa
and Resistance 1 MΩ and above
Standard (60 kg/cm2) and below
Values Wiring harness 1) Turn starting switch OFF.
discontinuity 2) Disconnect connectors L53 and R53.
or defective
contact) Wiring harness between L53 (Female) 1 and R53 (Female) 1 Resistance 1 Ω and below
Defective
4 monitor panel Front brake oil pressure = 5.88 MPa Resistance 1 Ω and below
Between L53 (60 kg/cm2) and above
(Female) 1 - body Front brake oil pressure = 5.88 MPa
(60 kg/cm2) and below
20-724 WA380-5
(10)
5
TROUBLESHOOTING FAILURE CODE [2G43ZG]
FAILURE CODE [2G43ZG]

Trouble Accumulator oil pressure (Rear brake circuit) low
E03 2G43ZG MON
Description of • The accumulator pressure sensor (Rear) circuit is opened 50 seconds after the engine started.
Trouble
Reaction
• The accumulator oil pressure (Rear brake circuit) is low.
Effect on ★The front brake may be disabled.
Machine
★The parking brake may remain ON.
Related • Can be checked with the monitoring function (Code: 40902_D-IN-17).
Information

Low accumulator
oil pressure
1 (Rear brake —
circuit)
Defective brake 4) Start engine.
oil pressure
2 sensor (Rear Rear brake oil pressure = 5.88 MPa
brake circuit) Between R54 (Male) (60 kg/cm2) and above
Possible Causes 1-2 Rear brake oil pressure = 5.88 MPa
and (60 kg/cm2) and below Resistance 1 MΩ and above
Standard
Values Wiring harness 1) Turn starting switch OFF.
discontinuity 2) Disconnect connectors L53 and R54.
or defective
contact) Wiring harness between L53 (Female) 7 - R54 (Female) 1 Resistance 1 Ω and below
4 Defective Rear brake oil pressure = 5.88 MPa (60
monitor panel Resistance 1 Ω and below
Between L53 kg/cm2) and above
(Female) 7 - body Rear brake oil pressure = 5.88 MPa (60
kg/cm2) and below Resistance 1 MΩ and above
WA380-5 20-725
(10)
5
TROUBLESHOOTING FAILURE CODE [AA1ANX]
FAILURE CODE [AA1ANX]

Trouble Air cleaner 1 clogged
E01 AA1ANX MON
Description of • The clogging sensor circuit for air cleaner is opened.
Trouble
Reaction
Effect on • Air cleaner 1 is clogged (The engine may be damaged).
Machine
Related • Can be checked with the monitoring function (Code: 40902, D-IN-20).
Information
1 Clogged air —
cleaner
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).
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.
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
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
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
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]
FAILURE CODE [AB00L6]

Action Code Failure Code Controller Code Defective battery charging circuit (Alternator terminal R signal
Trouble
E03 AB00L6 MON detected when engine stopped)
Description of • The alternator terminal R input voltage is 12 V or higher before the engine started.
Trouble
Reaction
Effect on • The engine cannot be started.
Machine • The service meter increases simply by key-on.
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
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
2) Disconnect connectors L52, ER1 and alternator terminal R.
4 Defective diode 4) Turn starting switch ON.
R24
Wiring harness between connector L52 (Female) H, ER1
(Female) 3 - alternator terminal R (E02)
20-728 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [AB00MA]
FAILURE CODE [AB00MA]

Action Code Failure Code Controller Code The battery charging circuit is out of order. (No signal from
Trouble
E03 AB00MA MON alternator R terminal, Abnormal detection)
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

Battery
1 deterioration —
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
Disconnection of 1) Starting switch OFF.

harness 2) Disconnect the connectors L52 and ER1 from the alternator R terminal.
3 (disconnection, 3) Connect a T-adaptor.
Possible Causes
and defective Harnesses among Connectors L52 (female) H, ER1 (female) 3 Resistance 1 Ω and below
Standard contact) and alternator R terminal (E02).
Values
2) Disconnect connectors L52, ER1 and alternator terminal R.
Ground fault of 3) Connect t-adapter.
4
harness
Connectors L52 (female) H, ER1 (female) 3 and alternator R
terminal (E02).
1) Starting switch OFF. 2) Disconnect the connector L52. 3) Insert a T-adaptor.
5 Defective Between L52 H and Engine start (Throttle : 1/2 or more) Voltage 27.5 - 29.5 V
monitor panel
machine body Engine stop Voltage 1 V or below
WA380-5 20-729
(10)
TROUBLESHOOTING FAILURE CODE [B@BAZG]
FAILURE CODE [B@BAZG]

Trouble Engine oil pressure low
E03 B@BAZG MON
Description of • The engine oil pressure sensor circuit is closed 15 minutes after the engine started and when the engine speed
Trouble is 1,500 rpm or higher.
Reaction
Effect on • The engine oil pressure is low (The engine may be damaged).
Machine
Information
1 Low engine oil —

pressure
Defective engine 3) Connect t-adapter.
2 oil pressure
sensor Between oil pressure Engine stopped Resistance 1 Ω and below
switch terminal (E29)
Possible Causes and body Engine rotating Resistance 1 MΩ and above
and
Standard 1) Turn starting switch OFF.
Values 2) Disconnect connectors L54 and E29.
3 Wiring harness 3) Connect t-adapter.
ground fault
Between L54 (Female) 2/E29 - body Resistance 1 MΩ and above
4 Defective
monitor panel
Between L54 Engine stopped Voltage 1 V and below
(Female) 2 - body Engine rotating Voltage 20 - 30 V
20-730 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@BAZK]
FAILURE CODE [B@BAZK]

Trouble Engine oil level low
E01 B@BAZK MON
Description of • The engine oil level sensor circuit is opened.
Trouble
Reaction
Effect on • The engine oil level is low (The engine may be damaged).
Machine
Information
1 Low engine oil —

level
Defective engine 3) Connect t-adapter.
2
oil level sensor Resistance 1 Ω and below
Between E26 (Male) Oil level is normal
Possible Causes 1 - body Oil level is low Resistance 1 MΩ and above
and
Standard Wiring harness 1) Turn starting switch OFF.
Values discontinuity 2) Disconnect connectors L54 and E26.
or defective
contact) Wiring harness between L54 (Female) A - E26 (Female) 1 Resistance 1 Ω and below
4 Defective
monitor panel
Between L54 Oil level is normal Resistance 1 Ω and below
(Female) A- body Oil level is low Resistance 1 MΩ and above
WA380-5 20-731
(10)
TROUBLESHOOTING FAILURE CODE [B@BCNS]
FAILURE CODE [B@BCNS]

Trouble Engine coolant temperature overheating
E02 B@BCNS MON
Description of • The engine coolant temperature is above 105 °C
Trouble
Controller • Triggers an alarm (Turns the engine coolant temperature caution lamp ON at 102 °C or above and issues this
Reaction failure code at 105 °C or above).
Effect on • The engine coolant temperature overheat alarm is issued (The engine may be damaged if operation continues).
Machine
Information

Overheating
1 engine coolant —
temperature
Defective engine 2) Disconnect connector E08.
2 coolant
temperature
sensor Between E08 (Male) Normal temperature (25 °C) Resistance 35 - 50 kΩ
Possible Causes 1-2 100 °C Resistance 3.1 - 4.5 kΩ
and
Values 2) Disconnect connectors L55 and E08.
Wiring harness 3) Connect t-adapter.
3
ground fault
Wiring harness between L55 (Female) 8/E08 (Female) 1 -
body
Defective 3) Connect t-adapter.
4 monitor panel
Between L55 Normal temperature (25 °C) Resistance 35 - 50 kΩ
(Female) 8- body 100 °C Resistance 3.1 - 4.5 kΩ
20-732 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@BCZK]
FAILURE CODE [B@BCZK]

Trouble Alarm indicating low coolant level
E01 B@BCZK MON
Description of • The coolant level sensor circuit is opened.
Trouble
Reaction
Effect on • The coolant level is low (The engine may be damaged).
Machine
Information

1 Low coolant level —
Defective coolant
2 Reserve tank low level and below
level sensor (abnormal) Resistance 1 MΩ and above
Between R32 (Male)
1-2 Reserve tank low level and above Resistance 1 Ω and below
(normal)
Possible Causes
and Wiring harness 1) Turn starting switch OFF.
Standard discontinuity 2) Disconnect connectors L54 and R32.
Values 3 (Disconnection 3) Connect t-adapter.
or defective
contact) Wiring harness between L54 (Female) 0 - R32 (Female) 1 Resistance 1 Ω and below
Defective
4 Reserve tank low level and below
monitor panel (abnormal) Resistance 1 MΩ and above
Between L54
(Female) 0- body Reserve tank low level and above Resistance 1 Ω and below
(normal)
WA380-5 20-733
(10)
TROUBLESHOOTING FAILURE CODE [B@HANS]
FAILURE CODE [B@HANS]

Trouble Hydraulic oil temperature overheating
E02 B@HANS MON
Description of • The hydraulic oil temperature is above 110 °C.
Trouble
Reaction
Effect on • The hydraulic oil temperature overheat alarm is issued (The pump/cylinder sealing may be damaged if opera-
Machine tion continues).
Information

Overheating
1 hydraulic oil —
temperature
Defective 2) Disconnect connector R47.
2 hydraulic oil
temperature
sensor Between R47 (Male) Normal temperature (25 °C) Resistance 35 - 50 kΩ
Possible Causes 1-2 100 °C Resistance 3.1 - 4.5 kΩ
and
Values 2) Disconnect connectors L55 and R47.
Wiring harness 3) Connect t-adapter.
3
ground fault
Wiring harness between L55 (Female) 7 /R47 (Female) 1 -
body
4 monitor panel
(Female) 7 - body 100 °C Resistance 3.1 - 4.5 kΩ
20-734 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [B@CENS]
FAILURE CODE [B@CENS]

Trouble Torque converter oil temperature overheating
E02 B@CENS MON
Description of • The torque converter oil temperature is above 130 °C.
Trouble
Controller • Triggers an alarm (Turns the torque converter oil temperature caution lamp ON at 120 °C or above and issues
Reaction this failure code at 130 °C or above).
Effect on • The torque converter oil temperature overheat alarm is issued (The torque converter may be damaged if opera-
Machine tion continues).
Information
1 Overheating —
torque converter
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
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 -

4 Defective
monitor panel
WA380-5 20-735
(10)
TROUBLESHOOTING FAILURE CODE [D182KZ]
FAILURE CODE [D182KZ]

Trouble The preheater relay coil is disconnected or shirt-circuited.
E01 D182KZ MON
Description of • The preheater relay drive circuit was disconnected or short-circuited with ground.
Trouble
Controller • The preheater relay can not be set to ON.
Reaction
Effect on • The machine does not start smoothly at the time of low temperature.
Machine
Related
—
Information

1) Starting switch OFF.
2) Replace the relay with another same relay.
3) Starting switch ON.
4) Set the forward-reverse lever to "R."
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.
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
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
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]
FAILURE CODE [D5ZHL6]

Trouble The starting switch "C" (IGN "C") is not set normally.
E01 D5ZHL6 MON
Description of • After the engine starts, no signal is input to the terminal of the starting switch "C" (IGN "C"). (The input circuit is
Trouble disconnected or short-circuited with the ground.)
Reaction
Effect on • The engine cannot start.(In case of ground fault, the fuse (B-1) is blown, and the starting switch is not set to
Machine "ON."
Related • The monitoring function (Code 40900, D-IN2)) can check input signals to the terminal of the starting switch "C"
Information (IGN "C").

1) Starting switch OFF. 2) Disconnect the starting switch terminal. 3) Connect a T-adaptor.
Defective starting When the starting switch is set to
1 Starting switch Resistance 1 Ω and below
switch "START."
terminals B and C
Other than the above Resistance 1 MΩ and above
Disconnection of 1) Starting switch OFF

harness 2) Disconnect the starting switch C terminal and the connectors L116
defective Harness between the starting switch C terminal (harness) and
contact) Resistance 1 Ω and below
L116 (female) 3.
Possible Causes
and Ground fault of 1) Starting switch OFF
Standard harness 2) Disconnect the starting switch C terminal and the connectors L116..
Values ★ When this 3) Insert a T-adaptor.
phenome-
3 non occurs,
Among the starting switch C terminal (harness), L116 (female)
the fuse (B-1) Resistance 1 MΩ and above
will be blown 3 - body
off.
1) Starting switch OFF. 2) Disconnect the connector L52. 3) Insert a T-adaptor. 4) Starting
switch ON.
Defective
4 When the starting switch is set to
monitor panel Between L52 2 - "START" Voltage 20 - 30 V
body
Other than the above Voltage 1 V or less
20-738 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DA80L4]
FAILURE CODE [DA80L4]

Trouble Auto grease input is abnormal.
E01 DA80L4 MON
Description of • The auto grease sensor input circuits A and B "open" or "close" at the same time.
Trouble
Reaction
Effect on • Auto greasing state, abnormal state and tank empty state cannot be checked.
Machine
Related • The monitoring function (Code 40900, D-IN-45) can check the auto grease input signals (2 systems, O/1).
Information

Disconnection of 2) Disconnect the connectors L52 and R38
harness 3) Connect a T-adaptor.
1 (disconnection,
defective Harnesses between L52 (female) 3 and R38 (female) 2. Voltage 1 V or less
contact)
Harnesses between L52 (female) B and R38 (female) 3. Voltage 1 V or less
2) Disconnect the connectors L52 and R38
2 Hot short-circuit
of harness
Among L52 (female) 3, R38 (female) 2 - body. Voltage 1 V or less
Among L52 (female) B, R38 (female) 3 - body. Voltage 1 V or less
2) Disconnect the connectors L52 and R38.
3) Insert a T-adaptor.
4) Disconnect the connector.
Possible Causes
and When the auto grease operates. Voltage 1 V or less
Standard Defective auto Between R38 2 -
3 grease controller body. When the auto grease does not operate
Values Voltage 20 - 30 V
(the tank is empty).
When the auto grease operates. Voltage 20 - 30 V
Between R38 3 -
body When the auto grease does not operate
Voltage 1 V or less
(the tank is empty).
★ When the above is normal, refer to the Auto Grease System Troubleshooting for the check.
2) Disconnect the connectors L52 and R38.
When the auto grease operates. Voltage 1 V or less
Between L52 3 -
Defective body. When the auto grease does not operate
4 Voltage 20 - 30 V
monitor panel (the tank is empty).
When the auto grease operates. Voltage 20 - 30 V
Between L52 B -
body When the auto grease does not operate
(the tank is empty). Voltage 1 V or less
★ When the above is normal, refer to the Auto Grease System Troubleshooting for the check.
WA380-5 20-739
(10)
TROUBLESHOOTING FAILURE CODE [DAF3KK]
FAILURE CODE [DAF3KK]

Action Code Failure Code Controller Code When the SW power supply (for operation) is ON, the NSW
Trouble
E03 DAF3KK MON power supply (for memory) is OFF.
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.
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

Defective fuse B-
1 3 The fuse shall be normal.
1) Starting switch OFF

2) Disconnect the battery relay B terminal and the connectors FS1 and L51.
Disconnection of
harness Harness between the battery relay B terminal and FS1 (female) Resistance 1 Ω and below
2 (disconnection, 1
defective
contact) Harness among FS1 (female) 1, L51 (female) 4 and 5 Resistance 1 Ω and below
Harness among LS1 (female) 9, 0, G, H, I, J and machine Resistance 1 Ω and below
body
2) Disconnect the battery relay B terminal, the connectors FS1, L51, L63, L80 (L72).
Possible Causes Among the battery relay B terminal, FS1 (female) 1 and
and Resistance 1 MΩ and above
3 Ground fault of machine body
Standard harness
Values Among FS1 (female) 1, L51 (female) 4 and 5 and machine Resistance 1 MΩ and above
body
★ When this system is short-circuited with the ground, the fuse B-3 is blown.
Among L51 4, 5 and machine body. Voltage 20 - 30 V
Among L51 4, 5-9, 0, G, H, I and J Voltage 20 - 30 V
4 Defective 1) Starting switch OFF.
monitor panel
Among L51 6, 7-9, 0, G, H, I and J Voltage 20 - 30 V
20-740 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DAF3KK]
WA380-5 20-741
(10)
TROUBLESHOOTING FAILURE CODE [DAF5KP]
FAILURE CODE [DAF5KP]

Trouble The 5V power supply abnormal output.
E01 DAF5KP MON
Description of • The 5V sensor power supply output line is short-circuited with the ground.
Trouble
Controller • The 5V power supply output stops until the starting switch is set to OFF.
Reaction • No load is displayed.
Effect on • Load detection is impossible. (No load is displayed.)
Machine
Related
—
Information

2) Disconnect the connectors F15.
Between F15 (male) C and A Resistance 4 - 6 kΩ
Defective lift arm 2) Disconnect the connectors F15.
1 angle sensor
Between F15 C - A Voltage 4.75 - 5.25 V
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
2) Disconnect the connector L51 and L55.
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
FAILURE CODE [DAF6KP]

Trouble The 24V power supply abnormal output.
E01 DAF6KP MON
Description of • The 24V sensor power supply output line is short-circuited with the ground.
Trouble
Controller • The 24V power supply output stops until the starting switch is set to OFF.
Reaction • Does not display the load.
Effect on • Load detection is impossible. (No load is displayed.).
Machine
Related
—
Information

Defective lift arm 4) Starting switch ON.
1 pressure sensor
(on bottom side) Between F16 (B) - (A) Voltage 20 - 30 V
When it operates Voltage 0.7 - 5.3 V
Between F16 (C) - (A)
When atmosphere is released. Voltage 0.5 - 1.5 V
Defective lift arm 4) Starting switch ON.
2 pressure sensor
(on head side) Between F17 (B) - (A) Voltage 20 - 30 V
When it operates Voltage 0.7 - 5.3 V
Possible Causes Between F17 (C) - (A)
and When atmosphere is released. Voltage 0.5 - 1.5 V
Standard
Values 1) Starting switch OFF.
2) Disconnect the connectors L51, F16 and F17.
3 Ground fault of 3) Connect a T-adaptor.
harness
Among L51 (female) E, F16 (female) (B), F17 (female) (B) - Resistance 1 MΩ and above
body.
2) Disconnect the connector L51, F16 and F17.
Between L51 E - body Voltage 20 - 30 V
Defective
4 Between L55 4 -
monitor panel body. When it operates Voltage 0.7 - 5.3 V
Between L55 9 - When it operates Voltage 0.7 - 5.3 V

body.
Among L55 4, 9 -
When atmosphere is released. Voltage 0.5 - 1.5 V
body.
20-744 WA380-5
(10)
WA380-5 20-745
(10)
TROUBLESHOOTING FAILURE CODE [DAFBKM]
FAILURE CODE [DAFBKM]

Trouble Incorrect information on model selection.
E03 DAFBKM MON
Description of • The model selection SW (SW1) is set to (A) - (F).
Trouble
Controller • It operates as "WA380".
Reaction
• Travel speed/engine speed indications and odometer indication do not agree with actual ones.
Effect on • The gear shift shock is large.
Machine
• The load meter weight is different from the actual weight.
Related
—
Information

Possible Causes At the normal time Positions (0) - (9)
Incorrect model
and 1 setting SW1 setting (on rear side of monitor)
Standard At abnormal time Positions (A) - (F)
Values
2 Defective —
monitor panel
20-746 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DAFSKQ]
FAILURE CODE [DAFSKQ]

Trouble Incorrect information on meter indication selection.
E01 DAFSKQ MON
Description of • The meter indication selection SW (SW3) is set to (9) - (F).
Trouble
Controller • It operates as indication in km/h.
Reaction
Effect on • Since machine speeds are calculated with standard tires, travel speed and odometer indications may not be
Machine normal.
Related • The monitoring function (Code : 30802, SW3) can check meter indication selection information (SW3) signals (0)
Information - (F).

Possible Causes At the normal time Positions (0) - (8)
Incorrect model
and 1 setting SW3 setting (on rear side of monitor)
Standard At abnormal time Positions (9) - (F)
Values
2 Defective —
monitor panel
WA380-5 20-747
(10)
TROUBLESHOOTING FAILURE CODE [DAQSKR]
FAILURE CODE [DAQSKR]

Action Code Failure Code Controller Code Abnormal S-NET Communication (between monitor panel and
Trouble
E03 DAQSKR MON transmission controller).
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.
Reaction
Effect on • The monitor does not display normally. (The shift indicator, travel speed/engine speed are not displayed.)
Machine
Related
—
Information

Disconnection of 1) Starting switch OFF
harness 2) Disconnect the connectors L56 and L62.
defective
contact) Harness betweenL56 (female) 1 - L62 (female) K. Resistance 1 Ω and below
Ground fault of 2) Disconnect L56 and L62.
Possible Causes 2 harness 3) Insert a T-adaptor.
and
Standard Among L56 (female) 1, L62 (female) K - body. Resistance 1 MΩ and above
Values
1) Starting switch OFF. 2) Disconnect L56, L62 (L72), L80 and L07. 3) Connect a T-adaptor. 4)
3 Hot short-circuit Starting switch ON.
of harness
Among L56 (female) 1, L62 (female) K - body. Voltage 1 V and below
1) Starting switch OFF. 2) Disconnect the connector L56 and L62. 3) Insert a T-adaptor. 4)
Starting switch ON.
Defective
4
monitor panel Among L56 1, 2 - body. Voltage 4-8V
Among L56 1, 2 - 4, 5 Voltage 4-8V
20-748 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DBQSKR]
FAILURE CODE [DBQSKR]

Action Code Failure Code Controller Code S-NET communication failure (Between monitor panel and
Trouble
E03 DBQSKR MON work equipment controller)
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

discontinuity
Wiring harness between L56 (Female) 1 - L72 (Female) K Resistance 1 Ω and below
2) Disconnect connectors L56, L62, (L72), L80, L82, and L07.
2 Wiring harness 3) Insert T-adapter.
ground fault
Possible Causes Between L56 (Female) 1/L72 (Female) K - body Resistance 1 MΩ and above
Standard 2) Disconnect connectors L56 and L72
Values
3 Wiring harness 3) Connect t-adapter.
hot-short 4) Turn starting switch ON.
Between L56 (Female) 1/L72 (Female) K - body Voltage 1 V or less
Defective 4) Turn starting switch ON.
4 monitor panel
Between L56 1/2 - body Voltage 4-8V
Between L56 1/2 - L56 4/5 Voltage 4-8V
20-750 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DB9SKR]
FAILURE CODE [DB9SKR]

Action Code Failure Code Controller Code S-NET communication failure (Between monitor panel and
Trouble
E03 DB9SKR MON work equipment controller)
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.
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

1 discontinuity 3) Connect T-adapter.
Wiring harness between L56 (Female) 1 - L72 (Female) K Resistance 1 Ω and below
Wiring harness 2) Disconnect connectors L56, L62, L72, L80, L82, and L07.
2 3) Insert T-adapter.
ground fault
Possible Causes Between L56 (Female) 1/L72 (Female) K - body Resistance 1 MΩ and above
Standard 2) Disconnect connectors L56 and L72.
Values Wiring harness 3) Connect t-adapter.
3
Between L56 (Female) 1/L72 (Female) K - body Voltage 1 V or less
4 Defective 4) Turn starting switch ON.
monitor panel
Between L56 1/2 - body Voltage 4-8V
Between L56 1/2- L56 4/5 Voltage 4-8V
WA380-5 20-751
(10)
TROUBLESHOOTING FAILURE CODE [DD15LD]
FAILURE CODE [DD15LD]

Action Code Failure Code Controller Code Monitor panel mode selector switch 1 [■] (Panel SW1) input
Trouble
E01 DD15LD MON error
Description of • The monitor panel mode selector switch 1 [■] (Panel SW1) input circuit remains closed for more than one
Trouble minute.
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.

Faulty monitor 3) Connect T-adapter.
panel mode
1
selector switch When monitor panel mode selector Resistance 1 Ω and below
1 [■] Between L07 switch 1 [■] is turned ON
(Female) 2 - 3
Other than above Resistance 1 MΩ and above

and
Standard 2 Wiring harness 3) Connect T-adapter.
Values
Between L52 (Female) G/L07 (Female) 3 - body Voltage 1 V or less
3 Defective
monitor panel
When monitor panel mode selector Voltage 20 - 30 V
Between L52 switch 1 [■] is turned ON
(Female) G - body
Other than above Voltage 1 V and below
20-752 WA380-5
(10)

Trouble Monitor panel mode selector switch 1 [◊] (Panel SW2) input
Description of • The monitor panel mode selector switch 1 [◊] (Panel SW2) input circuit remains closed for more than one
Trouble minute.
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.

1 panel mode
selector switch When monitor panel mode selector
1 [◊] Between L07 switch 1 [◊] is turned ON Resistance 1 Ω and below
(Female) 2- 1
and Wiring harness
Standard 2 hot-short 3) Connect T-adapter.
Values
Between L52 (Female) 8/L07 (Female) 1 - body Voltage 1 V or less
3 monitor panel
When monitor panel mode selector
Between L52 8 - switch 1 [◊] is turned ON Voltage 20 - 30 V
body
Other than above Voltage 1 V and below
WA380-5 20-753
(10)

Action Code Failure Code Controller Code Monitor panel mode selector switch 2 [<] (Panel SW3) input
Trouble
Description of • The monitor panel mode selector switch 2 < (Panel SW3) input circuit remains closed for more than one minute.
Trouble
Reaction
Machine
• The input signal (0 or 1) of the monitor panel mode selector switch 2 [<] (Panel SW3) can be verified with the
Information
• Since [<] switch is faulty, the monitoring function may not be activated.

panel mode
1
selector switch 2 When monitor panel mode selector Resistance 1 Ω and below
[<] Between L08 switch 2 [<] is turned ON
(Female) 3 -2
Standard 2 ground fault 3) Connect T-adapter.
Values
Between L54 (Female) 7/L08 (Female) 3 - body Resistance 1 MΩ and above
3
monitor panel When monitor panel mode selector
Between L54 7 - Voltage 1 V or less
switch 2 [<] is turned ON
body
20-754 WA380-5
(10)

Action Code Failure Code Controller Code Monitor panel mode selector switch 2 [<] (Panel SW4) input
Trouble
Description of • The monitor panel mode selector switch 2 [>] (Panel SW4) input circuit remains closed for more than one
Trouble minute.
Reaction
Machine
• The input signal (0 or 1) of the monitor panel mode selector switch 2 [>] (Panel SW4) can be verified with the
Information
• Since [<] switch is faulty, the monitoring function may not be activated.

panel mode
1
selector switch 2 When monitor panel mode selector Resistance 1 Ω and below
[>] Between L08 switch 2 [>] is turned ON
(Female) 1 - 2
Standard 2 hot-short 3) Connect T-adapter.
Values
Between L54 (Female) E/L08 (Female) 1 - body Resistance 1 MΩ and above
3
monitor panel When monitor panel mode selector
Between L54 E - Voltage 1 V or less
switch 2 [>] is turned ON
body
WA380-5 20-755
(10)
TROUBLESHOOTING FAILURE CODE [DD1CLD]
FAILURE CODE [DD1CLD]

Trouble Sub-total switch failure
E01 DD1CLD MON
Description of • The sub-total switch input circuit remains closed for more than one minute.
Trouble
Reaction
Effect on • The sub-total operation on the load meter does not work.
Machine
• This code is applied to the load meter specification.
Related • The input signal (0 or 1)of the sub-total switch can be verified with the monitoring function (Code: 40904, D-IN-
Information
32).

Faulty sub-total 2) Disconnect connector L15.
1 switch (BUCKET
LEVER FOR OPT
LDM) Between L15 When the sub-total switch is turned ON Resistance 1 Ω and below
(Female) (3) - (4) Other than above Resistance 1 MΩ and above
Possible Causes
and 2) Disconnect connectors L54 and 115.
Standard 2
ground fault 4) Turn starting switch ON.
Values
Between L54 (Female) (4)/L15 (Female) (3) - body Resistance 1 MΩ and above
3 monitor panel
Between L54 (4) - When the sub-total switch is turned ON Voltage 1 V or less
body Other than above Voltage 20 - 30 V
20-756 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DD1CLD]
12
WA380-5 20-757
(10)
TROUBLESHOOTING FAILURE CODE [DDS5L6]
FAILURE CODE [DDS5L6]

Trouble Decreased steering oil pressure
E03 DDS5L6 MON
Description of • The steering sensor circuit remains CLOSED when the engine speed is over 500 rpm.
Trouble
Reaction
Effect on • Due to detection of decreased steering oil pressure, the emergency steering pump (Motor) may cause steering
Machine control to be selected when the speed is over 1 km/h.
Related • Can be verified with the monitoring function (Code: 40904, D-IN-39).
Information

Decreased
1 steering oil —
pressure
Faulty steering
2 oil pressure With engine stopped Resistance 1 Ω and below
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
Wiring harness 2) Disconnect connectors L54, R36 and L61.
Between L54 (Female) F /R36 (Female) C - body
ground fault
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
20-758 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDS5L6]
12
WA380-5 20-759
(10)
TROUBLESHOOTING FAILURE CODE [DDY0LD]
FAILURE CODE [DDY0LD]

Trouble Cancel switch failure
E01 DDY0LD MON
Description of • The cancel switch input circuit remains closed for more than one minute.
Trouble
Reaction
Effect on • The cancellation of weight on the load meter is disabled.
Machine
Related • This code is applied to the load meter specification.
Information • The cancel switch input signal can be verified with the monitoring function (Code: 40904, D-IN-33).

Faulty cancel 2) Disconnect connector L15.
switch (BUCKET 3) Connect T-adapter.
1 LEVER FOR OPT
Between L15 When the cancel switch is turned ON Resistance 1 Ω and below
LDM)
(Female) (1) - (2) Other than above Resistance 1 MΩ and above

and
ground fault 4) Turn starting switch ON.
Values
Between L54 (Female) (13)/L15 (Female) (1) - body Resistance 1 MΩ and above
3 monitor panel
Between L54 (13) - When the cancel switch is turned ON Voltage 1 V or less
body Other than above Voltage 20 - 30 V
20-760 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DDY0LD]
12
WA380-5 20-761
(10)
TROUBLESHOOTING FAILURE CODE [DGE2KX]
FAILURE CODE [DGE2KX]

Action Code Failure Code Controller Code Engine coolant temperature (high temperature) sensor system
Trouble
E01 DGE2KX MON failure
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

Faulty engine 2) Disconnect connector E08.
coolant 3) Connect T-adapter.
1 temperature
sensor (for Between E08 Normal temperature (25 °C) Resistance 35 - 50 kΩ
monitor) (Female) 1 - 2 100 °C Resistance 3.1 - 4.5 kΩ
and
Values ground fault
Between L55 (Female) 8/E08 (Female) 1 - body Resistance 1 MΩ and above
3 Defective
monitor panel
Between L55(Female) Normal temperature (25 °C) Resistance 35 - 50 kΩ
8 - body 100 °C Resistance 3.1 - 4.5 kΩ
20-762 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DGE3L6]
FAILURE CODE [DGE3L6]

Action Code Failure Code Controller Code Abnormal connection of engine coolant temperature (low
Trouble
E01 DGE3L6 MON temperature) sensor system.
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

Defective engine 1) Starting switch OFF. 2) Disconnect the connector E09. 3) Connect a T-adaptor.
coolant
1 temperature (low 10 °C Resistance 9 kΩ approx.
temperature) Between E09 (male) 1 - 2
sensor 100 °C Resistance 0.3 kΩ approx.

