SM - WA470-3 SN20051 and Up PDF

Shop Manual
VEBM480104
WA470-3
Wheel Loader
Serial Number
WA470H20051 and up
© 2000
All Rights Reserved
Printed in Europe 03/2000
CONTENTS
01 GENERAL ......................................................................... 01-1
10 STRUCTURE AND FUNCTION ....................................... 10-1
20 TESTING AND ADJUSTING ............................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ................................... 30-1
40 MAINTENANCE STANDARD........................................... 40-1
00-2
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. Some of the
described service and repair techniques require the use of tools specially designed by
Komatsu for the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this
manual. The cautions accompanying these symbols must always be followed carefully. If any
dangerous situation arises or may possibly arise, first consider safety, and take the neces-
sary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION AND MAINTENANCE MANUAL
carefully BEFORE operating the machine!
Always follow the safety rules valid in your country carefully!
1. Before carrying out any greasing or repairs, Always keep the work area clean and make
read all the precautions given on the decals sure that there is no dirt or oil on the floor.
which are fixed to the machine. Never smoke while working.
Smoke only in the areas provided for smoking.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
PREPARATIONS FOR WORK
• Always wear safety glasses when hitting parts
with a hammer.
7. Before adding oil or making any repairs, park
• Always wear safety glasses when grinding
the machine on hard, level ground, and block
parts with a grinder, etc.
the wheels or tracks to prevent the machine
3. If welding repairs are needed, always have a from moving.
trained, experienced welder carry out the work.
8. Before starting work, lower blade, ripper, bucket
When carrying out welding work, always wear
or any other work equipment to the ground and
welding gloves, apron, glasses, cap and other
install the safety bar on the frame. If this is not
clothes suited for welding work.
possible, insert the safety pin or use blocks to
4. When carrying out any operation with two or prevent the work equipment from falling. In ad-
more workers, always agree on the operating dition, be sure to lock all the control levers and
procedure before starting. Always inform your hang warning signs on them.
fellow workers before starting any step of the
9. When disassembling or assembling, support the
operation. Before starting work, hang UNDER
machine with blocks, jacks or stands before
REPAIR signs on the controls in the operator's
starting work.
compartment.
10. Remove all mud and oil from the steps or other
5. Keep all tools in good condition and learn the
places used to get on and off the machine.
correct way to use them.
Always use the handrails, ladders or steps when
6. Decide a place in the repair workshop to keep getting on or off the machine. Never jump on or
tools and removed parts. Always keep the tools off the machine. If it is impossible to use the
and parts in their correct places. handrails, ladders or steps, use a stand to pro-
vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11. When measuring hydraulic pressure, check that 17. When removing components, be careful not to
the measuring tool is correctly assembled be- break or damage the wiring. Damaged wiring
fore taking any measurements. may cause electrical fires.
12. When removing the oil filler cap, drain plug or 18. When removing piping, stop the fuel or oil from
hydraulic pressure measuring plugs, loosen them spilling out. If any fuel or oil drips onto the floor,
slowly to prevent the oil from spurting out. wipe it up immediately. Fuel or oil on the floor
Before disconnecting or removing components can cause you to slip, or can even start fires.
of the oil, water or air circuits, first remove the
19. As a general rule, do not use gasoline to wash
pressure completely from the circuit.
parts. In particular, use only the minimum of
13. The water and oil in the circuits are hot when gasoline when washing electrical parts. Do not
the engine is stopped, so be careful not to get smoke!
burned.
20. Be sure to assemble all parts again in their
Wait for the oil and water to cool before carry-
original places.
ing out any work on the oil or water circuits.
Replace any damaged parts with new parts.
14. Before starting work, remove the leads from • When installing hoses and wires, be sure
the battery. Always remove the lead from the that they will not be damaged by contact with
negative (–) terminal first. other parts when the machine is being oper-
15. When raising heavy components, use a hoist or ated.
crane. 21. When installing high pressure hoses, make sure
Check that the wire rope, chains and hooks are that they are not twisted. Damaged tubes are
free from damage. dangerous, so be extremely careful when in-
Always use lifting equipment which has ample stalling tubes for high pressure circuits. Also,
capacity. check that connecting parts are correctly in-
Install the lifting equipment at the correct places. stalled.
Use a hoist or crane and operate slowly to
22. When aligning two holes, never insert your fin-
prevent the component from hitting any other
gers or hand. Be careful not to get your fingers
part. Do not work with any part still raised by
caught in a hole.
the hoist or crane.
16. When removing covers which are under internal 23. When assembling or installing parts, always use
pressure or under pressure from a spring, al- the specified tightening torques. When installing
ways leave two bolts in position on opposite protective parts such as guards, or parts which
sides. Slowly release the pressure, then slowly vibrate violently or rotate at high speed, be
loosen the bolts to remove. particularly careful to check that they are in-
stalled correctly.
00-4
F O R EW OR D GENERAL
F O R EW OR D
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel
an accurate understanding of the product and by showing them the correct way to perform repairs and make
judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are
further divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

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

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

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

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

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

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

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

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

300 600 900 1200 1500
the hook. Lifting angle (α) SAD00480
00-7
00-8
01 GENERAL
Up to SN WA470H20668:
Dimensions and weights ................................. 01- 3
Specifications ................................................. 01- 4
Weight table ................................................... 01- 6
List of lubricant and water ............................. 01- 7
From SN WA470H20669
up to SN WA470H20941:
Dimensions and weights ................................. 01- 8
Specifications ................................................. 01- 9
Weight table ...................................................01-11
List of lubricant and water ............................. 01-12
SN WA470H20942 and up:
Specifications ................................................. 01-13
Weight table ...................................................01-14
List of lubricant and water ............................. 01-15
Outlines of service .......................................... 01-16
General view of controls and gauges ............01-21
Torque list .................................................... 01-23
01-1
Blank for technical reason
01-2
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
DIMENSIONS, WEIGHTS AND OPERATING DATA

Up to SN WA470H20668
Buckets
Bucket capacity as per ISO 7546 m3 4,0 4,0 4,4 4,4

Pract. filling capacity (100-120%) m3 4,0 -4,8 4,0-4,8 4,4 - 5,3 4,4 - 5,3
Bucket width m 3,0 3,2 3,0 3,2
Specific density t/m3 1,8 1,8 1,6 1,6

Bucket weight w/o teeth kg 2.180 2.190 2.230 2.245
Stat. tipping weights, straight kg 17.860 17.950 17.830 17.920
Stat. tipping weights, articulated 40° kg 15.884 15.964 15.857 15.937
Breakout force hydraulic kN 184 201 184 201
Hydraulic lifting capacity, on ground kN 241 244 241 244
Operating weight kg 23.100 23.110 23.150 23.165
a Reach at full lift 45° mm 1.260 1.181 1.260 1.181

b Dumping height 45° mm 3.000 3.080 3.000 3.080
c Lift height, hinge pin mm 4.205 4.205 4.205 4.205
d Bucket to edge height mm 5.866 5.830 5.900 5.900
e Digging depth mm 71 71 71 71
f Carry height, hinge pin mm 510 510 510 510
A Overall length mm 8.790 8.645 8.760 8.645

B Wheelbase mm 3.400 3.400 3.400 3.400
C Bucket width mm 3.000 3.200 3.000 3.200
D Width less bucket mm 2.957 2.957 2.957 2.957
E Track width mm 2.210 2.210 2.210 2.210
F Ground clearance mm 525 525 525 525
H Overall height mm 3.550 3.550 3.550 3.550
* This dimensions refer Special bucket sizes: The 4,0/4,4 m3 standard buckets
to machines with 26,5 - 25 tyres. 3,8 m3 - v-edge bucket shown in the table can be supplied
4,0 m3- HD bucket with bold on cutting edge.
6,5 m3 - light material bucket
01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA470-3
H20001 - H20668
Serial No.
Weight
Operating weight (kg) 23,100
Bucket capacity (heaped) (m3) 4,4 (with BOC)
Travel speed FORWARD 1st (km/h) 6.4
FORWARD 2nd (km/h) 11.6
FORWARD 3rd (km/h) 21.6
FORWARD 4th (km/h) 37

Performance
REVERSE 1st (km/h) 6.7
REVERSE 2nd (km/h) 12.3
REVERSE 3rd (km/h) 22
REVERSE 4th (km/h) 37.5
Min. turning Center of outside wheel (mm) 6,320

radius
Overall length (mm) 8,645 (with BOC)
Overall width (chassis) (mm) 3,010
Bucket width (with BOC) (mm) 3,200

Overall height (top of cab) (mm) 3,550
(Bucket raised) (mm) 5,900
Wheelbase (mm) 3,400
Tread (mm) 2,210
Min. ground clearance (mm) 525

Dimensions
Height of bucket hinge pin (mm) 4,205
Dumping clearance (tip of BOC) (mm) 3,080
Dumping reach (edge of bucket) (mm) 1,181
Bucket dump angle (deg) 46
Bucket tilt angle (travel posture) (deg) 50
Digging depth (10° dump) (with BOC) (mm) 305
01-4
H20001 - H20668
Serial No.
Model S6D125
4-cycle, water-cooled, in-line,
Type 6-cylinder, direct injection, with turbocharger
No. of cylinders – bore x stroke (mm) 6 – 125 mm x 150 mm
Piston displacement (cc) 11,040
Flywheel horsepower (kW (PS)/rpm) 194 (264)

/2,200
Engine
Maximum torque (Nm (kgm)/rpm) 1,050 (107) / 1400
– –
High idling speed (rpm) 2,350 - 2,450
Low idling speed (rpm) 700 - 750
Starting motor 24 V 7.5 kW
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Torque converter 3-element, 1-stage, single-phase (Komatsu TCA38-4Z)
Spur gear, constant-mesh multiple-disc,

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

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

Axle, wheel
Rear wheel Center pin support full-floating type
Tire 26.5-25-16PR
Wheel rim 22.00 x 25TB
Front tire (bar) 3.0

Inflation pressure
Rear tire (bar) 2.0
Service brake Front-, rear-wheel independent system control,

sealed multiple-disc wet-type disc brake
Brakes
With hydraulic booster
Parking brake Drive shaft, wet type disc brake

Hydraulically released spring type
01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Serial No. H20001 - H20668
Engine 1120
Radiator 168
Transmission (including torque converter) 1,000
Center drive shaft 36
Front drive shaft 40
Rear drive shaft 19
Front axle 1,455

Rear axle 1,466
Front differential 235
Rear differential 244
Planetary carrier (each) 525
Axle pivot (rear axle) 148
Wheel (each) 243
Tire (each) 404
Steering valve 24
Steering cylinder (each) 38
Brake valve (R.H.) 8.5
Hydraulic tank 231
Hydraulic, PPC pump (tandem pump) 27
Steering, switch pump (tandem pump) 20
PPC valve 3
Main control valve 90
Lift cylinder (each) 192
Bucket cylinder 222
Engine hood 184
Front frame 1,816
Rear frame 1,435
Bucket link 89
Bellcrank 415
Lift arm (including bushing) 1,440

Bucket (with BOC) 1,967
01-6
GENERAL LIST OF LUBRICANT AND WATER
FILLING CAPACITIES AND SPECIFICATIONS OF THE LUBRICATING AND

OPERATING MEANS Up to SN WA470H20668
LUBRICANTS, FUEL ETC. AND FILLING CAPACITIES
Approx.
WA470-3 Temperature Viscosity filling
Lubricants, fuel etc. BI code ****) Quality grades
ranges ranges capacity in
litres
EO 1540 A CCMC D4 -10° to 50° C SAE 15W-40 *)

EO 1030 A or, if not available, -20° to 40° C SAE 10W-30 44
Engine Engine oil EO
EO 30 API CE or 0° to 40° C SAE 30 (38 **)
EO 10 API CF -4 ²) -20° to 10° C SAE 10W
CCMC D4
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W 60
API CD
Fuchs: RENOGEAR HYDRA ZF 20W-40*)