Disconnection of 2) Disconnect the connectors L55 and E09.
Possible Causes harness 3) Connect a T-adaptor.
and 2 (disconnection,
Standard defective Harness between L55 (female) 3 - E09 (female) 1. Resistance 1 Ω and below
Values contact)
Harness between L55 (female) 3 - E09 (female) 2. Resistance 1 Ω and below
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]
FAILURE CODE [DGH2KX]

Trouble Hydraulic oil temperature sensor system failure
E01 DGH2KX MON
Description of • The hydraulic oil temperature sensor input voltage is less than 0.98 V.
Trouble
Controller • Activates the hydraulic oil temperature overheat alarm. The failure is stored in the electrical system failure his-
Reaction tory only; not in the machine system failure history.
Effect on • The hydraulic oil temperature gauge is in the MAX position.
Machine
Information

Faulty hydraulic 3) Connect T-adapter.
1 oil temperature
sensor Between R47 (Male) Normal temperature (25 °C) Resistance 35 - 50 kΩ
1-2 100 °C Resistance 3.1 - 4.5 kΩ
and
Values ground fault
Between L55 (Female) 7/R47 (Female) 1 - body Resistance 1 MΩ and above
3 Defective
monitor panel
20-764 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DGT1KX]
FAILURE CODE [DGT1KX]

Trouble Torque converter oil temperature sensor system failure
E01 DGT1KX MON
Description of • The torque converter oil temperature sensor input voltage is less than 0.98 V.
Trouble
Controller • Activates the torque converter oil temperature overheat alarm. The failure is stored in the electrical system fail-
Reaction ure history only; not in the machine system failure history.
Effect on • The torque converter oil temperature gauge is in the MAX position.
Machine
Information

Faulty torque 2) Disconnect connector TC.C.
1 converter oil
temperature
sensor Between TC.C (Male) Normal temperature (25 °C) Resistance 35 - 50 kΩ
1-2 100 °C Resistance 3.1 - 4.5 kΩ
and
2) Disconnect connectors L55 and TC.C.
Values ground fault
Between L55 (Female) 2/TC.C (Female) 1 - body Resistance 1 MΩ and above
3 Defective
monitor panel
WA380-5 20-765
(10)
TROUBLESHOOTING FAILURE CODE [DHE4L6]
FAILURE CODE [DHE4L6]

Trouble Engine oil pressure sensor system failure
E01 DHE4L6 MON
Description of • The engine oil pressure sensor circuit remains open when the engine is not running.
Trouble
Reaction
• The decreased engine oil pressure alarm is disabled.
Effect on • After engine start has failed (Once the key is put ON the terminal C position), an erroneous alarm may be
Machine
issued.
Information

Decreased
1 engine oil —
pressure
2 Faulty engine oil
pressure sensor
When engine is NOT running Resistance 1 Ω and below
Between E29
Possible Causes When engine is running Resistance 1 MΩ and above
and
Values Wiring harness 2) Disconnect connectors L54 (Female) 2 and E29.
ground fault
Between L54 (Female) 2 - E29. Resistance 1 Ω and below
Defective 4) Connect L54.
4
monitor panel
Between L54 When engine is NOT running Voltage 1 V or less
(Female) 2 - body When engine is running Voltage 20 - 30 V
20-766 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DHPCKX]
FAILURE CODE [DHPCKX]

Trouble Bottom pressure sensor failure
E01 DHPCKX MON
Description of • The bottom pressure sensor input voltage is less than 0.5 V.
Trouble
Controller • Activates an alarm and disables load display.
Reaction
Effect on • Activates an alarm and disables load display.
Machine
Information • The bottom pressure signal (0.01 MPa) can be verified with the monitoring function (Code: 40400).

Faulty lift arm 4) Turn starting switch ON.
1 pressure sensor
(Bottom side) Between F16 (B) - (A) Voltage 20 - 30 V
When machine is in operation Voltage 0.7 - 5.3 V
When pressure is released to air Voltage 0.5 - 1.5 V
Wiring harness 2) Disconnect connectors L51, L55 and F16.
discontinuity 3) Connect T-adapter.
Possible Causes 2 (Broken wires or
and loose Between L55 (Female) (9) - F16 (Female) (C) Resistance 1 Ω and below
Standard connections)
Between L51 (Female) (15) - F16 (Female) (B) Resistance 1 Ω and below
Values
Wiring harness 2) Disconnect connectors L55, F16, F17.
ground fault
Between L55 (Female) (9), F16 (Female) (C) and body Resistance 1 MΩ and above
2) Disconnect connectors L51, F16 and F17.
Defective
4 monitor panel
Between L51 (15) - body Voltage 20 - 30 V
When machine is in operation Voltage 0.7 - 5.3 V
Between L55 (9) - body
20-768 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DHPCKX]
Missing Hardcopy page and diagram number
WA380-5 20-769
(10)
TROUBLESHOOTING FAILURE CODE [DHPDKX]
FAILURE CODE [DHPDKX]

Trouble Head pressure sensor failure
E01 DHPDKX MON
Description of • The head pressure sensor input voltage is less than 0.5 V.
Trouble
Reaction
Machine
Information • The head pressure signal (0.01 MPa) can be verified with the monitoring function (Code: 40500).

1) Turn starting switch OFF. 2) Disconnect connector F16. 3) Insert T-adapter.
Faulty head
1 pressure sensor Between F17 (B) - (A) Voltage 20 - 30 V
(Head side) When machine is in operation Voltage 0.7 - 5.3 V
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.
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]
FAILURE CODE [DKA0KX]

Trouble Lift arm angle sensor failure
E01 DKA0KX MON
Description of • The lift arm angle sensor input voltage is less than 1 V or more than 4 V.
Trouble
Reaction
Machine
Information • The lift arm angle signal (° ) can be verified with the monitoring function (Code: 06001).

1) Turn starting switch OFF. 2) Disconnect connector F15. 3) Insert T-adapter.
Between F15 (Male) (C) - (A) Resistance 4 - 6 kΩ
Faulty boom 3) Insert T-adapter.
1 angle sensor
Between F15 (C) - (A) Voltage 4.75 - 5.25 V
With lift arm fully raised Voltage 3.5 - 4.0 V
Between F15 (B) - (A)
With lift arm fully lowered Voltage 1.0 - 2.0 V
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors L51, L55 and F15 3) Connect T-adapter.
Possible Causes discontinuity
and 2 (Broken wires or Between L51 (Female) (16) - F15 (Female) (C) Resistance 1 Ω and below
Standard loose
Values connections) Between L55 (Female) (10) - F15 (Female) (B) Resistance 1 Ω and below
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
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]
FAILURE CODE [DV00KB]

Trouble Short-circuited alarm buzzer output system
E01 DV00KB MON
Description of • Hot-short has occurred in the alarm buzzer output circuit.
Trouble
Controller • The alarm buzzer output is stopped until the starting switch is turned OFF.
Reaction
Effect on • The alarm buzzer does not sound until the starting switch is turned OFF.
Machine
Related
Information

Faulty alarm 4) Turn starting switch ON and wait until 5 seconds have elapsed.
1 buzzer
With L20 2 Alarm buzzer sounds. Alarm buzzer is normal.
grounded to machine
body Alarm buzzer does not sound. Alarm buzzer is faulty.
Possible Causes Wiring harness 2) Disconnect connectors L51 and L20.
and 2 3) Connect T-adapter.
hot-short
Standard
Between L51 (Female) D, L20 (Female) 2 - body Voltage 1 V or less
Values
When starting switch is turned ON. Voltage 20 - 30 V
Defective
3 monitor panel 2 seconds after starting switch is turned Voltage 1 V or less
Between L51 D - ON (Alarm buzzer does not sound).
body
3 seconds after 2 seconds has elapsed
when starting switch was turned ON Voltage 17 - 30 V
(Alarm buzzer sounds).
WA380-5 20-773
(10)
TROUBLESHOOTING FAILURE CODE [DY30ME]
FAILURE CODE [DY30ME]

Action Code Failure Code Controller Code The emergency steering remains actuated for more than one
Trouble
E02 DY30ME MON minute
Description of • The emergency steering detector circuit remains open for more than one minute.
Trouble
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.
Information

Actuation of
emergency steering
1 for more than one —
minute
1) Turn starting switch OFF. 2) Disconnect connector R37. 3) Connect T-adapter.
When emergency steering is not turned ON Resistance 1 Ω and below
Faulty emergency
2 steering pressure Between R37 (Male) (C) - When pressure is released to air (For reference Resistance
switch 1 Ω and below
(A) purpose)
When emergency steering is turned ON (Under
high pressure) Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connectors L54 and R37.

discontinuity
3 (Broken wires or Between L54 (Female) 3 - R37 (Female) (C) Resistance 1 Ω and below
loose connections)
Between R37 (Female) (A) - body Resistance 1 Ω and below
1) Turn starting switch OFF. 2) Disconnect connector L54. 3) Insert T-adapter. 4) Turn starting switch ON.
Defective monitor
4 panel
When emergency steering is not turned ON Voltage 1 V or less
When emergency steering is turned ON (Under
high pressure) Voltage 20 - 30 V
1) Turn starting switch OFF. 2) Disconnect connector R36. 3) Connect T-adapter.

When engine is not running Resistance 1 Ω and below
Possible Causes Between R36 (Male) (C) - When pressure is released to air (For reference
and (A) Resistance 1 Ω and below
purpose)
Standard
Values Faulty steering When engine is starting Resistance 1 MΩ and above
5 pressure switch
When engine is not running Resistance 1 MΩ and above
Between R36 (Male) (B) - When pressure is released to air (For reference
(A) purpose) Resistance 1 MΩ and above
When engine is starting Resistance 1 Ω and below

1) Turn starting switch OFF. 2) Disconnect connectors L61 and R36. 3) Connect T-adapter. 4) Apply left brake
after engine starts.
6 Wiring harness
Between L61 (Female) G /R36 (Female) (C) - body Resistance 1 MΩ and above
ground fault
Between L61 (Female) M /R36 (Female) (B) - body Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connector S19. 3) Insert T-adapter.
Faulty emergency
7 steering manual When emergency steering switch is turned ON Resistance 1 Ω and below
Between S19 (Male) 4 -
switch 3 When emergency steering switch is turned OFF Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connectors L63, L126 and S19. 3) Insert T-adapter. 4) Turn starting
Wiring harness switch ON.
8 short circuit fault
Between L63 (Female) S/L126 (Female) 1 /S19 (Female) 4 - body Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connectors L126 and R15. 3) Insert T-adapter. 4) Turn starting
9 Wiring harness switch ON.
short circuit fault
Between L126 5/R15 - body Resistance 1 MΩ and above
Faulty emergency 1) Turn starting switch OFF. 2) Disconnect connector L126. 3) Insert T-adapter.
10 steering relay
(L126) Between L126 (Female) 3/L126 (Female) 5 - body Resistance 1 MΩ and above
20-774 WA380-5
(10)
TROUBLESHOOTING FAILURE CODE [DY30ME]

Possible Causes
and Faulty 1) Turn starting switch OFF.
Standard 11 emergency 2) Disconnect connectors R15 and R16 and two power supply wires (100B).
Values steering
actuating relay Between relay contacts Resistance 1 MΩ and above
WA380-5 20-775
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-1]
TROUBLESHOOTING CODE [MON-1]

Troubleshooting Failure Code Controller Code The parking brake indicator lamp does not light up when the
Code Trouble parking brake switch is turned ON (The parking brake indicator
MON-1 — (MON) switch circuit suffers a ground fault).
Description of • The parking brake detector circuit remains CLOSED when the parking brake switch is operated.
Trouble
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.
Information • The state of the parking brake switch can be verified with the monitoring function (Code: 40907, D-IN-23).

Faulty parking
1 brake —
Turn starting switch OFF. 2) Disconnect PB.SW connectors. 3) Connect T-adapter.

Faulty parking When parking brake oil pressure is above
2 brake indicator 0.6 MPa {6.1 kg/cm2} Resistance 1 Ω and below
Between PB.SW (Male)
switch 1-2
When parking brake oil pressure is below Resistance 1 MΩ and above
0.34 MPa {3.5 kg/cm2}
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.
Faulty parking Between PB.PS connectors (Male) 1 - 2 Resistance 10 - 40 Ω

6
brake solenoid Between PB.PS connectors (Female) 2 - body Resistance 1 Ω and below
Between PB.PS connectors (Male) 1 / 2 - body Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connector L01 and PB.PS. 3) Connect T-adapter. 4)
Wiring harness
7 short circuit fault Turn starting switch ON.
Between PB.PS connector (Female) 1 - 2 Voltage 1 V or less
20-776 WA380-5
(10)
WA380-5 20-777
5

Troubleshooting Failure Code Controller Code
Code The brake oil pressure caution lamp does not light up when the
Trouble
emergency brake is applied (Front circuit)
MON-2 — (MON)
Description of • The accumulator pressure sensor (Front) circuit remains CLOSED (i.e. front brake oil pressure is normal) when
Trouble the emergency brake is actuated.
Reaction
Effect on • The brake oil pressure caution lamp does not light up when the emergency brake is actuated and when the
Machine brake oil pressure is decreased.
Related • Can be verified with the monitoring function (Code: 40902_D-IN-16).
Information

Faulty brake oil 4) Start engine.
pressure sensor
1 (Front brake When front brake oil pressure is above
circuit) Between R53 (Male) 5.88 MPa {60 kg/cm2}
1-2 When front brake oil pressure is below
5.88 MPa {60 kg/cm2} Resistance 1 MΩ and above
Possible Causes
Standard Wiring harness 2) Disconnect connectors L53 and R53.
Defective
3 When front brake oil pressure is above
monitor panel 5.88 MPa {60 kg/cm2} Resistance 1 Ω and below
Between L53
(Female) 1 - body When front brake oil pressure is below Resistance 1 MΩ and above
5.88 MPa {60 kg/cm2}
20-778 WA380-5
(10)
5

Code The brake oil pressure caution lamp does not light up when the
Trouble
emergency brake is applied (Rear circuit)
MON-3 — (MON)
Description of • The accumulator pressure sensor (Rear) circuit remains CLOSED (i.e. rear brake oil pressure is normal) when
Trouble the emergency brake is actuated.
Reaction
Effect on • The brake oil pressure caution lamp does not light up when the emergency brake is actuated and when the
Machine brake oil pressure is decreased.
Related • Can be verified with the monitoring function (Code: 40902_D-IN-17).
Information

Faulty brake oil 4) Start engine.
pressure sensor
1 (Rear brake When rear brake oil pressure is above
circuit) Between R54 (Male) 5.88 MPa {60 kg/cm2}
1-2 When rear brake oil pressure is below
5.88 MPa {60 kg/cm2} Resistance 1 MΩ and above
Possible Causes
Standard Wiring harness 2) Disconnect connectors L53 and R54.
Defective
3 When rear brake oil pressure is above
monitor panel 5.88 MPa {60 kg/cm2} Resistance 1 Ω and below
Between L53
(Female) 7 - body When rear brake oil pressure is below Resistance 1 MΩ and above
5.88 MPa {60 kg/cm2}
WA380-5 20-779
(10)
5

Code Trouble The air cleaner clogging indicator lamp does not light ON
MON-4 — (MON)
Description of • When the air cleaner is clogged, the sensor circuit is in the CLOSE (Not clogged) state.
Trouble
Reaction
Effect on • The air cleaner caution lamp does not go OFF.
Machine
Information

Defective dust
1 indicator 1 —

Defective dust 2) Disconnect connector E33.
2 indicator relay 1 3) Connect T-adapter.
Between L112 (Male) 1 -2 Resistance 200 - 400 Ω
Harness 2) Disconnect connector L53, L112 and E33.
disconnection 3) Connect T-adapter.
3 (Disconnection Between L51 (Female) 6 - L112 (Female) 1 Resistance 1 Ω and below
or defective
connector Between L112 (Female) 2 - E33 (Female) 1 Resistance 1 Ω and below
contact)
Between E33 (Female) 2 - body Resistance 1 Ω and below
Possible Causes 4 ground fault 3) Connect T-adapter.
and
Standard Between L53 (Female) 3, L112 (Female) 4 - body Resistance 1 MΩ and above
Harness hot 3) Connect T-adapter.
5
short fault 4) Turn starting switch ON.
Between L53 (Female) 3, L112 (Female) 4 - body Voltage 1 V or below
Dust indicator normal (Air cleaner not
Voltage 20 - 30 V
Between L53 3 - clogged)
6 Defective body
monitor panel Dust indicator abnormal (Air cleaner
clogged) Voltage 1 V or below

Between L51 (Male) 6 - body Resistance 200 - 400 Ω
20-780 WA380-5
(10)
5
WA380-5 20-781
5

Code Trouble The engine oil pressure caution lamp does not light ON
MON-5 — (MON)
Description of • When the starting switch is ON (the engine stops), the engine oil pressure sensor circuit is in the OPEN state.
Trouble
Reaction
Effect on • The engine oil pressure caution lamp does not light ON.
Machine
Information

Defective engine 3) Connect T-adapter.
1 oil pressure
sensor Between oil pressure When the engine stops Resistance 1 Ω and below
switch pin (E29) -
body When the engine runs Resistance 1 MΩ and above
Possible Causes
Standard Harness 2) Disconnect connectors L54 and E29.
Values disconnection
Between L54 (Female) 2 - E29 Resistance 1 MΩ and above
Defective 3) Connect T-adapter.
3
monitor panel When the engine stops Resistance 1 V and below
Between L54
(Female) 2 - body When the engine runs Resistance 20 - 30 V
20-782 WA380-5
(10)

Code Trouble The engine oil level caution lamp does not light ON
MON-6 — (MON)
Description of • The engine oil level sensor circuit is in the CLOSE state.
Trouble
Reaction
Effect on • The engine oil level caution lamp does not light ON.
Machine
Information

Defective engine 3) Connect T-adapter.
1 oil level sensor
Between E26 (Male) Oil level normal Resistance 1 Ω and below
1 - body Oil level insufficient (Reduces) Resistance 1 MΩ and above
Possible Causes
Harness ground 2) Disconnect connectors L54 and E26.
Standard 2 fault 3) Connect T-adapter.
Values
Between L54 (Female) A, E26 (Female) 1 - body Resistance 1 MΩ and above
3 monitor panel
Between L54 Oil level normal Resistance 1 Ω and below
(Female) A - body Oil level insufficient (Reduces) Resistance 1 MΩ and above
WA380-5 20-783
(10)

Troubleshooting Failure Code Controller Code The engine coolant temperature caution lamp does not light ON
Code Trouble After the engine starts, the engine coolant temperature gauge
MON-7 — (MON) does not rise
Description of • The engine coolant temperature sensor circuit is always in the OPEN state.
Trouble
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.
Information

Defective engine 2) Disconnect connector E08.
coolant 3) Connect T-adapter.
1 temperature
Between E08 (Male) Normal temperature (25 °C) Resistance 35 - 50 kΩ
sensor
1-2 100 °C Resistance 3.1 - 4.5 kΩ
Possible Causes
Harness ground 2) Disconnect connectors L55 and E08.
Values
Between L55 (Female) 8, E08 (Female) 1 - body Resistance 1 MΩ and above
3 monitor panel
20-784 WA380-5
(10)
5

Code Trouble The coolant level caution lamp does not light ON
MON-8 — (MON)
Description of • The coolant level sensor circuit is always in the CLOSE state.
Trouble
Reaction
Effect on • When the coolant level is insufficient, the coolant level caution lamp does not light ON. (The engine may be
Machine damaged.)
Information

Defective coolant 3) Connect T-adapter.
1 level sensor
Between R32 (Male) Subtank low level or less (Abnormal) Resistance 1 MΩ and above
1-2 Subtank low level or more (Normal) Resistance 1 Ω or below
Possible Causes
Harness ground 2) Disconnect connectors L54 and R32.
Values
Between L54 (Female) 0, R32 (Female) 1 - body Resistance 1 MΩ and above
3 monitor panel
Between L54 Subtank low level or less (Abnormal) Resistance 1 MΩ and above
(Female) 0 - body Subtank low level or more (Normal) Resistance 1 Ω or below
WA380-5 20-785
(10)
5

Troubleshooting Failure Code Controller Code The hydraulic oil temperature caution lamp does not light ON
Code Trouble After the engine starts, the hydraulic oil temperature gauge
MON-9 — (MON) does not rise
Description of • The hydraulic oil temperature sensor circuit is always in the OPEN state.
Trouble
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.
Information

Defective 2) Disconnect connector R47.
hydraulic oil 3) Connect T-adapter.
1 temperature
Between R47 (Male) Normal temperature (25 °C) Resistance 35 - 50 kΩ
sensor
1-2 100 °C Resistance 3.1 - 4.5 kΩ
Possible Causes Harness 1) Turn starting switch OFF.
and disconnection 2) Disconnect connectors L55 and R47.
Standard 2 (Disconnection 3) Connect T-adapter.
Values or defective
contact) Between L55 (Female) 7 - R47 (Female) 1 Resistance 1 Ω and below
3
monitor panel Normal temperature (25 °C) Resistance 35 - 50 kΩ
Between L55
20-786 WA380-5
(10)

Troubleshooting Failure Code Controller Code The torque converter oil temperature caution lamp does not
Code light ON
Trouble After the engine starts, the torque converter oil temperature
MON-10 — (MON) gauge does not rise
Description of • The torque converter oil temperature sensor circuit is always in the OPEN state.
Trouble
Reaction
Effect on • The torque converter oil temperature caution lamp does not light ON.
Machine • After the engine starts, the torque converter oil temperature gauge does not rise.
Information

Defective torque 2) Disconnect connector TC.T
converter oil 3) Connect T-adapter.
1
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 Harness 1) Turn starting switch OFF.
and disconnection 2) Disconnect connectors L55 and TC.T
Standard 2 (Disconnection 3) Connect T-adapter.
Values or defective
contact) Between L55 (Female) 2 - TC.T (Female) 1 Resistance 1 Ω and below
3 Defective
monitor panel
WA380-5 20-787
(10)

Code Trouble The steering hydraulic caution lamp does not light ON
MON-11 — (MON)
Description of • The steering hydraulic sensor circuit is always in the OPEN state.
Trouble
Reaction
Effect on • At emergency steering self-check, the steering hydraulic caution lamp does not light ON.
Machine • The emergency steering self-check may not be performed.
Information

Defective
1 steering The engine stops Resistance 1 Ω and below
hydraulic sensor Between R36 (Male)
C-A
Atmosphere open (Reference) Resistance 1 Ω and below
Harness 1) Turn starting switch OFF.
disconnection 2) Disconnect connectors L54, R36, and L61.
2 (Disconnection 3) Connect T-adapter.
Between L54 (Female) F, R36 (Female) C - body
Possible Causes or defective
and contact) Resistance 1 Ω and below
Standard
2) Disconnect connectors L54, R36, and L61.
3 Harness hot 3) Connect T-adapter.
Between L54 (Female) F, R36 (Female) C - body Voltage 1 V or below
Defective
4 monitor panel The engine stops Resistance 1 Ω and below
Between L54
(Female) F - body Atmosphere open (Reference) Resistance 1 Ω and below
The engine starts Resistance 1 MΩ and above
20-788 WA380-5
(10)
5

Code Trouble Input fault in monitor panel mode switch 1 [■] (Panel SW1)
MON-12 — (MON)
Description of • The input circuit of the monitor panel mode switch 1 [■] (Panel SW1) is in the OPEN state.
Trouble
Reaction
Effect on • The monitor operation is impossible. (Not placed into the service mode.)
Machine
• The input signal (0/1) of the monitor panel mode switch 1 [■] (Panel SW1) can be checked with the monitoring
Related function (Code: 40901, D-IN-15).
Information
• Since the [■] switch is abnormal, the monitoring function may not be implemented.

1 monitor panel
mode switch 1 When the monitor panel mode switch 1
[■] Between L07 [■] is ON Resistance 1 Ω and below
(Female) 2 - 3
Others Resistance 1 MΩ and above
Harness 2) Disconnect connectors L51, L52, and L07.
2 (Disconnection
or defective Between L52 (Female) G - L07 (Female) 3 Resistance 1 Ω and below
contact)
Between L51 (Female) 4, 5, L07 (Female) 2 Resistance 1 Ω and below
Possible Causes
and Harness ground 1) Turn starting switch OFF.
Standard fault (At 2) Disconnect connectors L51, L52, and L07.
Values occurrence of a 3) Connect T-adapter.
ground fault, the
fuse blows Between L52 (Female) G and L07 (Female) 3 - body Resistance 1 MΩ and above
3 during switch
operation, and
the subsequence Between L51 (Female) 4, 5, L07 (Female) 2 - body Resistance 1 MΩ and above
operation is
impossible.)
4
monitor panel When the monitor panel mode switch 1
Between L52 G - Voltage 20 - 30 V
[■] is ON
body
Others Voltage 1 V and below
WA380-5 20-789
(10)
5

Code Trouble Input fault in monitor panel mode switch 1 [◊] (Panel SW2)
MON-13 — (MON)
Description of • The input circuit of the monitor panel mode switch 1 [◊] (Panel SW2) is in the OPEN state.
Trouble
Reaction
Effect on • The monitor operation is impossible.
Machine
• The input signal (0/1) of the monitor panel mode switch 1 [◊] (Panel SW2) can be checked with the monitoring
Information
• Since the [◊] switch is abnormal, the monitoring function may not be implemented.

monitor panel
1 mode switch 1 When the monitor panel mode switch 1
[◊] Between L07 [◊] is ON
(Female) 2 - 1
Harness 2) Disconnect connectors L51, L52, and L07.
2 (Disconnection
or defective Between L52 (Female) 8 - L07 (Female) 1 Resistance 1 Ω and below
contact)
Between L51 (Female) 4, 5 - L07 (Female) 2 Resistance 1 Ω and below
Possible Causes
and Harness ground 1) Turn starting switch OFF.
Standard fault (At 2) Disconnect connectors L51, L52, and L07.
Values occurrence of a 3) Connect T-adapter.
ground fault, the
fuse blows Between L52 (Female) 8, L07 (Female) 1 - body Resistance 1 MΩ and above
3
during switch
operation, and
the subsequence Between L51 (Female) 4, 5, L07 (Female) 2 - body Resistance 1 MΩ and above
operation is
impossible.)
4 Defective
monitor panel
When the monitor panel mode switch 1 Voltage 20 - 30 V
Between L52 8- [◊] is ON
body
Others Voltage 1 V and below
20-790 WA380-5
(10)
5

Code Trouble Input fault in monitor panel mode switch 2 [<] (Panel SW3)
MON-14 — (MON)
Description of • The input circuit of the monitor panel mode switch 2 [<] (Panel SW3) is in the OPEN state.
Trouble
Reaction
Machine
• The input signal (0/1) of the monitor panel mode switch 2 [<] (Panel SW3) can be checked with the monitoring
Information
• Since the [<] switch is abnormal, the monitoring function may not be implemented.

monitor panel
[<] Between L08 [<] is ON
(Female) 3 - 2
disconnection 2) Disconnect connectors L54 and L08.
contact) Between L54 (Female) 7 - L08 (Female) 3 Resistance 1 Ω and below
and
3 short fault
Between L54 (Female) 7, L08 (Female) 3 - body Voltage 1 V and below
4 monitor panel
When the monitor panel mode switch 2
Between L54 [<] is ON Voltage 1 V and below
(Female) 7 - body
Others Voltage 20 - 30 V
WA380-5 20-791
(10)
5

Code Trouble Input fault in monitor panel mode switch 2 [>] (Panel SW4)
MON-15 — (MON)
Description of • The input circuit of the monitor panel mode switch 2 [>] (Panel SW4)is in the CLOSE state continuously for 1
Trouble minute or more.
Reaction
Machine
• The input signal (0/1) of the monitor panel mode switch 2 [>] (Panel SW4) can be checked with the monitoring
Information
• Since the [>] switch is abnormal, the monitoring function may not be implemented.

monitor panel
[>] Between L08 [>] is ON
(Female) 1 - 2
contact) Between L54 (Female) E - L08 (Female) 1 Resistance 1 Ω and below
and
3 short fault
Between L54 (Female) E, L08 (Female) 1 - body Voltage 1 V and below
4 monitor panel
When the monitor panel mode switch 2
Between L54 [>] is ON Voltage 1 V and below
(Female) E - body
Others Voltage 20 - 30 V
20-792 WA380-5
(10)
5

Code Trouble Defective subtotal switch
MON-16 — (MON)
Description of • The subtotal switch input circuit is in the OPEN state.
Trouble
Reaction
Effect on • The load meter subtotal operation is impossible.
Machine
Information • The subtotal switch input signal (0/1) can be checked with the monitoring function (Code: 40904, D-IN-32).

Defective 2) Disconnect connector L15.
subtotal switch 3) Connect T-adapter.
1
(BUCKET LEVER Subtotal switch = ON Resistance 1 Ω and below
FOR OPTLDM) Between L15
(Female) (3) - (4) Others Resistance 1 MΩ and above
and contact) Between L54 (Female) (4) - L15 (Female) (3) Resistance 1 Ω and below
Between L54 (Female) (4), L15 (Female) (3) - body Voltage 1 V and below
4
monitor panel
Between L54 Subtotal switch = ON Voltage 1 V and below
(Female) (4) - body Others Voltage 20 - 30 V
WA380-5 20-793
(10)

Code Trouble Defective cancel switch
MON-17 — (MON)
Description of • The cancel switch input circuit is always in the OPEN state.
Trouble
Reaction
Effect on • The load meter weight cancel operation is impossible.
Machine
Information • The cancel switch input signal (0/1) can be checked with the monitoring function (Code: 40904, D-IN-33).

Defective cancel 2) Disconnect connector L15.
switch (Bucket 3) Connect T-adapter.
1
lever for Cancel switch = ON Resistance 1 Ω and below
OPTLDM) Between L15
(Female) (1) - (2) Others Resistance 1 MΩ and above
and contact) Between L54 (Female) (13) - L15 (Female) (1) Resistance 1 Ω and below
Between L54 (Female) (13), L15 (Female) (1) - body Voltage 1 V and below
4
monitor panel
Between L54 Cancel switch = ON Voltage 1 V and below
(Female) (13) - body Others Voltage 20 - 30 V
20-794 WA380-5
(10)

Code Trouble Defective bottom pressure sensor (Hot short fault)
MON-18 — (MON)
Description of • The input voltage from the bottom pressure sensor is 5.3 V and above.
Trouble
Reaction
Effect on • The alarm does not function and the load is not displayed.
Machine
Information • The bottom pressure signal (0.01 MPa) can be checked with the monitoring function (Code: 40400).

Defective lift arm 4) Turn starting switch ON.
1 pressure sensor
(Bottom side) Between F16 (B) - (A) Voltage 20 - 30 V
At running Voltage 0.7 - 5.3 V
At atmosphere Voltage 0.5 - 1.5 V
Possible Causes Harness hot 1) Turn starting switch OFF.
and short fault 2) Disconnect connector F16.
Standard 2 (Contact with 3) Connect T-adapter.
Values power supply 4) Turn starting switch ON.
harness) Between L55 (Female) (9), F16 (Female) (C) - body Voltage 1 V and below
2) Disconnect connector L51, F16 and F17.
Defective
3 monitor panel
Between L55 (9) - At running Voltage 0.7 - 5.3 V

body At atmosphere Voltage 0.5 - 1.5 V
WA380-5 20-795
(10)

Code Trouble Defective head sensor
MON-19 — (MON)
Description of • The input voltage from the head pressure sensor is 5.3V and above.
Trouble
Reaction
Effect on • The alarm does not function and the load is not displayed.
Machine
Information • The bottom pressure signal (0.01 MPa) can be checked with the monitoring function (Code: 40500).