Komatsu: AXO 75
Universal
Caltex: RPM TRACTOR HYDRAULIC FLUID
Axles with standard transmission and NRS
Chevron: TRACTOR HYDRAULIC FLUID
locking differentials hydraulic oil
Texaco: TDH OIL
type Mobil: MOBILAND SUPER UNIVERSAL
KWA 022 W-1
KWA 022 W-2
CCMC D4 2x65
or engine oil EO EO 30 - SAE 30
or, if not available,
API CD
Axles with multi-disc

locking differentials Universal
type transmission and NRS Fuchs: RENOGEAR HYDRA ZF 20W-40*)
KWA 022 W-3 hydraulic oil
KWA 022 W-4
Hydraulic oil HYD HYD 0530 HVLP, HVLP D -35° to 50° C ISO VG 46 *)
CCMC D4
or engine oil EO EO 10 or, if not available, -35° to 40° C SAE 10W
Hydraulic system, 240
API CD
steering, brakes (155 **)
HEES
or hydraulic oil ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50° C
BIO-E-HYD
technology)
Long-life coolant with
anti-frost and rust Anti-frost and rust
Cooling system SP-C 68
prevention prevention
SP-C
CFPP class B up to 0°C
CFPP class D up to -10°C
Fuel tank Diesel fuel ³) DIN-EN 590 400
CFPP class E up to -15°C
CFPP class F up to -20°C
Grease nipples, Multi-purpose grease -10° to 50° C NLGI 2 *)

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

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

²) If no engine oil of the API CE or API CF-4 specification is available, API CC or API CD-classified engine oil can be used alternatively. The
oil change intervals must be split in half in this case, however.
³) If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal. With a sulphur content of more than 1.0
%, the oil change interval must be 1/4 normal.
****) BI codes are the "standard lubricants" for construction machinery and vehicles of the Hauptverband der Deutschen Bauindustrie e.V.
(BI). The brochure "Regelschmierstoffe für Baumaschinen- und Fahrzeuge" (Standard Lubricants for Construction Machinery and
Vehicles" can be obtained from bookstores or Bauverlag GmbH, Wiesbaden and Berlin, under the ISBN no. 3-7625-3102-1.
U:\DTP\BA470gb\FÜLL-BI.TBL 02.97
01-7
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
DIMENSIONS, WEIGHTS AND OPERATING DATA

SN WA470H20669 and up
Buckets
Bucket capacity as per ISO 7546 m3 4,2 4,3 4,6 4,7

Pract. filling capacity (100-120%) m3 4,2 -5,0 4,35-5,22 4,6 - 5,52 4,75 - 5,7
Bucket width m 3,0 3,17 3,0 3,17
Specific density t/m3 1,8 1,75 1,6 1,55

Bucket weight w/o teeth kg 2.107 2.186 2.228 2.308
Stat. tipping weights, straight kg 18.310 18.219 18.119 18.125
Stat. tipping weights, articulated 40° kg 16.090 15.992 15.898 15.895
Breakout force hydraulic kN 181,2 182,5 171,9 176,1
Hydraulic lifting capacity, on ground kN 243,3 246,7 243,4 243,1
Operating weight kg 23.367* 23.447* 23.487* 23.567*
a Reach at full lift 45° mm 1.276 1.266 1.326 1.301

b Dumping height 45° mm 3.000 3.005 2.938 2.963
c Lift height, hinge pin mm 4.220 4.220 4.220 4.220
d Bucket to edge height mm 5.880 5.844 5.914 5.910
e Digging depth mm 57 57 57 57
f Carry height, hinge pin mm 425 425 425 425
A Overall length mm 8.594 8.584 8.669 8.634

B Wheelbase mm 3.400 3.400 3.400 3.400
C Bucket width mm 3.000 3.170 3.000 3.170
D Width less bucket mm 2.885 2.885 2.885 2.885
E Track width mm 2.210 2.210 2.210 2.210
F Ground clearance mm 489 489 489 489
H Overall height mm 3.474 3.474 3.474 3.474
* This dimensions refer Special bucket sizes: The standard buckets shown in the
to machines with 3,8 m3 - v-edge bucket table can be supplied with bold on
26,5-25 L3 XHA tyres. 4,1 m3- HD bucket cutting edge.
6,5 m3 - light material bucket
01-8
SPECIFICATIONS
Serial No. H20669 to H20941
Model Cummins MTA 11 (STC)

Flywheel horsepower (kW (PS)/rpm) 202 (275)/ 2.100

Engine
Maximum torque (Nm/rpm) 1.299 / 1300
Spec. fuel consumption (g/kWh) 208

High idling speed (rpm) 2.200 - 2.300
Low idling speed (no load) (rpm) 750 - 780

Power train
Transmission

Axle, wheel
Tire 26.5-25

Inflation pressure
Rear tire (bar) 2.0

Brakes

01-9

Serial No. H20669 to H20941
Type Articulated steering

Steering
system
Structure Recirculating ball type

Hydraulically actuated
Hydraulic pump type Gear pump
Hydraulic pump 302
Delivery Switch pump 122

( l /min.)
Steering pump 124
PPC/brake pump 62
Hydraulic system
Control valve
Set pressure for work equipment 2-spool type

(MPa (bar)) 20.58 (210)
Set pressure for steering Spool type

(MPa (bar)) 20.58 (210)
Boom cylinder Reciprocating piston

No. – bore x stroke (mm) 2 – 180 x 746
Cylinder
Bucket cylinder Reciprocating piston

Steering cylinder Reciprocating piston

equipment
Actuation lever Mono (Double/Joystick as Option)

Work
Bucket edge type Flat edge with BOC
01-10

WEIGHT TABLE
Unit: kg
Serial No. H20669 - H20941
Engine 981
Radiator 168
Rear drive shaft 19
Front axle 1,455

Rear axle 1,466
Wheel (each) 243
Tire (each) 404
Steering valve 24
Hydraulic tank 231
PPC valve 3
Bucket cylinder 222
Engine hood 184
Front frame 1,816
Rear frame 1,435
Bucket link 89
Bellcrank 415

Bucket 2,107
01-11


OPERATING MEANS From SN WA470H20669 up to H20941
Approx.
litres

EO 10 API CF -4 ²) -20° to 10° C SAE 10W
CCMC D4
60
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W
(60 **)
API CD

Komatsu: AXO 75
Universal
transmission and NRS
Axles with standard Chevron: TRACTOR HYDRAULIC FLUID
hydraulic oil
locking differentials Texaco: TDH OIL
KWA 022 W-1
KWA 022 W-2
2x65
CCMC D4
API CD

KWA 022 W-4
CCMC D4
API CD
HEES
BIO-E-HYD
technology)

SP-C


MPG-A KP2N-20


U:\DTP\BA470gb\470gb_mc\füllmc.TBL 07.97
01-12

H20942 and up
Serial No.
Model Komatsu SA6D125E-2

Flywheel horsepower (kW (PS)/rpm) 194 (264) / 2,200

Engine
Maximum torque (Nm (kgm)/rpm) 1,050 (107) / 1400
– –
High idling speed (rpm) 2,350 - 2,450
Low idling speed (rpm) 700 - 750

Power train
Transmission


Axle, wheel
Tire 26.5-25-16PR

Inflation pressure
Rear tire (bar) 2.0

Brakes

01-13

WEIGHT TABLE
Unit: kg
Serial No. H20942 and up
Engine 1250
Radiator 168
Rear drive shaft 19
Front axle 1,455

Rear axle 1,466
Wheel (each) 243
Tire (each) 404
Steering valve 24
Hydraulic tank 231
PPC valve 3
Bucket cylinder 222
Engine hood 184
Front frame 1,816
Rear frame 1,435
Bucket link 89
Bellcrank 415

Bucket (with BOC) 1,967
01-14


OPERATING MEANS WA470H20942 and up
Approx.
litres

EO 10 API CF -4 ²) -20° to 10° C SAE 10W
CCMC D4
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W 60
API CD

Komatsu: AXO 75
Universal
Axles with standard transmission and NRS
Chevron: TRACTOR HYDRAULIC FLUID
locking differentials hydraulic oil
Texaco: TDH OIL
KWA 022 W-1
KWA 022 W-2
CCMC D4 2x65
API CD

KWA 022 W-4
CCMC D4
API CD
HEES
BIO-E-HYD
technology)
SP-C

MPG-A KP2N-20


U:\DTP\BA470gb\FÜLL-BI.TBL 02.97
01-15

GENERAL LUBRICANT AND WATER
Note 1
Axle oils (AXO)
The selection of the oils depends on the equipment of the axle:
1a: Standard axles TPD (without multi-disc limited-slip differential)
Characteristics: Type KWA 022 W-1, front

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

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

Type KWA 022 W-4, rear
These must be filled with
FUCHS: RENOGEAR HYDRA ZF 20W-40
The use of not recommended axle oils may cause unnormal noises from the differential.
01-16
GENERAL OUTLINES OF SERVICE
• Only use original Komatsu parts for replacement.

• When changing or adding oil, do not use a different type of oil.
• Unless otherwise specified, the oil and coolant used at the time of shipment are as shown in the table
below.
Item Lubricating and operating means
Engine Engine oil: API CD, SAE 10W-30
Transmission Engine oil: API CD, SAE 10W
For machines with standard differential TPD:

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

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

ASTM D975: No. 1 in winter (from October to March)
Radiator Komatsu super coolant AF-ACL, mixed with 30 % water
Air conditioner cfw free refrigerant R 134a
**) For more details refer to Note1.
Oil
• Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high
pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature given in the Operation and Maintenance Manual.
Even if the oil is not dirty, always replace the oil after the specified interval.
• Oil can be compared to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from penetrating.
The majority of problems with machines are caused by the entry of such impurities.
Take particular care not to let any impurities penetrate when storing or adding oil.
• Never mix oils of different grades or brands.
• Always add the specified amount of oil.

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

For details of the mixing ratios, see "24.2.2 CLEANING THE INSIDE OF THE COOLING SYSTEM".
• If the engine overheats, wait for the engine to cool before adding coolant.
• If the coolant level is low, it will cause overheating and corrosion due to the air in the coolant.
01-18
GREASE
• Grease is used to prevent twisting and noise at the joints.
• The nipples not included in the maintenance section are nipples for overhaul, so they need not be lubricated.
If any part becomes stiff after being used for a long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off
the old grease in places where sand or dirt in the grease would cause the rotating parts to wear.
STORING OIL AND FUEL

• Keep oil and fuel indoors to prevent any water, dirt or other impurities from penetrating.
• When keeping barrels for a long period, lay down the barrel on its side so that the filler port is at the side
(to prevent moisture from being sucked in).
If barrels have to be stored outside, cover them with a waterproof sheet or take other measures to protect
them.
• To prevent any change in quality during long term storage, be sure to use in the order of 'first in - first out'
(use the oldest oil or fuel first).
FILTERS
• Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working under severe conditions, it is necessary to consider replacing the filters at shorter
intervals according to the oil and fuel (sulfur content) being used.
• Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
• When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are
found, please contact your Komatsu distributor.
• Do not open packs of spare filters until just before they are to be used.
• Always use original Komatsu filters.
BIODEGRADABLE HYDRAULIC OILS AND LUBRICANTS

• The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for Komatsu
machines is permitted. For information on the products cleared for use and best suited for your application
contact our authorized service workshops.
01-19
OUTLINE OF ELECTRIC SYSTEM

• If the wiring gets wet or the insulation is damaged, the electric system leaks resulting in hazardous
malfunctions of the machine.
• Maintenance work at the electric system includes: (1) check fan belt tension, (2) check damage or wear to
the fan belt and (3) check battery fluid level.
• Never remove or disassemble any electric components installed in the machine.
• Never install any electric components other than those specified by Komatsu.
• Be careful to keep the electric system free of water when washing the machine or when it is raining.
• When working on the seashore, carefully clean the electric system to prevent corrosion.
• The optional power source must never be connected to the fuse, starter switch, or battery relay.
01-20
GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
GENERAL VIEW OF CONTROLS AND GAUGES

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

23 Cigarette lighter GENERAL VIEW
24 Safety lock
25 Maintenance monitor
30 Turn signal pilot lamp

31 High beam pilot lamp
32 Centralized checking lamp
33 Engine pre-heating pilot lamp
34 Pilot lamp for front working lamp
35 Pilot lamp for rear working lamp
36 Transmission cut-off selector pilot lamp
37 Parking brake pilot lamp
38 Central warning lamp
39 Speedometer
40 Transmission shift indicator
41 ALS Electronic
42 Auto-greasing switch
43 HOLD signal Main monitor
44 Emergency steering operating monitor
45 Work mode selector switch / SN: WA470H21164
46 Autoshift transmission pilot switch /
SN: WA470H21104
50 Fuel gauge
51 Engine cooling water temperature gauge
52 Torque converter oil temperature gauge
57 Service meter
58 Air cleaner clogging warning pilot lamp
59 Charge monitor
60 Brake oil pressure warning pilot lamp
61 Engine oil pressure warning lamp
62 Engine oil level warning pilot lamp
63 Engine water level warning lamp
Maintenance monitor
01-21