Defective head 4) Turn starting switch ON.
1 pressure sensor
(Head side) Between F17 (B) - (A) Voltage 20 - 30 V
At running Voltage 0.7 - 5.3 V
At atmosphere open Voltage 0.5 - 1.5 V
Possible Causes Harness hot 1) Turn starting switch OFF.
and short fault 2) Disconnect connectors F17.
Standard 2 (Contact with 3) Connect T-adapter.
Values power supply 4) Turn starting switch ON.
harness) Between L55 (Female) (4), F17 (Female) (C) - body Voltage 1 V and below
2) Disconnect connector L51 and F17.
Defective
3 monitor panel
Between L55 (4) - At running Voltage 0.7 - 5.3 V

body At atmosphere open Voltage 0.5 - 1.5 V
20-796 WA380-5
(10)

Code The alarm buzzer does not sound or stop.
Trouble
(Disconnection in alarm buzzer output system, or ground fault)
MON-20 — (MON)
Description of • A disconnection or ground fault occurs in the alarm buzzer output circuit.
Trouble
Reaction
Effect on • The alarm buzzer does not sound or stop.
Machine
Related —
Information

2) Disconnect connectorL20.
Defective alarm 4) Connect connector L20.
1 5) 5 sec. lapsed after the starting switch was turned ON.
buzzer
The alarm buzzer sounds Alarm buzzer normal
L20 2 to body earth
The alarm buzzer does not sound. Alarm buzzer abnormal
Harness 2) Disconnect connectors FS3 and L20.
2
(Disconnection Harness between L51 (Female) D - L20 (Female) 2 Resistance 1 Ω and below
or contact fault)
Harness between FS3 (Female) 9 - L20 (Female) 1 Resistance 1 Ω and below
and 2) Disconnect connectors L51, FS3, and L20.
Standard 3) Connect T-adapter.
Values
Harness ground Between L51 (Female) D, L20 (Female) 2 - body Resistance 1 MΩ and above
3 fault
Between FS3 (Female) 9 and L51 (Female) 6, 7, L20 (Female)
1 and body
★ In this case, fuse B-9 blows, and the monitor does not Resistance 1 MΩ and above
start.
Turn starting switch ON. Voltage 20 - 30 V
Defective
4 For 2 sec. after the starting switch was
monitor panel Voltage 1 V and below
Between L51 D - turned ON. (The alarm buzzer sounds.)
body
For 1 sec. after 2 sec. lapsed after the
starting switch was turned ON. (The Voltage 17 - 30 V
alarm buzzer does not sound.)
WA380-5 20-797
(10)
5
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
H-1 The machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-802

H-2 The lock-up clutch is not released (The engine stops) (When the lock-up clutch is provided) . 20-804
H-3 a The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak,
and the gear is not shifted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-805
H-3 b The torque converter lock-up clutch is not let in (When the lock-up clutch is provided) . . . . . 20-807
H-4 Shocks are large at the times of starting and shifting gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808
H-5 Time lag is large at the times of starting and shifting gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
H-6 The torque converter oil temperature is high. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-812
H-7 The steering wheel does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813
H-8 The steering wheel is heavy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
H-9 The steering wheel fluctuates or is strongly shocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
H-10 The machine steers to one side when traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
H-11 The right and left swing radii are different . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
H-12 The brake does not work or does not work well . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-816
H-13 The brake is not released or is dragged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817
H-14 The brake is not released or dragged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
H-15 The Lift arm does not rise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-819
H-16 The Lift arm moves slowly or the Lift arm rising force is insufficient . . . . . . . . . . . . . . . . . . . . . 20-820
H-17 When rising, the Lift arm comes to move slowly at specific height . . . . . . . . . . . . . . . . . . . . . . . 20-821
H-18 The Lift cylinder cannot hold down the bucket (The bucket rises in the air) . . . . . . . . . . . . . . . . 20-821
H-19 Hydraulic drifts of the Lift arm occur often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
H-20 The Lift arm wobbles during operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
H-21 When the control lever is switched from "HOLD" to "RAISE," the Lift arm falls temporarily . . . 20-822
H-22 The bucket does not tilt back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-823
H-23 The bucket moves slowly or the tilting-back force is insufficient . . . . . . . . . . . . . . . . . . . . . . . . . 20-824
H-24 The bucket comes to operate slowly in the midst of tilting-back . . . . . . . . . . . . . . . . . . . . . . . . . 20-825
H-25 The bucket cylinder cannot hold down the bucket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-825
H-26 Hydraulic drifts of the bucket occur often . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-825
H-27 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD") . . 20-826
H-28 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily . . . . . 20-826
H-29 The control levers of Lift arm and bucket do not move smoothly and heavy . . . . . . . . . . . . . . . 20-827
H-30 E.C.S.S. does not work, and there is pitching and bouncing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-828
WA380-5 20-801
(10)
TROUBLESHOOTING H-1
H-1 The machine does not start

Ask the operator about the following: Cause
• Has the machine come not to start suddenly? Torque Converter Torque Main Relief Parking
ECMV Transmission
--> Seizure of clutch, breakage of parts Charging Pump Converter Valve Brake
Did the machine cause any abnormal noise at the
a b c d e f g h i j k l m n o
time and where?
Inspection before diagnosis
Defective operation of parking brake solenoid valve

Defective operation of torque converter relief valve
• Does the machine monitor function normally?
• Has the machine monitor displayed any failure
code of the electrical system?
The relevant clutch piston seal is defective
The parking brake piston seal is defective

The relevant clutch shaft seal is defective
• Did you smell deteriorated or burnt transmis-
sion oil?
Set pressure drop of main relief valve
Defective operation of relevant ECMV

Internal breakage of torque converter
• Have the transmission filter and strainer been
Internal breakage of transmission
War or seizure of relevant clutch

clogged?
The charging pump is defective
Clogging of last change filter

• Can you find any damage or oil leak from the
appearance?
Air intake on suction side

• Has the drive shaft been broken?
The PTO is defective
• 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 { { { {
Metal (Aluminum, copper, iron, etc.) powers

5 are adhered to the transmission filter or the { { {
strainer
6 The speed is higher at { { { { { { { {

When the stall speed of all gear speeds
the torque converter is
measured The speed is higher at
7 { { { { {
specific gear speeds
The oil pressure is low
8 at all gear speeds { { { { { { {
9 When the ECMV output The oil pressure is low { { { {

at specific gear speeds
(Clutch) oil pressure is
measured The oil pressure does
10 not become stable as { {
the gauge touches the
oil
11 When the torque converter relief (Inlet) oil { { { { { {

pressure is measured, the oil pressure is low
*1 Proceed to the paragraph of "Defective clutch and ECMV Specifying Method (Check by Failure Code)."
20-802 WA380-5
(8)
TROUBLESHOOTING H-1
Defective Clutch and ECMV Specifying Method

Cause
(Check by Failure Code)
★ For the checking method of failure code display, see the paragraph of "Special
Functions of Machine Monitor."
★ When replacing the ECMV for diagnosis, remove mud and dust around the ECMV Transmission ECMV
completely and clean it, and then tighten the mounting bolt with the
specified torque.
★ For the following diagnoses, start the engine and select the manual mode: a b c d e f g h i j k l
Table of Applicable Clutches Clutch

F R 1st 2nd 3rd 4th
Wear or seizure of 2nd clutch disk or wear of piston seal

Wear or seizure of 3rd clutch disk or wear of piston seal
Wear or seizure of 4th clutch disk or wear of piston seal
Wear or seizure of 1st clutch disk or wear of piston seal
Wear or seizure of R clutch disk or wear of piston seal
Wear or seizure of F clutch disk or wear of piston seal
In the Automatic Mode ●
Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
N
Defective operation of 1st clutch ECMV (Fill switch)

Defective operation of R clutch ECMV (Fill switch)
{ { { {
Defective operation of F clutch ECMV (Fill switch)

In the Manual Mode
F1 ● ●
F2 ● ●
Gear Speed
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 {
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 {
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 {
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 {
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 {
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
Defective operation of lock-up ECMV
Seizure of lock-up clutch

Remedy
No. Diagnosis X X
1 The lock-up oil pressure does not come to 0 {

The clutch is not released even when the lock-up oil pressure is
2 0 {
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
• 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
Defective seal of work equipment and steering system hydraulic

Check of abnormality
Breakage of oil cooler and pipe (After torque converter outlet)

Clogging of oil cooler and pipe (After torque converter outlet)
• Execute digging and measure traveling speeds
on a level ground and on a slope to check
pump shaft (Mixing of hydraulic oil in transmission case)

whether the abnormality actually occurs or is a
matter of operator's sense
Defective operation of torque converter relief valve

• Is any failure code of the electrical system dis-
played on the machine monitor?
• Are the transmission oil level and the oil type
appropriate?
Defective seal of relevant clutch piston
Defective seal of parking brake piston

Defective operation of relevant ECMV
Drop of main relief valve set pressure
• Haven't the transmission filter and strainer been
Defective seal of relevant clutch shaft

clogged?

• Is any external oil leak found on the mating faces
Air intake on pump suction side
Oil leak inside torque converter

of pipes and valves around the torque converter

and the transmission?
• Isn't the wheel brake or the parking brake being
dragged?
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
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

Cause
specified torque.

F R 1st 2nd 3rd 4th

●

In the Automatic Mode

N

{ { { {

In the Manual Mode

F1 ● ●
F2 ● ●
Gear Speed
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
cannot be changed.
Remedy Failure
Diagnosis
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)

• Has the torque converter lock-up clutch come not to be let in suddenly?
a b c d e f g
→ Internal seizure or breakage
• Did any abnormal noise occur at the time? → Breakage of parts
Wear of lock-up clutch piston seal ring

Defective operation of lock-up ECMV

• Is the transmission oil level appropriate?
Wear of input shaft seal ring

Crack on lock-up clutch case
Wear of lock-up clutch disk
• Isn't oil leaking outside?
• 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

• Did shocks become large suddenly?
Main
Did any abnormal noise occur at the time and Converter Relief ECMV Transmission Parking Sensor
Charging Brake
where? Pump Valve
• Did shocks become large gradually?
→ Wear of related equipment, defective seal a b c d e f g h i j k l
Defective operation of transmission oil temperature sensor

• Did any of the following abnormal phenomena occur
at the same time: The traveling speed is slow, the
Defective return (Release) of relevant clutch piston

braking is weak, the uphill travelling power is weak,
the gear is not shifted.
→ Execute H-3
Defect of transmission controller system

Defective operation of main relief valve
Defective operation of relevant ECMV★

• Is any failure code of the electrical system displayed
on the machine monitor?

• Are the transmission oil level and the oil type appro-
priate?
clogged?
• Is any external oil leak found on the mating faces of

pipes and valves around the torque converter and
the transmission?
• Isn't the engine speed high at the time of low idling?
• Isn’t play of each drive shaft large?
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 { { { { { {
4 (Clutch) oil pressure is The oil pressure is low { { {
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

Cause
completely and clean it, and then tighten the mounting bolt with the specified
torque.

F R 1st 2nd 3rd 4th


N

In the Manual Mode { { { {

F1 ● ●
F2 ● ●
Gear Speed
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
cannot be changed.
Remedy Failure
Diagnosis
WA380-5 20-809
(10)
TROUBLESHOOTING H-5
H-5 Time lag is large at the times of starting and shifting gear

• Did the time lag become large suddenly?
Main
Did any abnormal noise occur at the time and Converter Relief ECMV Transmission Parking Sensor
Charging Brake
where? Pump Valve
• Has the time lag become large gradually?
→ Wear of related equipment, defective seal a b c d e f g h i j
Defective operation of transmission oil temperature sensor

• Did any of the following abnormal phenomena occur
at the same time: The traveling speed is slow, the
braking is weak, the uphill travelling power is weak,
the gear is not shifted → Execute H-3
Defective operation of relevant ECMV★



• Is any failure code of the electrical system displayed
on the machine monitor?
• Are the transmission oil level and the oil type appro-

priate?
clogged?
• Is any external oil leak found on the mating faces of
pipes and valves around the torque converter and

the transmission?
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 { { { {
3 any abnormal noise occurs from the charging { {
pump or the transmission filter
The torque converter oil temperature is heated
4 abnormally high { { { {
5 The oil pressure is low { { { { {

When the ECMV output at all gear speeds
(Clutch) oil pressure is
measured The oil pressure is low
6 { { {
★ 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

Cause
specified torque.

F R 1st 2nd 3rd 4th


N

In the Manual Mode { { { {

F1 ● ●
F2 ● ●
Gear Speed
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
cannot be changed.
Remedy Failure
Diagnosis
WA380-5 20-811
(10)
TROUBLESHOOTING H-6
H-6 The torque converter oil temperature is high

• Does the oil temperature rise when the torque converter
stalls and does the temperature fall at the time of no load? Torque
Torque Main
Converter Converter Torque
→ Selection of improper gear speed Charging Converter
Relief Transmission Others
Did any abnormal noise occur at the time and where? Pump Oil Cooler Valve
• Does the oil temperature rise only at the time of lifting?
→ Improvement of operating method a b c d e f g h i j k l
Defective seal of work equipment and steering system hydraulic pump

• Measure the torque converter oil temperature to find if the
oil temperature is really high. → The torque converter oil
Breakage of oil cooler and pipe (After torque converter outlet)

Clogging of oil cooler and pipe (After torque converter outlet)
temperature gauge is defective
shaft (Mixing of hydraulic oil in transmission case)

• Are the coolant level in the radiator and the belt tension
appropriate?
• Are the oil level in the transmission and the oil type
appropriate?
• Haven't the transmission filter and strainer been clogged?

• Aren't the transmission filter and the strainer clogged?

Note: When the inspection result was "Engine Degradation,"

proceed to Engine System Troubleshooting (S Mode).
Oil leak inside torque converter
Clogging of breather
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
2 Traveling speed, braking force and uphill travelling { { { { { { { { { { {

power do not occur at all gear speeds
Traveling speed, braking force and uphill travelling
3 {
power do not occur at specific gear speeds
4 The transmission oil level rises and falls { { {
Metal powders (Aluminum, copper, iron, etc.) are
5 { { {
adhered to the transmission filter and the strainer
The engine low idling and high idling speeds are
6 measured to be abnormal { { {
7 When the stall speed of the torque converter is mea- { { { { { { { { {

sured, the speed is high
The oil pressure drops as
8 {
the oil temperature rises
The oil pressure is low at
9 all gear speeds { { { { {
(Clutch) oil pressure is The oil pressure is low at
10 measured {
specific gear speeds
The oil pressure does not
11 become stable as the { {
gauge vibrates
When the torque converter relief (Inlet) oil pressure is
12 measured, the oil pressure is low. (Nos. 9-11 are nor- { { {
mal.)
When the oil pressure at the torque converter outlet
13 is measured, the oil pressure is low. (No. 12 is nor- {
mal.)
20-812 WA380-5
(10)
TROUBLESHOOTING H-7
H-7 The steering wheel does not turn

• Has the steering wheel come not to turn suddenly?
Hydraulic Pump Valve Others
→ Breakage of steering-related equipment
• Was there the sign that the steering wheel did not turn smoothly?
a b c d e f
→ Wear inside steering-related equipment, defective seal
Defect inside steering cylinder (Breakage of piston seal)

Breakage of hydraulic
pump, PTO or pump
• Are the oil level in the hydraulic tank and the oil type appropriate?
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?
Breakage inside steering gear box

Steering and switch pump
Steering relief valve
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
H-8 The steering wheel is heavy

• Has the steering wheel come not to turn suddenly?
Tank Pump Valve Others
→ Breakage of steering-related equipment
• Was there the sign that the steering wheel did not turn smoothly?
a b c d e f g h i
→ Wear inside steering-related equipment, defective seal
The hydraulic pump is defective
The hydraulic oil return side filter is clogged or the bypass valve is defective
Defect inside steering valve

• Are the oil level in the hydraulic tank and the oil type appropriate?
• Aren't the steering gear box mounting portion, the column and the linkage
abnormal?
• Has the steering valve control lever stopper been adjusted properly?
• Is or isn't oil leaking from the hydraulic hoses, valves, cylinders, etc.?
Defect inside steering cylinder (Oil leak from piston seal)

• Are or aren't the center hinge pin bearing, the steering cylinder pin and
bushings galled?
Defect inside steering gear box (Bearing, worm nut)

• Tire air pressure
Improper play adjustment of steering gear box

Check of Abnormality
• Measure the steering wheel operating effort and the time taken to swing
the steering to check if there is any abnormality according to the criterion
values.
Steering and switch pump
Clogging of oil cooler

Steering relief valve
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
H-9 The steering wheel fluctuates or is strongly shocked

• Are the oil level in the hydraulic tank and the oil type appropriate? Valve Cylinder
• Are the steering gear box mounting section, the column and the linkage
a b c
normal?
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?
• 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."
Misalignment of steering valve selector spool

Safety valve
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 {
3 When accelerated in travel, the machine fluctuates { { {

4 When the engine starts, the machine fluctuates {
H-10 The machine steers to one side when traveling
Cause: The steering valve is defective

• Misalignment of spool
Cause: Oil leak inside steering cylinder
Cause: Irregular tire air pressure
H-11 The right and left swing radii are different
Cause: Improper adjustment of steering linkage

Difference between right and left halves, stopper locking position
(Valve relief sound is heard at the end of swing.)
WA380-5 20-815
(8)
TROUBLESHOOTING H-12
H-12 The brake does not work or does not work well

• Has the brake come not to turn suddenly?
→ Breakage of brake
• Has the brake come not to work gradually?
a b c d e f g h i j
→ Wear of seals, lining, disk
Defective seal of accumulator piston, insufficient gas pressure

Metal contact due to complete wear of brake lining in axle
• Is the hydraulic oil level appropriate?
• Is the play of brake pedal appropriate?
• Oil leak from brake tube and connector, deformation of tube
Insufficient scuffing of pilot pump (For charge)

• Tire air pressure and state of tire tread
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Defective seal of brake piston in axle
Defective operation of charge valve

• Measure the braking force and check referring to the standard value table if
the brake does not work practically.
The brake in axle is defective
Mixing of air in brake circuit
Defect inside brake valve

Remedy ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆
No.
1 When the brake pedal is stepped on, only a little resistance is felt { { { {
2 When the brake pedal is stepped on, a strong resistance is felt {
3 To get the specified braking force, an abnormal leg-power is required { { { { {
4 When the brake works, an abnormal noise occurs from the axle brake { {
5 The machine does not travel well. (Insufficient drawbar pull) {
When the four wheels are jacked up, the axle is placed on a table and
6 the brake is applied at the first forward speed, only a specific wheel { { { { { {
rotates
An airflow is observed in bleeding air from the brake circuit, and the
7 brake returns to normal after the bleeding {
8 Brake oil leaks abnormally from the axle during inspection {

9 Much metal powders are mixed in the axle oil {
The brake pedal leg-power and stroke are normal, but the brake does
10 { { { {
not work well
11 The brake does not work often when the engine is stopped { { { {
12 The accumulator is not charged, and a buzzer sounds { { {
13 The brake works after some time lag {
20-816 WA380-5
(10)
H-13 The brake is not released or is dragged

• Has the brake pedal returned completely?
• Is the parking brake released completely? a b c
Defect inside brake valve (Stocking of piston)
Defective operation of brake piston in axle

• Abnormal heat of brake
• Does the machine travel smoothly by inertia on a level ground?
Abnormal lining of brake in axle

Remedy ∆ ∆ ∆
No.
Diagnosis X X X
1 The brake pedal is released, but the brake is still applied { { {
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)
H-14 The brake is not released or dragged

• Check if the emergency parking brake release valve is closed. (When this
valve is open, the parking brake is always released.)
• Check if the parking brake is automatically applied when the engine stops. a b c d e
Being pinched due to peeling of parking brake disk lining

Insufficient oil level due to defect of transmission valve
Broken harness of parking brake switch line
Defective operation of parking brake piston

Defect inside parking brake solenoid valve
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)
H-15 The Lift arm does not rise

Work
• Has the Lift arm come not to work suddenly → Seizure or breakage of Tank Pump
Steering PPC
Equipment Cylinder
each equipment Valve Valve Valve
• Did any abnormal noise occur at the time (And where)?
a b c d e f g h i j
Clogging of pump suction port or mixing of much air in oil

• Was there the phenomenon that the Lift arm worked slowly?
→ Wear of parts or deformation of spring
The hydraulic pump and the switch pump are defective

• Is the oil level in the hydraulic tank appropriate?
Breakage inside valve body (Lift arm spool)

• Is the stroke of the Lift arm control lever appropriate?

Defective operation of demand spool
Damage of Lift cylinder piston seal

Defective operation of relief valve
The pump PTO does not drive
Defective operation of spool

The PPC pump is defective
Remedy C ∆ ∆ ∆ ∆ ∆ ∆
No.
Diagnosis ∆ X X X X X X X X X
1 The bucket cannot operate and the Lift arm cannot rise { { { { { { { {
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)
H-16 The Lift arm moves slowly or the Lift arm rising force is insufficient

• Is the stroke of the Lift arm control lever appropriate? Work
Tank Steering PPC Cutoff
Equipment Cylinder
Pump Valve Valve Valve Valve
Check of Abnormality a b c d e f g h i
Defective operation or improper adjustment of main relief valve

• Rising force and speed problem are closely related, and this problem
occurs as insufficient rising speed at first. Measure the Lift arm ris-
Defective operation or improper adjustment of cutoff valve

ing speed when the Lift arm is loaded and make sure referring to the
criterion table that the speed is abnormal.
Wear or breakage inside valve body (Lift arm spool)

Damage of Lift cylinder piston seal


Remedy C ∆ ∆ ∆ ∆ A ∆ ∆
No.
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 {
4 The hydraulic pump is causing an abnormal noise { {

When the engine is at full throttle, the steering operation is
5 light and too fast {
6 When the engine is at full throttle, the steering operation is { {

heavy and slow
7 Large hydraulic drift of cylinder { {
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)
H-17 When rising, the Lift arm comes to move slowly at specific height

• Deformation of Lift cylinder in appearance
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."

• Is the stroke of the Lift arm control lever appropriate?
Cause
• Defective seat of suction valve on the Lift cylinder rod side of work equipment valve
• Oil leak from Lift cylinder piston seal
H-19 Hydraulic drifts of the Lift arm occur often
Ask the operator about the following:

• Have hydraulic drifts come to occur often suddenly? → Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? → Wear of parts

• Is the Lift arm spool at the neutral position? → The spool detent is defective
Diagnosis and Cause

• Does any leaking noise occur inside the Lift cylinder when hydraulic drift is measured? → The cylinder packing is defective
H-20 The Lift arm wobbles during operation
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.
Diagnosis and Cause

Check at first the hydraulic drift and if the Lift cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see "H-19. Hydraulic drifts of the Lift arm occur often."
2. When the Lift cylinder cannot lift the machine, see "H-18. The Lift cylinder cannot hold down the bucket."
3. When the Lift cylinder comes to enable to lift the machine after the Lift arm is operated several times with the normal hydraulic
drift and after the boom cylinder operates to full stroke → The cause is vacuum generated inside the cylinder
★ Frequent hydraulic drifts → The suction valve on the Lift cylinder rod side is defective
WA380-5 20-821
(10)
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)
H-22 The bucket does not tilt back

Work
• Has the bucket come not to work suddenly → Seizure or breakage of each Tank Pump
Steering PPC
Equipment Cylinder
equipment Valve Valve Valve
• Did any abnormal noise occur at the time (And where)?
a b c d e f g h i j

• Was there the phenomenon that the bucket worked slowly?
→ Wear of parts or deformation of spring

• Is the stroke of the bucket control lever appropriate?
Breakage inside valve body (Bucket spool)

Damage of bucket cylinder piston seal

The pump PTO does not drive
The relief valve is defective

The PPC pump is defective
The spool is defective

Remedy C ∆ ∆ ∆ ∆ ∆ Α X X
No.
Diagnosis ∆ X X X X X X X
1 The Lift arm cannot operate and the bucket cannot tilt back { { { { { { {
The bucket can lift the machine but cannot tilt back, or the Lift arm
2 operates but the Lift arm cannot tilt back { { {
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 { {
6 and too fast {

7 {
and slow
WA380-5 20-823
(8)
H-23 The bucket moves slowly or the tilting-back force is insufficient

• Is the stroke of the bucket control lever appropriate? Work
Tank Steering PPC Cutoff
• Seizure of work equipment linkage bushing (Does any abnormal noise Equipment Cylinder
Pump Valve Valve Valve Valve
occur?)
a b c d e f g h i j
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
• 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
Defective operation or improper adjustment of main relief valve
Defective operation or improper adjustment of cutoff valve

Wear or breakage inside valve body (Bucket spool)
Damage of bucket cylinder piston seal

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 { {
5 {
and too fast
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)
H-24 The bucket comes to operate slowly in the midst of tilting-back

• Deformation of bucket cylinder in appearance
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."
H-25 The bucket cylinder cannot hold down the bucket
See "H-23. The bucket moves slowly or the tilting-back force is insufficient."

• Is the stroke of the bucket control lever appropriate?
Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal
H-26 Hydraulic drifts of the bucket occur often
Ask the operator about the following:

• Have hydraulic drifts come to occur often suddenly? → Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? → Wear of parts

• Is the bucket spool at the neutral position? → Seizure of link bushing or the spool detent is defective
• 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)
The bucket wobbles during travel with cargo (The work equipment valve is set to
H-27 "HOLD")

• Pin of work equipment linkage and "play of bushing" (Is any abnormal noise heard?)
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)
H-29 The control levers of Lift arm and bucket do not move smoothly and heavy
Check of Abnormality Cause

• Refer to the criterion value table and check if the lever operating efforts PPC Valve Work Equipment Valve
are large practically.
a b c d e f g h i j
Strain of valve body due to uneven tightening of valve mounting bolt
Improper roundness between work equipment valve body and spool

Improper clearance between work equipment valve body and spool
Defective operation of work equipment valve spool detent
Improper roundness between PPC valve body and spool
Improper clearance between PPC valve body and spool
Foreign matter pinched in work equipment valve spool

Foreign matter pinched in PPC valve spool
The work equipment valve spool is bent

The PPC valve spool is bent
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 {
The levers totally come not to move smoothly during operation

4 irrespective of oil pressure and oil temperature { { { { {
WA380-5 20-827
(8)
H-30 E.C.S.S. does not work, and there is pitcing and bouncing
E.C.S.S.: Electronically controlled suspension system

Ask the operator the following questions. Cause
• Did the problem suddenly start? Sole- Accu- Con- Sen-
noid mula- trolle sor
Yes = Related equipment broken valve tor r
• Was there any abnormal noise when this happened?
Where did the noise come from? a b c d
• Did the problem gradually appear?

Yes = Wear of related parts, defective seal
Checks before troubleshooting

• Is operation of E.C.S.S. switch correct?
• Are the DIP switches and rotary switches on the back side of the main moni-
tor set correctly?
(See TESTING AND ADJUSTING, Adjusting machine monitor.)
Where did the noise come from?
• Are failure codes [D191KA] and [D191KB] displayed?
Defective seal, leakage of gas from high-pressure accumulator

(For details, see Troubleshooting for transmission system (TM mode).)
Defective actuation of solenoid valve (SOL1)
Defective actuation of controller
Defective speed sensor
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
2 E.C.S.S. does not work when traveling loaded Q Q

3 E.C.S.S. does not work when traveling unloaded Q Q
When E.C.S.S. is actuated when traveling loaded, boom drops greatly
4 Q
(more than 30 cm)
5 E.C.S.S. does not work at all Q Q Q Q
20-828 WA380-5
(10)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)

Connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-912
Electrical system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918
Troubleshooting Code [E-1-a] (The engine does not start. (Starting system)). . . . . . . . . . . . . . . . . 20-920
Troubleshooting Code [E-1-b] (The engine does not start. (Engine stop solenoid system)) . . . . . 20-924
Troubleshooting Code [E-2] (The engine does not stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-926
Troubleshooting Code [E-3] (Preheating is impossible or constant) . . . . . . . . . . . . . . . . . . . . . . . 20-928
Troubleshooting Code [E-4] (The engine power modes cannot be selected) . . . . . . . . . . . . . . . . 20-930
Troubleshooting Code [E-5] (The front wiper does not function) . . . . . . . . . . . . . . . . . . . . . . . . . 20-932
Troubleshooting Code [E-6] (The rear wiper does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-935
Troubleshooting Code [E-7] (The side wiper does not function (If equipped)). . . . . . . . . . . . . . . 20-936
Troubleshooting Code [E-8] (The wind washer does not function) . . . . . . . . . . . . . . . . . . . . . . . . 20-937
Troubleshooting Code [E-9] (The headlamp (Lo beam) does not light on). . . . . . . . . . . . . . . . . . 20-940
Troubleshooting Code [E-10] (The headlamp (Hi beam) does not function) . . . . . . . . . . . . . . . . . 20-943
Troubleshooting Code [E-11] (The clearance lamp does not light on (Small lamp)) . . . . . . . . . . . 20-945
Troubleshooting Code [E-12] (The turn signal does not blink). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-946
Troubleshooting Code [E-13] (The horn does not sound) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-948
Troubleshooting Code [E-14] (The air conditioner does not work or does not stop). . . . . . . . . . . 20-950
WA380-5 20-901
5

Electrical system.
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

conditioner)

A23 Yazaki 2 W-4
conditioner)
W-3

WA380-5 20-903
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

Kyoritsu
ES

21-2
AMP1722
CL5 S (W) 16 M-2
conditioner)
conditioner)
20-904 WA380-5
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
WA380-5 20-905
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
lamp)
20-906 WA380-5
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
WA380-5 20-907
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
20-908 WA380-5
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
switch)
W-3,

R13 L-1 O-1 X-6 F-2
WA380-5 20-909
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E

R65 DT-T 6 Cooler automatic tilt motor switch (If equipped). L-4
stick)
S14 DT-T 6 N-8 I-2
stick)
20-910 WA380-5
(10)
5
20-912 WA380-5
WA380-5 20-913
5
20-914 WA380-5
5
WA380-5 20-915
5
20-916 WA380-5
5
WA380-5 20-917
5
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM
ELECTRICAL SYSTEM DIAGRAM
20-918 WA380-5
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-A]
[E-1-a]
TROUBLESHOOTING CODE: [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.
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.).

Specific 1.26 and
gravity above
1 Defective battery 25 V and
Voltage above

Among battery relay terminals R13, R01,
R04 and machine body. Voltage 20 - 30 V

2) Disconnect the connector S31 and the terminal R13.
3) Insert a T-adapter.
Harness among S31 (female) 2, battery
relay and the terminal R13.
2 Disconnection between battery ★ Measure continuity from S31 (female) Continuity Yes
relay body and related harness
2 in the diode range.
Between battery (+) terminal and (-) termi- Voltage 20 - 30 V
nal.
1) Starting switch OFF. 2) Disconnect the (-) terminal of the battery relay.
Harness between battery relay (-) terminal Resistance 1 Ω and
and machine body. below
1) Starting switch OFF. 2) Disconnect the connector E01.
3) Insert a T-adapter. 4) Starting switch "Start."
Possible Causes and Between E01 1 and machine body. Voltage 20 - 30 V
Disconnection between n start-
Standard Values 3 ing motor and related harness 1) Starting switch ON.
Between starting motor B terminal and Voltage 20 - 30 V
machine body
3) Insert a T-adapter. 4) Starting switch ON.
4 Defective alternator (regulator)
1 V and
Between E01 2 and machine body Voltage below
Among S31 1, 2, 3 and machine body
(Starting switch "Start" between 3 and Voltage 20 - 30 V
machine body)
2) Disconnect the starting switch terminals B, BR and C.
1 Ω and
Between starting switch terminal B and BR Resistance below
Disconnection between starting
5 switch and related harness
Between starting switch terminal B and C Resistance 1 Ω and
below
1) Stating switch OFF. 2) Disconnect the connectors S31, FS3 and
L116.
3) Connect a T-adapter.
Harness between S31 (female) 1 and FS3 1 Ω and
Resistance
(female) 1 below
Harness between S31 (female) 1 and L116 1 Ω and
(female) 3 Resistance below
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)

1) Stating switch OFF. 2) Disconnect the connector TEL.
Harness between TEL (female) 7 and 1 Ω and
Disconnection between Resistance
TEL (female) 8 below
6 short connector (TEL) and
related harness 1) Stating switch OFF. 2) Disconnect the connectors TEL and L116.
Harness between TEL (male) 8 and L116 Resistance 1 Ω and
(female) 3 below
1) Stating switch OFF. 2) Disconnect the connectors L79 and L116.
3) Connect a T-adapter. 4) Shifter switch "Neutral."
5) Starting switch "Start."
Between L113 4 and machine body. Voltage 20 - 30 V
Between L113 3 and machine body. Voltage 20 - 30 V
1 V and
Between L113 1 and machine body. Voltage
below
1) Stating switch OFF. 2) Disconnect the relays L113 and L116.
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.
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.
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."
9 Disconnection between shift 1) Stating switch OFF. 2) Disconnect the connectors L04 and FS4.
switch and related harness
Harness between L04 (female) 1 and 1 Ω and
FS4 (female) 2. Resistance below
1) Stating switch OFF. 2) Disconnect the connector R26.
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)
Trouble (Starting system)
E-1-a) — —
1) Stating switch OFF. 2) Disconnect the connector R27.
Between R27 (male) 2 and 1.
side in the diode range. Continuity Yes
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
1) Stating switch OFF. 2) Disconnect the connectors E01, R26 and R27.
Harness between E01 (female) 1 and Resistance 1 Ω and
Harness between E01 (female) 1 and 1 Ω and
Resistance
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
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.
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.
12 Defective FNR switch mode
selector switch 1 V and
Between S04 4 and machine body. Voltage below
20-922 WA380-5
(10)
5
WA380-5 20-923
5
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
TROUBLESHOOTING CODE: [E-1-b]
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.
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.)