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

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

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

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

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

43. Hold signal MAIN MONITOR
44. Emergency steering operating monitor
45. Work mode selector switch / SN: WA470H21164
46. Autoshift transmission pilot switch /
SN: WA470H21104
50. Fuel gauge

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

58. Air cleaner clogging warning pilot lamp
59. Charge monitor
60. Brake oil pressure warning pilot lamp
61. Engine oil pressure warning lamp
62. Engine oil level warning pilot lamp
63. Engine water level warning lamp
MAINTENANCE MONITOR
01-22

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

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

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

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

30 46 1720 ± 190 175 ± 20 1270 ± 140
33 50 2210 ± 240 225 ± 25 1630 ± 180
36 55 2750 ± 290 280 ± 30 2030 ± 210
39 60 3280 ± 340 335 ± 35 2420 ± 250
NOTE
When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use
excessive tightening torque: doing so will damage the plastic parts.
01-23
01-24
10 STRUCTURE AND FUNCTION
Power train .......................................................... 10-3 Brake ............................................................... 10-179

Power train system .............................................. 10-4 Parking brake control ....................................... 10-181
Torque converter, transmission piping .................. 10-6 Parking brake .................................................. 10-182
Transmission hydraulic system diagram ............... 10-7 Parking brake valve .......................................... 10-183
Transmission hydraulic circuit diagram ................ 10-8 Hydraulic piping ............................................... 10-201
Torque converter .................................................. 10-9 Work equipment hydraulic system diagram ..... 10-202
Transmission ...................................................... 10-21 Work equipment hydraulic circuit diagrams ..... 10-204
Clutch ................................................................ 10-23 Work equipment lever linkage .......................... 10-210
Transmission control valve .................................. 10-41 Hydraulic tank ............................................... 10-210-1
Transmission solenoid valve ............................... 10-44 Breather ........................................................ 10-210-2
Main relief valve ................................................. 10-46 PPC valve ........................................................ 10-211
Torque converter outlet port valve ....................... 10-47 PPC relief valve................................................ 10-219
Priority valve ...................................................... 10-48 Accumulator (for PPC valve) ............................ 10-220
Directional selector valve .................................... 10-52 Cut-off valve ..................................................... 10-221
H-L selector valve and range selector valve ........ 10-53 Main control valve............................................. 10-223
Emergency manual spool ................................... 10-55 Relief valve ....................................................... 10-231
Electronic control modulation valve (ECMV) ....... 10-56 Safety valve (with suction) ................................ 10-232
Pilot oil filter ....................................................... 10-59 Suction valve .................................................... 10-233
Accumulator valve .............................................. 10-60 Hydraulic safety system ................................... 10-243
Flow valve........................................................... 10-62 Work equipment linkage .................................. 10-251
Drive shaft ......................................................... 10-81 Bucket ............................................................. 10-253
Axle .................................................................... 10-82 Bucket positioner and boom kick-out ............... 10-254
Differential ......................................................... 10-84 Machine monitor system .................................. 10-281
Final drive .......................................................... 10-91 Transmission auto-shift control system ............. 10-289
Axle mount, center hinge pin .............................. 10-92 Transmission controller .................................... 10-294
Steering piping ................................................. 10-111 E.C.S.S. (Electronic Controlled........................ 10-311
Steering column, orbit-roll ................................ 10-112 Suspension System) ........................................ 10-311
Orbit-roll valve .................................................. 10-114 ALS-system ..................................................... 10-315
Steering demand valve ..................................... 10-115 Sensors ........................................................... 10-331
Overload relief valve ......................................... 10-116 Engine starting circuit ...................................... 10-337
Steering relief valve .......................................... 10-118 Engine stop circuit ........................................... 10-338
Operation of demand valve ............................... 10-119 Preheating circuit............................................. 10-339
Emergency Steering ........................................ 10-129 Ribbon Heater .................................................. 10-340
Brake piping .................................................... 10-151 Electric transmission control ............................ 10-361
Brake circuit diagram....................................... 10-152 Combination switch .......................................... 10-362
Brake valve ...................................................... 10-153 Kick-down, hold-switch .................................... 10-364
Charge valve .................................................... 10-158 Transmission electric circuit diagram ............... 10-365
Accumulator for brake system ......................... 10-162 Transmission cut-off switch .............................. 10-370
Slack adjuster .................................................. 10-163 Transmission cut-off function ........................... 10-371
Brake pressure regulating valve ....................... 10-174 Electric parking brake control .......................... 10-372
Accumulator for PPC valve .............................. 10-176 Air-conditioner ................................................. 10-451
Brake Accumulator unit .................................... 10-177 Wiring diagrams .............................................. 10-601
10-1

10-2
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
1. Transmission (counter shaft 4. Rear axle 7. Front drive shaft

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

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

2. Torque converter 6. Transmission control valve
3. Radiator 7. Transmission
4. Oil cooler 8. Oil filter
10-6
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

(Conditions: Engine at low idling, transmission shift lever at neutral)
10-7
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case 12. Torque converter outlet valve 24. Range selector valve
2. Strainer 13. Oil cooler 25. Accumulator
3. Torque converter charging 14. Transmission lubrication 26. Parking brake valve
pump 15. Emergency manual spool 27. Parking brake
4. Flow valve 16. Solenoid valve (FORWARD) 28. 4th clutch
5. Oil filter 17. Directional selector valve 29. 3rd clutch
6. Pilot reducing valve 18. Solenoid valve (REVERSE) 30. 2nd clutch
7. Pilot oil filter 19. REVERSE clutch 31. 1st clutch
8. Priority valve 20. FORWARD clutch 32. Accumulator
9. Electronic modulation valve 21. Solenoid valve (H-L selection)
10. Main relief valve 22. H-L selector valve
11. Torque converter 23. Solenoid valve (range selec-
tion)
10-8
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
1. Breather Specifications
2. Housing Model: TCA38-4Z
3. Steering, witch tandem pump mount Type: 3 element, 1 stage, 1 phase
4. Hydraulic, PPC tandem pump mount Stall torque ratio: 3.15
10-9
5. Flywheel 9. Stator A. Inlet port

6. Drive case 10. Transmission input shaft B. Outlet port
7. Turbine 11. Housing
8. Pump
10-10
Path of motive force

• The torque converter is installed between the
engine and the transmission.
The motive force from the engine enters drive
case (6) from flywheel (5).
Drive case (6), pump (8), and PTO gear (drive)
(12) are each secured by bolts and are rotated
directly by the rotation of the engine.
The motive force of pump (8) uses oil as a
medium to rotate turbine (7) and transmit the
motive force to transmission input shaft (10).
• The motive force of drive case (6) is used as
the motive force to drive the gear pump through
PTO gear (drive) (12).
Flow of oil
• The oil supplied from the torque converter charging
pump enters inlet port A, passes through the oil
passage of stator shaft (13), and flows to pump (8).
The oil is given centrifugal force by pump (8), en-
ters turbine (7), and transmits the energy of the oil
to the turbine. Turbine (7) is fixed to transmission
input shaft (10), so the motive force is transmitted to
the transmission input shaft.
The oil from turbine (7) is sent to stator (9), and
enters the pump again. However, part of the oil is
sent from the stator through outlet port B to the
cooler.
10-11
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER

1. Relief valve
2. Element
3. Center bolt
4. Drain plug
Specifications
Filter mesh size: 10 microns
Filtering area: 8900 cm2
Relief pressure: 0.3 MPa (3.25 bar)
Operation
• The oil from the torque converter charging pump
enters filter inlet port A. It is filtered from the
outside of element (2) to the inside, and flows to
outlet port B.
• If element (2) becomes clogged with dirt, or the

oil temperature is low and the pressure rises at
inlet port A, the oil from inlet port A opens relief
valve (1) and flows directly to outlet port B in
order to prevent damage to the pump or element
(2).
10-12
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1. Torque converter charging pump

2. Transmission input shaft
3. Torque converter housing
4. Accumulator
5. Oil filter (pilot)
6. Rear output coupling
7. Transmission
8. Parking brake (wet type multiple disc)
9. Front output coupling
10. Oil filter
11. Transmission control valve
12. PTO
13. Transmission oil filler
10-21
14. PTO gear (No. of teeth: 65) 28. 3rd gear (No. of teeth: 49)
15. PTO gear (No. of teeth: 76) 29. 3rd gear (No. of teeth: 43)
16. PTO gear (No. of teeth: 74) 30. 3rd clutch
17. 1st clutch (No. of teeth: 26) 31. 4th clutch
18. FORWARD clutch 32. REVERSE, 2nd shaft
19. Input gear (No. of teeth: 30) 33. 2nd gear (No. of teeth: 26)
20. Torque converter 34. 2nd clutch
21. PTO drive gear (No. of teeth: 74) 35. 2nd gear (No. of teeth: 50)
22. FORWARD gear (No. of teeth: 48) 36. REVERSE clutch
23. REVERSE gear (No. of teeth: 46) 37. FORWARD, 1st shaft
24. 3rd, 4th shaft 38. 1st gear (No. of teeth: 26)
25. 4th gear (No. of teeth: 53) 39. 3rd gear (No. of teeth: 37)
26. Output shaft 40. Countershaft
27. Output gear (No. of teeth: 41) 41. 4th gear (No. of teeth: 27)
10-22
Outline
• The transmission is installed behind the torque • The transmission uses the combination of the
converter. The motive force from the torque forward or reverse clutches and the four speed
converter passes through the transmission input clutches to shift to F1 – 4 or R1 – 4, and
shaft and enters the transmission. transmits the motive force from the input shaft to
the output shaft.
CLUTCH
FORWARD, 1ST CLUTCH
1. Spacer 5. FORWARD, 1st cylinder a. 1st clutch oil port

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

2. Thrust washer 6. 2nd, REVERSE cylin- 10. Spacer b. REVERSE clutch
3. 2nd gear der 11. 2nd, REVERSE shaft oil port
4. 2nd gear 7. REVERSE clutch c. Lubrication oil port
8. REVERSE gear
3RD, 4TH CLUTCH
1. Spacer 5. 3rd clutch 9. Thrust washer a. 3rd clutch oil port

2. Thrust washer 6. 3rd, 4th cylinder 10. Spacer b. 4th clutch oil port
3. 3rd gear 7. 4th clutch 11. 3rd, 4th shaft c. Lubrication oil port
4. 3rd gear 8. 4th gear
10-24
Operation of clutch
When operated
• The oil sent from the transmission valve passes
through the oil passage inside shaft (1), and
goes to the rear face of piston (5) to actuate the
piston.
• When piston (5) is actuated, separator plate (2)
is pressed against clutch disc (3) and forms
shaft (1) and clutch gear (4) into one unit to
transmit the motive force.
When not actuated