1) Starting switch OFF. 2) Disconnect the connector R72. 3) Connect a
Defective fuel cut solenoid T-adapter.
1
relay
Between R72 (male) 1 and 2. Resistance 50 - 90 Ω
1) Starting switch OFF. 2) Disconnect the connector E34. 3) Connect a
T-adapter.
Between E34 (male) A and C.
2 Defective fuel cut solenoid.
Resistance 0.6 - 1.0 Ω
Between E34 (male) B and C. Resistance 37 - 46 Ω
1) Starting switch OFF. 2) Disconnect the connector L91. 3) Insert a T-
adapter. 4) Connect the connector.
Starting switch 24 V and
"ON." Voltage above
Between L91 1 and 2
Starting switch Voltage 16 V and
3 Defective timer "Start." above
For 2 to 4 sec.
16 V and
from Starting Voltage above
Between L91 5 and 6 Switch "ON."
Other than the 1 V and
Voltage
above below
1) Starting switch OFF. 2) Disconnect the connectors E34, L91, S31,
R12, R68, R72 and L102. 3) Connect a T-adapter.
Harness between R12 and R68. Resistance 1 Ω and

below
1 Ω and
A.
Harness between R69 and E34 (female)
Resistance
below
Possible Causes and Stan- Harness between S31 (female) 4 and 1 Ω and
L91 (female) 1. Resistance below
dard Values
1 Ω and
E34 (female) B.
Harness between S31 (female) 4 and Resistance
Disconnection of harness below
4 (Disconnection, defective
contact) Harness between L91 (female) 5 and 1 Ω and
Resistance
R72 (female)1. below
Harness between L91 (female) 6 and 1 Ω and
R72 (female) 2. Resistance below
Harness between L91 (female) 4 and Resistance 1 Ω and
R102 (female) D. below
Between L91 (female) 2 and machine 1 Ω and
Resistance
body. below
Between E34 (female) C and machine 1 Ω and
body. Resistance below
1) Starting switch OFF. 2) Disconnect the connectors E34, L91, S31,
R12, R68, R72 and L102. 3) Connect a T-adapter.
1 Ω and
Among R12, R68 and machine body. Resistance
above
Among R69, E34 (female) A and 1 Ω and
machine body. Resistance above
★ In the above two cases, the flow blow fuse is blown.
5 Ground fault of harness
1 Ω and
E34 (female) B and machine body.
Among S31 (female) 4, L91 (female) 1,
Resistance
above
L91 (female) 5, R72 (female) 1 and 1 Ω and
machine body. Resistance above
1 Ω and
E34 (female) B
Harness between L91 (female) 1 and
Resistance above
★ In the above three cases, the fuse B-1 is blown.
20-924 WA380-5
(10)
5
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
WA380-5 20-925
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-2]
TROUBLESHOOTING CODE: [E-2]

Troubleshooting Code Failure Code Controller Code
Trouble The engine does not stop.
E-2 — —
Description of Trouble The engine stop solenoid system is out of order, and the engine does not stop.
Effect on Machine Even if the starting switch (ignition key switch) is set to "OFF," the engine does not stop.

1) Starting switch OFF. 2) Disconnect the connector R72. 3) Connect a
Defective fuel cut solenoid T-adapter.
1
relay
Between R72 (male) 1 and 2. Resistance 50 - 90 Ω
T-adapter.
Between E34 (male) A and C.
2 Defective fuel cut solenoid.
Resistance 0.6 - 1.0 Ω
Between E34 (male) B and C. Resistance 37 - 46 Ω
1) Starting switch OFF. 2) Disconnect the connector L91. 3) Insert a T-
adapter. 4) Connect the connector.
Starting switch 24 V and
"ON." Voltage above
Between L91 1 and 2
Starting switch Voltage 16 V and
Possible Causes and Stan- "Start." above
dard Values 3 Defective timer
16 V and
For 2 to 4 sec. Voltage
above
Between L91 5 and 6 from Starting
Switch "ON." 1 V and
Voltage below
★ Unless the engine stops when the connector L91 is disconnected,
the timer needs not be inspected.
T-adapter.
Between E34 (male) A and machine Voltage 1 V and
body. below
4 Hot short-circuit of harness Between E34 (male) B and machine 1 V and
Voltage
body. below
★ Unless the engine stops when the connector E34 is disconnected,
the cause is the solenoid or the fuel circuit system (mechanical sys-
tem).
20-926 WA380-5
(10)
WA380-5 20-927
5

Troubleshooting Code Failure Code Controller Code Preheating is impossible or con-
Trouble stant.
E-3 — —
Description of Trouble The preheating system is out of order, and preheating is impossible or constant.
Effect on Machine Preheating is impossible or constant.
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.

1) Starting switch OFF. 2) Disconnect the connectors E05, E06 and E07.
★ Solid part check
1 Defective intake air heater relay Between E05 and machine body. Resistance 19 - 25 Ω
Between E06 When the relay is ON Resistance 1 Ω and below

andE07 When the relay is OFF Resistance 1 MΩ and above
1) Starting switch OFF. 2) Disconnect the heater terminal.
2 Defective intake air heater
Between heater terminal and ground Resistance
1) Starting switch OFF. 2) Disconnect the connectors L102, E05, E06,
E07, R11 and heater terminal. 3) Connect a T-adapter.
Disconnection of harness (Dis- Resistance 1 Ω and below
3 connection, defective contact) E05.
(Intake air heater system) Harness between R11 and E06. Resistance 1 Ω and below
Harness between E07 and heater termi- Resistance 1 Ω and below
nal.
1) Starting switch OFF. 2) Disconnect the connectors L102, E05, E06,
E07, R11 and heater terminal. 3) Connect a T-adapter.
Among L102 (female) 4, E05 and Resistance 1 MΩ and above
machine body
★ In cases other than the above, the fuse B-0 will be blown.
4 Ground fault of harness (Intake
air heater system) Among R11, E06 and machine body Resistance 1 MΩ and above
Among E07, heater terminal and Resistance 1 MΩ and above
machine body
In case other than the above two paragraphs, the slow blow fuse will
be blown.
Possible Causes and 1) Starting switch OFF. 2) Disconnect the connector E09. 3) Connect a
Standard Values T-adapter.
Defective engine coolant tem-
5 perature sensor At the time of 10 °C Resistance 7 - 11 kΩ
Between E09
(male) (A) and (B) At the time of 100 °C Resistance 0.1 - 0.5 kΩ
1) Starting switch OFF. 2) Disconnect the connectors L55 and TWH. 3)
Ground fault of harness (Engine Insert a T-adapter.
6 coolant temperature sensor sys-
tem) Among L55 (female) 3, E09 (A) and Resistance 1 MΩ and above
machine body
1) Starting switch OFF. 2) Disconnect the connector L55. 3) Connect a
T-adapter.
7 Defective monitor panel Between L55 At the time of 10 °C Resistance 7 - 11 kΩ
(female) 3 and
machine body At the time of 100 °C Resistance 0.1 - 0.5 kΩ
1) Starting switch OFF. 2) Disconnect the connector L114. 3) Connect
a T-adapter.
Between L114 (male) 1 and 2 Resistance 200 - 400 kΩ
1) Starting switch OFF. 2) Disconnect the connector L114. 3) Replace
8 Defective preheater relay the preheater relay (114) with another relay. 4) Starting switch ON.
The preheater relay (L114) is
The machine operates normally. out of order.
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)
WA380-5 20-929
(7)

Troubleshooting Code Failure Code Controller Code The engine power modes cannot
Trouble
E-4 — — be selected.
Description of Trouble The engine power mode system is out of order, and the power modes cannot be selected.
Effect on Machine The engine power modes cannot be selected.

1) Starting switch OFF. 2) Disconnect the connector S21. 3) Connect a T-
adapter.
★ Solid part check
1 Defective power mode
selector switch In the economy
Between S01 (male) mode Resistance 1 MΩ and above
1 and 4
In the power mode Resistance 1 Ω and below
1) Starting switch OFF. 2) Replace L115 with any other relay. 3) Starting
switch "ON."
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
machine body
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
Standard Values Resistance 1 Ω and below
L102 (female) 0
★ In the above two cases, the economy mode cannot be selected.
machine body Resistance 1 Ω and below
Harness between L88 (female) 7 and Resistance 1 Ω and below

L102 (female) 8
★ In the above two cases, the economy mode cannot be changed to the
power mode, and the power mode cannot be changed to the economy
mode.
1) Starting switch OFF. 2) Disconnect the connectors S21, L102 and L61.
Among S21 (female) 4, L61 (female) 6,
L102 (female) 7 and machine body
Among L88 (female) 3, L102 (female) 0
and machine body Resistance 1 MΩ and above
★ In the above two cases, the economy mode cannot be selected.
4 Ground fault of harness Among FS3 (female) 5, L88 (female) 4, Resistance 1 MΩ and above
L102 (female) 6 and machine body
★ In the above case, the fuse B-6 will be blown.
Among L88 (female) 7, L102 (female) 8
and machine body
★ In the above two cases, the economy mode cannot be changed to the
power mode, and the power mode cannot be changed to the economy
mode.
20-930 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code The engine power modes
Trouble
E-4 — — cannot be selected.

1) Starting switch OFF. 2) Disconnect the connectors S21, L102 and
L61. 3) Connect a T-adapter. 4) Starting switch ON.
Among S21 (female) 4, L61 (female) 6, 1 V and
Voltage
L102 (female) 7 and machine body below
Possible Causes and Stan- ★ In the above case, the fuse B-6 will be blown when the power
dard Values 5 Hot short-circuit of harness mode is selected.
Among L88 (female) 7, L102 (female) 8 1 V and
Voltage
and machine body below
★ In the above case, the economy mode is changed to the power
mode, and the power mode is changed to the economy mode
automatically without operation.
WA380-5 20-931
(10)

Trouble The front wiper does not function
E-5 — —
Description of Trouble • Since a fault occurs in the front wiper, switch timer, or harness, the front wiper does not function
Effect on Machine • The front wiper does not function

2) Disconnect connector C12.
Between C12 2 - body (Wiper switch Lo) Voltage 20 - 30 V
1 Front wiper motor fault
Between C12 1 - body (Wiper switch Hi) Voltage 20 - 30 V
Between C12 6 - body Voltage 20 - 30 V
When the wiper switch is turned OFF during running of the wiper, the voltage
is applied between the C12 5 - body until the wiper motor stops
1) Turn starting switch OFF
Between L31 3 - body Voltage 20 - 30 V
2 Wiper timer (relay) fault
Between L31 4 - body (Wiper switch INT) Voltage 20 - 30 V
Between L31 2 - body (Wiper switch washer
Possible Causes and side) Voltage 20 - 30 V
Standard Values
Between L31 5 - body (The voltage is output intermittently by wiper switch
INT) 20 to 30 V → 0 V → 20 to 30 V → 0 V repeated
3 Front wiper switch fault
Between L21 (Male) 7 - 5 (Wiper switch Lo) Resistance 1 Ω and below
Between L21 (Male) 7 - 4 (Wiper switch Hi) Resistance 1 Ω and below
Between L21 (Male) 7 - 2 (Wiper switch Resistance 1 Ω and below
INT)
Between L21 (Male) 3 - 5 (Wiper switch
INT)
20-932 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code The front wiper does not func-
Trouble
E-5 — — tion

2) Disconnect connectors L21, L31, and C12.
Harness between L21 (Female) 2 -
L31 (Female) 4
Between L21 (Female) 2, L31
(Female) 4 - body Resistance 1 MΩ and above
Harness between L21 (Female) 3 - Resistance 1 Ω and below

L31 (Female) 5
Harness disconnection or (Female) 5 - body
ground fault
4 ★ Fuse A-7 blows in ground Harness between L21 (Female) 5 - Resistance 1 Ω and below
C12 (Female) 2
fault case.
Between L21 (Female) 5, C12
Possible Causes and (Female) 2 - body Resistance 1 MΩ and above
Standard Values
C12 (Female) 1
Between L21 (Female) 4, C12
(Female) 1 - body
C12 (Female) 5 Resistance 1 Ω and below
Between L31 (Female) 6, C12 Resistance 1 MΩ and above

(Female) 5- body
2) Disconnect connectors FS4, L21, C12, C15, C43, C44, and C45.
Harness disconnection or 3) Connect T-adapter
ground fault
5 ★ Fuse A-7 blows in ground Harness between L21 (Female) 7 - Resistance 1 Ω and below
FS4 (Female) 7
fault case.
Between L21 (Female) 7, FS4
WA380-5 20-933
(10)
5
20-934 WA380-5
5

Trouble The rear wiper does not function
E-6 — —
Description of Trouble • Since a fault occurs in the rear wiper, switch, or harness, the rear wiper does not function.
Effect on Machine • The rear wiper does not function.

1 Rear wiper motor fault Between C15 2 - body (Wiper switch Lo) Voltage 20 - 30 V
Between C15 1 - body Voltage 20 - 30 V
2 Rear wiper switch fault 2) Disconnect connector L21.
Between L21 (Male) 7 - 9 (Wiper switch Lo) Resistance 1 Ω and below
Between L21 (Male) 8 - 9 (Wiper switch Resistance 1 Ω and below
Possible Causes and OFF)
Standard Values
2) Disconnect connectors L21 and C15.
Harness between L21 (Female) 8 - C15
Between L21 (Female) 8, C15 (Female) 3 - Resistance 1 MΩ and above

body
Harness disconnection Harness between L21 (Female) 9 - C15

or ground fault (Female) 2
3 ★ Fuse A-7 blows in
Between L21 (Female) 9, C15 (Female) 2 -
ground fault case. body Resistance 1 MΩ and above
2) Disconnect connectors FS4, L21, C12, C15, C43, C44, and C45.
Harness between L21 (Female) 7 - FS4
Between L21 (Female) 7, FS4 (Female) 7 - Resistance 1 MΩ and above

body
Related circuit diagram (See item E-5.)
WA380-5 20-935
(10)
5
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.
Effect on Machine • The side wiper does not function.

2) Disconnect connectors C44 and C45.
• Right side wiper
1 Side wiper fault is applied between the C44 2 - body until the wiper motor stops
Between C44 4 - body (Power) Voltage 20 - 30 V
• Left side wiper
2 Side wiper switch fault 2) Disconnect connector C43.
Possible Causes and
Standard Values Between C43 (Female) 3 - 2 (Wiper switch
Lo) Resistance 1 Ω and below
Between C43 (Female) 2 - 1 (Wiper switch Resistance 1 Ω and below

OFF)
2) Disconnect connectors C43, C44, and C45.
Harness between C43 (Female) 2 - C44
(Female) 1 (C45 (Female) 1) Resistance 1 Ω and below
Between C43 (Female) 2, C44 (Female) 1 Resistance 1 MΩ and above

(C45 (Female) 1 - body)
Harness between C43 (Female) 1 - C44
Harness disconnection Resistance 1 Ω and below
(Female) 2 (C45 (Female) 2)
or ground fault
3 ★ Fuse A-7 blows in Between C43 (Female) 1, C44 (Female) 2
(C45 (Female) 2) Resistance 1 MΩ and above
ground fault case.
2) Disconnect connectors L21, L31, FS4, R43, R45, C12, C15, C43, C44, and
C45.
Harness between C43 (Female) 3 - FS4 Resistance 1 Ω and below
(Female) 7
Between C43 (Female) 3, FS4 (Female) 7 -
and body
20-936 WA380-5
(10)
5
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
does not function.
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).

2) Disconnect connectors R43 and R45.
1 Washer motor fault • Front washer motor
Between R43 1 - body Voltage 20 - 30 V
• Rear washer motor
Between R45 1 - body Voltage 20 - 30 V
• Common to front switch and rear switch
• Front switch
Possible Causes and Between L21 (Male) 7 - 6 (Washer switch
Standard Values 2 Wiper switch fault Resistance 1 Ω and below
ON)
Between L21 (Male) 7 - 6 (Washer switch
OFF)
• Rear switch
Between L21 (Male) 7 - 0 (Washer switch
ON) Resistance 1 Ω and below
Between L21 (Male) 7 - 0 (Washer switch Resistance 1 MΩ and above

OFF)
Between L21 (Male) 7 - 9, and 0 (Washer
wiper Lo switch ON)
Wiper timer (Relay) fault
3 (Front wiper only) Between L31 3 - body Voltage 20 - 30 V
Between L31 2 - body (Washer switch ON) Voltage 20 - 30 V
Between L31 5 - body (0.2 - 0.8 sec. after the Voltage 20 - 30 V
washer switch was turned ON)
WA380-5 20-937
(10)
5
Troubleshooting Code Failure Code Controller Code The wind washer does not func-
Trouble
E-8 — — tion

2) Disconnect connectors L21, R43, R45, and L31.
• Front washer motor circuit
R43 (Female) 1 Resistance 1 Ω and below
Between L21 (Female) 6, R43 Resistance 1 MΩ and above

(Female) 1 - body
L31 (Female) 2
(Female) 2 - body
Harness disconnection or Harness between L21 (Female) 3 -

Possible Causes and L31 (Female) 3 Resistance 1 Ω and below
Standard Values ground fault
4 ★ Fuse A-7 blows at occur-
Between L21 (Female) 3, L31 Resistance 1 MΩ and above
rence of a ground fault. (Female) 3 - body
• Rear washer motor circuit
Between L21 (Female) 0, R45 Resistance 1 MΩ and above

(Female) 1 - body
2) Disconnect connectors L21, L31, FS4, R43, R45, C12, C15, C43, C44,
and C45.
FS4 (Female) 7
Between L21 (Female) 7, FS4
20-938 WA380-5
(10)
WA380-5 20-939
5
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
headlamp (Lo beam) does not light on.
Effect on Machine • The headlamp (Lo beam) does not light on.

2) Disconnect the connector HEAD of the left and right.
1 Lamp fault
Between HEAD 2 (Left and right) - body
Voltage 20 - 30 V
(Lamp switch: 2nd row)
(Lamp switch: 2nd row, Dimmer switch: Lo) Voltage 20 - 30 V
Possible Causes and
Standard Values Between L02 2 - body (Lamp switch: 2nd
row) Voltage 20 - 30 V
Between L02 4 - body (Lamp switch: 2nd Voltage 1 V and below

row, Dimmer switch: Lo)
Lamp switch or dimmer
2 switch fault Between L02 4 - body (Lamp switch: OFF,
Voltage 20 - 30 V
Dimmer switch: Hi)
Between L02 (Male) 1 - 2 (Lamp switch:
2nd row)
Between L02 (Male) 4 - 6 (Dimmer switch:
Lo) Resistance 1 Ω and below
20-940 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code The headlamp (Lo beam) does
Trouble
E-9 — — not light on

2) Disconnect connectors L02, FS4, FS5, left HEAD and right HEAD.
FS4 (Female) A
Between L02 (Female) 1 - FS4
(Female) A harness - body Resistance 1 MΩ and above

FS5 (Female) 4
Between L02 (Female) 2 - FS5
(Female) 4 harness - body
Harness between FS5 (Female) 5 -
right HEAD (Female) 2
Between FS5 (Female) 5 - right HEAD
(Female) 2 harness - body Resistance 1 MΩ and above
Harness between FS5 (Female) 6 - Resistance 1 Ω and below

Harness disconnection or left HEAD (Female) 2
Possible Causes and ground fault Between FS5 (Female) 6 - left HEAD
Standard Values 3 ★ Fuses A-1, A-12, and A-13 Resistance 1 MΩ and above
2 harness - body
blow at occurrence of a
ground fault.
right HEAD (Female) 1 Resistance 1 Ω and below
Between L02 (Female) 4 - right HEAD Resistance 1 MΩ and above

Harness between L02 (Female) 4 - left
HEAD (Female) 1
Between L02 (Female) 4 - left HEAD
Harness between FS5 (Male) 4 - 5 Resistance 1 Ω and below

(Including fuse A-13)
Between FS5 (Male) 4 - 5 harness -
body
Harness between FS5 (Male) 4 - 6
(Including fuse A-12) Resistance 1 Ω and below
Between FS5 (Male) 4 - 6 harness - Resistance 1 MΩ and above

body
WA380-5 20-941
(10)
20-942 WA380-5
5
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
headlamp (Hi beam) does not light on.
Effect on Machine • The headlamp (Hi beam) does not light on.

2) Disconnect the connector HEAD on the left and right.
1 Lamp fault
Between HEAD 2 (Left and right) - body Voltage 20 - 30 V
(Lamp switch: 2nd row)
Voltage 20 - 30 V
(Lamp switch: 2nd row, dimmer switch: Hi)
Between L02 2 - body (Lamp switch: 2nd
row) Voltage 20 - 30 V
Between L02 3 - body (Lamp switch: 2nd Voltage 1 V and below

row, Dimmer switch: Hi)
Lamp switch or dimmer Between L02 3 - body (Lamp switch: OFF,
2 Voltage 20 - 30 V
switch fault Dimmer switch: Lo)
Between L02 (Male) 1 - 2 (Lamp switch: Resistance 1 Ω and below
Possible Causes and 2nd row)
Standard Values
Between L02 (Male) 3 - 6 (Dimmer switch:
Hi)
2) Disconnect connectors L02, FS4, FS5, and left HEAD and right HEAD.
(Female) A Resistance 1 Ω and below
Between L02 (Female) 1 - FS4 (Female) A Resistance 1 MΩ and above

harness - body
Harness disconnection Harness between L02 (Female) 2 - FS5
or ground fault Resistance 1 Ω and below
(Female) 4
★ Fuses A-1, A-12, and
3 A-13 blow at occur- Between L02 (Female) 2 - FS5 (Female) 4
harness - body Resistance 1 MΩ and above
rence of a ground
fault. Harness between FS5 (Female) 5 - right Resistance 1 Ω and below
HEAD (Female) 2
Between FS5 (Female) 5 - right HEAD
Harness between FS5 (Female) 6 - left
HEAD (Female) 2 Resistance 1 Ω and below
Between FS5 (Female) 6 - left HEAD 2 har- Resistance 1 MΩ and above

ness - body
WA380-5 20-943
(10)
Troubleshooting Code Failure Code Controller Code The headlamp (Hi beam) does
Trouble
E-10 — — not light on

right HEAD (Female)
Between L02 (Female) 3 - right HEAD
(Female) harness - body Resistance 1 MΩ and above
Harness between L02 (Female) 3 - left Resistance 1 Ω and below

HEAD (Female)
Between L02 (Female) 3 - left HEAD
Harness disconnection or Resistance 1 MΩ and above
Possible Causes and ground fault (Female) harness - body
Standard Values 3 ★ Fuses A-1, A-12, and A-13 Harness between FS5 (Male) 4 - 5
blow at occurrence of a (Including fuse A-13) Resistance 1 Ω and below
ground fault.
Between FS5 (Male) 4 - 5 harness - Resistance 1 MΩ and above
body
Harness between FS5 (Male) 4 - 5 Resistance 1 Ω and below
(Including fuse A-12)
Between FS5 (Male) 4 - 5 harness -
body
20-944 WA380-5
(10)
5
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,
the clearance lamp does not light on.
Effect on Machine • The clearance lamp does not light on (Small lamp).

2) Disconnect the connector COMB1 (Left and right).
1 Lamp fault 4) Turn starting switch ON.
Between COMB1 1 (Left and right) - body
Voltage 20 - 30 V
(Lamp switch: 1st row)
Between L02 5 - body (Lamp switch: 1st
Voltage 20 - 30 V
2 Lamp switch fault row)
Between L02 (Male) 1 - 5 (Lamp switch: 1st
row)
2) Disconnect connectors L02, FS4, FS5, and left HEAD and right HEAD.
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
harness - body
Between L02 (Female) 2 - FS5 (Female) 4 Resistance 1 MΩ and above

harness - body
Harness disconnection Harness between L02 (Female) 2 - COMB1
or ground fault right (female) 1
★ Fuses A-1, A-14, and
3 Between FS5 (Female) 2 - COMB1 right
A-15 blow at occur- (Female) 1 harness - body Resistance 1 MΩ and above
rence of a ground
fault. Harness between FS5 (Female) 3 - COMB1 Resistance 1 Ω and below
right (Female) 1
Between FS5 (Female) 3 - COMB1 right
Harness between FS5 (Male) 1 - 2 (Includ-
ing fuse A-13) Resistance 1 Ω and below
Between FS5 (Male) 1 - 2 harness - body Resistance 1 MΩ and above

Harness between FS5 (Male) 1 - 3 (Includ-
ing fuse A-12) Resistance 1 Ω and below
Between FS5 (Male) 1 - 3 harness - body Resistance 1 MΩ and above

Between COMB (Female) (Left and right) 3 -
body Resistance 1 Ω and below
WA380-5 20-945
(10)
5

Trouble The turn signal does not blink
E-12 — —
• Since a disconnection (Ground fault) occurs in the switch, relay, or harness in the turn signal system, the
turn signal does not blink.
Effect on Machine • The turn signal does not blink.

Between L111 4 - body (Power) Voltage 20 - 30 V
Between L111 3 - body (Turn signal switch Voltage 20 - 30 V
= Neutral)
1 Turn signal relay fault
Between L111 2 - body (Turn signal switch
Voltage 20 - 30 V
= Neutral)
Between L111 (Male) 3 - 4 (Between con-
tacts)
Possible Causes and 4) Turn starting switch ON.
Standard Values
Between L03 2 - body (Turn signal switch: L 20 - 30 V and 0 V
or R) Voltage repeated
Between L03 3 - body (Turn signal switch: Voltage 20 - 30 V and 0 V
R) repeated
2 Turn signal switch fault Between L03 4 - body (Turn signal switch: 20 - 30 V and 0 V
Voltage
L) repeated
Between L03 (Male) 2 - 3 (Turn signal
switch: R)
Between L03 (Male) 2 - 4 (Turn signal
switch: L) Resistance 1 Ω and below
Between flasher unit pin 3 - body Voltage 20 - 30 V
3 Flasher unit fault
Between flasher unit pin 4 - body (Turn sig- 20 - 30 V and 0 V
nal switch L or R) Voltage repeated
20-946 WA380-5
(10)

Trouble The turn signal does not blink
E-12 — —
2) Disconnect connectors L101, L03, FS3, COMB1 (Left and right), R30,
R31, and flasher unit pins 3 and 4.
flasher unit pin 3 Resistance 1 Ω and below
Between L101 (Female) 3 - flasher Resistance 1 MΩ and above

unit pin 3 harness - body
flasher unit pin 4
Between L03 (Female) 2 - flasher unit
pin 4 harness - body Resistance 1 MΩ and above

FS3 (Female) 5 Resistance 1 Ω and below
Between L101 (Female) 5 - FS3 Resistance 1 MΩ and above

Harness disconnection or COMB1 right (Female) 3
Possible Causes and
Standard Values ground fault Between L03 (Female) 3 - COMB1
4 ★ Fuse B-5 blows at occur- right (Female) 3 harness - body Resistance 1 MΩ and above
rence of a ground fault.
COMB1 left (Female) 3
Between L03 (Female) 4 - COMB1 left
Between L03 (Female) 3 - R31 Resistance 1 MΩ and above

R30 (Female) 1
Between L03 (Female) 4 - R30
Between COMB1 (Female) (Left and Resistance 1 Ω and below

right) 3 - body
Between R30 (Female) 6, R31
(Female) 6 - body
Between flasher unit pin 1 - body Resistance 1 Ω and below
WA380-5 20-947
(10)
5

Trouble The horn does not sound
E-13 — —
• Since a disconnection or (Ground fault) occurs in the switch, relay, horn, or harness in the horn system,
the horn does not sound.
Effect on Machine • The horn does not sound.

3) Connect T-adapter (Insert).
Between L119 1, 3 - body (Power) Voltage 20 - 30 V
Between L110 2 - body (Horn switch: OFF) Voltage 20 - 30 V
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
Between L119 (Male) 1 - 2 (Coil resistance) Resistance 200 - 400 Ω
Between L119 (Male) 3 - 5 (Between pints) Resistance 1 MΩ and above
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)
3 Horn fault
Between horn pin - body (Horn switch: ON) Resistance 35 - 45 Ω
2) Disconnect the horn pin, horn switch pin, and connectors L103 and FS4.
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
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 -
Harness between horn pin - L103 (Female) Resistance 1 Ω and below

B
Between horn pin, L103 (Female) B - body Resistance 1 MΩ and above
20-948 WA380-5
(10)
WA380-5 20-949
5
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.
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.

Check the fuse B-D. When the fuse is blown,
1) Starting switch OFF. 2) Disconnect the connectors FS3 and A7. 3) Insert a
T-adapter.
Among FS3 (female) E, A7 (female) 2 and
machine body Resistance 1 MΩ and above
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.
Harness between C47 Starting switch ON. Voltage 20- 30 V

Defective power supply (female) 8 and A Starting switch OFF. Voltage 1 V and below
of control amplifier (Dis-
2 connection or short-cir- When the above is abnormal,
Possible Causes and cuit of harness for 1) Starting switch OFF. 2) Disconnect the connectors 47 and F3. 3) Insert a
Standard Values control amplifier) T-adapter.
Harness between C47 (female) 8 and FS3 Resistance 1 Ω and below
(female) F
Between C47 (female) A and machine body. Resistance 1 Ω and below
1) Starting switch OFF. 2) Disconnect the connectors A7, A8, A9, A10, A11
and A14. 3) Connect a T-adapter.
Between A7 (female) Starting switch ON. Voltage 20- 30 V

1 and machine body Starting switch OFF. Voltage 1 V and below
Harness between A8 Starting switch ON. Voltage 20- 30 V

(female) 1 and 4 Starting switch OFF. Voltage 1 V and below
Defective power supply Harness between A8 Starting switch ON. Voltage 20- 30 V
of relay (Disconnection (female) 1 and 4
3 or short-circuit of har- Starting switch OFF. Voltage 1 V and below
ness for relay) Starting switch ON. Voltage 20- 30 V
Harness between A10
(female) 1 and 4 Starting switch OFF. Voltage 1 V and below
(female) 1 and
machine body Starting switch OFF. Voltage 1 V and below
(female) 1 2 and
machine body Starting switch OFF. Voltage 1 V and below
20-950 WA380-5
(10)
5
Troubleshooting Code Failure Code Controller Code The air conditioner does not
Trouble
E-14 — — work or does not stop.