• If the oil from the transmission valve is shut off,
the pressure of the oil acting on the rear face of
piston (5) drops.
The piston is returned to its original position by
wave spring (6), so shaft (1) and clutch gear (4)
are separated.
10-25
FORWARD 1ST
Operation
• In the case of FORWARD 1st, FORWARD clutch • The 1st clutch is engaged, so the motive force
(18) and 1st clutch (17) are engaged. The mo- transmitted to the FORWARD 1st cylinder passes
tive force transmitted from the torque converter through 1st clutch (17) and is transmitted from
to input shaft (2) is transmitted to gear (19), 1st gear (38) to 2nd clutch gears (35, 33). It
which is installed to the input shaft. then passes through 3rd clutch gear (28) and
• Each clutch disc of FORWARD clutch (18) and output gear (27) and is transmitted to output
1st clutch (17) is engaged by the oil pressure shaft (26).
applied to the piston.
• The motive force from the torque converter
passes from input shaft (2) through gear (19)
and is transmitted to FORWARD gear (22). When
FORWARD clutch (18) is engaged, the motive
force is transmitted to the FORWARD 1st cylin-
der.
10-26
FORWARD 2ND
Operation
• In the case of FORWARD 2nd, FORWARD • The motive force is transmitted to REVERSE
clutch (18) and 2nd clutch (34) are engaged. 2nd cylinder gear (43) and REVERSE 2nd shaft
The motive force transmitted from the torque (32), which are meshed with the FORWARD 1st
converter to input shaft (2) is transmitted to gear cylinder gear. 2nd clutch (34) is engaged, so
(19), which is installed to the input shaft. the motive force transmitted to the REVERSE
• The clutch discs of FORWARD clutch (18) and 2nd shaft passes through the 2nd clutch and
2nd clutch (34) are engaged by the oil pressure goes from 2nd gear (33) through 3rd gear (28)
applied to the piston. and output gear (27), and is transmitted to out-
• The motive force from the torque converter put shaft (26).
and is transmitted to FORWARD gear (22). FOR-
WARD clutch (18) is engaged, so the motive
force is transmitted to FORWARD 1st cylinder
gear (42).
10-27
FORWARD 3RD
Operation
• In the case of FORWARD 3rd, FORWARD clutch • The motive force is transmitted through RE-
(18) and 3rd clutch (30) are engaged. The mo- VERSE 2nd cylinder gear (43) and REVERSE
tive force transmitted from the torque converter 2nd shaft (32), which is meshed with the FOR-
to input shaft (2) is transmitted to gear (19), WARD 1st cylinder gear, and is transmitted to
which is installed to the input shaft. 3rd, 4th cylinder gear (44) and 3rd, 4th shaft
• The clutch discs of FORWARD clutch (18) and (24). 3rd clutch (30) is engaged, so the motive
3rd clutch (30) are engaged by the oil pressure force passes through the 3rd clutch and goes
applied to the piston. from 3rd gear (28) through output gear (27),
• The motive force from the torque converter and is transmitted to output shaft (26).
and is transmitted to FORWARD gear (22).
FORWARD clutch (18) is engaged, so the mo-
tive force is transmitted to FORWARD 1st cylin-
der gear (42).
10-28
FORWARD 4TH
Operation
• In the case of FORWARD 4th, FORWARD clutch • The motive force is transmitted through RE-
(18) and 4th clutch (31) are engaged. The mo- VERSE 2nd cylinder gear (43), which is meshed
tive force transmitted from the torque converter with the FORWARD 1st cylinder gear, and is
to input shaft (2) is transmitted to gear (19), transmitted to 3rd, 4th cylinder gear (44) and
which is installed to the input shaft. 3rd, 4th shaft (24). 4th clutch (31) is engaged,
• The clutch discs of FORWARD clutch (18) and so the motive force transmitted to the 3rd, 4th
4th clutch (31) are engaged by the oil pressure shaft passes through the 4th clutch and goes
applied to the piston. from 4th gear (25) through 4th counter gear
• The motive force from the torque converter (41), countershaft (40), and 3rd counter gear
passes from input shaft (2) through gear (19) (39), is transmitted to 3rd gears (29) and (28),
and is transmitted to FORWARD gear (22). FOR- and then passes through output gear (27), and
WARD clutch (18) is engaged, so the motive is transmitted to output shaft (26).
force is transmitted to FORWARD 1st cylinder
gear (42).
10-29
REVERSE 1ST
Operation
• In the case of REVERSE 1st, REVERSE clutch • The motive force is transmitted to FORWARD
(36) and 1st clutch (17) are engaged. The mo- 1st cylinder gear (42) and FORWARD 1st shaft
tive force transmitted from the torque converter (37), which are meshed with REVERSE 2nd
to input shaft (2) is transmitted to gear (19), cylinder gear (43). 1st clutch (17) is engaged,
which is installed to the input shaft. so the motive force transmitted to the FOR-
• With reverse clutch (36) and 1st clutch (17), WARD 1st shaft passes through 1st clutch (17)
each clutch disc is engaged by the oil pressure and is transmitted from 1st gear (38) to 2nd
applied to the piston. gears (35, 33), passes through 3rd gear (28)
• The motive force from the torque converter and output gear (27) and is transmitted to output
passes from input shaft (2) through gear (19) shaft (26).
and is transmitted to REVERSE gear (25). When
REVERSE clutch (36) is engaged, the motive
force is transmitted to the REVERSE 2nd cylin-
der.
10-30
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL VALVE
1. Upper valve a. Main oil pressure measure- e. Pilot pressure measurement

2. Lower valve ment port port
3. Solenoid valve b. Clutch oil pressure measure- f. Measurement port for torque
4. Electronic modulation valve ment port converter outlet port oil pres-
5. Emergency manual spool c. Measurement port for torque sure
converter inlet port oil pres- g. To oil cooler
sure h. Parking brake oil pressure
d. Priority pressure measurement measurement port
port i. From pump
Outline
• The oil from the pump passes through the flow • The T/M-controller senses the travel speed and
valve and torque converter oil filter, enters the the engine speed when the machine is traveling.
transmission, and is divided into the pilot circuit The T/M-controller actuates the proportional so-
and clutch actuation circuit. The priority valve lenoid valve according to the command current
adjusts the delivery pressure of the pump and from the transmission controller to control the oil
ensures the pilot pressure and oil pressure used flow and oil pressure. This allows the clutch to
to release the parking brake. engage smoothly and reduces the shock when
• The pressure of the oil flowing to the clutch shifting gear.
circuit is regulated by the electronic modulation In addition, when the machine is traveling, the
valve. The transmission is automatically shifted clutch pressure is kept constant.
to the optimum speed range, and the appropri- The pressure of the oil flowing to the pilot valve
ate clutch is actuated. is regulated by the pilot reducing valve, and
In addition, the oil relieved by the main relief actuates the directional and range spools as the
valve is supplied to the torque converter. solenoid valves are switched ON or OFF.
• When the directional and range spools are
switched, the oil, whose pressure regulated by
the modulation valve, is supplied to the selected
clutch to provide the necessary speed range.
10-41
UPPER VALVE
1. Upper valve body 8. Directional selector valve

2. Emergency manual spool 9. Solenoid valve
3. Pilot reducing valve 10. Range selector valve
4. Torque converter outlet port valve 11. Priority valve
5. Main relief valve 12. Parking brake valve
6. Electronic modulation valve (ECMV) 14. H-L selector valve
7. Lower valve body
10-42
LOWER VALVE
10-43
TRANSMISSION SOLENOID VALVE
1. Solenoid valve [] for FORWARD selector 3. Solenoid valve [] for H-L selector
2. Solenoid valve [] for REVERSE selector 4. Solenoid valve [] for range selector
Actuation table for solenoid valve and clutch
Solenoid valve

F • 1 ¡ ¡
Structure
F • 2 ¡
• The transmission solenoid valve is installed to
the lower valve of the transmission valve. When F • 3 ¡ ¡
the speed lever is operated, the movement is F • 4 ¡ ¡ ¡
converted to electricity, and this opens or closes
N
each solenoid valve to move the spool inside the
transmission valve. R•1 ¡ ¡
R•2 ¡
R•3 ¡ ¡
R•4 ¡ ¡ ¡
10-44
Function
• When the speed lever in the operator’s com-
partment is operated, the four solenoid valves
installed to the transmission control valve are
switched ON or OFF to actuate the directional
selector spool, H-L selector spool and range
selector spool`.
Operation
1. Solenoid valve OFF
The oil from pilot reducing valve (1) flows to
ports a and b of H-L selector spool (2) and
range selector spool (3). The oil at a and b is
blocked by solenoid valves (4) and (5), so se-
lector spools (2) and (3) are moved to the right
in the direction of arrow.
As a result, the oil from the pump flows to the
2nd clutch.
2. Solenoid valve ON
When the speed lever is operated, the drain
ports of solenoid valves (4) and (5) open. The
oil at ports a and b of selector spools (2) and
(3) flows from ports c and d to the drain circuit.
Therefore, the pressure in the circuits at ports a
and b drops, and the spools are moved to the
left in the direction of the arrow by return springs
(6) and (7).
As a result, the oil at port e flows to the 4th
clutch and switches from 2nd to 4th.
10-45
MAIN RELIEF VALVE
Function
• The main relief valve regulates the pressure of
the oil flowing to the clutch circuit and distrib-
utes the oil flow between the clutch circuit and
the torque converter.
Operation
1. The oil from the pump passes through the prior-
ity valve, then through ports A and B of until the
main relief valve (1) specified pressure is
reached, and flows to the clutch valve.
2. If the pressure is above the specified value, the

oil which has passed through main relief valve
(1) orifices c and d presses poppet (2), moving
main relief valve (1) to the right, and is released
to port E, maintaining the pressure at the speci-
fied value. The oil released from port E flows to
the torque converter.
10-46
TORQUE CONVERTER OUTLET PORT

VALVE
Function
• The torque converter outlet port valve is installed
in the outlet line of the torque converter and

adjusts the maximum pressure of the torque
converter.
Operation
• The oil at port a passes through the orifice in
spool (1) and flows to port c.
• When the pressure at port a rises, the pressure
at port c also rises. This overcomes the tension
of spring (2) and moves spool (1) to the left in

the direction of the arrow to allow oil to flow from
port a to port b.
• If the pressure at port a becomes even higher,
spool (1) is moved further to the left in the
direction of the arrow, and the oil flows from
port a to port b and drain port d. (Cold relief)
10-47
PRIORITY VALVE
Function
• The priority valve regulates the delivery pres-
sure of the pump, and ensures the pilot pres-
sure and oil pressure for releasing the parking
brake.
In addition, if the pressure in the circuit goes
above the specified pressure, it acts as a relief
valve to protect the hydraulic circuit.
Operation
1. The oil from the pump enters port a and sepa-
rates into the oil flowing to parking brake valve
(1), priority valve (2) and the pilot circuit.
2. The oil at port a passes through priority valve

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

above the measured value, priority valve (2)
moves further to the left and is connected to the
drain circuit from port e, protecting the hydrau-
lic circuitry.
10-48
10-49
TRANSMISSION OIL PRESSURE SYSTEM DIAGRAM

Operation of FORWARD 1st
10-50
• The oil from the pump passes through the filter,

then passes through the pilot circuit and priority
valve, and is divided to the clutch actuation
circuit and the torque converter circuit.
• When the speed lever is operated to F1, FOR-
WARD solenoid valve (1) is actuated. The oil
which was filling port a is drained, directional
spool (4) is moved to the left, and clutch oil
pressure port b and FORWARD clutch oil pres-
sure port b’ are connected.
At the same time, oil fills the circuit and pushes
the H-L selector spool (5) fully to the right to
prevent H-L selector solenoid valve (2) from
being actuated. In addition, the oil is drained
and range selector spool (6) is pushed fully to
the left to actuate range selector solenoid valve
(3).
In this condition, 1st clutch oil pressure port d is
connected to oil pressure port c of the H-L
selector valve and the range selector valve.
• At the same time, the oil flowing through priority
valve (7) to the clutch actuation circuit passes
through the modulation valve, and then flows to
the FORWARD clutch and 1st clutch through
directional spool (4), H-L selector spool (5), and
range selector spool (6).
• When the oil completely fills the clutch cylinder,
the pressure rises gradually because of the
action of the modulation valve (9). When it
reaches the set pressure, the FORWARD and
1st clutches are completely engaged.
10-51
DIRECTIONAL SELECTOR VALVE
Operation
1. When at neutral
• Solenoid valves (4) and (5) are OFF and the
drain port is closed. The oil from the pilot circuit
passes through the oil hole in the emergency
manual spool and fills ports a and b of the
directional spool.
• In this condition, P1 + spring force (1) = P2 +
spring force (2), so the balance is maintained.
Therefore, the oil at port c does not go to the
FORWARD or REVERSE clutch.
2. When at FORWARD
• When the directional lever is placed at the FOR-
WARD position, solenoid valve (4) is switched
ON and drain port d opens. The oil which is
filling port a is drained, so P1 + spring force (1)
< P2 + spring force (2). When this happens, the
directional spool moves to the left, and the oil at
port c flows to port e and is supplied to the
FORWARD clutch.
10-52
H-L SELECTOR VALVE AND RANGE SELECTOR VALVE

• The H-L and range selector valves are operated
Function according to the combination of the solenoid
• When the gear shift lever is operated, electric valves, making it possible to select the speed
signals are sent to the solenoid valves paired (1st to 4th).
with the H-L selector valve and range selector
valve.
Operation
1. 2nd speed
• When solenoid valves (1) and (2) are OFF, the
drain port is closed. The oil P1 from the pilot
circuit overcomes the force of the H-L selector
spool (4) and range selector spool (5) springs
(3) and moves spools (4) and (5) to the left. The
oil in the clutch circuit passes from H-L selector
spool (4) port a through range selector spool (5)
port b and is supplied to the 2nd clutch.
10-53
2. 4th speed 3. 1st and 3rd speeds