When the above six items are abnormal, check the following
1) Starting switch OFF. 2) Disconnect the connectors A7, A8, A9, A10,
A11, A14 and FS3. 3) Connect a T-adapter.
Harnesses among A7 (female) 1, A8
(female) 1, A9 (female) 1, A10 Resistance 1 Ω and below
(female) 1, A11 (female) 1, A14
(female) 1 2 and FS3 (female) F
Defective power supply of
3 relay (Disconnection or short- Among A8 (female) 4, A9 (female) 4, Resistance 1 Ω and below
A10 (female) 4 and machine body
Possible Causes and circuit of harness for relay)
Standard Values 1) Starting switch OFF. 2) Disconnect the connectors A12, A13 and A1.
Among A12 (female) 3 4, A13
(female) 3 4, A1 (female) 1 and Resistance 1 Ω and below
machine body.
In cases other than the above, each relay and its connection harness
are abnormal.
1) Starting switch OFF. 2) Disconnect the connectors B01 and B02. 3)
Defective condenser ground Connect a T-adapter.
4 (Disconnection of condenser
harness) Among B01 (female) 3 B02 (female) Resistance 1 Ω and below
3 and machine body.
WA380-5 20-951
(10)
5
20-952 WA380-5
(10)
5
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts ................................................................................................. 20-1002

S-1 Starting performance is poor (Starting always takes time) ........................................................ 20-1006
S-2 Engine does not start
(1) Engine does not turn ......................................................................................................... 20-1007
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ..................... 20-1008
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) .................. 20-1009
S-3 Engine does not pick up smoothly (Follow-up is poor) ............................................................. 20-1010
S-4 Engine stops during operations ................................................................................................ 20-1011
S-5 Engine does not rotate smoothly (Hunting) .............................................................................. 20-1012
S-6 Engine lacks output (or lacks power) ........................................................................................ 20-1013
S-7 Exhaust smoke is black (Incomplete combustion) .................................................................... 20-1014
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................ 20-1015
S-9 Oil becomes contaminated quickly ........................................................................................... 20-1016
S-10 Fuel consumption is excessive ................................................................................................. 20-1017
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down ........................................ 20-1018
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ........................................................ 20-1019
S-13 Oil level rises (Water, fuel in oil) ............................................................................................... 20-1020
S-14 Coolant temperature becomes too high (Overheating) ............................................................ 20-1021
S-15 Abnormal noise is made ........................................................................................................... 20-1022
S-16 Vibration is excessive ............................................................................................................... 20-1023
WA380-5 20-1001
(7)
(10)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLE-

SHOOTING CHARTS
This troubleshooting chart is divided into three sec-

tions: questions, check items, and troubleshoot-
ing.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspection without using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final
confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in [B] are items
that can be obtained from the user, depending on
the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under [C] in
the chart on the right correspond to this.
Causes
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of prob-
ability, starting with the causes that have been (b) (2) (3)
marked as having the highest probability form
information gained from [Questions] and [Check
items].
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-1002 WA380-5
(9)
(7)
The basic method of using the troubleshooting chart is

as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high probabil-
ity are marked with .
Check each of the [Questions] are [Check items] in
turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for that
item to make final confirmation of the cause.
Causes
1. For [Confirm Section, ask repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with to use as reference
)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)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
Causes
• Insufficient intake of air
• Improper condition of fuel injection
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
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Match marks on fuel injection pump are out of alignment

Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Troubleshooting
Speed of some cylinders does not change when operating

on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-1004 WA380-5
(9)
(7)
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 shows that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA380-5 20-1005
(7)
(9)
TROUBLESHOOTING S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but
engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C or below, ASTM
D975 No. 2 diesel fuel is used)
★ Battery charging rate Causes
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
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

Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items
Timing lock on fuel injection pump does not match

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

Heater mount does not become warm
Is voltage 26–30V between alternator terminal B and terminal E Yes
with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
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
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
»Adjust
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
» Use a test stand
20-1006 WA380-5
(10)
(7)
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn Causes
General causes why engine does not turn

• Seizure inside engine
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
Questions

Condition of horn when Horn does not sounds
starting switch is turned
ON Horn volume is low
Speed of rotation is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
Check items
move out
When starting switch is turned to ON, there is no clicking

sound
Battery terminal is loose
Troubleshooting of defective wiring in starting circuit
When starting switch is turned ON, linkage is not actuated

When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
connected, engine starts
Troubleshooting
2) When terminal B and terminal C of starting motor are

3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and
terminal E
When ring gear is inspected directly, tooth surface is found to
be chipped
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
—
WA380-5 20-1007
(7)
(9)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes

out (Fuel is not being injected)
General causes why engine turns but not exhaust smoke

comes out
• Supply of fuel impossible
• Supply of fuel extremely small
• Improper selection of fuel (particularly in winter)
Selection of fuel according to Causes

Type of ambient temperature
fuel –22 –4 14 32 50 68 86 104°F
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

Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
When starting switch is turned ON, linkage is not actuated
Check items
When fuel filter is drained, fuel does not come out

1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
Inspect feed pump directly

When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-1008 WA380-5
(9)
(7)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but

engine does not start (Fuel is
being injected) Causes
.)
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
defe
(rac
fuel
nt
er
le in
d ba
i
ke a
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
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items
1) Little fuel comes out even when injection pump piping

sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
Troubleshooting
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
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA380-5 20-1009
(7)
(9)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up smoothly Causes

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
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
Troubleshooting
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 valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-1010 WA380-5
(7)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations Causes
• Seized parts inside engine
c.)
r , et
)
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
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
Engine overheated and stopped

stopped
Engine stopped slowly
There was hunting and engine stopped
Replacement of filters has not been carried out according
to Operation Manual
Fuel level lamp lights up
Engine rotates, but stops when power train is operated
Check items
Does not turn at all

When it is attempted to Turns in opposite direction
turn by hand using
barring tool Moves amount of backlash
Shaft does not turn
Troubleshooting of chassis
Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
Troubleshooting
When gear train is inspected, it does not turn

Rotates when pump auxiliary equipment is removed
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
WA380-5 20-1011
(7)
(10)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly Causes
• Air in fuel system
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
Occurs at a certain speed range
Questions
Occurs at low idle

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
to Operation Manual
Rust, water are found when fuel tank is drained
Check items
When feed pump is operated,

1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-1012 WA380-5
(9)
(7)
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power) Causes
General causes why engine lacks output
ent
stm
m
y
seat
spra
hrag
adju
tank
lve
tive
diap or diap
e
d va
fuel
renc
ctiv
efec
m
er
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
Suddenly
Power was lost
Gradually
Questions

to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idle speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
WA380-5 20-1013
(7)
(9)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
d)
ad
)
tion
eize
d he
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
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
20-1014 WA380-5
(7)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
★ Do not run the engine at idle for more than 20 Causes
minutes continuously. (Both low and high idle)
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
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in clutch or TORQFLOW transmission or damper
chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
Troubleshooting
clogged with dirty oil

There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA380-5 20-1015
(7)
(10)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
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
Questions

Non-specified oil is being used
Black
Carry out troubleshooting for “S-7 Exhaust smoke is black”.

Excessive
Amount of blow-by gas
Check items
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

When breather element is inspected directly, hose is
broken or is found to be clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger oil drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-1016 WA380-5
(9)
(7)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Causes
• Leakage of fuel
)
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
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
When exhaust manifold is touched immediately after starting engine,

temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Troubleshooting
When control rack is pushed, it is found to be heavy, or does not return

When check is made using delivery method, injection timing is found
to be incorrect
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
WA380-5 20-1017
(7)
S-11 Oil is in coolant, or coolant

spurts back, or coolant level
goes down
General causes why oil in coolant Causes
• Internal leakage in lubrication system

• Internal leakage in cooling system
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
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
shooting
Trouble-

Pressure-tightness test of cylinder head shows there is leakage
Replace
Replace
Replace
Replace
Replace
Remedy
20-1018 WA380-5
(10)
(7)
S-12 Oil pressure caution lamp lights

up (Drop in oil pressure)
General causes why oil pressure lamp lights up
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
★ Standards for engine oil selection
Selection of oil according to Causes

Type of oil ambient temperature
–30 –20 –10 0 10 20 30 40°C
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

Questions

Operation Manual
Caution lamp lights up
Lights up at low idle
Condition when oil Lights up at low, high idle
pressure lamp lights up
Lights up on slopes
Sometimes lights up
Check items
There is crushing, leakage from hydraulic piping (external)

Oil level sensor lamp lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Carry out troubleshooting
for “S-13 Oil level rises”.
When oil filter is inspected, it is found to be clogged

Troubleshooting

Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
WA380-5 20-1019
(7)
(9)
S-13 Oil level rises (Water, fuel in oil)

★ If there is oil in the coolant, carry out troubleshooting Causes
for “S-11 Oil is in coolant, or coolant spurts back, or
coolant level goes down”.
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

There is oil in radiator cooling water
Fuel must be added more frequently
Exhaust smoke is white
When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
Check items
an abnormal number of bubbles appear, or water spurts back

Oil level goes down in clutch, TORQFLOW transmission,
or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting

Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1020 WA380-5
(10)
(7)
S-14 Coolant temperature becomes too

high (Overheating)
General causes why coolant temperature becomes too Causes
high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
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
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
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Power train oil temperature enters red range faster than
engine water temperature
Temperature difference between top and bottom radiator tanks

Carry out troubleshooting for chassis.
is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
When water filler port is inspected, core is found to be clogged

When function test is carried out on thermostat, it does not
open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
WA380-5 20-1021
(7)
(10)
S-15 Abnormal noise is made

★ Judge if the noise is an internal noise or an external Causes
noise.
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
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
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)
S-16 Vibration is excessive

★ If there is abnormal noise together with the vibra- Causes
tion, carry out troubleshooting also for “S-15
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
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
WA380-5 20-1023
(7)
30 DISASSEMBLY AND ASSEMBLY
How To Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

Precautions When Carrying Out Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Removal and Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Removal and Installation of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
Removal and Installation of Radiator and Fan Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
Removal and Installation of Aftercooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Removal and Installation of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Removal and Installation of Nozzle Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
Removal and Installation of Fan and Fan Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
Removal and Installation of Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
Removal and Installation of Parking Brake Disc Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
Removal and Installation of Torque Converter and Transmission Assembly . . . . . . . . . . . . . . . . . . . 30-41
Disassembly and Assembly of Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
Disassembly and Assembly of Transmission Clutch Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Disassembly and Assembly of Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
Disassembly and Assembly of Torque Converter Assembly (Standard Specification) . . . . . . . . . . . . 30-80
Disassembly and Assembly of Torque Converter Assembly (Lock-Up Specification). . . . . . . . . . . . . 30-84
Removal and Installation of Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
Removal and Installation of Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Disassembly and Assembly of Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
Disassembly and Assembly of Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
Removal and Installation of Center Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
Removal and Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
Removal and Installation of Cab and Floor Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
Removal and installation of operator's cab glass (Stuck glass). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
Removal and Installation of Transmission, Work Equipment, and PPC Pump Assembly . . . . . . . . . . 30-140
Removal and Installation of Steering, Switching, and Fan Pump Assembly . . . . . . . . . . . . . . . . . . . . 30-141
Removal and Installation of Steering Demand Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
Removal and Installation of E.C.S.S. Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
Removal and Installation of Work Equipment Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-144
Disassembly and Assembly of Hydraulic Cylinder Assembly (Steering, Lift, and Bucket
Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146
Removal and Installation of Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-154
Removal and Installation of Work Equipment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
Removal and Installation of Counter Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
Removal and Installation of Air Conditioner Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
Removal and Installation of Air Conditioner Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
Disassembly, Assembly of Operator's Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
WA380-5 30-1
(10)
(7)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF
ASSEMBLIES
Special tools Installation
• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
are intended for.
t: Special tools which cannot be substi-
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Special tools which are very useful if stand for the following.
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:
doing the work.
This mark gives guidance or precau-

This mark shows that there are instruc-

[*1] :
tions or precautions for installing parts.
6:
This mark shows oil or water to be
drained.
4 : Mass of a part or component.
30-2 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY OF

ASSEMBLIES
Special tools Assembly
• Special tools which are deemed ncessary for dis- • Section titled ASSEMBLY contain procedures,
assembly and assembly are listed in this section. precautions and the know-how for the work, as
• List of the special tools contains the following well as the amount of oil or water to be added.
kind of information. • Various symbols used in the ASSEMBLY Sec-
1) Neccessity tion are explained and listed below.
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-
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:
doing the work.
This mark gives guidance or precau-

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
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precau-
tions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions (mm)

Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or coolant, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydrau-
lic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylin-
der 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
WA380-5 30-5
(10)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79{T-{{{-{{{{ can not be supplied (they are items to be locally manufac-
tured).
★ Necessity: : Cannot be substituted, should always be installed (used)
z: Extremely useful if available, can be substituted with commercially available
part.
New/remodel: N: Tools with new part numbers, newly developed for this mode.
R: Tools with upgraded part numbers, remodeled from items already available
for other modeles.
Blank: Tools already available for other models, used without any modification
★ Tools marked { in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
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
Torque converter 790-501-5200 Unit repair stand z 1 Disassembly, assembly of torque

B
assembly 790-901-2110 Bracket z 1 converter assembly
790-901-2150 Plate z 1
WA380-5 30-7
(10)
2
(7)
Nece New/ Sket

Q’ty remo
del
793T-522-1140 Push tool 1 N {
1 Press fitting of bearing (wheel side)
793T-522-1150 Spacer 1 N {
2 797T-423-1290 Push tool 1 { Press fitting of bearing (Deff. side)
Axle assembly J
3 793T-522-1160 Push tool 2 N { Press fitting of oil seal sleeve
793T-522-1171 Seal support 2 N {
4 Assembly of axle housing
01016-30860 • Bolt 6
790-501-5000 z
1 or
Disassembly, assembly of differen-
D1 790-501-5200 Unit repair stand z tial assembly
2 790-901-2110 Bracket z
3 790-901-1331 Plate z
1 793T-522-1110 Push tool {
D2 2 790-101-5421 Grip Press fitting of oil seal
3 01010-81240 Bolt
1 793T-522-1110 Push tool {
Differential assembly 2 793T-522-1120 Spacer {
D3 Press fitting of dust seal
3 790-101-5421 Grip
4 01010-81240 Bolt
D4 790-201-2740 Push tool
Press fitting of pinion gear bearing
D5 793T-522-1130 Push tool N {
1 790-301-1720 Adapter
2 799-101-5002 Hydraulic kit
D6 Check of brake oil for leakage
3 793-605-1001 Brake tester
4 790-101-1102 Hydraulic pump
No-load operating torque of limited
D7 796-751-1510 Wrench 1
slip differential
1 790-101-2300 Push puller 1
2 793-520-2370 Push tool 1
3 793-520-2350 Push tool 1
Removal, installation of center hinge
Center hinge pin E1 4 793-520-2540 Guide 1 pin
5 793-520-2360 Bar 2
6 790-101-1102 Hydraulic pump 1
7 790-101-2102 Puller (30 tons) 1
30-8 WA380-5
(10)
2
Nece New/ Sket

Q’ty remo
del
790-502-1003 Repair stand z 1 Disassembly, assembly of hydraulic
1 cylinder assembly
790-101-1102 Hydraulic pump z 1
790-102-2303 Wrench assembly z 1
2 or For steering cylinder head
790-330-1100 Wrench assembly z 1
790-302-1270 Socket (Width
3
across flats: 50 mm) z 1 For steering cylinder piston nut
790-102-4300 Wrench assembly z 1 For boom and bucket cylinder pis-

4 tons
790-102-4310 Pin z 1
5 790-720-1000 Expander z 1
796-720-1640 Ring z 1
07281-00909 Clamp z 1
796-720-1680 Ring z 1 For assembly of piston ring
Hydraulic cylinder 6
I 07281-01589 Clamp z 1
assembly
796-720-1690 Ring z 1
07281-01919 Clamp z 1
790-201-1702 Push tool kit z 1
• 790-101-5021 Grip z 1
For assembly of cylinder head
7 • 01010-80816 Bolt z 1
bushing
• 790-201-1751 Push tool z 1
• 790-201-1841 Push tool z 1
790-201-1500 Push tool kit z 1
• 790-101-5021 Grip z 1
For assembly of cylinder head dust
8 • 01010-80816 Bolt z 1 seal
• 790-201-1560 Plate z 1
• 790-201-1650 Plate z 1
799-703-1200 Service tool kit 1
Vacuum pump
799-703-1100
(100V) 1
Air conditioner Vacuum pump

assembly
X 799-703-1110
(220V) 1 Charging of air conditioner gas
Vacuum pump
799-703-1120 (240V) 1
799-703-1401 Gas leak detector 1

2-1 793-498-1120 Clear plate 2
2-2 793-498-1130 plate 2
Operator’s cab glass X Installation of operator’s cab glass
2-3 793-498-1110 Magnet 2
3 793-498-1210 Lifter (Suction cups) 2
WA380-5 30-9
(10)
2
(7)
SPECIAL TOOL ILLUSTRATIONS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2-1 Push tool

D3-1 Push tool
D3-2 Spacer
30-10 WA380-5
(9)
2
D5 Push tool
F2 Lifting tool
WA380-5 30-11
(9)
2
(7)
H1 Bracket
H3 Push tool
30-12 WA380-5
(9)
2
H4 Spacer
H5 Push tool
WA380-5 30-13
(9)
2
(7)
H6 Push tool
H8 Push tool
30-14 WA380-5
(9)
2
H9 Spacer
H10 Push tool
CWW10424
WA380-5 30-15
(9)
2
(7)
J1-1 Push tool
J1-2 Spacer
30-16 WA380-5
(9)
2
J2 Push tool
J3 Push tool
WA380-5 30-17
(9)
2
(7)
J4 Seal support
K1 Bracket
30-18 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY

REMOVAL 3) Disconnect the air conditioner hoses (4)
and (5) and also disconnect the overflow
hose of the reservoir tank from the clamp.
WARNING! Park the machine on 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. Apply the parking
brake and put the blocks under the
wheels. CPW10702
WARNING! Disconnect the battery (-)

terminal in advance.
1. Degas the air conditioner. [*1]

2. Drain coolant.
3. Engine hood assembly
See Paragraph 2 of "Removal of Cylinder
Head Assembly" to remove the engine hood 4) Disconnect the air conditioner hoses (6)
assembly. and (7) at the air conditioner compressor
4. Bulkhead assembly (8) and remove the hose clamps to bring
1) Disconnect the transmission breather them to the bulkhead side.
hose (1).
2) Remove the connector (3) of the engine
stop solenoid relay (2).
CPW10703
CPW10701
WA380-5 30-19
(10)
2
(7)
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
6) Remove the connector (11).

7) Sling the bulkhead assembly and remove
the mounting bolts (12) and (13).
8) Remove the lock bolts to the right and to
the left of the rubber sheet. 5. Disconnect the starting motor wiring harness
★ Find them carefully because they are (15), the air heater replay wiring harness
located below the main frame and (R11) and (16), the engine ground wiring har-
cannot be found easily. ness (17), the emergency steering motor wir-
ing harness (18) and the connectors (19) and
(20).
6. Disconnect the car heater hose (21).
CPW10705
CPW10707
9) Lift the bulkhead assembly a bit and pull

out the two drain hoses of the air condi-
tioner unit from the clamp. (Machine right
side) 7. Disconnect the car heater hose (22) and
remove the clamp.
8. Disconnect the radiator outlet hose (23).
CPW10708
30-20 WA380-5
(9)
2
9. Lift and remove the muffler assembly (24). 15. Disconnect the turbo outlet hose (37).
4 Muffler assembly: 36 kg
10. Disconnect the aftercooler outlet hose (25).

11. Disconnect the radiator inlet hose (26).
12. Disconnect the aeration hose (27). CPW10711
CPW10709
16. Disconnect the accelerator cable (38). [*2]

17. Disconnect the fuel suction hose (39) and
return hose (40) and remove the clamp from
the engine. [*3]
18. Remove the clamp and disconnect the tube
(41) from the engine.
13. Air cleaner bracket

1) Remove the dust indicator connector (28).
2) Disconnect the ground wiring harness
(29) and also remove the heater replay
(30).
3) Disconnect the breather hose (31) from CPW10712
the head cover, remove the clamps (32)
and (33) and bring it to the left side of the
engine.
4) Remove the fuel filter (34) from the
bracket.
5) Remove the air cleaner bracket (35).
14. Disconnect the spill hose (36).
19. Disconnect the wiring harness (42) from the

emergency motor and bring it to the engine
side.
20. Remove the engine oil drain valve (43).
CPW10710
CPW10713
WA380-5 30-21
(9)
2
(7)
21. Engine assembly 6) Remove the engine assembly (48) from

1) Use a lever block to sling the engine the torque converter by adjusting the lift-
assembly. ing height and angle with the lever block
2) Remove the engine mounting bolts (44) and the crane.
and (45).
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
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOL 4) Remove the baffle mounting brackets (6)
and (7).
New/Modified
Necessity
Quantity
Sketch
Part
Symbol Part Number Name
A1 790-331-1110 Wrench ● 1
REMOVAL

1. Drain coolant.
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)
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
10) Lift the engine hood assembly (18) slowly

and remove it. 5. Air cleaner bracket
1) Remove the dust indicator sensor connec-
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
3. Disconnect the dust indicator hose and the air

intake hose (19) and remove the air cleaner
assembly (20). [*1]
CPW10725
30-24 WA380-5
(9)
2
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
15. Remove the head cover (41). [*8]

9. Disconnect the turbo outlet pipe (33). [*4] ★ Before removing it, clean the area around
10. Remove the exhaust connector (34) and the it.
bracket (35). [*5] 16. Disconnect 6 pieces of the high-pressure
11. Remove the heat shielding board (36). injection pipe (42). [*9]
17. Disconnect the spill hose (43).
CPW10729
CPW10732
12. Disconnect the turbo lubrication hose (37)

and the drain tube (38). [*6] 18. Remove the holder (44) and then remove the
nozzle holder assembly (45). [*10]
CPW10730
CPW10733
WA380-5 30-25
(9)
2
(7)
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
19. Remove the rocker arm assembly (46). [*11] INSTALLATION

★ Loosen the locknut and also loosen the
adjustment nut 2 - 3 turns. • Carry out installation in the reverse order to
removal.
[*1]
Bolt of air cleaner mounting

clamp:
9.8 - 11.76 Nm {1.0 - 1.2 kgm}
CPW10734
Clamping bolt on air intake hose
turbo side:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
[*3]
Nut of air intake pipe intermediate

20. Remove the push rod (47). [*12]
clamp:
10.8 - 26.5 Nm {1.1 - 2.7 kgm}
[*4]
Nut of clamp on turbo side:

6.9 - 8.8 Nm {0.7 - 0.9 kgm}
CPW10735
Nut of pipe intermediate clamp:
10.8 - 26.5 Nm {1.1 - 2.7 kgm}
[*5]
Nut of exhaust connector clamp:

6.9 - 8.8 Nm {0.7 - 0.9 kgm}
21. Cylinder assembly [*13] [*6]

Remove 26 pieces of the head bolt (48) and
Joint on turbo lubrication hose cyl-
then remove the cylinder head assembly
inder block side:
(49).
19.6 - 28.4 Nm {2.0 - 2.9 kgm}
4 Cylinder head assembly: 52 kg [*7]
Tighten the exhaust manifold

mounting bolt following the proce-
dures below and apply the torques
below.
CPW10736 • First turn: In the order from the first

one shown in the figure,
23.5 ± 4 Nm {2.4 ± 0.4 kgm}
• Second turn: From the 1st to 4th bolts
only shown in the figure,
23.5 ± 4 Nm {2.4 ± 0.4 kgm}
• Third turn: In the order from the first
one shown in the figure,
43.1 ± 6 Nm {4.4 ± 0.6 kgm}
30-26 WA380-5
(9)
2
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
• Fourth turn: From the 1st to 4th bolts [*13]

only shown in the figure, • Install the cylinder head assembly follow-
43.1 ± 6 Nm {4.4 ± 0.6 kgm} ing the procedures below:
★ Check that there is no dust and foreign
matter on the cylinder head mounting
surface and inside the cylinder.
1) Attach the cylinder head gasket to the cyl-
inder block.
★ Check that the gasket is correctly
nested in the block hole.
2) Lift the cylinder head assembly and set it
into the cylinder block.
3) Tighten the cylinder head mounting bolts
in the order shown in the figure.
Apply engine oil to the

threaded portion and the seat
surface of the mounting bolt.
[*8]
Cylinder head mounting bolts:
Head cover mounting bolts:
23.5 ± 3.9 Nm {2.4 ± 0.4 kgm} First time: Tighten them in the order
from [1] - [26] by applying
[*9] the torque of,
70 ± 5 Nm {7.1 ± 0.51 kgm}
High-pressure injection pipe Second time:Check that all of the bolts
sleeve nut: have been tightened in the
24 ± 4 Nm {2.45 ± 0.41 kgm} same order with the above
torque.
[*10]
Third time: Tighten the long bolts ([1],
★ Clean the nozzle holder mounting portion, [2], [7], [8], [9], [10], [15], [16],
check that there is no foreign matter [17], [18], [23], [24], [25] and
inside the sleeve and then assemble the [26]) with the torque of,
holder and the nozzle holder assembly. 145 ± 10 Nm {14.8 ± 1.0 kgm}
★ Apply a little engine oil to the rubber Fourth time: Check that the long bolts in
boots. the third time have been
[*11] tightened with the above
• When installing the rocker arm assembly, torque.
check that the rocker arm ball is certainly At the end: When the A1 tool is used,
nested in the push rod. tighten the bolts 90° ± 5°
additionally in the order
Rocker arm assembly mounting from [1] to [26] with the
bolt: 65 ± 5 Nm {6.6 ± 0.5 kgm} angle tightening wrench
(Tool A).
Rocker arm adjustment screw lock- When the tool A is not used,
nut: 24 ± 2.4 Nm {2.45 ± 0.24 kgm} place counter marks on the
bolts and the heads and
• See the paragraph of "Adjustment of tighten the bolts 90° ± 5°
Valve Clearance" in Inspection and additionally.
Adjustment and adjust the valve clear-
ance.
[*12]
• Check that the push rod is certainly
nested in the tappet.
★ Rotate the push rod to check if it
rotates smoothly.
WA380-5 30-27
(9)
2
(7)
RADIATOR AND
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION FAN MOTOR
OF RADIATOR ASSEMBLY
AND FAN MO-
REMOVAL AND INSTALLATION

OF RADIATOR AND FAN
MOTOR ASSEMBLY
DJW05921
REMOVAL
1. Drain engine coolant.
Head Assembly" and remove the engine hood
assembly.
3. Remove the lock and the hinge mounting
bolt, remove the hydraulic oil cooler assem-
bly (1) and bring it to the engine side.
4. Disconnect the fuel tank air bleeding hose (2).
CPW10739
5. Remove the cover (3).

6. Disconnect the hydraulic hoses (4), (5), and
(6) from the motor. [*1]
• 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.
Hose clamping bolt:

5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
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
REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION

OF AFTERCOOLER ASSEMBLY OF FUEL INJECTION PUMP
REMOVAL SPECIAL TOOL
New/Modified
Necessity
Quantity
Sketch
Symbol Part Number Part Name
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

1. Remove the rubber sheet (1) and baffle (2).

CPW10745
CPW10746
INSTALLATION
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
9. Use the tool G1 to rotate the crankshaft in the

positive rotation direction to push the gear in
the compression top dead point positioning
pin (10) of the No. 1 cylinder.
★ Press the pin lightly to the gear and rotate 14. Use the tool G4 to pull the drive gear of the
it slowly. injection pump, and loosen the engagement
with the shaft.
CPW10752
10. Disconnect the west gate hose (11) and then

disconnect the boost compensator tube (12). 15. Remove 2 pieces of the mounting bolt (17)
11. Disconnect 6 pieces of the high-pressure and 4 pieces of the mounting nut (18) and
injection pipe (13) from the pump, and then remove the fuel injection pump assem-
remove the clamp in the middle. [*6] bly (22). [*8]
CPW10750 CPW10753
WA380-5 30-31
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
INSTALLATION 3) Reverse the position of the timing pin

(20), bring the groove of the timing pin to
• Carry out installation in the reverse order to the pointer (21) in the pump and tighten
removal. the plug (19) temporarily.
[*1] ★ When the tooth of the pointer (21)
★ See the paragraph of "Adjustment of does not match the hole of the timing
Engine Stop Solenoid" in Inspection and pin, turn the shaft of the fuel injection
Adjustment and adjust the solenoid. pump to match the pointer tooth of
the hole.
[*2]
★ See the paragraph of "Adjustment of
Accelerator Pedal" in Inspection and
Adjustment and adjust engine speed.
[*3]
Joint bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
[*4]
Joint bolt:
8 ± 2 Nm {0.8 ± 0.2 kgm}
[*5]
Joint bolt: 4) Align the pump cam shaft to the pump

36 ± 5 Nm {3.67 ± 0.51 kgm} drive gear, assemble the fuel injection
pump assembly (22) and tighten the
[*6] mounting nut (18) and bolt (17).
Sleeve nut: Nut: 44 ± 6 Nm {4.49 ± 0.6 kgm}

24 ± 4 Nm {2.45 ± 0.41 kgm}
[*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).
assembly.
2. Disconnect the dust indicator hose and the air
intake hose (1), and remove the air cleaner
CPW10754 assembly (2). [*1]
CPW10755
7) Remove the plug (19), reverse the posi-

tion of the timing pin (20) to set it in and
attach the plug to the injection pump.
Plug: 14.7 Nm {1.5 kgm}
8) Tighten the drive nut (15) of the fuel injec- 3. Remove the muffler assembly (3).
tion pump permanently.
Nut: 4 Muffler assembly: 36 kg

178 ± 13 Nm {18.2 ± 1.3 kgm}
9) Carry out the following installations in the

reverse order to removal.
CPW10756
4. Air cleaner bracket

1) Remove the dust indicator sensor connec-
tor (4).
2) Disconnect the ground wiring harness (5),
and remove the heater relay (6).
3) Remove the clamps (8) and (9) of the
breather hose (7) from the bracket (11).
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]
Bolt of air cleaner mounting

clamp:
9.8 - 11.76 Nm {1.0 - 1.2 kgm}
[*2]
[*3]
Nut of air intake pipe intermediate

clamp:
10.8 - 26.5 Nm {1.1 - 2.7 kgm}
[*4]
7. Remove the air intake connector (14). High-pressure injection pipe

★ Remove it for No. 4 and No. 5 nozzle sleeve nut:
holder assemblies. 24 ± 4 Nm {2.45 ± 0.41 kgm}
8. Disconnect 6 pieces of the high-pressure
[*5]
injection pipe (15). [*4]
9. Disconnect the spill hose (16). ★ Clean the nozzle holder mounting portion,
check that there is no foreign matter
inside the sleeve and assemble it.
★ Apply a little engine oil to the rubber
boots.
CPW10759
30-34 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
FANOF FAN
AND AND
FAN FAN MOTOR
MOTOR AS-
ASSEMBLY
REMOVAL AND INSTALLATION OF FAN AND FAN MOTOR

ASSEMBLY
REMOVAL 2. Remove the connector (5) and then remove
the backup buzzer (6).
3. Remove the connector (7) of the fan motor
solenoid.
4. Remove the motor cover (8).
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
5. Disconnect the hydraulic hoses (9), (10) and

(11).
6. Remove the fan guards (12), (13), (14), and
(15).
3) Remove 4 pieces of the mounting bolt

and then remove the grille (4).
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
4 Fan and motor assembly: 45 kg REMOVAL
WARNING! Park the machine on a flat

stop the engine. Apply the parking
CPW10765 brake and put the block under the
wheels.
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
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
8. Remove the clamp (10) of the fan motor hose

from the fuel tank.
★ Around the center on the top of the fuel 3) Remove the left mounting bolt (17), the
tank. right mounting bolt (18) and the rear
9. Disconnect the fuel suction hose (11), return mounting bolt (19) of the fuel tank. [*1]
hose (12) and the spill hose (13) from the fuel
tank side.
CPW10798
CPW10795
10. Remove the left mounting bolt (14) and the

right mounting bolt (15) of the transmission
oil cooler from the fuel tank. CPW10799
★ Keep the cooler body as it is.
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
1 793T-607-1190 Bracket ● 1
CPW10800 K 2 722-14-13130 Plate ● 1
3 01011-62020 Bolt ● 1
REMOVAL
stop the engine. Put the blocks under
INSTALLATION the wheels.
• Carry out installation in the reverse order to 1. Drain transmission oil.

removal. 2. Remove the drive shaft (2). [*1]
[*1]
Fuel tank mounting bolt:

824 - 1,030 Nm {84 - 105 kgm}
CPW10766
3. Remove the bolt (3) and then remove the

washer (4), the retainer (5) and the
coupling (6). [*2]
CPW10767
30-38 WA380-5
(10)
2
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
6. Loosen the mounting bolts (11) of the brake

cover (10) equally, and remove the cover (10) 10. Use the tools K1, K2, and K3 to push the
and the spring (12). brake disc and the plate inside and to remove
★ Since the mounting bolts are pressed the snap ring (16).
with the brake spring, loosen them ★ For the tools K2 and K3, the yoke mount-
equally. ing bolt and the retainer can be used.
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)
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]
Coupling mounting bolt:

Adhesive (LT-2)
Coupling mounting bolt:

490 - 608 Nm {50 - 62 kgm}
[*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)
★ Bring the counter mark a of the piston to

the counter mark b of the housing, and
then install them.
CPW10774
30-40 WA380-5
(9)
2
5
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION
TORQUE CONVERTER ANDOFTRANSMISSION
TORQUE CONVERTER AND
ASSEMBLY
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND

TRANSMISSION ASSEMBLY
REMOVAL
7. Remove the drive shaft (2). [*3]
stop the engine. Put the blocks under
the wheels. CPW10766
1. Degas the air conditioner. [*1]

2. Drain oil from the transmission and the
hydraulic tank.
See Paragraph 2 of "Removal of Cylinder 8. Wiring and piping of emergency steering
Head Assembly" and remove the engine hood pump
assembly. 1) Disconnect the connector (3).
4. Bulkhead assembly 2) Disconnect the pump inlet hose (4) and
See Paragraph 4 of "Removal of Engine the outlet hose (5).
Assembly" to remove the bulkhead assembly.
5. See the Paragraph of "Removal of Cab and
Floor Frame Assembly" to remove the cab
and floor frame assembly.
6. Remove the universal joint assembly
(1). [*2]
CPW10777
CPW10776
3) Disconnect the motor wiring harness (6)

and the ground wiring harness (7).
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
2) Disconnect the steering pump outlet pipe

12. Piping of torque converter and transmission (18) and the switch pump outlet pipe (19)
1) Remove the clamp (12) of the wiring har- from the pump.
ness.
2) Disconnect the outlet hose (13) to the oil
cooler and the return hose (14) from the
cooler.
CPW10783
CPW10780
3) Remove the connector of the pressure

switch (21).
4) Remove the clamps (22) and (23) and then
remove the bracket (24) of the pipes (18)
13. Disconnect the steering, the switch and the and (19).
fan pump suction tube (15).
14. Disconnect the suction tube (16) of the work
equipment and the PPC pump.
CPW10784
CPW10781
30-42 WA380-5
(9)
2
5
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION
TORQUE CONVERTER ANDOF TRANSMISSION
TORQUE CONVERTER AND
ASSEMBLY
16. Pump piping 20. Torque converter and transmission assembly

1) Remove the clamp (25) and disconnect 1) Use a lever block to sling the torque con-
the pump outlet pipe (20) of the work verter and transmission assembly.
equipment. 2) Loosen the left mounting bolt (35) and the
2) Disconnect the PPC pump outlet hose right mounting bolt (36) of the engine.
(26). [*4]
3) Disconnect the fan pump control pressure
hose (27), the pump outlet hose (28), the
fan pump drain hose (29) and the fan
motor drain hose (30).
★ Before disconnecting them, place
counter marks on them. CPW10787
CPW10785
3) Remove the left mounting bolt (37) and

the right mounting bolt (38) of the trans-
mission and lift it a bit, then remove the
left bracket (39). [*5]
★ Do not loosen the adjustment bolt (43)
for positioning at the time of installa-
17. Disconnect the hose (31) from the transmis- tion.
sion filter, and remove the elbow (32).
18. Remove the clamp of the transmission wiring
harness (33).
19. Disconnect the strainer (34) from the bracket
and bring it to the frame side.
CPW10788
CPW10786
WA380-5 30-43
(9)
2
(7)
DISASSEMBLY AND ASSEMBLYREMOVAL AND CONVERTER
TORQUE INSTALLATION OFTRANSMISSION
AND TORQUE CONVERTER AND
ASSEMBLY
4) Lift the torque converter and transmission INSTALLATION

assembly (42) 100 mm or so, place the
block [1] between the engine flywheel • Carry out installation in the reverse order to
case and the rear axle and hold the removal.
engine rear portion. [*1]
• Fill the air conditioner with gas (R134a).
[*2] [*3]
★ When installing the coupling and the
drive shaft, check that the spider cap key
is perfectly nested in the key slot of the
counter yoke, and tighten the bolts.
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
[*4]
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
5) Remove 12 pieces of the mounting bolts [*5]

(41) of the flywheel case (40) and on the Mounting bolt:
torque converter side. 490 - 608 Nm {50 - 62 kgm}
★ In order to position the transmission, tighten
the mounting bolts so that the clearance a
with the adjustment screw becomes even.
CPW10790
DJW05922
6) Pull out and remove the torque converter

and transmission assembly (42) from the
flywheel. [*6]
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
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY

SPECIAL TOOL
5) Sling the pump assembly (6) and remove
New/Modified
Necessity
2 pieces of the mounting bolt (7).
Quantity
Sketch
793T-607-1210 Lifting tool ● 2 {

F 2
793-607-1230 Pin ● 2
DISASSEMBLY CPW10802
1. Transmission, work equipment and PPC

pump assembly
1) Set the torque converter and transmission
assembly (1) on the blocks [1] and [2].
2) Disconnect the suction tube (2).
3) Disconnect the hoses (3) and (4) and the
breather hose (5).
4) Remove the retainer (10). 2. Steering, switch and fan pump
Sling the pump assembly (8) and remove 2
pieces of the mounting bolt (9).
CPW10801
CPW10803
WA380-5 30-45
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
3. Emergency steering pump assembly 6. Filter and brake hose

Remove the plate mounting bolt and then 1) Disconnect the hose (21) and remove the
remove the emergency steering pump filter (22).
assembly (11). 2) Disconnect the brake hose (23).
CPW10804 CPW10807
4. Pipes 7. Valve assembly

1) Remove the connector (12) and then 1) Remove 16 sets of the connector (24) and
remove the block (13).
then remove the wiring harness assembly
2) Disconnect the hose (14) and remove the
flow control valve (15). (25).
3) Disconnect the tube (16) and remove the ★ Before removing the connectors,
nipple (17). check their numbers.
2) Use the eyebolt [3] and the shackle [4] to
sling the valve assembly (26), and remove
10 pieces of the mounting bolt (where is
blacked without bolt).
CPW10805
CPW10808
5. Transmission mount and level gauge

1) Remove the left transmission mount (18).
2) Remove the level gauge (19).
★ Fix the upper and lower holders (20)
with a wrench so that they do not
rotate, then remove the bolt.
CPW10806
30-46 WA380-5
(9)
2
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
9. Torque converter and rear case assembly

1) Turn the torque converter and the trans-
mission assembly (29) to show the torque
converter side up and set it on the block
[5].
2) Remove 20 pieces of the case mounting
bolt (30).
CPW10813
CPW10810
11. PTO gear (for transmission and work equip-

ment PPC pump)
3) Use a lever block to sling the torque con- 1) Remove the snap ring (34).
verter and rear case assembly (31), and
disconnect and remove the transmission
case with the forcing screw [6].
CPW10814
CPW10811
WA380-5 30-47
(9)
2
(7)
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
12. Clutch pack assembly

1) Remove the seal ring (44) from the shaft.
CPW10816
CPW10819
4) Pull out the shaft (40) and remove the

PTO gear (41).
2) Use the tool F2 to lift and remove the 1st
speed and 4th speed clutch assembly (45)
and the 2nd speed and 3rd speed clutch
assembly (46) at the same time.
5) Remove the snap ring (35) and the plate

(36) from the shaft (40).
6) Remove the bearing (43) and the inner
race (59) from the shaft (40).
3) Use the eyebolt [11] to lift and remove the
forward-reverse clutch assembly (47).
30-48 WA380-5
(9)
2
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
14. Reverse idle gear

1) Remove the bolt (49) and the plate (50).
2) Use a forcing screw to remove the cover
(56).
★ Check the thickness and the quantity
of the shims (57) in advance.
CPW10822
CPW10825
2) Use the puller [12] to remove the gear (51)

and the bearing (52).
3) Remove the bearing (52) and the plate
(53).
3) Remove the outer race (58) from the cover
(56).
WA380-5 30-49
(9)
2
(7)
ASSEMBLY
ASSEMBLY 3. Reverse idle gear

1) Attach the plate (53).
1. Cover (on the 2nd speed clutch side) 2) Use the push-tool to attach the bearing
1) Attach the outer race (58) to the cover (52) with the counter mark B.
(56). 3) Attach the outer race (52-1) to the gear
(51).
2) Set the removed shim (57) in the cover

(56) and tack-weld the cover. 4) Set the spacer (52-2) and attach the gear
★ In order to adjust the shim here after (51).
the clutch assembly is assembled. 5) Use the push-tool to attach the bearing
(52) with the counter mark A.
2. Bearing (on the 1st speed clutch side)
Use the push-tool to attach the bearing (54) to
the housing.
CPW10827
6) Attach the plate (50) and tighten the bolt

(49).
Bolt: Adhesive (LT-2)
Bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10822
30-50 WA380-5
(10)
2
TRANSMISSION ASSEM-
ASSEMBLY
4. Yoke 4) Attach the seal ring (44) to the shaft.

Attach the yoke (48).
5. Clutch assembly Seal Ring: Grease (G2-LI)
1) Face the brake side down and set the
front case on the block.
2) Use the eyebolt [11] to attach the forward-
reverse clutch assembly (47).
CPW10819
CPW10821
6. PTO gear (for transmission, work equipment

and PPC pump)
1) Attach the bearing (60) to the rear case
3) Use the tool F2 to combine the 1st speed (31).
and 4th speed clutch assembly (45) and ★ The snap ring is mounted on the
the 2nd speed and 3rd speed clutch steering, the switch and the fan pump
assembly (46) and attach them at the sides.
same time.
★ When it is difficult to set the roller
bearing on the 1st speed clutch side,
remove the bearing and set it to the
shaft side to attach it.
2) Use the push-tool to attach the inner race

(59) and the bearing (43) to the shaft (40).
3) Attach the plate (36) and the snap ring
(35).
WA380-5 30-51
(9)
2
(7)
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
5) Attach the woodruff thrust plate (39), and

plate (38) and the snap ring (37) to the 7. Torque converter assembly
shaft. 1) Set the torque converter assembly (32) on
the block [7], and attach 1 piece of the
guide bolt [8].
2) Lift the rear case (31), meet respective
bolt holes with each other and attach the
rear case to the torque converter.
CPW10816
CPW10831
CPW10815 3) Tighten 6 pieces of the stator shaft

mounting bolt (33).
Bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10813
30-52 WA380-5
(9)
2
TRANSMISSION ASSEM-
ASSEMBLY
8. Rear case assembly 9. Adjusting procedures of taper roller bearing

1) For each clutch assembly, make the shim of 2nd speed and 3rd speed clutch
extension of the seal ring from the shaft assembly
equal. 1) Face the parking brake side up and set the
2) Attach the guide bolt [9] to the front case. transmission assembly on the block.
3) Use the lever block to lift the rear case 2) Pull the brake piston with the bolt (63) to
assembly (31) and to attach it to the shaft release the parking brake.
of the clutch assembly.
Case mating face:

Gasket sealant (LG-4)
• For the applying procedures, see the

illustration DJW05923. CPW10838
CPW10832
3) Pull out the shim temporarily set in the

paragraph of 1-2) of Assembly, attach the
cover (56) and tighten all mounting bolts
by applying the torque of 9.8 ± 0.98 Nm
{1.0 ± 0.1 kgm}.
4) Use the hole on the end face of the shaft
(64) or the output shaft coupling to give
the shaft 20 turns, and check bolt torques.
★ When bolt torques are different,
repeat 3) and 4).
DJW05923 5) When bolt torques become equal, mea-
sure the clearances at four places (circular
equal division) (3-place equal division is
also acceptable) to find the average clear-
ance.
★ To check if the bearing is not inclined,
however, check if the bearing is set
properly or if there is any other rea-
son where measured values differ
more than 0.15 mm. Take a proper
4) Tighten 20 pieces of the mounting bolt measure so that the bearing is not
(30). inclined.
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10839
CPW10833
WA380-5 30-53
(9)
2
(7)
ASSEMBLY
6) A shim increases measured clearances by 11. Speed sensor

+ 0.25 - + 0.3 mm. 1) Screw the sensor (27) in until it touches
7) Set the selected shim (57) in and attach the outside surface of the gear (61).
the cover (56). ★ Before attaching the sensor, make
sure that the gear is at the most out-
Mounting bolt: side of the mounting face.
98 - 123 Nm {10 - 12.5 kgm} ★ When you screw the sensor in with a
8) Attach the cover (55). wrench, stop screwing just before the
gear then let the sensor touch the
gear by hand.
2) After the sensor (27) touched the gear
(61), give the sensor a half to a turn in
reverse and fix it with the locknut (62).
★ When fixing the sensor with the lock-
CPW10840 nut, fix the other nut with a wrench
and tighten the locknut.
Sensor threaded portion:

Gasket sealant (LG-5)
Sensor locknut:
58.8 - 78.4 Nm {6 - 8 kgm}
10. Speed sensor and oil temperature sensor

1) Attach the oil temperature sensor (28).
Oil temperature sensor:

Gasket sealant (LG-5) DJW05924
Oil temperature sensor:
29.4 - 49 Nm {3 - 5 kgm}
CPW10834 12. Valve assembly

1) Attach 2 pieces of the guide bolt [10] to
the case.
2) Use the eyebolt [3] and the shackle [4] to
lift and install the valve assembly (26).
2 pieces of mounting bolt a:

44.1 - 53.9 Nm {4.5 - 5.5 kgm}
8 pieces of other bolts:

58.8 - 73.5 Nm {6 - 7.5 kgm}
30-54 WA380-5
(9)
2
TRANSMISSION ASSEM-
ASSEMBLY
3) Attach the wiring harness assembly (25) 15. Pipes

and connect 16 sets of the connector (24). 1) Attach the nipple (17) and connect the
tube (16).
Mounting bolt:
9.8 - 12.7 Nm {1.0 - 1.3 kgm}
2) Attach the front control valve (15) and

CPW10835 connect the hose (14).
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
29.4 - 39.2 Nm {3 - 4 kgm}
3) Attach the block (13), and connect the

13. Filter and brake hose mounting connector (12).
1) Connect the brake hose (23).
2) Attach the filter (22) and connect the hose
(21).
CPW10805
CPW10807
16. Emergency steering pump assembly

Install the emergency steering pump assem-
bly (11).
14. Transmission mount and level gauge
1) Attach the level gauge (19).
★ Fix the upper and lower holders (20)
with a wrench so that they do not
rotate, and tighten the bolts.
Mounting bolt: CPW10804

12.7 - 13.7 Nm {1.3 - 1.4 kgm}
2) Attach the left transmission mount (18).
CPW10806
WA380-5 30-55
(9)
2
(7)
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
18. Transmission, work equipment and PPC

pump assembly
1) Lift and install the pump assembly (6),
and tighten 2 pieces of the mounting bolt
(7).
CPW10802
2) Attach the strainer (10).
30-56 WA380-5
(9)
2
WA380-
5 TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND OFCLUTCH
ASSEMBLY CYLINDER PACK
TRANSMISSION CLUTCH
HEAD ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK

ASSEMBLY
SPECIAL TOOLS
2. Forward gear
1) Remove spacer (1) and thrust washer (4)
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
1 793-607-1110 Seal holder ■ 1 N

C3
2 793-607-1120 Seal holder ■ 1 N
C12 799-301-1500 Oil leak tester kit ■ 1
DISASSEMBLY
WARNING! When loading the clutch

pack on the block, take care so that the
clutch pack may not slip from your
hands with oil and so that your finger
may not get caught between the block 3. End plate
and clutch pack. 1) Use C clamp [3] or the like to press end
plate (6) and to dismount snap ring (7).
2) Dismount end plate (6).
DISASSEMBLY OF FORWARD AND
REVERSE CLUTCH PACKS
[FORWARD CLUTCH SIDE]
1. Bearing
Mount bearing race puller [1] on bearing (3)
and push the shaft with a press, then dis- cpw10573
mount bearing (3).
★ When the bearing is dismounted, the
clutch assembly drops. So catch the
clutch assembly by a cushion seat.
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
★ If the piston is tilted and will not dismount,

push the piston again.
★ If the piston is dismounted by force, note that
the inside surface of the cylinder is damaged.
2) Dismount plate (9), disc (10) and spring
(11).
[REVERSE CLUTCH SIDE]
6. Bearing
Mount bearing race puller [4] on reverse gear
(16) and use hydraulic cylinder [5] to dis-
mount bearing (15).
cpw10575
Dismount thrust washer (12). cpw10974
3) Dismount thrust washer (12).
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
7. Reverse gear 2. 1st gear

1) Dismount spacer (17), thrust washer (18) 1) Remove snap ring (32) and dismount
and reverse gear (16). thrust washer (33) and 1st gear (34).
2) Dismount needle bearing (19) from the
reverse gear.
cpw10586
cpw10579

1st gear.
8. End plate
9. Clutch plate
10. Piston
★ Disassemble procedures 8. - 10. In the
same manner as the procedures 3. - 5. at
the reverse clutch side.
cpw10587
DISASSEMBLY OF 1ST AND 4TH
CLUTCH PACK
[1ST CLUTCH SIDE]
1. Idler gear
Use puller [7] to dismount inner race (30) and
idler gear (31).
3. End plate
1) Use C clamp [8] or the like to press end
plate (36) and dismount snap ring (37).
cpw10585
cpw10588
WA380-5 30-59
(9)
2
PACK ASSEMBLY
4. Clutch plate [4TH CLUTCH SIDE]

(40) from the housing. 6. Bearing
Use puller [9] to pull out 4th gear (46) and dis-
mount bearing (43).
cpw10589
cpw10975
2) Dismount thrust washer (41).
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).
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.
★ If the piston is tilted and will not dismount,

push the piston again.
★ If the piston is dismounted by force, note that
the inside surface of the cylinder is damaged.
30-60 WA380-5
(10)
2
TRANSMISSION
TRANSMISSION CLUTCH
DISASSEMBLY OF 2ND AND 3RD 3. End plate

CLUTCH PACK 1) Use C clamp [11] or the like to press end
plate (54) and dismount snap ring (55).
[3RD CLUTCH SIDE]
1. Bearing
1) Apply puller [10] to 3rd gear (53) and dis-
mount bearing (49) and 4th gear (50).
cpw10598
cpw10976
4. Clutch plate
(58) from the housing.
2. 3rd gear
1) Dismount thrust washer (52) and 3rd gear
(53).
cpw10599
cpw10596
2) Dismount thrust washer (58a).
2) Dismount needle bearing (53a) from 3rd

gear (53).
cww10977
WA380-5 30-61
(10)
2
PACK ASSEMBLY
5. Piston 7. 2nd gear

Make air blow into the 3rd clutch side oil hole 1) Dismount thrust washer (62) and 2nd gear
of the shaft and dismount piston (59). (63).
cpw10600 cpw10979
2) Dismount needle bearing (64) from 2nd

gear (63).
cpw10602
cpw10605
★ If the piston is tilted and will not dis-

mount, push the piston again.
★ If the piston is dismounted by force, note
that the inside surface of the cylinder is
damaged. 8. End plate
9. Clutch plate
10. Piston
[2ND CLUTCH SIDE]
★ Disassemble procedures 8. - 10. in the
6. Bearing same manner as the procedures 3. - 5. at
1) Use forcing screw [12] to pull out output the 3rd clutch side.
gear (60) and dismount bearing (60a).
2) Remove output gear (60).
cpw10978
30-62 WA380-5
(10)
2
TRANSMISSION
TRANSMISSION CLUTCH
ASSEMBLY 3. Clutch plate

ASSEMBLY OF THE FORWARD AND 1) Alternately assemble plate (68), disc (69)
and spring (70) in this order.
REVERSE CLUTCH PACKS ★ Assemble disc (69) after having
[REVERSE CLUTCH SIDE] immersed it in clean transmission oil
for two minutes or more.
1. Piston seal ★ Take care so that spring (70) and disc
Assemble piston seal (66) in piston (65). (69) will not overlap.
★ When assembling a new piston seal, use ★ Carefully assemble the plate and the
tool C3-1 to assemble it after the seal spring so that they will not bite into
the ring groove of the clutch housing.
having run in (it takes two or three min-
utes).
★ If the seal is assembled in the cylinder
without making the seal run in, note that
the seal is damaged.
Tool C3-1 inside surface:
Transmission oil cpw10608
cww10606
2) Mount spring plate (71)
★ Mount it facing identification mark U
upward.
2. Reverse side piston

1) Mount reverse side piston (65). cpw10609
★ Take care so that the piston seal will
not be damaged.
Piston sliding surface:

Transmission oil
2) Mount thrust washer (67).

4. End plate
1) Mount end plate (72).
plate (72).
3) Mount snap ring (73).
cpw10607
cpw10610
WA380-5 30-63
(9)
2
PACK ASSEMBLY
5. Reverse gear, bearing [FORWARD CLUTCH SIDE]

1) Assemble needle bearing (19) in the
reverse gear (16) and mount it fitting the 6. Forward side piston
internal gear of the disc. 1) Make the piston seal run in the same
2) Mount thrust washer (18), spacer (17) and manner as the reverse clutch side and
assemble it in piston (14).
bearing (15) in this order. 2) Assemble piston (14) in the same manner
as the reverse side piston.

Transmission oil
cpw10579
cpw10576
3) The clearance a between spacer (17) and

thrust washer (18) is within a standard
value.
Standard value a: 0.3 - 0.7 mm.
★ Measure the clearance a using a dial
gauge or clearance gauge. 7. Clutch plate
1) Alternately assemble plate (9), disk (10)
and spring (11) in this order.
★ Assemble them in the same manner
as the reverse clutch side.
cww10980
cpw10575
2) Mount spring plate (8)

★ Mount it facing identification mark U
sideways.
cpw10574
30-64 WA380-5
(9)
2
PACK ASSEMBLY
8. End plate 10. Clutch pack operation test

1) Mount end plate (6). Use tool C12 to make compressed air blow in
2) Use C clamp [3] or the like to press needle the oil hole of the shaft and each clutch oper-
plate (6) and mount snap ring (7). ates.
★ If the gear at the side where air blew in is
secured, the clutch operates normally.
cpw10573
cww10982
9. Reverse gear, bearing

1) Assemble needle bearing (5) in the for-
ward gear (2) and mount it fitting the
ASSEMBLY OF 1ST AND 4TH
internal gear of the disc.
2) Mount thrust washer (4) and spacer (1). CLUTCH PACK
[4TH CLUTCH SIDE]
1. Piston seal
Assemble piston seal (76) in piston (75).
★ When assembling a new piston seal, use
tool C3-2 to assemble it after the seal
having run in (it takes two or three min-
cww10973
utes).
★ If the seal is assembled in the cylinder

Transmission oil
3) Press-fit bearing (3) and check that the

clearance b between spacer (1) and thrust
washer (4) is within a standard value.
Standard value b: 0.24 - 0.76 mm
cww10617
cww10981
★ Measure the clearance b using a dial

gauge or clearance gauge.
WA380-5 30-65
(9)2
PACK ASSEMBLY
2. 4th side piston 4. End plate

1) Mount 4th side piston (75). 1) Mount end plate (82).
★ Take care not to damage the piston seal. 2) Use C clamp [14] or the like to press end
plate (82) and mount snap ring (83).
Contact surface of piston seal: ★ Check that snap ring (83) is correctly
Transmission oil inserted in the groove.
cpw10620
cpw10618
5. 4th gear, bearing

1) Assemble needle bearing (47) in the 4th
3. Clutch plate gear (46) and mount it fitting the internal
Alternately assemble plate (79), disc (80) and gear of the disc.
spring (81) in this order. 2) Mount thrust washer (45) and spacer (44),
★ Assemble disc (80) after having then use tools C2-1 and C2-2 to press-fit
immersed it in clean transmission oil bearing (43).
for two minutes or more.
★ Take care so that spring (81) and disc
(80) will not overlap.
★ Carefully assemble the plate (79) and
the spring (81) so that they will not
bite into the ring groove of the clutch
housing.
cpw10593
cpw10619
30-66 WA380-5
(10)
2
PACK ASSEMBLY
3) Check that the clearance c between 7. Clutch plate

spacer (44) and thrust washer (45) is Alternately assemble plate (38), disc (39) and
within a standard value. spring (40) in the housing.
Standard value c: 0.28 - 0.72 mm ★ Assemble them in the same manner as
★ Measure the clearance c using a dial the 4th side.
cpw10589
8. End plate
[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
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
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
cpw10586
10. Idler gear

1) Assemble idler gear (31) and use tools
C2-1 and C2-2 to press-fit inner race (30).
11. Clutch pack operation test

Use tool C12 to make compressed air blow in
the oil hole of the shaft and each clutch oper-
ates.
★ If the gear at the side where air blew in is
secured, the clutch operates normally.
cpw10624
30-68 WA380-5
(9)
2
TRANSMISSION
TRANSMISSION CLUTCH
ASSEMBLY OF 2ND AND 3RD 3. Clutch plate

CLUTCH PACK Alternately assemble plate (88), disc (89) and
spring (90) in this order.
[2ND CLUTCH SIDE]
★ Assemble disc (89) after having
1. Piston seal immersed it in clean transmission oil
Assemble piston seal (86) in piston (85). for two minutes or more.
★ When assembling a new piston seal, use ★ Take care so that spring (90) and disc
tool C3-2 to assemble it after the seal (88) will not overlap.
having run in (it takes two or three min- ★ Carefully assemble the plate and the
utes). spring so that they will not bite into
★ If the seal is assembled in the cylinder the ring groove of the clutch housing.

Transmission oil
cpw10631
4. End plate
plate (91) and mount snap ring (92).
2. 2nd side piston

1) Mount 2nd side piston (85).
★ Take care so that the piston seal may
not be damaged.
Piston seal sliding surface:

Transmission oil
cpw10632
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
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
cpw10605
cpw10979 [3RD CLUTCH SIDE]

7. 3rd side piston
1) Make the piston seal run in the same
manner as the 2nd clutch side and assem-
ble piston (59).
2) Assemble piston (59) in the same manner
as the 2nd clutch side piston.
6. Idler gear, bearing Piston sliding surface:

1) Mount idler gear (60). Transmission oil
3) Mount thrust washer (58a).
cpw10633
cwp10600
2) Use tool C2-3 to press-fit bearing (60a).
30-70 WA380-5
(10)
2
TRANSMISSION
TRANSMISSION CLUTCH
8. Clutch plate 11. 4th gear, bearing

Alternately assemble plate (56), disc (57) and 1) Assemble 4th gear (50).
spring (58) in the housing. 2) Use tools C2-4 to press-fit bearing (49).
★ Assemble them in the same manner as
the 2nd side.
cpw10599
3) Check that the clearance f between 4th

gear (50) and thrust washer (52) is within
a standard value.
9. End plate Standard value f: 0.28 - 0.72 mm
Use C clamp [11] or the like to press end plate ★ Measure the clearance f using a dial
(54) and dismount snap ring (55). gauge or clearance gauge.
cpw10598
12. Clutch pack operation test

10. 3rd gear Use tool C12 to make compressed air blow in
1) Assemble needle bearing (53a) in 3rd the oil hole of the shaft and each clutch oper-
gear (53) and mount it fitting the internal ates.
gear of the disc. ★ If the gear at the side where air blew in is
2) Mount thrust washer (52). secured, the clutch operates normally.
WA380-5 30-71
(10)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF PARKING
PARKING BRAKE
BRAKE ASSEM-
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE ASSEMBLY

SPECIAL TOOLS 3. Gauge assembly
1) Remove six mounting bolts and use forc-
ing screw [1] to dismount gauge assem-
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
793T-607-1130 Push tool ● 1 |

3 790-101-5421 Grip ● 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-
5. Spring cover 8. Plate, spring, disc

Evenly loosen mounting bolt (15) and dis- 1) Use tool H1 to dismount snap spring (19).
mount cover (16).
★ Because the mounting bolt is pressed
with the brake spring, evenly loosen the
total number of mounting bolts.
cpw10935
cpw10933
2) Dismount hub (20).

3) Dismount plate (21), spring (22) and disc
(23).
★ Ten plates, nine springs and nine
6. Spring discs.
Dismount spring (17).
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
PARKING BRAKE
BRAKE ASSEM-
ASSEMBLY
10. Output shaft assembly ASSEMBLY

1) Use eyebolt [4] to hang and dismount out-
put shaft assembly (27). 1. Outer race, oil seal (rear drive side)
2) Dismount gear (28) from output shaft 1) Use push tool [5] to mount outer race (31)
assembly (27). on the transmission case.
3) Dismount bearing (29).
cww10940 does not

match hardcopy size
cpw10938
2) Use tool H8 to mount oil seal (33) on the

transmission case.
11. Oil guide
Dismount oil guide (30). Oil seal press fit surface:
Liquid gasket
12. Outer race, oil seal (rear drive side) (Three Bond 1110B)
1) Dismount outer race (31).
2) Dismount dust seal (32). • Lightly cover the inner face of the
3) Dismount oil seal (33). housing and wipe off excess.
Oil seal lip surface:

Silicone grease
(Three Bond 1855)
3) Use tools H8 and H9 to mount dust seal

(32).
cpw10939 Clearance portion between oil
seal and dust seal: Silicone
grease (Three Bond 1855)
30-74 WA380-5
(10)
2
PARKING
PARKING ASSEMBLY
BRAKE ASSEM-
2. Oil guide 3) Use eyebolt [4] to mount output shaft

Mount oil guide (30). (27).
★ Take care so that the oil seal will not
Mounting bolt: be damaged.
Adhesive (LT-2)
cpw10942 cpw10944
3. Output shaft assembly 4. Brake housing

1) Use tool H6 to mount bearing (29) on out- 1) Attach snap ring (25) to brake housing
put shaft (34). (24) and mount plate (26).
★ Coat the bearing with oil seal.
2) Mount guide bolt [6].

2) Mount gear (28) on output shaft (34). 3) Use eyebolt [3] to mount brake housing
★ Face the gear with a long flange to the (24) on the transmission case.
bearing side.
O-ring: Grease (G2-LI)
cpw10946
WA380-5 30-75
(10)
2
PARKING BRAKE
BRAKE ASSEM-
ASSEMBLY
5. Mount hub (20).

7. Spring cover
Both ends of the hub: Anti-fric- Use eyebolt [3] to mount spring cover (16)
tion composition (LM-G) aligning it to eyebolt [6].
★ Check that the spring is correctly con-
tained in the cover.
cpw11189
★ To measure the rotation torque of only

the bearing accurately, do not install the
parking brake disc, oil seal, and dust seal
8. Bearing assembly
of the output shaft when assembling.
1) Use tool H5 to mount bearing (14) on
boss (13).
6. Piston
2) Mount bearing assembly (12).
1) Assemble the o-ring in the piston.
O-ring: Grease (G2-LI)
2) Use the eyebolt to mount piston (18).