• When solenoid valves (1) and (2) are ON, the • For the 1st speed, solenoid valve (1) is OFF,
drain port is open. The oil from the pilot circuit solenoid valve (2) is ON, and the oil in the
passes through solenoid valves (1) and (2) and clutch circuit passes from H-L selector spool
is drained, so H-L selector spool (4) and range (4) port a through range selector spool (5)
selector spool (5) are moved to the right by the port e and is supplied to the 1st clutch.
force of springs (3). The oil in the clutch circuit • For the 3rd speed, solenoid valve (1) is ON,
passes from H-L selector spool (4) port c through solenoid valve (2) is OFF, and the oil in the
range selector spool (5) port d and is supplied clutch circuit passes from H-L selector spool
to the 4th clutch. (4) port c through range selector spool (5)
port f and is supplied to the 3rd clutch.
10-54
EMERGENCY MANUAL SPOOL
Function
• If there should be a failure in the electrical
system and the directional solenoid valve cannot
be actuated, it is possible to actuate the FOR-
WARD or REVERSE clutch manually.
Operation
1. When emergency manual spool is at neutral
• The oil from upper valve (pilot reducing valve)
passes around emergency manual spool (1) and
is blocked by solenoid valves (2) and (3).
• During normal operations, the emergency manual
spool is at the neutral position.
2. When emergency manual spool is actuated

(FORWARD)
When emergency manual spool (1) is pushed
in, port a is connected to the drain port, and the
oil in chamber b is drained. When this happens,
directional spool (4) moves to the left in the
direction of the arrow. Oil then flows to the
FORWARD clutch and the clutch is engaged.
Pulling the machine see page 10-56
10-55
ELECTRONIC CONTROL MODULATION VALVE (ECMV)
Structure of ECMV
• The ECMV (Electronic Control Modulation Valve)
consists of a proportional solenoid valve and the
ECMV spool.
Proportional solenoid valve and ECMV

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

solenoid acts on the pressure control spool and
generates the oil pressure shown in the diagram on
the right.
Therefore, by controlling the command current, it is
possible to change the propulsion force, actuate the
pressure control valve, and control the oil flow and
oil pressure
Operation of ECMV
The ECMV is controlled by the command current
sent from the transmission controller to the propor-
tional solenoid. The relationship between the clutch
pressure and the command current for the propor-
tional solenoid in the ECMV is as shown in the
diagram on the right.
10-56
1. Before shifting gear

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

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

Immediately after oil fills the clutch chamber, the
command current to the solenoid is dropped to
the set value for the initial pressure. Therefore,
the propulsion force of shaft (2) of the propor-
tional solenoid valve becomes smaller, and the
clutch pressure becomes the set value for the
initial pressure.
10-57
4. Adjusting pressure
When the electric current flows to proportional
solenoid (1), a propulsion force proportional to
the current is generated. This propulsion force
of shaft (2) of solenoid (1) is adjusted by the oil
pressure at the clutch port applied to spool (3)
so that it is in balance with the reaction force.
In other words, the clutch pressure is controlled
by controlling the command current sent to so-
lenoid (1).
Manual operation of ECMV

If the machine must be moved in an emergency,
such as when there is any failure in the electrical
system of the transmission control, it is possible to
use manual operation to engage the transmission.
(For details, see the operation and maintenance
manual.)
Method of engaging
(i) Disconnect all connectors to the transmission
control valve.
(ii) Remove the manual selector lock plate, then
push in or pull out the spool.
FORWARD: Pull out
REVERSE: Push in
(iii) Push in the adjustment screw of the proportional
solenoid valve to the end.
Speed range when engaged: 2nd
10-58
PILOT OIL FILTER
1. Oil filter seat Specifications

2. Element Filtering area: 170 cm2
3. Case Filter mesh size: 105 µ
A. Inlet port
B. Outlet port
10-59
ACCUMULATOR VALVE
1. Piston (FORWARD clutch) Outline

2. Piston (1st clutch) • The accumulator valve is installed in the FOR-
3. Piston (2nd clutch) WARD, 1st, 2nd clutch circuit. When the trans-
4. Body accumulator mission shifts gear, the accumulator valve slowly
5. Spring (2nd clutch) reduces the oil pressure to the clutch that was
6. Stopper (2nd clutch) first engaged in order to prevent loss of torque
7. Stopper (1st clutch) and to reduce the transmission shock when
8. Stopper (FORWARD clutch) shifting gear. It temporarily stores the clutch oil
9. Spring (FORWARD clutch) pressure in order to allow gear shifting to be
10. Spring (1st clutch) carried out smoothly without any time lag.
(To make it possible to reduce the oil pressure
to the clutch slowly, there are throttles installed
in the directional spool and selector spool of the
transmission control valve.)
10-60
Operation
1. Shifting down when digging (kick-down F2 à
F1)
When the transmission is in F2, oil pressure is
stored in the 2nd clutch accumulator.
When the kick-down is operated, the F1 clutch
is engaged, but the oil pressure in the accumu-
lator is maintained for the 2nd clutch until the
torque is transmitted to the 1st clutch. In this
way, it is possible to shift gear smoothly without
losing the torque.
Moving out after digging (F1 à R2)

When the transmission is in F1, oil pressure is
stored in the accumulator for the FORWARD
clutch and 1st clutch.
When shifting to R2 after completing digging
operations, the R2 clutch is engaged, but the oil
pressure for the FORWARD clutch and 1st clutch
is maintained in the accumulator. This makes it
possible to reduce the loss of torque due to the
reaction force to the product being handled,
and to move back smoothly without shock.
10-61
FLOW VALVE
1. Valve body a. To transmission clutch circuit

2. Valve spool b. From pump
c. To transmission lubrication circuit
Operation
• The oil from the pump flows to the transmission
clutch circuit but when it becomes greater than
the specified flow, the flow valve acts to send oil
to the transmission lubrication circuit.
• When the oil from the pump becomes greater
then the specified flow, valve spool (2) moves
and part of the oil from the oil pump flows to the
transmission lubrication circuit.
10-62
CHECK VALVE
Outline
• The check valve is mounted on the fitting sur-

face of the transmission valve (lower valve) and
transmission case.
• A check valve is provided in the farward/reverse
valve`s drain circuit, stabilizing shifting perform-
ance when shifting between forward and re-
verse.
1. Directional spool
2. check valve
10-63
MODULATION VALVE
1. Body
2. Coil ass’y
3. Case
4. Adjustment screw
5. Plunger
6. Shaft
TRANSMISSION SOLENOID VALVE
1. Nut 6. Pin
2. Core ass’y 7. Spring
3. Coil ass’y 8. Valve seat
4. Plunger 9. Body
5. Spring 10. Connector
10-64
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft

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

2. Oil filler 5. Breather
3. Brake 6. Level plug
10-82
STRUCTURE AND FUNCTION AXLE
REAR AXLE
1. Final drive 5. Breather

2. Brake 6. Level plug
3. Differential 7. Drain plug
4. Oil filler
10-83
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
1. Shaft Specifications
2. Bevel gear Type: Spiral bevel gear, splash lubrica-
3. Bevel pinion tion
4. Side gear Reduction ratio: 4.10
5. Pinion Differential type: Torque proportioning, splash lu-
brication
10-84
REAR DIFFERENTIAL
4. Side gear Reduction ratio: 4.10
5. Pinion Differential type: Torque proportioning, splash lu-
brication
10-85
DIFFERENTIAL
FRONT DIFFERENTIAL WITH LSD
4. Side gear Differential type: Limited slip differential, splash lu-
5. Pinion brication
10-86
DIFFERENTIAL
REAR DIFFERENTIAL WITH LSD
4. Side gear Differential type: Limited slip differential, splash lu-
5. Pinion brication
10-87
LIMITED SLIP DIFFERENTIAL
Function
• Because of the nature of their work, 4-wheel drive

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

acting on the differential cage (1) is transmitted to
the cross pins (3) via the two thrust rings (2)
which are unable to revolve radially, but are ar-
ranged in the differential cage in such a manner
that they can move in an axial direction. The reac- 1) Crownwheel
tion forces which occur, when torque is transmitted, 2) Differential cage
exert outward axial forces on the wedge shaped 3) Cover
surfaces (4) of the thrust rings (2) , thereby produc- 4) Axle shaft sun wheel
ing a pressure on the discs. As the outer discs (5) 5) Differential planet pinion (bevel pinion)
are locked in the differential cage (1) and the inner 6) Cross pins
discs (6) are splined to the sun wheels (7), a 7) Thrust rings
relative rotation of the axle shafts to the differential 9) Outer disc
cage is rendered more difficult. 10) Inner disc
11) Thrust washer
• The outward forces produce in the multidisc brakes 13) Wedged shaped surface on thrust rings
a load dependant locking tor,que, which is always
directly proportional to the input torque. The locking
effect adapts itself to the changing engine torque
and also to the torque increase produced by the
different gear speeds. This is a special advantage
for heavy duty off-road applications, where large
torques must be transmitted.
10-88
Outline
• The motive force from the drive shaft passes
through bevel pinion (1) and is transmitted to
bevel gear (5). The bevel gear changes the
direction of the motive force by 90°, and at the
same time reduces the speed. It then transmits
the motive force through differential (4) to sun
gear shaft (2).
When driving straight forward

• When the machine is driven straight forward,
the rotating speed of the left and right wheels is
the same, so pinion gear (4) inside the differen-
tial assembly is sent through pinion gear (4)
and side gear (3) and is transmitted equally to
left and right sun gear shafts (2).
When turning
• When turning, the rotating speed of the left and
right wheels is different, so pinion gear (4) and
side gear (3) inside the differential assembly
rotate in accordance with the difference between
the rotating speed of the left and right wheels.
The motive force of carrier (6) is then transmit-
ted to sun gear shafts (2).
10-89
STRUCTURE AND FUNCTION FINAL DRIVE
TORQUE PROPORTIONING DIFFEREN- Ordinary differential

TIAL
Function
• Because of the nature of their work, 4-wheel-drive
loaders have to work in places where the road
surface is bad. In such places, if the tires slip, the
ability to work as a loader is reduced, and also the
life of the tire is reduced. The torque proportioning
differential is installed to overcome this problem.
• In structure it resembles the differential of an auto-
mobile, but differential pinion gear (3) has an odd
number of teeth. Because of the difference in the
resistance from the road surface, the position of
meshing of pinion gear (3) and side gear (4)
changes, and this changes the traction of the left
and right tires.
Torque proportioning differential
Operation
When traveling straight (equal resistance from road
surface to left and right tires)
• If the resistance from the road surface to the left
and right wheels is the same, the distance be-
tween pinion gear (2) and meshing point “a” of left
side gear (1) is the same as the distance between
pinion gear (2) and meshing point “b” of right side
gear (3).
• Therefore the left side traction TL and the right
side traction TR are balanced.
When traveling on soft ground (resistance from road

surface to left and right tires is different)
• On soft ground, if the tire on one side slips, the
side gear of the tire on the side which has least
resistance from the road surface tries to rotate
forward. Because of this rotation, the meshing of
pinion gear (2) and side gear changes.
• If left side gear (1) rotates slightly forward, the
distance between the pinion gear and the meshing
point “a” of the left side gear becomes longer than
the distance between the pinion gear and the mesh-
ing port “b” of the right side gear. The position is
balanced as follows.
a x TL = b x TR
The ratio between the distances to “a” and “b” can
change to 1 : 1.38.
• Therefore when the ratio of the distances to “a”
and “b” is less than 1 : 1.38 (that is, the difference
between the resistance from the road surface to
the left and right tires is less than 38%), the pinion
gear will not rotate freely, so drive force will be
given to both side gears, and the tires will not slip.
Because of this effect, the tire life can be increased
by 20 – 30%, and at the same the operating effi-
ciency is also increased.
10-90
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Axle shaft
2. Ring gear (No. of teeth: 67)
3. Planet gear (No. of teeth: 24)
4. Planetary carrier
5. Sun gear (No. of teeth: 17)
6. Wheel
Outline
• The final drive uses a planetary gear mecha-
nism to obtain a large drive force, and transmits
the drive force to the tires.
Operation
• The motive force transmitted to sun gear (5)
from the differential through axle shaft (1) is
transmitted to planet gear (3). The planet gear
rotates inside ring gear (2), which is fixed, and
transmits the motive force to wheel (6), which is
installed to the planetary carrier.
10-91
STRUCTURE AND FUNCTION AXLE MOUNT, CENTER HINGE PIN
AXLE MOUNT, CENTER HINGE PIN
1. Front axle Outline