★ Mount the piston aligning the counter
mark a of the piston with the counter
mark b of the housing.
3) Mount spring (17).
cpw10947
cpw10950
30-76 WA380-5
(9)
2
PARKING
PARKING ASSEMBLY
BRAKE ASSEM-
9. Gauge assembly 11. Adjusting rotation torque of output shaft with

1) Use push tool [7] to mount outer race (11) shim
on the gauge. 1) Tighten 6 cage mounting bolts (40) tem-
porarily without setting the shim.
9.8 ± 0.98 Nm {1 ± 0.1 kgm}
2) Rotate the shaft to the right by 10 turns

and to the left by 10 turns, and then check
the tightening torque.
3) If the tightening torque has changed,
repeat 1) and 2).
4) When the tightening torque does not
change any more, insert the shim and
tighten 6 cage mounting bolts (40) to the
specified torque.
Cage mounting bolt (40):

2) Mount gauge assembly (7). 98 - 123 Nm {10 - 12.5 kgm}
★ Do not install the shim.
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
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
14. Plate, spring, disc

1) Alternately assemble plate (21), spring
15. Gauge assembly
(22) and disc (23).
1) Use tool H3 to mount oil seal (10) on the
★ Ten plates, nine springs and nine
gauge.
discs.
Oil seal press fit surface:
Liquid gasket
(Three Bond 1110B)
• Lightly cover the inner face of the

housing and wipe off excess.
AJS01622
Silicone grease
(Three Bond 1855)
2) Use tools H3 and H4 to mount dust seal

(9) on the gauge.
Clearance portion between the

oil seal and dust seal:
Silicone grease
(Three Bond 1855)
30-78 WA380-5
(10)
2
PARKING
PARKING ASSEMBLY
BRAKE ASSEM-
16. Coupling (front drive)

1) Mount coupling (6).
2) Attach holder (5) and washer (4) and
tighten bolt (3).
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)
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEM-

BLY (STANDARD SPECIFICATION)
SPECIAL TOOLS
2) Disassemble the turbine and case assem-
bly in the following procedure.
Simplified Drawing
New/Revised
i) Dismount pilot (4).
Necessity
Quantity
Symbol Part
Number Part Name ii) Remove snap ring (5) and dismount
plate (1).
790-501-5000 Unit repair stand ● 1
790-501-5200 Unit repair stand ● 1

B
790-901-2110 Bracket ● 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
iv) Dismount the mounting bolt and dis-

connect turbine (6) and boss (18).
v) Dismount bearing (8) from the case.
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
CONVERTER ASSEMBLY OF TORQUE CONVERTER
(STANDARD AS-
SPECIFICATION)
5. Turbine, case assembly

3. Stator shaft 1) Assemble the turbine and the case
1) Mount seal ring (16) on stator shaft (11). assembly in the following procedure.
i) Mount bearing (8) on the case.
★ Press-fit the ring until it touches the
Seal ring: Grease (G2-LI) case.
★ Average the overhang of the seal ring.
ii) Mount turbine (6) on boss (18).
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)
iv) Attach plate (1) and mount snap ring

(5).
v) Mount pilot (4).
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
27.5 - 34.3 Nm
{2.8 - 3.5 kgm}
2) Mount stator shaft pump assembly (2) on

turbine case assembly (3).
Mounting bolt: Adhesive (LT-2)
Mounting bolt:
21.6 - 28.4 Nm {2.2 - 2.9 kgm}
cpw10378
WA380-5 30-83
(10)
2
TORQUE CONVERTER OF(LOCK-UP
ASSEMBLY TORQUE CONVERTER AS-
SPECIFICATION)
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEM-

BLY (LOCK-UP SPECIFICATION)
SPECIAL TOOLS
3) Fine disassembly of stator shaft and
pump assembly
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)
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).
4) Remove bolt (25a) and disconnect turbine

(25) and boss (27).
ii) Remove bushings (18) and (19) from

race and free wheel assembly (15) and
dismount free wheel (20) from race
(21).
WA380-5 30-85
(9)
2
SPECIFICATION)
5) Dismount bearing (28) from complete ASSEMBLY

housing (36).
6) Remove complete housing mounting bolt ★ Assemble each component after having
(30). cleaned it thoroughly and having checked
that there are no dirt and scratches.
★ Check that the snap ring is inserted correctly
in the groove.
1. Complete turbine
Mount turbine (25) on boss (27) and tighten
bolt (25a).
Bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
7) Fine disassembly of complete housing

assembly
i) Dismount piston (37) from complete
housing (36).
ii) Dismount seal ring (38) from piston
(37).
iii) Dismount seal ring (39) from com-
plete housing (36).
2. Turbine and case

Load complete turbine (31) on block [5] and
set drive case (33).
★ Height h of block [5]: About 90 mm
8) Dismount disc (40) from drive case (33).
30-86 WA380-5
(9)
2
SPECIFICATION)
3. Disc
Mount disc (40).
★ Coat the sliding surface of the disc with
engine oil and mount the disc.
2) Use eyebolt [9] to hang complete housing

assembly (32) and load it on drive case
(33).
3) Tighten mounting bolt (30).
4. Complete housing assembly Mounting bolt:
1) Fine assembly of complete housing Adhesive (LT-2)
i) Mount seal ring (39) on complete
housing (36). Mounting bolt:
27.5 - 34.3 Nm {2.8 - 3.5 kgm}
External surface of seal
ring: Grease (G2-LI)
ii) Mount seal ring (38) on piston (37)

and mount it on complete housing
(36).
★ Because seal ring (38) has the
assembly orientation, assemble it
as shown in the following dia-
gram.

ring: Grease (G2-LI)
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
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}
9. Stator shaft and pump assembly

1) Fine assembly of stator shaft pump
assembly
i) Use push tool [12] to press-fit bearing
(11) in guide (12).
★ After having press-fit the bearing,
drop the engine oil by 6 cc and
rotate the bearing ten times.
8. Stator assembly
1) Fine assembly of stator association
i) Assemble free wheel (20) in race (21)
and mount bushings (18) and (19)
using an expansion fit.
★ Coat the sliding surface of the
bushing and free wheel with
engine oil.
★ Take care not to damage the
sprag of the free wheel.
★ Assembly the free wheel facing
the arrow mark displayed on the
cage end surface to the turbine
side (input side).
ii) Set guide bearing assembly (8) and
gear (10) in pump (9) and tighten
mounting bolt (7).
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
iii) Mount seal ring (6) on stator shaft (5). ★ When the direction of stator rota-
tion differs from the above
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
2) Use eyebolt [14] to load turbine case

assembly (3) on stator shaft pump assem-
bly (2), then temporarily tighten mounting
v) Use tool B2 to tighten nut (4).
bolt (1).
★ Screw the bolt in the stator shaft 3) Reverse the turbine case and tighten the
and tighten the nut not so as to mounting bolt.
turn the nut with bar [3].
Mounting bolt:
Nut: Adhesive (LT-2) Adhesive (LT-2)
Nut: 147.1 - 176.5 Nm Mounting bolt:

{15 - 18 kgm} 27.3 - 34.3 Nm {2.8 - 3.5 kgm}
vi) Mount stator assembly (13) rotating it

clockwise.
★ Check the direction of stator rota-
tion viewed from the turbine side
(input side).
Clockwise direction: Turn with no
load
Counterclockwise: Lock
WA380-5 30-89
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR
REARAXLE
AXLE ASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY

REMOVAL
6. Disconnect connector (8) (R56) of rear brake
oil temperature sensor.
WARNING! Park a machine at a hori-
zontal place and load the frame lock bar
on the frame, then put the locks under
the front wheel.
1. Push up the machine body by work equip-

ment and put block [1] under the frame in cpw10891
front of the rear wheel, then raise the rear of
the machine body.
2. Dismount the rear axle assembly by hanging
tire (1) using a money belt and dismounting
mounting bolt (2). [*1]
★ Dismount the opposite side in the same
procedure.
7. Dismount universal joint (9). [*2]
cpw10889
cpw10892
3. With reference to the item of "Dismounting

Fuel Tank Assembly", dismount the fuel tank 8. Disconnect brake hose (10). [*3]
assembly.
4. Disconnect lubrication tubes (3) and (4) and
dismount elbow (5).
5. Loosen nut (6) and face engine oil drain hose
(7) to the rear.
cpw10890
30-90 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
ASSEMBLY
9. Rear axle assembly 3) Dismounting of rear support

1) Temporarily hang rear axle assembly (11) i) Remove cover (12), holder (13), thrust
and hold support (12) with transmission (14) and spacer (15) and dismount
jack [2], then dismount the right and left rear support (16). [*7]
4 Rear support:
of mounting bolt (13). [*4]
140 kg
ii) Dismount cover (17) from the rear

support and dismount dust seal (18)
and bushing (19). [*8] [*9]
cpw10894
2) Simultaneously drop the crane and the

transmission jack [2] and dismount rear
axle assembly (11). [*5] [*6]
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
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]
Mounting bolt for cover (12)

and holder (13):
Adhesive (LT-2)
Mounting bolt for cover (12)

and holder (13):
245 - 309 Nm {25 - 31.5 kgm}
djw05928
[*8]
★ Mount bushing facing the chamfering
side to the opposite side of cover (17).
[*9]
★ Mount dust seal (18) facing the lip out-
wards.
• (19) is a bushing.
djw05926
30-92 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY

REMOVAL
5. Disconnect drive shaft (5). [*3]
WARNING! Park a machine at a hori-
zontal place and load the frame lock
bar on the frame, then put the blocks
under the rear wheel.
1. Push up the machine body by work equip-

ment and put block [1] under the frame in
front of the rear wheel, then raise the rear of
the machine body.
★ Ground the work equipment by setting
the bucket in the dump position.
2. Dismount the rear axle assembly by hanging
tire (1) using a money belt and dismounting
mounting bolt (2). [*1]
6. Dismount the front axle assembly by tempo-
rarily hanging the front axle assembly and
dismounting the respective four mounting
bolts (7) at the left and right. [*4]
4 Front axle assembly: 930 kg
cpw10884
3. Dismount cover (3) of the machine body

front.
4. Disconnect brake tube (4). [*2]
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
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY

SPECIAL TOOLS
3. Axle housing 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)
3) Change the hanging position of the lifting

tool and raise axle housing assembly (8)
vertically.
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-
4. Planetary carrier assembly 5. Ring gear

1) Remove axle shaft mounting bolt (9) and Use puller [2] to dismount ring gear (12) from
hang and dismount planetary carrier housing assembly (13) raising the gear on the
assembly (10). average.
★ Assemble spacer [3] on the bolt tip of the
puller and adjust the height.
★ Take care so that the pawl of the puller
will not be removed from the ring gear.
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.
2) Dismount shim (11).

★ Record the thickness of the shim and
refer to it at assembly.
Need cpw10303
WA380-5 30-95
(9)
2
AXLE HOUSING
HOUSING ASSEM-
ASSEMBLY
7. Axle shaft bearing 9. Planetary carrier

1) Punch spring pin (21) of planetary carrier
WARNING! Do not remove the (20) so that it is contained in shaft (22).
bearing by applying heat or dis- ★ Take care not to punch the spring pin.
mount it by fusing it.
1) Mount bearing race puller [6] at the bot-

tom of bearing (16) and secure it cor-
rectly.
2) Tighten the bolt and dismount bearing
(16).
3) Dismount sleeve (17a).
2) Use the press to pull out shaft (22).
3) Pull out spring pin (21) from shaft (22).

4) Dismount pinion gear (23) and spacer (24)
from planetary carrier (20).
8. Axle housing
Dismount bearing outer races (18) and (19)
and oil seal (17) from axle housing (14).
30-96 WA380-5
(10)
2
AXLE
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.
2) Use push tool [8] to mount oil seal (17) on

housing (14).

Grease (G2-LI)
2) Use tool J1 to press-fit bearing (16) in

axle shaft (15).
WA380-5 30-97
(9)
2
AXLE HOUSING
HOUSING ASSEM-
ASSEMBLY
3) Raise axle shaft (15) on block [7] and 3. Selecting shims

secure it correctly. 1) After bearings (16) and (26) are fitted well,
4) Install the tool J4 under the oil seal (17a). measure the truning force of hole h of
★ Adjust oil seal (17a) with tool J4 so axle housing (14).
that the top of tool J4 will be lightly in • Turning force (static friction):
contact with oil seal (17a) and the
clearance will be even. 49.0 - 93.1 N {5 - 9.5 kg} (Front, Rear)
★ Do not install planetary carrier (20).
★ Including seal resistance.
5) Sling axle housing (14) horizontally and

mount it on the shaft slowly.
6) Press-fit bearing (26).
★ Produce running in rotating with tool
J2 the housing.
★ Press-fit the end play until it reaches
0.1 mm.
Bearing: Axle oil
7) Pull out tools J4 horizontally.
★ If the turning force is below the standard

value, press fit the bearings again and
perform the work in step 1).
★ If the turning force exceeds the standard
value, adjust it according to following to
following steps 2) - 4).
30-98 WA380-5
(10)
2
AXLE
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).
5) Install planetary carrier (20) to the spline

of axle shaft (15) without the gear and
place spacer (24).
★ Just place spacer (24) on planetary
carrier (20). Do not tighten the bolt.
6) Use a depth micrometer to measure the
distance H from the end surface of spacer
(24) to the axle shaft end surface.
Assume the value in which the thickness t
of spacer (24) is subtracted from H is
(H - t).
• Thickness of shim = (H - t) + 0.05
0
WA380-5 30-99
(10)
2
AXLE HOUSING
HOUSING ASSEM-
ASSEMBLY
3) Press-fit the shaft aligning shaft (22) and 5. Ring gear

spring pin hole (22a). Press-fit ring gear (12) in axle housing (14)
and insert pin (12a).
Shaft: Oil (axle oil) ★ Assemble the housing by aligning the
housing and the pin hole of the ring gear.
★ Carefully press-fit the ring gear horizon-
tally so that the ring gear will not be tiled.
★ Align shaft (22) and spring pin hole

(21) and punch spring pin (21) so as to
be made the same level (j portion)
with carrier (20). 6. Planetary carrier assembly
1) Assemble shim (11) selected in item 6) of
procedure 3. on the axle shaft end sur-
face.
2) Mount planetary carrier assembly (10)
and tighten mounting bolt (9).
★ Correctly degrease and clean the bolt
mounting hole and mounting bolt of
the axle shaft.
WARNING! When assembling

the planetary shaft, sufficiently
take care so that the finger will
not be caught in the gears.
Mounting bolt: Adhesive

(LT-2)
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
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
7. Axle housing assembly

1) Degrease and clean axle housing (14) and
the mounting surface of differential hous-
ing (30) and evenly coat the mounting
surface with the liquid gasket.
Housing mating face: 3) Tighten the mounting bolt by mounting it

Liquid gasket LG-6 on a diagonal line.
3 Housing mounting bolt:

(Locktite 515)
490 - 680 Nm {50 - 62 kgm}
8. Lubrication
1) Tighten the drain plug and lubricate to a
specified level from the oil filler port.
5 Axle oil (front, rear):

38 liters
2) Remove the oil level plug and check that

the oil is provided near the lower edge of
the plug hole.
WA380-5 30-101
(10)
2
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY

SPECIAL TOOLS
1. Brake piping
Disconnect the tube (1).
New/Improved
Illustration
Necessity
2. Oil temperature sensor (rear differential)
Quantity
Symbol Product No. Product Name
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
1 793T-522-1110 Push tool ■ 1 N {
D2 2 790-101-5421 Grip ■ 1
3 01010-81240 Bolt ■ 1
1 793T-522-1110 Push tool ■ 1 N {
2 793T-522-1120 Spacer ■ 1 N {
D3
3 790-101-5421 Grip ■ 1
4 01010-81240 Bolt ■ 1
D4 790-201-2740 Push tool ■ 1
D5 793T-522-1130 Push tool ■ 1 N {
1 790-301-1720 Adapter ■ 1 3. Axle housing assembly

Remove the axle housing assembly on the
2 799-101-5002 Hydraulic kit ■ 1
D6 left and right, referring to section, "Disassem-
3 793-605-1001 Brake tester ■ 1 bling Axle Housing Assembly."
4 790-101-1102 Hydraulic pump ■ 1 4. Differential assembly
Put the differential assembly (7) on the block
D7 796-751-1510 Wrench ■ 1
[1] to make it stable. (Otherwise, attach to tool
D1.)
★ When using tool D1, remove the cage
DISASSEMBLY assembly according to step 8.
5. Cover
★ The subsequent photos and illustrations
Remove the cover (8).
show the front differential as an example,
excluding the portions described separately.
★ For the front and rear differentials, the inter-
nal structures are the same, excluding the
appearance.
CPW10332
30-102 WA380-5
(10)
2
ASSEMBLY
6. Brake 7. Cage assembly

1) Remove the shaft (9). 1) Lift the differential case and turn up the
2) Remove the bolt (10) and also remove the cage assembly.
outer plate (11). 2) Remove the bolt (17) and also remove the
3) Remove the disk (12), spring (13), and coupling (19) with the protector (18).
plate (14). ★ Do not remove the protector from the
★ Mark so that the parts on the left and coupling unless required.
right are not mixed.
CPW10336
CPW10333
3) Attach the lift bolt [2] and temporarily lift

the cage assembly (20).
★ Mark index symbols on the cage and
differential case so that they smoothly
match at assembly.
4) Remove the bolt (21).
CPW10334 5) Screw the pull-up bolt and pull up the
case assembly until the o-ring appears.
6) Lift the cage assembly and remove it.
4) Blow air into the brake tube joint unit (15) CPW10337
and remove the piston (16).
CPW10335
WA380-5 30-103
(9)
2
7) Remove the shim (22). 9. Differential carrier assembly

★ Record the number of shims to refer 1) Remove the differential carrier assembly
to at assembly. (23) from the differential case (25).
★ Take care not to remove the lift tool.
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
2) Remove all the bearing carrier attachment

bolts, and attach the guide bolt [3].
3) Screw the pull-up bolt [4], and remove the
bearing carrier (24).
★ Identify so that the bearing carriers on
the left and right are not mixed.
★ Confirm the shim thickness and num-
ber of shims to refer to at assembly.
CPW10340
30-104 WA380-5
(9)
2
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).
5) Remove the spherical washer (37) and

pinion gear (35) from the detached spider
shaft (36).
2) Remove the bearing (27) from the plane

half (28).
6) Remove the side gear (34) and thrust

washer (30).
3) Remove the thrust washer (30) from the

bevel gear flange half assembly (29), and
also remove the side gear (34).
WA380-5 30-105
(9)
2
7) Reverse the bevel gear flange half assem-

bly (29) and remove the bolt. Then detach 2) Remove the 2 plates (61) and 2 disks (62).
the bevel gear (43) and bearing (27).
3) Remove the pressure ring (63) and side

11. Disassembly of differential carrier assembly gear (64).
(Limited slip differential specification)
★ Identify right and left parts to avoid confu-
sion.
★ Put mating marks on the cover (58)
and case (59) for reference purposes
when re-assembling.
4) Remove the pinion gear (65) and spider

shaft (66).
★ When removing the cover (58), it is

detached with the washer (60) fitted in
a groove at the back.
30-106 WA380-5
(10)
2
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
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.
3) Attach the spacer (51).

3) Remove the spacer (51) and bearing inner
race (52) from the pinion gear (45).
4) Stand the pinion gear (45) and attach the

cage (44).
5) Use tool D4 to press the bearing (46) in
ASSEMBLY the pinion gear while turning the cage
(44).
1. Pinion gear and cage ★ Coat the accelerator oil on the bearing
1) Attach the bearing outer races (47) and inner race.
(48) to the cage (44).
30-108 WA380-5
(9)
2
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
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}
2) Press the bearing (27) in the flange half

(29).
7) Attach the thrust washer (30) and side

gear (34).
3) Press the bearing (27) in the plane half

(28).
30-110 WA380-5
(9)
2
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
9) Attach the spider shaft (36), pinion gear

(35), and spherical bush (37).
4. Assembly of differential carrier assembly

(Limited slip differential specification)
★ Assemble right and left parts according to
identifications made at the time of taking
them apart.
1) Press the bearing outer race (24b) until it
comes into contact with the right and left
bearing carriers (24) using push tool [10].
10) Assemble the side gear (34) in the bevel

gear flange half assembly (29).
11) Grease the thrust washer (30) and adhere
the thrust washer (30) matching the AJS01646
dowel pin of the plane half (28), so that it
does not drop at assembly.
★ Take care of the front and back at
assembly of the thrust washer.
Thrust washer:
Grease (G2-LI)
★ Take care not to overgrease.
WA380-5 30-111
(10)
2
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)
AJS01648 Plate and disk: Axle oil
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
8) Install the pressure ring (68) and side

gear (67).
AJS01638
30-112 WA380-5
(10)
2
ASSEMBLY
9) Install the pinion gear (65) and spider

shaft (66).
AJS01635
AJS01637
12) Adjust the clearance between the case

and plate.
i) Using depth gauge [11], measure dis-
10) Install the side gear (64) and pressure tance d from the end face of case (59)
ring (63). to the end face of plate (61).
• Distance d: 0.2 - 0.6 mm
ii) If distance d is out of the standard
range, replace the plate with the one
with proper thickness so that distance
d will be in the standard range.
★ Replace the plates on both right
AJS01636 and left sides so that the total
thickness of the 2 plates on each
side will be the same, and then
perform the above procedure
from step 7).
• Thicknesses of plates (Rear)
: 3.0 mm (Part No. 424-22-27450)
: 3.1 mm (Part No. 424-22-27460)
11) Install the disk (62) and plate (61) 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) AJS01649
Plate and disk: Axle oil
9JS02261
WA380-5 30-113
(10)
2
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
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).
2) Attach the o-ring (24a) and seal (24b) to

the bearing carriers (24) on the left and
right.
9JS02427
5. Gear cover
Attach the gear cover (26) to the differential
case.
3) Attach the guide bolt [3] in the bearing

carrier attachment holes on the left and
right of the differential case.
CPW10342
CPW10366
WA380-5 30-115
(10)
2
4) Attach the removed shim (22) to the bear- 7. Cage assembly

ing carriers (24) on the left and right, then 1) Insert the o-ring (20a) in the groove of the
fasten the bearing carrier attachment bolt cage assembly (20).
(24c).
O-ring: Oil (Axle oil)
★ Fasten the bevel gear while turning it.
Bearing: ★ Coat the oil slightly.

Axle oil
Mounting bolt:
157 - 196 Nm {16 - 20 kgm}
2) Attach the guide bolt [6] to the differential

carrier assembly (7), assemble the
removed shim (22), then mount the cage
assembly (20).
5) Use the push-pull gauge [5] to measure ★ At assembly, turn the thinner side of
the preload of the bevel gear. the shim to the cage.
★ Activation rotation power:
13.7 - 37.3 N {1.4 - 3.8 kg} Attachment bolt:
245 - 309 Nm {25 - 31.5 kgm}
★ When the activation rotation power is
outside the reference value, adjust the
shim thickness. 3) Securely fasten the coupling attachment
bolt temporarily tightened in step 2.
Attachment bolt:
Adhesive (LT-2)
Attachment bolt:
490 - 608 Nm {50 - 62 kgm}
CPW10368
30-116 WA380-5
(10)
2
ASSEMBLY
8. Back rash adjustment

1) Use the dial gauge [7] to measure the
back rash of the bevel gear.
★ Back rash reference value:
0.25 - 0.33 mm
★ Measure the back rash at three por-
tions on the circumference of the
bevel gear. Then confirm that an error
for each measurement value is in the
range of 0.1 mm.
CPW10372
2) To obtain the back rash in the reference

value, move a part of the shim of the
bevel gear to the reverse side.
★ At movement of the shim, do not
change the total thickness of the left
and light.
★ When the back rash is too high, move
a part of shim b to shim a.
★ When the back rash is too low, move
a part of shim a to shim b.
WA380-5 30-117
(9)
2
9. Tooth contact inspection

Knead the Komeitan with the spindle oil and coat it on 7 - 8 teeth of the bevel gear. While holding down
the bevel gear by hand and braking, turn the pinion gear forward and backward, and inspect the tooth
contact.
Follow the procedure to adjust the tooth contact state.
Tooth Contact Cause Adjustment
Correct contact To adjust the pinion gear, increase or decrease the
Remain the tow side about 5 mm and gauge shim.
confirm that all teeth to the heel side To adjust the bevel gear, follow the same proce-
come into contact 50%, centering the dure as of the back rash.
pitch line.
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
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
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
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
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
4) Send air in brake oil port A and adjust the

piston operation.
2) Attach the disk (12), spring (13), and plate

(14) in sequence.
★ Put a spring on another, matching
their notched parts, and attach the
springs together so that the notched
parts are in the range marked by ★
below. (A indicates the brake oil port.) CPW10375
CPW10334
11. Cover
Attach the cover (8) to the differential case (7).
Cover attachment side:

Liquefied gasket
(Lock tight 515)
Mounting bolt:
157 - 196 Nm {16 - 20 kgm}
CPW10332
WA380-5 30-119
(9)
2
12. Accelerator housing 14. Oil temperature sensor (rear differential)

Attach the accelerator housing assembly on 1) Attach the oil temperature sensor (5) and
the left and right, referring to section "Assem- connect the connector.
bly of Accelerator Housing Assembly."
Oil temperature sensor screw
13. Brake oil leakage inspection unit:
1) Attach tools D6-1 and D6-2 to the brake Liquefied gasket (LG-5)
tube attachment port A of the differential
case (7), then bleed the attachment cylin- Oil temperature sensor:
der. 29.4 - 49.0 Nm {3 - 5 kgm}
2) Use tool D6-4 to increase the pressure up
to 1.4 MPa {14 kg/cm2}. 2) Attach the cover (3).
★ Leave the unit with
1.4 MPa {14 kg/cm2} for five minutes, 15. Brake tube
then confirm that the pressure lowers 1) Attach tube (1).
up to 0.3 MPa {3.5 kg/cm2}.
3) If no oil lekage is found by the check men-
tioned above, increase the pressure up to
4.9 MPa {50 kg/cm2}.
★ Leave the unit with 4.9 MPa {50 kg/
cm2} for five minutes, then confirm
that the pressure lowers up to 0.1
MPa {1 kg/cm2}.
★ If there is no oil leakage, remove the
brake piston and check the damage of
o-ring and seal then assemble them.
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
REMOVAL AND INSTALLATION OF CENTER HINGE PIN

SPECIAL TOOLS
4. Center drive shaft
New/Improved
Illustration
Necessity
Remove four bolts (5a) and disconnect the
Quantity
center drive shaft (5).
1 790-101-2300 Push puller ■ 1
2 793-520-2370 Push tool ■ 1
3 793-520-2350 Push tool ■ 1
E1 4 793-520-2540 Guide ■ 1
5 793-520-2360 Bar ■ 2
6 790-101-1102 Hydraulic pump ■ 1
7 790-101-2102 Puller (30 tons) ■ 1
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.
1. Work equipment assembly

Remove the work equipment assembly, refer-
ring to section "Removal and Installation of
Work Equipment Assembly."
2. Cab and floor frame assembly
Remove the cab and floor frame assembly,
referring to section "Removal and Installation
of Cab and Floor Frame Assembly."
3. Steering cylinder pin and bracket
1) Remove the bolt (1) and detach the rod
pins (2) of the steering cylinders on the
left and right.
2) Disconnect the steering rod (4) and
remove the bracket (3).
WA380-5 30-121
(10)
2
6. Hydraulic piping 7. Frame support

★ Tag the detached hose so that it can be 1) Jack up the rear frame (17a). While adjust-
identified. ing the height, insert the block [1] on the
1) Detach the PPC hoses (6), (7), (8), and (9). left and right of the rear frame.
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.
3) Detach the work equipment valve drain

hose (14a) and front brake hose (14b).
8. Lower hinge pin

Remove the lock bolt (18) and detach the
lower hinge pin (18a).
30-122 WA380-5
(9)
2
9. Upper hinge pin 10. Detachment of frame

1) Remove the mounting bolt and detach the Carefully pull out the front frame (17b) for-
retainer (19). ward and detach it from the rear frame (17a).
★ Confirm the number of shims inserted ★ Confirm whether the front frame is com-
between the retainer and frame, and pletely detached from the rear frame.
their thickness. ★ Remove the frame lock bar.
2) Remove the lock bolt (20). While adjusting ★ Take care that the lower spacer of the
the height, pull out the upper hinge pin upper hinge does not engage with the
(21). rear frame.
★ Carefully adjust the height so that the
★ Take care of the balance at detachment.
pin can be pulled out by hand.
3) Remove the spacer (22).
11. Lower hinge

1) Pull out the bush (23) from the rear frame.
★ Remove the upper and lower bushes
of the lower hinge together.
WA380-5 30-123
(10)
2
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.
3) Remove the dust seal (25) from the

retainer. 2) Remove the dust seal (28) from the
★ Also remove the dust seal from the retainer.
frame.
3) Remove the spacer (29) and dust seal (30)

4) Remove the bearing (26). from the front frame.
30-124 WA380-5
(9)
2
4) Remove the bearing (31).
3) Fasten the retainer (27) equally with three

mounting bolts and select a shim so that
the maximum of clearance a between the
INSTALLATION retainer and hinge is 0.1 mm or less. Then
1. Upper hinge assemble the retainer.
1) Attach tool E1-1 to the top of the upper
Mounting bolt:
hinge of the front frame (17b) and set the
19.6 ± 2.0 Nm {2.0 ± 0.2 kgm}
bearing (31) onto tool E1-4. Then install
(At adjustment of shim)
the hinge from the upper side and press
it. 4) After adjusting the shim, fasten all the
★ At pressing, use tool E1-4 as a guide. retainer mounting bolts with the specified
★ Take care that the bearing does not torque.
incline.
Mounting bolt:
★ Sufficiently grease the bearing.
Adhesive (Lock tight 2701)
★ The bearing is clearance-adjusted.
The bearing (31) must be replaced Mounting bolt:
together with the spacers (22) and 98 - 123 Nm {10 - 12.5 kgm}
(29).
2) Press the dust seal (28) in the retainer

(27).
★ At pressing, turn the dust seal lip out-
side.
Seal lip: Grease (G2-LI)
WA380-5 30-125
(10)
2
5) Assemble the dust seal (30) and spacer

(29) from the lower side of the front
frame.
side.
★ Assemble the spacer (29) from the
lower side so that the more largely
chamfered side faces to the bearing
side.
3) Fasten the retainer (24) equally with three

mounting bolts and select a shim so that
the maximum of clearance b between the
retainer and hinge is 0.1 mm or less. Then
assemble the retainer.
Mounting bolt:
19.6 ± 2.0 Nm {2.0 ± 0.2 kgm}
4) After adjusting the shim, fasten all the

retainer mounting bolts with the specified
2. Lower hinge
1) Use tool E1 to press the bearing (26) in torque.
the front frame (17b).
Mounting bolt:
★ At pressing, use tool E1-4 as a guide.
★ Take care that the bearing does not
3
incline. Mounting bolt:
★ Sufficiently grease the bearing. 98 - 123 Nm {10 - 12.5 kgm}
2) Press the dust seal (25) in the retainer

(24).
side.
Seal lip: Grease (G2-LI)
30-126 WA380-5
(10)
2
5) Press the dust seal (25) from the upper

side of the front frame. Pin mounting bolt:
★ At pressing, face the dust seal lip out- 205.9 ± 19.6 Nm {21.0 ± 2.0 kgm}
side. (At adjustment of shim)
3) Fasten all the pins and retainer mounting
Seal lip: Grease (G2-LI) bolts with the specified torque.
6) Bush Pin mounting bolt:

Press the bush (23) in the lower hinge of 205.9 ± 19.6 Nm {21.0 ± 2.0 kgm}
the rear frame using the puller [4]. Retainer mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
Pin and retainer mounting bolt:
3. Frame coupling
WARNING! Use a bar to match the pin

holes. Absolutely do not insert fingers.
★ Be sure to match the pin holes.
1) Insert the upper hinge pin (21) and assem-
ble the spacer (22).
Hinge pin circumference:

Grease (G2-LI)
4) Insert the lower hinge pin (18a) and fasten

the lock bolt (18).
2) Attach the retainer (19) to the upper hinge

pin (21) and fasten it equally with three
bolts. Then select a shim so that clearance
c between the hinge and retainer is
0.2 mm or less, and assemble the
retainer.
★ After adjusting the shim, temporarily
fasten the retainer mounting bolt so 4. Carry out installation in reverse order to
that it does not turn. removal.
WA380-5 30-127
(9)
2
5
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CAB
CAB ASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF CAB ASSEMBLY

REMOVAL
2) Disconnect connectors (5), (6), and (7) in
the right front.
WARNING! Park the machine in a horizon-
★ Connector numbers: CL1, CL2, and
tal place, set the frame lock bar in the
CL5.
frame, and ground the work equipment.
6. Detach the window washer hoses (8) and (9).
Then stop the engine, apply the parking
brake, and put the blocks under the wheels.
1. Disconnect the (-) terminal of the battery.

2. Remove the left and right covers under the
cab assembly.
3. Ladder and fender assembly and fender and
step assembly
Remove the left ladder and fender assembly
and right fender and step assembly, referring
to items 5 and 6 in section "Removal of Cab
and Floor Frame Assembly."
4. Remove the covers (1) and (2).
★ Slightly pull out the cover (2) toward you,
then disconnect the connector of the cigar
lighter (3). 7. Remove the cover (10).
8. Disconnect the connectors (11), (12), and (13).
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

brake, and put blocks under the wheels.
Collect the air conditioner refrigerant (R134a).