2. Front frame • Front frame (2) and rear frame (4) are joined by
3. Rear axle hinge pins (5) and (6) through the bearings. In
4. Rear frame addition, the steering cylinders are connected
5. Upper hinge pin to the left and right front and rear frames, and
6. Lower hinge pin the angle of articulation of the frame (the turn-
7. Rear axle ing angle) is adjusted according to the move-
ment of the cylinders.
10-92
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
1. Main control valve 5. Switch pump

2. Steering valve 6. Steering pump
3. Steering cylinder (right) 7. Hydraulic pump
4. Hydraulic tank 8. PPC pump
9. Steering cylinder (left)
10-111
STRUCTURE AND FUNCTION STEERING COLUMN, ORBIT-ROLL
STEERING COLUMN, ORBIT-ROLL
1 Steering wheel 3 Tilt lever
2 Steering column 4 Orbit-roll
Outline
• The orbit-roll steering is fully hydraulically operated. • When the steering wheel is turned, the orbit-
There is no mechanical steering connection between roll passes oil to the steering demand valve.
the front and rear machine frame. The steering ac- The amount of oil is proportional to the turn-
tion is achieved through pipes, hoses and the steering of the steering wheel. The steering de-
ing cylinders. mand valve is moved to the left or right de-
pending on the turned direction of the steer-
ing wheel.
10-112
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR STEERING
HYDRAULIC CIRCUIT DIAGRAMM FOR STEERING
1. Steering pump 6. Stop valve 11. Steering cylinder

2. Switch pump 7. Demand valve 12. Oil cooler
3. PPC pump 8. Relief valve 13. Oil filter
4. Filter 9. Steering spool 14. Hydraulik tank
5. Orbit-roll 10. Saftey valve (With suction) 15. Breather
16. Acc. charging valve
10-113
STRUCTURE AND FUNCTION 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 12. Ceck valve
10-114
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
STEERING DEMAND VALVE
1. Safety valve (with suction) A. To steering cylinder

2. Check valve B. To steering cylinder
3. Steering spool Pa. From orbit-roll
4. Relief valve Pb. From orbit-roll
5. Flow control spool P1. From steering pump
P2. From switch pump
PB. To work equipment circuit
T. To tank (oil cooler)
10-115
OVERLOAD RELIEF VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
• The overload relief valve is installed to the steer-
ing valve. It has the following two functions:
When the steering valve is at neutral, if any
shock is applied to the cylinder, and an abnor-
mal pressure is generated, the oil is relieved
from this valve. In this way, it functions as a
safety valve to prevent damage to the cylinder
or hydraulic piping. On the other hand, if nega-
tive pressure is generated at cylinder end, it
functions as a suction valve to prevent a vacuum
from forming.
Operation
Acting as relief valve
• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. Oil
passes through the hole in poppet (1) and acts
on the different areas of diameters d1 and d2,
so check valve poppet (3) and relief valve pop-
pet (2) are firmly seated in position.
• When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens. The oil flows around pilot poppet (4),
passes through the drill hole, and flows to port
B.
10-116
• When pilot poppet (4) opens, the pressure at

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

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

• When negative pressure is formed at port A,
the difference in area of diameters d3 and d4
causes check valve poppet (3) to open. When
this happens, the oil from port B flows to port A,
and prevents any vacuum from forming.
10-117
STEERING RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The steering relief valve is inside the steering
valve, and sets the maximum circuit pressure
of the steering circuit when the steering valve is
actuated. When the steering valve is being ac-
tuated, if the steering circuit goes above the set
pressure of this valve, oil is relieved from this
valve. When the oil is relieved, the flow control
spool of the demand valve is actuated, and the
oil is drained to the steering circuit.
10-118
Operation of demand valve
Steering spool at neutral
• The oil from the steering pump enters port A • When the pressure at pressure-receiving cham-
and the oil from the switch pump enters port B. ber (I) reaches a certain level (set by spring
• When steering spool (2) is at neutral, pressure- (5)), notch (f) opens and the oil from the steer-
receiving chamber (II) is connected to the drain ing pump flows to the drain circuit. At the same
circuit through orifice (b), and notch (c) is closed. time, notch (g) closes, and all the oil from the
• Notch (c) is closed, so the pressure of the oil at switch pump all flows to the main control valve.
port A and port B rises. This pressure passes
through orifice (a), goes to pressure-receiving
chamber (I), and moves demand spool (1) to
the left in the direction of the arrow.
10-119
Steering spool operated
• Engine at low speed
• When steering spool (2) is pushed (operated), • The merged oil passes through notches (c) and
pressure-receiving chamber (II) and the drain (d), pushes up load check valve (4), and flows
circuit are shut off, and at the same time, notch to the cylinder. The return oil from the cylinder
(c) opens. passes through notch (e) and enters the drain
• Because of this, the pressure in pressure-re- circuit.
ceiving chamber (II) rises, and demand spool • In this condition, the pressure before passing
(1) moves to the right in the direction of the through notch (c) is sent to pressure-receiving
arrow until notch (h) closes. chamber (I) and the pressure after passing
• The passage from port B to the main control through notch (c) is sent to pressure- receiving
valve is shut off, the oil from the switch pump chamber (II).
pushes up merge check valve (3), and the oil is Demand spool (1) acts to keep the differential
merged with the oil at port A from the steering pressure on both sides of notch (c) at a con-
pump. stant value. Therefore, an oil flow which matches
the opening of notch (c) is discharged from the
cylinder port. These pressure differences (con-
trol pressures) are set by spring (5).
10-120
OPERATION OF DEMAND VALVE
• When the pressure in the circuit rises and • When flow control spool (6) moves, the oil from
reaches the pressure set by adjustment screw the steering pump is drained, and the oil from
(1) and spring (2), pilot poppet (4) opens and the switch pump id released to the main control
the oil is drained. valve, so the pressure in the steering circuit is
• When this happens, the balance between the prevented from going above the set value.
pressure in pressure-receiving chamber (I) and
pressure-receiving chamber (II) is lost, so de-
mand spool (6) moves to the left in the direction
of the arrow.
10-121
Engine at high speed
é ê
• No support oil is needed from the switch pump, • The oil from the steering pump passes through
so the steering pump pressure rises until notch notches (c) and (d), pushes up load check valve
(g) closes and the merge passage at port B is (4), and flows to the cylinder. The return oil
shut off. from the cylinder passes through notch (e) and
• The pressure difference on both sides of notch flows to the drain circuit.
(c) is controlled only by notch (f), and the ex- • Notch (g) is closed, so the oil from the switch
cess oil from the steering pump is drained from pump is sent from port B to the main control
notch (f) to the drain circuit. (At this point, notch valve.
(g) is fully closed.)
10-122
STRUCTURE AND FUNCTION STEERING VALVE
FLOW AMP
1. Steering spool 4. Return spring 7. Capscrew a: Throttle

2. Valve housing 5. Cap 8. Return spring b: Throttle
3. Spring seat 6. Piston 9. Flow amp notch A: From orbit-roll valve
B: From orbit-roll valve
C: Damper chamber
D: Passage (inside housing)
• 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 PiB are connected through the orbit-
roll to the drain (neutral) circuit, so steering spool
(1) is kept at neutral by return spring (4).
10-123
2. Spool actuated (oil flows to port PiA)
• When oil flows to port PiA, the pressure inside the • Port PiB is connected to the drain circuit
cap at end A rises and moves steering spool (1) in through the orbit-roll valve, so the oil flowing
the direction of the arrow. to end B is drained.
• The oil entering from port PiA passes through the • the pressure generated at port PiA is propor-
hole in spring seat (3), through flow amp notch (9) tional to the amount of oil flowing in, so
in steering spool (1), and then flows to the opposite steering spool (1) moves to a position where
end (B end). Piston (6) is also pushed up and oil the opening of the flow amp notch balances
fills damper chamber C. the pressure generated with the force of return
spring (4).
10-124
3. Spool returning (steering wheel stopped, flow of oil

to port PiA cut)
• When the steering wheel (orbit-roll valve) is stopped, • In this way, the return speed of steering spool
ports PiA and PiB are both connected to the drain (1) is made slower.
circuit through the orbit-roll valve. For this reason,
steering spool (1) is returned to the neutral position
by return spring (4).
• In damper chamber C, at first, piston (6) and spring
seat (3) are closed (in item 2), when the damper
camber becomes full, piston (6) and spring seat (3)
are almost closed because of piston return spring
(8); the oil damper chamber C passes through
throttle a and returns to port PiA.
10-125
Operartion of steering valve
Neutral
• The steering wheel is not being operated, so • When the pressure at ports A and B rises, flow
steering spool (1) does not move. control spool (4) moves to the left in the direc-
• The oil from the steering pump enters port A. tion of the arrow, and the oil from the steering
The oil from the switch pump enters port B. pump passes through port C of the spool and is
drained.
The oil from the switch pump passes through
port D, and all flows to the main control valve.
10-126
Turning right
• When the steering wheel is turned to the right, The oil from the left and right cylinders passes
the pressure oil from the Orbit-roll valve acts on through load check valve (3) of the steering
steering spool (1), and steering spool moves to spool, and is drained.
the left in the direction of the arrow. The oil from the switch pump enters port B,
The oil from the steering pump enters port A, pushes flow control spool (2) to push open check
passes through demand spool (2) to steering valve (5), and is merged with the oil from the
spool (1). It then pushes open load check valve steering pump.
(4) of the spool, and flows to the bottom end of
the left cylinder and the rod end of the right
cylinder to turn the machine to the right.
10-127
Turning left
• When the steering wheel is turned to the left, The oil from the left and right cylinders passes
the pressure oil from the Orbit-roll valve acts on through load check valve (4) of the steering
steering spool (1), and steering spool moves to spool, and is drained.
the right in the direction of the arrow. The oil from the switch pump enters port B,
The oil from the steering pump enters port A, pushes flow control spool (2) to push open check
flows through flow control spool (2) to steering valve (5), and is merged with the oil from the
spool (1). It then pushes open load check valve steering pump.
(3) of the spool, and flows to the rod end of the
left cylinder and the rod end of the right cylinder
to turn the machine to the left.
10-128
STRUCTURE AND FUNCTION EMERGENCY STEERING
EMERGENCY STEERING
Outline:
• The following two pages provide a summary of the
emergency steering installed in the WA-3H ma-
chines. These show the location of components and
flow of hydraulic oil for the WA470-3H during vari-
ous operating conditions; the summary applies ac-
cordingly for all other WA-3H machines.
Operating modes
1. Switch ignition on
• The red control lamp on the main monitor
flashes.
2. Motor started
goes out.
3. The machine is driven in any gear

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

not pump any hydraulic oil and the machine coasts.
• There is no steering pressure present.
• The control pressure generated by the steering pump
is not present either.
• The change-over valve is switched over by spring
force.
• The emergency steering pump is driven by the
transmission via the wheels, axles and cardan shafts,
and sucks hydraulic oil from the tank and pumps it
through the flow indicator to the change-over valve.
• The red control lamp on the main monitor flashes
because the generated control pressure has col-
lapsed.
• The change-over valve is now switched so that the
hydraulic oil being pumped by the emergency steer-
ing pump is fed into the steering circuit. A non-
return valve in the line section prevents hydraulic oil
from flowing back to the steering pump.
10-129

EMERGENCY STEERING Up to SN WA470H21064

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

2. Steering pump 8. Check valve
3. Emergency steering pump 9. Input port emergency steering pump
4. Change-over valve 10. Suction piping emergency steering pump
5. Flow indicator 11. Drain
6. Pressure switch
10-130