Remove the engine assembly, referring to
item 2 in "Removal of Cylinder Head Assem-
3) Lift the cab assembly (18) and remove it. bly."
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
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
6. Temporarily lift the right fender assembly

step (6), and remove the attachment bolts.
4 Right ladder and fender assembly:

50 kg
10. Detach the earth harness (10) and car heater

hoses (11) and (12).
7. Disconnect 11 pairs of wiring connectors (7).

★ Connector numbers: LT1, FL1, FL2, FL3,
LR1, LR4, LR5, LR6, LR8, LR9, and LR10.
11. Detach the PPC valve inlet hose (13) and

return hose (14).
★ Remove the clamp on the brake accumu-
lator and pull up hose (13) above the floor
frame.
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).
3) Lift the cab and floor frame assembly and

remove it.
13. Detach PPC hoses (22), (23), (24), (25), and ★ Pull up the PPC hose and accelerator
remove the clamp of the hoses. cable and remove the assembly.
4 bly:
★ Mark index symbols on each hose before
detaching. Cab and floor frame assem-
1,290 kg
INSTALLATION
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
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS)
GLASS
REMOVAL AND INSTALLATION OF OPERATOR'S CAB

GLASS (STUCK GLASS)
SPECIAL TOOL
a If the glass is narrow, you may cut the
adhesive by the following method. Insert
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
1. Using seal cutter [1], cut the adhesive

between broken window glass (1) and opera-
tor's cab (2).
a The broken window glass may be

removed with knife [4] and a screw-
driver. (If the screwdriver is applied
directly to the normal window glass, the
glass will be broken.)
CPW11601 a When using knife [4], insert a screwdriver
in the cut to widen it and move the knife
forward.
CPW11607
2. Remove the window glass.
30-132 WA380-5
(9)
2
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
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (2) and window glass (3) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly. 4. Stick both-sided adhesive tape (4) along the
a Clean the all black part on the back side of inside edge of the glass sticking section.
the window glass. • Size of both-sided adhesive tape: 7 x 4.8
a After cleaning the sticking surfaces, leave mm
them for at least 5 minutes to dry. a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
CPW11604
CPW11606
WA380-5 30-133
(9)
2
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS)
GLASS
a Take care the corner (part "b") of both-

sided adhesive tape (4) will not float.
CPW11614
CPW11633
3) Using tool X3 (suction cups), place win-

dow glass (3) on tool X2-1 (5 mm spacer)
and match it to the operator's cab.
a When sticking the both-sided adhesive
tape around a side or a rear window
glass, start at center of the top and make a
clearance of about 5 mm at end joint (c).
CPW11615
CWW11608
4) Check the clearance between window

glass (3) and operator's cab (2) on both
sides and adjust it evenly.
5) Stick tape [6] between window glass (3)
5. Position the replacement glass. and operator's cab (2) and draw position-
1) Stick X2-2 (thin steel sheet) to tool X2-1 ing line (a).
(spacer) with adhesive. 6) Cut the tape between window glass (3)
• Spacer thickness ( t ) : 5 mm and operator's cab (2) with a knife, and
2) Match tool X2-3 (magnet) to tools X2-1 then remove the window glass.
and X2-2 and set them to the 2 lower a Do not remove the tapes left on the
places of the window glass sticking part window glass and operator's cab
of operator's cab (2). before installing the window glass.
CPW11613 CPW11616
30-134 WA380-5
(10)
2
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS
GLASS)
a Parts to be coated with primer: Apply

6. Apply primer. the primer all over dimension (d) on the
outside of the both-sided adhesive
a The using limit of primer (5) is 4 months
tape.
after the date of manufacture. Do not use
primer (5) after this limit. • Dimension to apply primer (d):
23 mm
a Use the primer within 2 hours after
unpacking it. a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
a Even if the primer is packed again just
dry.
after it is unpacked, use it within 24 hours
after it is unpacked for the first time. a If the glass primer is applied by mis-
(Discard the primer 24 hours after it is take, wipe it off with white gasoline.
packed.) (If wrong primer is applied, the glass
will not be stuck.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it.
(If the primer is unpacked just after
taken out of the refrigerator, water CPW11610
will be condensed. Accordingly, leave
the primer at the room temperature
for a sufficient time.)
2) When reusing primer brush (6), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer glass primer.
CWW11624
CPW11609
4) Evenly apply glass primer (8) to the black

part of window glass (3) to be stuck.
2 Glass primer: SUNSTAR GLASS

3) Evenly apply paint primer (7) to the parts PRIMER 580 SUPRE
on the outside of both-sided adhesive
tape on operator's cab (2) which will be a Do not apply the primer more than 2
coated with the adhesive. times.
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
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.)
CWW11625 2) Cut the tip of the adhesive nozzle (11) so

that dimensions ( f ) and (g) will be as fol-
lows.
• Dimension ( f ) : 10 mm
• Dimension (g): 12 mm
CPW11617
CPW11611
3) Set adhesive cartridge (9) to caulking gun

[7].
7. Apply adhesive. a An electric caulking gun is more effi-
a Use either of the 2 types of the adhesive. cient.
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
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).
5) Apply adhesive (12) to the outside of CPW11614

both-sided adhesive tape (4) of the opera-
tor's cab.
a Before applying the adhesive, check
that the primer is applied to the sur-
face to which the adhesive will be
applied.
2) Using tool X3, raise and place window

glass (3) on tool X2-1 (5-mm spacer) and
stick it to the operator's cab.
a Match the lines of the match tapes
CPW11619 stuck in step 1.
a Stick the glass within 10 minutes after
applying the adhesive.
a Before sticking the glass, check that
the primer is applied to the surface to
which the glass will be stuck.
a Apply adhesive (12) to dimensions (h)

and ( j ) of both-sided adhesive tape
(4) of operator's cab (2).
• Dimension (h): 10 mm
• Dimension ( j ) : 12 mm (Approx.
twice as high as adhesive tape) CPW11622
a Apply adhesive (12) higher than both-
sided adhesive tape (4).
a Apply the adhesive evenly.
CWW11620
WA380-5 30-137
(9)
2
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
3) After sticking window glass (3), press it

evenly.
a Press all over the window glass to the
degree that the window glass will be
stuck to the both-sided adhesive tape.
a Do not press the window glass to
strongly.
CWW11629
CPW11623
9. Cure the stuck window glass for a certain

time.
a Curing time before removing tool X2-1
(5-mm spacer) (at temperature of 20°C
and humidity of 60%): 10 hours
a Curing time before operating vehicle: 1
day
30-138 WA380-5
(9)
2
OPERATOR'SOF
CAB
OPERATOR'S
GLASS (STUCK
CAB GLASS
GLASS)
2) Fill the joint of the glasses with caulking

material (15).
a The usable period of the following
caulking material is 4 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
2 Caulking material: SUNSTAR
PENGUINE SEAL NO. 2505
CPW11631
3) Remove the caulking material projected

from the joint with cardboard [8], etc.
CPW11632
4) Remove the masking tapes from the win-

dow glass.
11. Remove the primer and adhesive from the
operator's cab and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glass, do not give an
impact to it.
WA380-5 30-139
(9)
2
TRANSMISSION, WORK EQUIPMENT, AND PPC PUMP
DISASSEMBLY AND ASSEMBLY ASSEMBLY
REMOVAL AND INSTALLATION OF TRANSMISSION, WORK
REMOVAL AND INSTALLATION OF TRANSMISSION, WORK EQUIP-

MENT, AND PPC PUMP ASSEMBLY
REMOVAL


Remove the engine hood assembly, referring
to item 2 in "Removal of Cylinder Head
Assembly."
Remove the bulk head assembly, referring to
6. Temporarily lift the transmission, work equip-
item 4 in "Removal of Engine Assembly."
ment, and PPC pump assembly (8), then
4. Remove the cab floor frame assembly, refer-
ring to "Removal of Cab and Floor Frame remove the attachment bolts.
4 control pump assembly: 37 kg

Assembly." Transmission, work equipment, and
5. Detach the suction tube (1), PPC pump outlet
hose (2), work equipment pump outlet tube
(3), transmission pump suction tube (4), and
outlet hose (5).
★ For tube (1), remove the clamp (6), in
advance.
★ For tube (3), loosen the clamp (7), in front
of the transmission, in advance.
INSTALLATION
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
REMOVAL AND INSTALLATION OF STEERING, SWITCHING, AND

FAN PUMP ASSEMBLY
REMOVAL


Remove the engine hood assembly, referring
to item 2 in "Removal of Cylinder Head
Assembly."
Remove the bulk head assembly, referring to
item 4 in "Removal of Engine Assembly."
4. Remove the cab floor frame assembly, refer-
ring to "Removal of Cab Floor Frame Assem- 7. Temporarily lift the steering, switching, and
bly." fan pump assembly (11), and remove the
5. Detach the suction tube (1), transmission mounting bolts.
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
WA380-5 30-141
(10)
2
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OFDEMAND
STEERING STEERINGVALVE
DEMAND VALVE
ASSEMBLY
REMOVAL AND INSTALLATION OF STEERING DEMAND VALVE

ASSEMBLY
REMOVAL
4. Use the lift bolt [1] and shackle [2] to tempo-
rarily lift the steering demand valve assembly
(9), and remove the plate bolts.
4
frame, and ground the work equipment. Steering demand valve assembly:
Then stop the engine, apply the parking 26 kg
1. Disconnect the steering rod (1).

2. Detach the return tube (2) and drain hose (3).
INSTALLATION
removal.
3. Detach the steering pump outlet tube (4),
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 AND INSTALLATION OF E.C.S.S. VALVE 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.
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.
WARNING! Remove the remaining pres-

sure of the circuit, referring to "Removal of
Remaining Pressure From E.C.S.S. Circuit."
1. Detach the lift cylinder bottom-side hose (1),

head-side hose (2), and work equipment
valve return hose (3).
INSTALLATION
removal.
2. Detach the work equipment pump hose (4)

and accumulator hose (5).
3. Disconnect the wiring connector (6).
WA380-5 30-143
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF WORK EQUIPMENT
WORK EQUIPMENT VALVE
VALVE ASSEMBLY
REMOVAL AND INSTALLATION OF WORK EQUIPMENT VALVE

ASSEMBLY
REMOVAL
3. Remove the cover (2) in front of the machine.
4. Detach the horns (3) and (4).
tal place, set the frame lock bar in the ★ Horns: 303 Hz for connectors F03 and F04,
frame, and ground the work equipment. 333 Hz for connectors F05 and F06.
WARNING! Dump the work equipment

bucket and raise the lift arm until it
becomes horizontal. While supporting the
lift arm with the block [1] and jack [2], stop
the engine. Then use the work equipment
lever to remove the accumulated pressure
of the accumulator.
5. Disconnect the wiring connector (5).

6. Detach the PPC tube for bucket side (6) and
lift arm side (7).
1. Drain the hydraulic tank oil about 20 liters.

2. Loosen the plug (1) of the hydraulic tank filter
to prevent the tank oil from being flowed.
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.
12. Remove the attachment bolts of the work

9. Detach the steering demand valve hose (13), equipment valve assembly (19). Then use the
work equipment pump outlet tube (10), and lift bolt [1] and shackle [2] to remove it.
E.C.S.S. valve → lift arm head hose (14).
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
removal.
WA380-5 30-145
(10)
2
HYDRAULIC CYLINDER ASSEMBLY (STEERING, LIFT, AND
DISASSEMBLY AND ASSEMBLY BUCKET
DISASSEMBLY AND ASSEMBLY CYLINDER ASSEMBLY)
OF HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEM-

BLY (STEERING, LIFT, AND BUCKET CYLINDER ASSEMBLY)
SPECIAL TOOLS DISASSEMBLY
1. Set the cylinder assembly (1) to tool I1.
2. Cylinder head piston rod assembly
New/Improved
Illustration
Necessity
Quantity
• Steering cylinder assembly
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
796-720-1680 Ring ● 1 2) Pull out the cylinder head piston rod

6 assembly (3) from the cylinder (4).
I 07281-01589 Clamp ● 1
★ When the piston rod assembly is
796-720-1690 Ring ● 1 pulled out from the cylinder, oil leaks.
07281-01919 Clamp ● 1 Prepare an oil receiver.
790-201-1702 Push tool kit ● 1
• 790-101-5021 Grip ● 1
7 • 01010-80816 Bolt ● 1
• 790-201-1751 Push tool ● 1
• 790-201-1841 Push tool ● 1
790-201-1500 Push tool kit ● 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
• Lift and bucket cylinder assembly

1) Remove the cylinder head (2) attachment
bolts.
Cylinder Width across flats of bolt (mm)
Lift cylinder 24
Bucket cylinder 27
• Lift/bucket cylinder assembly

1) Set the cylinder head and piston rod
assembly (3) to tool l1.
2) Pull out the cylinder head piston rod

assembly (3) from the cylinder (4).
★ When the piston rod assembly is
pulled out from the cylinder, oil leaks.
Prepare an oil receiver.
2) Remove the piston assembly turn stopper

screw (3).
★ Screw size: M12 X pitch 1.75.
3. Piston and cylinder head

1) Set the cylinder head and piston rod
assembly (3) to tool l1.
2) Use tool l3 to remove the nut (5).
★ Width across flats of nut: 50 mm.
3) Remove the piston (6) and also detach the
cylinder head (2).
WA380-5 30-147
(9)
2
★ 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).
3) Use tool l4 to remove the piston assem- • Lift/bucket cylinder assembly

bly (6).
Detach the wear ring (8), piston ring (9),
★ When not using tool l4, use the notch
and o-ring backup ring (10) from the pis-
hole (diameter 10.2) to loosen the pis-
ton.
ton assembly.
4) Remove the head assembly (2).
30-148 WA380-5
(9)
2
5. Detailed disassembly of cylinder head assem- ASSEMBLY

bly
• Steering cylinder assembly ★ Take care not to damage the packing, dust
1) Remove the o-ring backup ring (11). seal, and o-ring.
2) Remove the snap ring (12), and also ★ To insert the backup ring, do not put it in the
detach the dust seal (13). assembly unreasonably. Heat it with hot
3) Remove the rod packing (14). water of about 50 - 60 °C, then insert it.
4) Remove the buffering (15). 1. Detailed assembly of head assembly
5) Remove the bush (16). • Steering cylinder assembly
6) Remove the o-ring (17). 1) Use tool l7 to press the bush (16).
2) Assemble the buffering (15).
3) Assemble the rod packing (14).
4) Use tool l8 to attach the dust seal (13),
and fix it with the snap ring (12).
5) Attach the backup ring and o-ring (11).
6) Attach the o-ring (17).

1) Remove the o-ring backup ring (11).
2) Remove the snap ring (12) and also
detach the dust seal (13).
3) Remove the rod packing (14).
4) Remove the buffering (15).
5) Remove the bush (16).
WA380-5 30-149
(10)
2
2) Remove the piston ring (9) from tool l5

• Lift/bucket cylinder and assemble it in the piston (6).
1) Use tool l7 to press the bush (16). 3) Use tool l6 and fasten the piston ring (9).
2) Assemble the buffering (15). 4) Assemble the wear ring (8).
3) Assemble the rod packing (14).
4) Use tool l8 to attach the dust seal (13) and
fix it with the snap ring (12).
5) Attach the backup ring and o-ring (11).

1) Use tool l5 to expand the piston ring (9).
★ After the piston ring is set to the tool,
turn the handle 8 - 10 times to expand
it.
★ For illustration, see CWW11008.
2) Remove the piston ring (9) from tool l5,
then assemble it in the piston (6).
3) Use tool l6 to fasten the piston ring (9).
4) Assemble the wearing (8).
5) Assemble the o-ring and backup ring (10).
★ To insert the backup ring, do not put it
in the assembly unreasonably. Heat it
with hot water of about 50 - 60 °C,
then insert it.
2. Detailed assembly of piston assembly

1) Use tool l5 to expand the piston ring (9).
★ After the piston ring is set to the tool,
turn the handle 8 - 10 times to expand
it.
30-150 WA380-5
(10)
2
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.

1) Set the piston rod (18) to tool l1.
2) Assemble the head assembly (2).
WA380-5 30-151
(10)
2
• 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
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)
Lower hole Lower hole Tap used Tap depth

drill diameter depth
10.3 27 12 X 1.75 20
iii) After processing, eliminate chips and

dusts, then carefully clean the tapped
hole part.
30-152 WA380-5
(10)
2
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.

1) Set the cylinder (4) to tool l1.
2) Lift the cylinder head piston rod assembly
and assemble it in the cylinder (4).
3) Attach the cylinder head assembly (2) to
the cylinder.
★ Fasten the bolt so that the dimension
of the leveler plate of the bucket cylin-
der is as shown in the illustration.
Attachment bolt:
Cylinder Nm {kgm}
Lift cylinder 250 ± 25 {25.5 ± 2.5}
Bucket cylinder 343 ± 34.3 {35 ± 3.5}
WA380-5 30-153
(10)
2
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF HYDRAULIC
HYDRAULIC TANK
TANK ASSEM-
ASSEMBLY
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL

WARNING! Operate the work equipment

operation lever 10 times or more to remove
the accumulated pressure of the PPC cir-
cuit.
1. Drain the hydraulic tank oil.

2. Right fender step assembly
Remove the right fender step assembly, refer-
ring to item 6 in "Detachment of Cab and 7. Detach the emergency pump suction tube
Floor Frame Assembly." (10).
3. Remove the cover on the lower right of the
cab.
4. Remove the ladder (1) and covers (2) and (3).
5. Detach the brake valve return tube (4), work

machine valve return tube (5), PPC valve
return hose (6), and hydraulic oil cooler return
tube (7).
6. Detach the work machine pump suction tube
(8) and steering switch fan pump suction tube
(9).
30-154 WA380-5
(10)
2
HYDRAULIC
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OF TANK
HYDRAULIC ASSEMBLY
TANK ASSEM-
8. Hydraulic tank assembly ATTACHMENT

1) Temporarily lift the hydraulic tank assem-
bly. • Carry out installation in reverse order to
2) Remove the attachment bolts (11) under removal.
the hydraulic tank. • Filling hydraulic oil
3) Remove the attachment bolts (12) and Pour the hydraulic oil (specified oil) up to the
(13) before and after the hydraulic tank. predetermined level.
4) Lift the hydraulic tank assembly (14) to

remove it.
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 AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY
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.
★ Install the block [1] between the cylinder
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.
3. Lift cylinder rod pin

1) Remove the rod pin plate (5-1).
★ Install the support stand [2] at the end
of the lift arm and remove the accu-
mulated pressure in the hydraulic
2) Remove the bucket hinge attachment pin pipe.
(2).
[*2]
WARNING! Absolutely do not

insert fingers into the pin hole.
★ If shims are inserted, check the num-

ber of shims.
3) Move the machine backward and detach
the bucket.
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 Lift cylinder: 170 kg
5. Bell crank and bucket link

1) Temporarily lift the bucket link (9), pull
d
instal of work equipment assembly
out the attachment pin (10), then remove
from the bell crank. [*8]
4 Bucket link:
4. Lift arm, bell crank, and bucket link
1) Remove the boom kick-out switch (7). 55 kg
[*5]
2) Remove the potentiometer (22).

2) Temporarily lift the bell crank (11), pull
[*6]
out the attachment pin (12), then remove
from the lift arm.
4 Bell crank: 320 kg
3) Temporarily lift the lift arm, bell crank,

and bucket link (8). Then remove the lift
arm attachment pin, and lift arm for
removal. [*7]
WA380-5 30-157
(10)2
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT ASSEMBLY
6. Dust seal and bush INSTALLATION

1) Remove the dust seal (14) and bush (15)
from the lift arm (13). [*9] • Installation is in reverse order to removal.
[*1]
• Bucket link
1) Lift the bucket link, and attach the
cord ring (21), fitting the hole of the
attachment pin (1). Then insert shims
so that clearance a is equal on the left
and right, assemble the pin (1), and
tighten with the bolt.
★ Take care that the cord ring is not
engaged.
★ Clearance a: 1.5 mm or less.
WARNING! When fitting

the pin hole position, abso-
2) Pull out the dust seal (16) and bush (17) lutely do not insert fingers
from the bell crank (11). in the pin hole.
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.
WARNING! When fitting

the pin hole position, abso-
lutely do not insert fingers
in the pin hole.
30-158 WA380-5
2(9)
ASSEMBLY WORK EQUIPMENT ASSEMBLY
[*6]
• Perform the calibration, referring to "Han-
dling of Road Meter" in the instruction
manual.
[*7]
WARNING! When fitting the pin

hole position, absolutely do not
insert fingers in the pin hole.
★ Clearance d: 1.5 mm or less.
[*3]
• Bucket cylinder
WARNING! When fitting the

pin hole position, absolutely do
not insert fingers in the pin
hole.
• Adjust the bucket positioner, referring
to "Adjustment of Bucket Positioner"
in Inspection and Adjustment.
[*4]
• Lift cylinder
[*8]
WARNING! When starting the
★ Fix the bucket link to the bell crank using a
engine, confirm that the for-
wire.
ward/backward lever is set to
the neutral level and the park- ★ Take care that the cord ring is not
ing brake is applied. engaged.
[*9]
WARNING! When fitting the • Dust seal, bush
pin hole position, absolutely do Press the bush (15) in the bucket link, bell
not insert fingers in the pin crank, and lift arm respectively using a
hole. press. Then assemble the dust seal.
★ Clearance c: 1.5 mm or less. Bush:
Grease (G2-LI)
[*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
REMOVAL AND INSTALLATION OF COUNTER WEIGHT

REMOVAL
2. Temporarily lift the counter weight (5), then
WARNING! Disconnect the (-) termi- remove two attachment bolts (6) and (7) for
nal of the battery. each side. Next detach the 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-
ASSEMBLY SEMBLY
AIR CONDITIONER UNIT ASSEMBLY
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT

ASSEMBLY
SPECIAL TOOL
4. Cover
New/Modified
Necessity
Quantity
1) Remove the cover (2) on the lower left of
sketch
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
799-703-1401 Gas leak tester ■ 1

CPW10233
REMOVAL
WARNING! Park the machine in a

horizontal place, and put down the
bucket on the ground.
WARNING! Attach the frame lock bar

to the frame, apply the parking brake, 2) Remove the cover (3) on the lower rear
put blocks under the wheels. right of the operator’s seat.
WARNING! Disconnect the (-) termi-

nal of the battery.
1. Collect the air conditioner refrigerant (R134a).

[*1]
2. Detach the cab assembly, referring to CPW10234
"Removal and Installation of Cab Assembly".
3. Heater unit hose
• Detach the heater unit hose (1) under the
floor.
3) Detach the connector (4) (CN-L11) at the

rear of the operator’s seat, and remove
the covers (5) and (6).
CPW10235
WA380-5 30-161
(10)2
ASSEMBLY SEMBLY
5. Duct 3) Disconnect six connectors of the relay

Remove the duct (7). case.
• (15) : CN-L101 • (16) : CN-L102
• (17) : CN-L103 • (18) : CN-L104
• (19) : CN-L105 • (20) : CN-L106
4) Remove the relay cases (21) and (22).
CPW10236
6. Cool-heat box assembly

1) Detach five connectors of the fuse box.
• (8) : CN-FS1 • (9) : CN-FS2
• (10) : CN-FS3 • (11) : CN-FS4
• (12) : CN-FS5
5) Remove the cool-heat box assembly (23).
6) Remove the box (24).
CPW10237
CPW10240
2) Disconnect the connectors (12) (CN-L19),

(13) (CN-L20), and (14) (CN-DL) at the rear
of the operator’s seat.
CPW10238
30-162 WA380-5
2(9)
ASSEMBLY SEMBLY
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
8. Air conditioner unit assembly

1) Loosen the bolt (27), and detach the air INSTALLATION
conditioner unit pipe (28). [*2]
★ After the pipe is detached, cover the • Carry out installation in reverse order to
pipe with a cock so that no foreign removal.
matter will contaminate the pipe [*1]
openings. ★ Using tool X, charge the air conditioner
2) Disconnect the connectors (29) (CN-A3), circuit with air conditioner refrigerant
(30) (CN-A1), and (31) (CN-A2). (R134a).
[*2]
★ Do not remove the cock until just before
the pipe is attached.
O-ring and screw unit:

Compressor oil for R134a
CPW10242
(DENSO ND-OIL8, ZEXEL:
ZXL100PG (Equivalent to
PAG46))
Pipe mounting bolt:

8 - 12 Nm {0.8 - 1.2 kgm}
WA380-5 30-163
(10)2
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRES-
DISASSEMBLY AND ASSEMBLY SOR ASSEMBLY
AIR CONDITIONER COMPRESSOR
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRES-

SOR ASSEMBLY
SPECIAL TOOL
5. Disconnect the pipe connector (5).
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
799-703-1401 Gas leak tester ■ 1
REMOVAL
WARNING! Park the machine in a

horizontal place, set the frame lock bar
in the frame, and ground the work
equipment. Then stop the engine,
apply the parking brake, and put
blocks under the wheels.
WARNING! Disconnect the (-) termi-

nal of the battery. INSTALLATION
1. Open the left cover of the engine side.
Compressor oil for R134a (DENSO
5
2. Collect the air conditioner refrigerant
(R134a). [*1] ND-OIL8, ZEXEL: ZXL100PG (Equiv-
3. Detach the V-belt tension adjusting bolt (1) alent to PAG46)) :
and fixing bolt (2), then remove the plate 180 ml
(3). [*2]
4. Slide the air conditioning compressor to the • Carry out installation in reverse order to
engine side, and remove the V-belt (4) from removal.
the pulley of the compressor.
[*1]
• Using tool X, charge the gas (R134a) in
the air conditioning unit.
[*2]
• Adjusting tension of air conditioner com-
pressor belt
1) Let the compressor fall down to the
side of the side cover, then adjust the
tension of the V-belt.
★ For the belt tension dimension,
refer to the standard value table.
[*3]
O-ring and screw portions.

Compressor oil for R134a (DENSO
ND-OIL8, ZEXEL: ZXL100PG
(Equivalent to PAG46))
Pipe mounting bolt:
8 - 12 Nm {0.8 - 1.2kgm}
30-164 WA380-5
2(10)
ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
DISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY

★ The procedure for disassembling and assembling the operator's seat assembly [air-suspension (manu-
factured by ISRIUG HAUSEN)] is shown below.
★ Although the machine of the joystick steering specification is not equipped with the left armrest, its
operator's seat assembly are also disassembled and assembled according to the following procedure.
A: Headrest E: Left-hand armrest

B: Back seat F: Suspension cover
C: Cushion seat G: Rails
D: Right-hand armrest
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).. .
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
2) Remove back seat hinge mounting bolt

(6) (M8 bolt).
CJH12306
★ Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring back seat (4) down forward.
CJH12304
CJF12307
30-166 WA380-5
(9)
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).. .
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
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of 1) Remove right-hand hinge cover (17).
right-hand armrest (10). 2) Remove plastic plate (18) from the rear
with screwdriver [1], etc.
★ Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
CJH12313
4) Turn right-hand armrest (10) up by 180

degrees.
★ If the armrest is not turned, you can-
not apply the tool to upper mounting CJH12316
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B).
CJH12314
30-168 WA380-5
(9)
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.
4) Remove 4 mounting bolts (20), cushion

rear fixing plate (21), 2 cushion rails (22),
and 4 bushings (23).
CJH12320
CJH12318
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
5) Remove 3 metallic suspension cover clips

(24).
CJH12321
CJH12319
WA380-5 30-169
(10) .
(9)..
2) Slide rails (28) to the rear end. ASSEMBLY

3) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part 1. Rails
of each rail. [*6] 1) Put height adjustment washers (31)
between rails (28) and suspension, and
then set rails (28) in position.
CJH12322
CJH12324
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part 2) Set rails (28) to the front end and install 1
of each rail, and then remove rails (28). lock washer (30) and 1 hexagon socket
[*7] head bolt (29) to each rail.
3 Hexagon socket head bolt:

21.4 - 27.6 Nm {2.18 - 2.82 kgm}
CJH12323
CJH12323
★ Take care not to lose height adjust-

ment washers (31) between the rails
and suspension.
CJH12324
30-170 WA380-5
(10)
(9)
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.
3 Hexagon socket head bolt:

21.4 - 27.6 Nm {2.18 - 2.82 kgm}
CJH12319
CJH12322
3) Set 4 bushings (23) and 2 cushion rails

(22), and then install cushion rear fixing
plate (21), and 4 mounting bolts (20).
2. Suspension cover 3 Cushion rail mounting bolt:

1) Set suspension cover (27) in position and 21.4 - 27.6 Nm {2.18 - 2.82 kgm}
install 6 plastic suspension cover clips
(small) (25) and 2 plastic suspension
cover clips (large) (26).
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place CJH12318
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
CJH12320 4) Install 4 suspension cover fixing rings

(19).
CJH12317
WA380-5 30-171
(10) .
(9)..
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.
3 Upper and lower armrest mount-

ing bolt:
CJH12325
21.4 - 27.6 Nm {2.18 - 2.82 kgm}
5) Install 2 plastic caps (14).
CJH12326
3. Armrest
• The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) simi-
larly.)
6) Tighten armrest hinge mounting bolt (13).

★ Tighten the bolt so that the arm will
CJH12311 move smoothly.
• Operating effort at armrest end:
49 - 78.4 N {5 - 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16)

for each bolt and set right-hand armrest CJH12312
(10) in position.
CJH12315
30-172 WA380-5
(10)
(9)
4. Cushion seat 5. Back seat

1) Slide in the cushion seat from the front of 1) Insert the left side of back seat (4), and
the fitting position. then lower and set the right side.
★ If cushion seat (8) is slid to the rear, it
is locked by cushion stopper wire (9).
CJH12328
CJH12327
2) Install back seat hinge mounting bolt (6).
3 Back seat hinge mounting bolt:

21.4 - 27.6 Nm {2.18 - 2.82 kgm}
CJH12306
WA380-5 30-173
(10) .
(9)..
3) Connect 3 air hoses (5) to the rear left of

back seat (4).
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
Power train oil circuit diagram

(without torque converter lockup clutch)............................................................................................ 90- 3
Power train oil circuit diagram
(with torque converter lockup clutch)................................................................................................. 90- 5
Brake oil circuit diagram .......................................................................................................................... 90- 7
Work equipment hydraulic circuit diagram ............................................................................................... 90- 9
Work equipment hydraulic circuit diagram
(For electric work equipment lever) ................................................................................................... 90- 11
Electrical circuit diagram
1/8 (1/4) ............................................................................................................................................ 90- 13
1/8 (2/4) ............................................................................................................................................ 90- 15
1/8 (3/4) ............................................................................................................................................ 90- 17
1/8 (4/4) ............................................................................................................................................ 90- 19
2/8 (1/4) ............................................................................................................................................ 90- 21
2/8 (2/4) ............................................................................................................................................ 90- 23
2/8 (3/4) ............................................................................................................................................ 90- 25
2/8 (4/4) ............................................................................................................................................ 90- 27
3/8 .................................................................................................................................................... 90- 29
4/8 .................................................................................................................................................... 90- 31
5/8 .................................................................................................................................................... 90- 33
6/8 .................................................................................................................................................... 90- 35
7/8 .................................................................................................................................................... 90- 37
8/8 .................................................................................................................................................... 90- 39
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)

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SEBM024710

Machine model Serial number

WA380-5 60001 and up

• WA380-5 mounts the SAA6D114E-2 engine.

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

20 TESTING AND ADJUSTING ............................................................. 20-1

30 DISASSEMBLY AND ASSEMBLY ................................................... 30-1

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

( ) Page to be deleted Discard

Pages having no marks are not revised at this time.

LIST OF REVISED PAGES

Revision Revision Revision Revision Revision

q 00- 1 (10) 10- 5 10-48 q 10-91 (10) 10-134

20-262 q 20-345 (10) q 20-401 (10) 20-514 (9) q 20-572 (10)

q 30- 115 (10) 30-174 (9)

IMPORTANT SAFETY NOTICE

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

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

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

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

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

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

• Used as lubricant for sliding portion (to

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)