Function
• 8 pistons (17) are located in the pump housing
(16) in star formation. The stroke movement is
achieved with the cam shaft (14) which runs on
roller bearings. The heads of the pistons (17)
run on a slide ring (12) which itself is mounted
on a slide bearing (13) mounted on the cam.
The pistons (17) are kept in constant contact
with the slide ring (12) by springs (18). The
springs (18) are located in the hollow-drilled
pistons (17) and rest against the sealing screws.
The pump sucks in via the cam space of the
pump housing. The pistons, which have several
inlet holes around their circumference, immerse
downwards into the cam space so that oil can
flow into the inside of the piston through the inlet
holes. The inlet holes are closed again during
the upward movement by the cylinder wall after
a specific stroke distance. The oil pumped by
the further upward movement of the pistons is
fed through axial holes from the cylinder spaces
into a ring space which is sealed by a common
plate valve (10). The plate valve is held in place
by a waveform spring washer. The oil is dis-
charged via the plate valve (10) in the ring
collecting area in the cover which is connected
to the discharge connection hole. The plate valve
(10) carries out a waveform motion during this
action corresponding to the consecutive piston
strokes. A fairly even delivery of approx. 25 l/
min. sets in during acceleration at rotational 1 Circlip
speeds representing a travel speed of approx. 2 Deep-groove ball bearing
19 km/h. This characteristic results from the 3 Spacer ring
constantly decreasing time for the oil to flow 4 Double-lipped waveform sealing ring
from the cam space into the piston interior. The 5 O-ring
pump’s delivery characteristics are the same for 6 Pump cover, drive side
forward and reverse drive. 7 O-ring
8 Needle bearing
9 Waveform spring washer
10 Plate valve
11 Thrust ring
12 Slide ring
13 Slide bearing between cam shaft 14
and slide ring 12
14 Cam shaft
15 O-ring
16 Pump housing
17 Piston
18 Spring
19 Sealing ring
20 Sealing screw
21 Pump cover
10-131
CHANGE-OVER VALVE EMERGENCY STEERING

P. Input pressure emergency pump

PP. PPC pressure
D. To steering circuit
T. To tank
L. Connector pressure switch
10-132

EMERGENCY STEERING
Outline:
• The following two pages provide a summary of the
emergency steering installed in the WA-3H ma-
chines. These show the location of components and
flow of hydraulic oil for the WA320-3H during vari-
ous operating conditions; the summary applies ac-
cordingly for all other WA-3H machines.
Operating mode with time relay

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

from the steering pump and the machine is coast-
ing.
• There is no steering pressure present.
• The emergency steering pump is switched on
by a pressure switch (3 bar). When the emer-
gency steering pump is in operation, hydraulic
oil is sent to the steering line and the green
control lamp on the main monitor is on.
• The red control lamp on the main monitor is on
because the steering pressure has collapsed.
• A check valve prevents hydraulic oil from flow-
ing back to the steering pump.
10-133

EMERGENCY STEERING SN WA470H21065 and up

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

2. Pressure switch (3 bar) 8. Suction line
3. PPC pump 9. Priority valve for steering pump
4. Steering pump
5. Switch pump
6. Hydraulic pump
10-134

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

2. Bearing plates P Pressure port
4. Drive shaft
5. Layshaft
6. Mounting plate
7. Endcover
8. Seal combination
9. Pressure area
10. Channel
10-135

EMERGENCY STEERING PUMP

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

2. Check port (M10x1)
3. Pressure relief valve (120 ±7 bar)
4. Starter relay (24V, 80A)
10-136

WIRING DIAGRAM EMERGENCY STEERING

Operating mode with time relay
S109
Ground
Description Description
H111 Lamp steering oil pressure B305 Sender emergency steering pump pressure (7 bar)
H306 Lamp emergency steering pump B307 Sender air pressure (3 bar)
S109 Plug for taster test emergency steering pump K159 Time relay (6 sec.) for test emergency steering pump
V118 Diode K161 Relay emergency steering pump
XFS Connector fuses K414 Rpm sensor emergency steering pump
XL Connector platform P426 Main Monitor
XR Connector rear frame M160 Emergency steering pump
10-137

HYDRAULIC DIAGRAM EMERGENCY STEERING

1 1A
3
CF
H PSP
1. Pump and motor (emergency steering pump)

1A. Pressure relief valve (120 ±7 bar)
2. Pressure switch (7 bar)
H Port from hydraulic tank

P SP Port from steering pump
CF Outlet port to steering
10-138

STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
1. Brake valve (right) 10. PPC brake pump

2. Hydraulic tank 11. Transmission control valve
5. Rear brake 13. Parking brake
6. Charge valve 14. Brake valve (left)
7. Accumulator 15. Front brake
8. Slack adjuster 16. Slack adjuster
9. Rear brake 17. Front brake
10-151
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM

Park brake circuit Foot brake circuit

1 Transmission 9 Pump
2 Pump 10 Filter
3 Priority valve 11 Accumulator charge valve
4 Park brake cylinder 12 Check valve
5 Pressure switch 13 Low pressure switch
6 Park brake valve 14 Accumulators: One front axle, one rear axle
7 Accumulator 15 L.H. brake valve
8 Check valve 16 R.H. brake valve
17 Slack adjuster rear axle
18 Slack adjuster front axle
19 Wheel cylinders
20 T/M cut-off
21 Brake light switch
10-152
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE Up to SN WA470H20440

BRAKE VALVE (RIGHT)
1. Brake pedal (left, right brake) 9. Spool (left brake)

2. Rod (right brake) 10. Cylinder (left brake)
3. Pilot piston (right brake)
4. Spool (right brake) A. Pilot port (right brake)
5. Upper cylinder (right brake) B. To rear brake (right brake)
6. Spool (right brake) C. To front brake (right brake)
7. Lower cylinder (right brake) D. Drain (left, right brake)
8. Rod (left brake) E. To pilot port (left brake)
F. Port P
10-153
BRAKE VALVE (LEFT) Up to SN WA470H20440
Outline
• There are two brake valves installed in parallel mission solenoid valve electrically and set the
under the front of the operator’s cab, and these transmission to neutral.
are actuated by depressing the pedal.
• When the right pedal is depressed, oil is sent to
the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
In addition, the left brake pedal operates the
transmission cut-off switch to actuate the trans-
10-154
Operation
Brake applied (right brake valve)
Upper portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C
and actuates the rear brake cylinders.
Lower portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the front
brake cylinders.
Brake applied (left brake pedal)

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

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

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

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

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

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

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

• If the pressure at port P (pump pressure) goes
above the set pressure of the relief valve (R3),
the oil from the pump pushes spring (3). Ball
(11) is pushed up and the oil flows to the tank
circuit, so this sets the maximum pressure in
the brake circuit and protects the circuit.
10-161
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
ACCUMULATOR FOR BRAKE SYSTEM

1. Valve
2. Top cover
3. Cylinder
4. Piston
Function Specifications
• The accumulator is installed between the charge Gas used: Nitrogen gas
valve and the brake valve. It is charged with Charge amount: 3000 cc
nitrogen gas between cylinder (3) and free pis- Charging pressure
ton (4), and uses the compressibility of the gas for service brake: 3.4 ± 0.15 MPa
to absorb the pulse of the hydraulic pump or to (35 ± 1.5 bar) (at 50°C)
maintain the braking force and to make it possi- Charging pressure
ble to operate the machine if the engine should for parking brake: (15 bar) (at 50°C)
stop.
10-162
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder
2. Cylinder
3. Check valve
4. Piston
5. Spring
A. Inlet port
B. Outlet port
Function Specifications
• The slack adjuster is installed in the brake oil Piston actuation pressure:
line from the brake valve to the brake piston. It 0.01 +0.01 +0.1
0 MPa (0.1 0 bar)
acts to provide a fixed time lag when the brake Check valve cracking pressure:
is applied. 0.93 ± 0.05 MPa (9.5 ± 0.5 bar)
Check valve closing pressure:
0.6 ± 0.05 MPa (6.0 ± 0.5 bar)
10-163
Operation
1. When brake pedal is depressed
• Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil dis-
charged from the brake valve flows from port P
of the slack adjuster and is divided to left and
right cylinders (2), where it moves piston (4) by
stroke S to the left and right.
• When this is done, brake piston (7) moves by a

distance of stroke S. In this condition, the closer
the clearance between the brake piston and
disc is to 0, the greater the braking force be-
comes.
• If the brake pedal is depressed further, and the

oil pressure discharged from the brake valve
goes above the set pressure, check valve (3)
opens and the pressure is applied to port C to
act as the braking force.
Therefore, when the brake is applied, the time
lag is a fixed value.
10-164
2. When brake pedal is released

• When the brake is released, piston (4) is re-
turned by brake return spring (8) by an amount
equivalent to the oil for stroke S, and the brake
is released.
In other words, return stroke T of brake piston
(7) is determined by the amount of oil for stroke
S of the slack adjuster. The time lag of the
brake is always kept constant regardless of the
wear of the brake disc.
10-165
BRAKE CIRCUIT DIAGRAM

Serial Number: WA470H20441 - H20617
Park brake circuit Foot brake circuit

1 Transmission 9 Pump
2 Pump 10 Filter
3 Priority valve 11 Accumulator charge valve
4 Park brake cylinder 12 Check valve
5 Pressure switch 13 Low pressure switch
6 Park brake valve 14 Accumulators: One front axle, one rear axle
7 Accumulator 15 L.H. brake valve
8 Check valve 16 R.H. brake valve
17 Brake cylinder
18 T/M cut-off
19 Brake light switch
20 Slack adjuster
21 Switch valve
10-166
BRAKE VALVE (DUAL CIRCUIT)

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

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

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

2.1 / 2.2 To the wheel brakes
2.4 / 2.5 Pressure check points
5.1 / 5.2 Return ports to the tank
A Spring assembly
C1, C2 Spool valve
R1, R2 Springs
10-167

Partial braking:
• When the brake valve is operated hydraulic pres- • When the braking process is ended a con-
sure, proportional to the actual foot force, is ap- nection is again established between brake
plied to the brakes. The spring assembly (A) be- cylinder 2.1 / 2.2 and the drain 5.1 / 5.2,
neath the base plate (E) is designed so that brak- pressure ports 1.1 and 1.2 are closed.
ing pressure changes according to the foot plate
(B) angle. In the lower braking range the vehicle • The arrangement of pistons in the valve
can be braked proportionally. ensures that even if one braking circuit fails
the other remains fully operational. This is
• If the vehicle is braked more, piston (C1) is moved achieved by means of the mechanical ac-
down with the increased spring pressure (A). The tuation of both pistons and requires slightly
piston (C1) applies spring pressure (R1) to the more pedal pressure.
lower piston (C2). The pistons cut off the outlet
ports 5.1 and 5.2. Further movement opens the Limiting braking pressure:
ports 1.1 and 1.2 allowing oil pressure to pass to
the wheel brake cylinders. The applied foot force • The movement restriction screw (D) on the
now determines the braking force. The pistons base plate (E) below the pedal (B) is used
(C1) and (C2) are held in a stable position be- to limit the brake pedal movement. This in
tween the applied foot force and the spring pres- turn limits the applied braking pressure.
sure plus the applied brake hydraulic
pressure.When this point is reached ports 1.1 / Failure of a circuit:
1.2 and 5.1 / 5.2 are closed and the applied pres-
sure at 2.1 and 2.2 is held. • In the event of the lower brake circuit fail-
ing, the upper circuit will remain operational.
Full braking: Piston (C1) is operated mechanically by
spring (A). In the event of the upper circuit
• When the brake pedal (B) is fully actuated piston failing, piston (C1) and spring (A) will me-
(C1) moves into mechanical contact with piston chanically
(C2). Ports 5.1 and 5.2 close. Ports 1.1 and 1.2
open and full brake pressure is allowed to flow to
the brakes.
10-168
BRAKE VALVE (SINGLE CIRCUIT)

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

• Pedal restriction screw (D) on base plate
(E) below pedal (B) is used to limit the
braking pressure. This will cause the accu-
mulator pressure building up in the braking
system to be limited.
10-169
BRAKE HYDRAULIC CIRCUIT DIAGRAM

Serial Number: WA470H20618 and up
1. Transmission Foot brake circuit

2. Pump 9. Pump
3. Priority valve 10. Filter
4. Park brake cylinder 11. Low pressure switch
5. Pressure switch 12. Accumulators: One front axle, one rear axle
6. Park brake valve 13. Switch valve
7. Accumulator 14. L.H. brake valve
8. Check valve 15. R.H. brake valve
16. T/M cut-off
17. Brake light switch
18. Slack adjuster
19. Brake cylinder
10-170

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

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

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

2.1 / 2.2 To the wheel brakes
2.4 / 2.5 Pressure check points
5.1 / 5.2 Return ports to the tank
A Pilot pressure from left
brake pedal
10-171

Partial braking: Full braking:
• When the brake valve is operated hydraulic pres- • When the brake pedal is fully actuated, a
sure, proportional to the actual foot force, is ap- final position is reached and ports 1.1 and
plied to the brakes. The spring assembly beneath 1.2 are connected to port 2.1 / 2.2 at the
the base plate is designed so that braking pres- brakes while drain ports 5.1 / 5.2 are closed.
sure changes according to the foot plate angle. In • When the braking process is ended a con-
the lower braking range the vehicle can be braked nection is again established between brake
proportionally. cylinder 2.1 / 2.2 and the drain 5.1 / 5.2,
pressure ports 1.1 and 1.2 are closed.
• If the vehicle is braked more, the upper piston is • The arrangement of pistons in the valve
moved down with the increased spring pressure. ensures that even if one braking circuit fails
The upper piston applies spring pressure to the the other remains fully operational. This is
lower piston. The pistons cut off the outlet ports achieved by means of the mechanical ac-
5.1 and 5.2. Further movement opens the ports tuation of both pistons and requires slightly
1.1 and 1.2 allowing oil pressure to pass to the more pedal pressure.
wheel brake cylinders. The applied foot force now
determines the braking force. The pistons are held
in a stable position between the applied foot force Failure of a circuit:
and the spring pressure plus the applied brake
hydraulic pressure. When this point is reached • In the event of the lower brake circuit fail-
ports 1.1 / 1.2 and 5.1 / 5.2 are closed and the ing, the upper circuit will remain operational.
applied pressure at 2.1 and 2.2 is held. The piston is operated mechanically by the
springs. In the event of the upper circuit
failing, the lower circuit will remain opera-
tional. The lower piston and is operated
mechanically by the springs and the piston.
• If the left brake valve is operated, a pres-
sure establishes at port 2.1 and passes to
port 3 of the right brake valve. This pres-
sure operates a piston in the right brake
pedal that operates the brake slide. Oil flows
from ports 1.1 / 1.2 to the cylinder ports 2.1
/ 2.2 (brake).
10-172
BRAKE VALVE (SINGLE CIRCUIT)

Function: 2.1 for the wheel brake cylinders.

• The purpose of the brake valve is to sensitively The foot force applied now determines the
increase and decrease the braking pressure when output braking pressure. The control slide is
the brake pedal is actuated. held in the control position by the force
applied (spring assembly) and the hydraulic
Operation: pressure below the slide (balance of forces).
After output of the braking pressure, the
Ready Position slide is in a partial braking position, causing
• When the braking system is ready for operation, ports 1.1 and 5.1 to close and holding the
its accumulator pressure acts directly on port 1.1 pressure in port 2.1.
of the brake valve. A connection is established
between ports 2.1 and 5.1 so that the wheel brake Full Braking Position
(port 2) is pressureless via the return (port 5). • When the pedal is fully actuated, an end
position of the brakes is reached and a
Partial Braking connection established between accumula-
• When the brake valve is actuated, an amount of tor port 1.1 and brake cylinder port 2.1.
hydraulic pressure is output as a ratio of the foot Return 5.1 is closed at this point.
force applied. • When the braking process is ended, a con-
• The spring assembly beneath base plate is de- nection is once again established between
signed in such a way that the braking pressure brake cylinder port 2.1 and return port 5.1,
changes depending on the angle. In the lower brak- closing accumulator port 1.1.
ing pressure range, the vehicle can be slowed
sensitively. Limiting the Braking Pressure
• When the braking process is commenced, the slide • The pedal restriction screw on the base
is mechanically actuated via a spring assembly. plate below the pedal is used to limit the
As the slide moves downward, it will first close braking pressure. This will cause the accu-
return 5 via the control edge, thus establishing a mulator pressure building up in the braking
connection between accumulator port 1.1 and port system to be limited.
1.1 From accumulator
2.1 Control pressure to port 3
5.1 Return port
10-173
STRUCTURE AND FUNCTION BRAKE SYSTEM
BRAKE PRESSURE REGULATING VALVE

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

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

Switch off pressure: 100 -8 bar
max. operating pressure: 110 bar
Charging process:
• When the accumulator pressure drops to a preset the connection between port 1 and port 5 is
value, spring pressure C will force the control reestablished. The pump oil flow returns to
valve B to move to the charge detent position E2. the tank. Check valve D ensures that ac-
Oil flows via orifice F to the spring chamber of cumulator pressure is maintained. The
valve A. This causes valve A to float. A minimum safety valve J check max. pressure of 100
oil flow goes to the return port 5 and back to the bar. The pressure switch 28 operates at 52
tank, the maximum oil flow goes to ports 21 / 23 bar.
via check valve D. Pressure in the accumulators
rises to approx. 150 bar. The control valve B
returns to the discharge detent position E1 and
10-174
ACCUMULATOR (FOR BRAKE)

Gas pressure: 35 bar

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

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

vided by a diaphragm (C). The one chamber con-
tains nitrogen (B). The other chamber (A) is con-
nected to the hydraulic system. When the hydrau-
lic pressure rises oil enters the accumulator and
compresses the nitrogen. The gas volume de-
creases and the pressure rises. When the hydrau-
lic pressure falls the gas volume increases and
forces the hydraulic oil out of the accumulator into
the hydraulic circuit.
• The diaphragm is fitted with a disc seal (D). This

will close the acccumulator when there is no hy-
draulic pressure.
10-175
ACCUMULATOR FOR PPC VALVE

Gas pressure: 17 bar

Capacity: 0,48 l
Function
• The accumulator is installed between the hy-
draulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under
their own weight by using the pressure of the
nitrogen gas compressed inside the accumula-
tor to send the pilot oil pressure to the main
control valve to actuate it.
Operation
• After the engine stops , if the PPC valve is at
"Hold", chamber A inside the bladder is com-
pressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa (30
bar). When this happens, the bladder is ex-
panded by the pressure of the nitrogen gas in
chamber A, and the oil inside chamber B is
used as the pilot pressure to actuate the main
control valve.
10-176
BRAKE ACCUMULATOR UNIT

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

Switch on press. 70 +8 bar
Switch off press. 100 -8 bar
Outline
• The brake accumulator unit consists of the pres-
sure regulating valve, a hydraulic block, accumu-
lators for service brake and PPC circuit (emer-
gency boom lowering); a check valve for PPC
pressure and a hydraulic oil filter.
1. Decompression spindel
2. Decal
3. Strainer
J. Pressure regulating valve
10-177
BRAKE ACCUMULATOR UNIT
2
8
10
Front
axle
1 10
Rear
axle
5
3
6
1. Housing
2. PPC pressure filter
3. Pressure limiting valve
(PPC pressure)
4. PPC pressure accumulator
5. Check valve
6. Checkpoint PPC pressure
7. Brake pressure accumulator
9. By-pass valve
10. Checkpoint brake pressure
10-178
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear (No. of teeth: 138)
6. Inner gear (No. of teeth: 105)
7. Plate
8. Disc
10-179
STRUCTURE AND FUNCTION BRAKE
Function
• Service brakes are wet-type multiple-disc brakes
and are installed to all four wheels.
Operation
• When the brake pedal is depressed, the pres-
sure oil from the brake valve moves brake pis-
ton (4) to the right in the direction of the arrow.
This brings disc (8) and plate (7) into contact,
and friction is generated between the disc and
plate. The wheel is rotating together with the
disc, so the machine speed is reduced and the
machine is stopped by this friction.
• When the brake pedal is released, the pressure

at the back face of brake piston (4) is released,
so the piston is moved to the left in the direction
of the arrow by the force of return spring (2),
and the brake is released.
10-180
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake lever and valve 3. Transmission (built in parking brake)

2. Transmission control valve 4. Parking brake emergency release
Outline
• The parking brake is a wet type multiple-disc brake • When the parking brake is applied, the neu-
built into the transmission. It is installed to the out- tralizer relay is switched on and the trans-
put shaft bearing, and uses the pushing force of a mission control unit keeps the transmission
spring to apply the brake mechaniclly and hydraulic in neutral, but the last selected gear is still
power to release the brake. shown on the monitor display.
• When the parking brake lever (1) installed in the • Emergency release of the parking brake is
operator's compartment is switched ON, the park- possible. It can used when moving the ma-
ing brake valve shuts off the oil pressure to the chine if the machine has stopped because of
parking brake and the parking is applied. When the trouble in the engine or transmission unit. If
parking brake lever is switched OFF, the oil pres- the engine is OFF and the parking brake
sure flows to the parking brake cylinder and the accumulators are empty, the parking brake
parking brake is released. is locked by spring force.
10-181
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
1. Output shaft Outline

2. Disc • The parking brake is a wet-type multiple-disc
3. Plate brake. It is actuated mechanically by a spring
4. Piston and applies the braking force to output shaft (1)
5. Spring of the transmission.
6. Emergency release (3 screws) • The pushing force of spring (5) pushes piston
(4) and plate (3) and disc (2) into contact and
applies the braking force to stop output shaft
(1).
10-182
STRUCTURE AND FUNCTION PARKING BRAKE VALVE
PARKING BRAKE VALVE

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

• When the parking brake lever is put in the OFF
position, the drain circuit is closed. The oil from
the pump flows to the brake cylinder, the spring
is compressed and the parking brake is re-
leased.
Park brake circuit
1 Transmission
2 Pump
3 Pressure control valve 27 bar
4 Park brake cylinder
5 Pressure switch
6 Park brake valve
7 Accumulator
8 Check valve
10-183
10-184
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
Outline • Control of the maximum pressure in the hy-
• The hydraulic system consists of the work equip- draulic circuit is carried out by the relief valve
ment circuit and the steering circuit. The work inside the main control valve. A safety valve
equipment circuit controls the actuation of the (with suction) is installed in the bucket cylin-
bucket and attachments. der circuit to protect the circuit.
• The oil in hydraulic tank (4) is sent to main • Accumulator (10) is installed in the PPC pilot
control valve (1) by hydraulic pump (12). If the circuit, and makes it possible to lower the
spools for the bucket and boom in the main boom to the ground even when the engine
control valve are at the HOLD position, the oil has stopped.
flows to the drain circuit of the main control • Hydraulic tank (4) is a pressurized sealed
valve, is filtered by the filter inside the hydraulic type and has a breather equipped with a re-
tank, and then returns to the tank. lief valve. This makes it possible to pressu-
• When the work equipment control levers are rize the inside of the tank and also to prevent
operated, the PPC valve bucket spool or boom any negative pressure, thereby preventing any
spool is actuated, and the spools of the main cavitation of the pump.
control valve are actuated by hydraulic pres-
sure to send the oil from the main control valve
to boom cylinder (15) or bucket cylinder (2) to
operate the boom or bucket.
1. Main control valve

2. Bucket cylinder
3. Steering valve
4. Hydraulic tank
5. PPC valve
6. Solenoid valve
7. Switch pump
8. Steering pump 12. Hydraulic pump
9. Acc. charg. valve 13. PPC, brake pump
10. Accumulator 14. Steering cylinder
11. Radiator 15. Boom cylinder
10-201
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM

(Conditions: Engine at low idling, work equipment control levers at HOLD)
10-202
10-203
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

10-204
1. Hydraulic tank
2. Oil filter
3. Breather
4. T.C. pump
5. Hydraulic pump
6. PPC, brake pump
7. Steering pump
8. Switch pump
9. Filter
10. Accumulator charge valve
11. Accumulator
12. PPC valve
13. Orbit-roll
14. Steering stop valve
15. Steering valve
16. Flow control spool
17. Relief valve
18. Steering spool
19. Safety valve with suction
20. Cut-off valve
21. Steering cylinder
22. Relief valve
23. Bucket spool
25. Float selector valve
26. Unload valve
27. Boom spool
28. Suction valve
29. Slow return valve
30. Boom cylinder
31. Bucket cylinder
32. Cooler
35. Security valve
36. Emerg. steering pump
37. Emerg. steering valve
10-205

From SN WA470H20633
up to SN WA470H21064
ALS
28
37
29
25
26
24
22
21
210
27
23
36
20
19
18
12
17
16
15
34
35
31
14
12
13
11A
10
1
31
3
11B
9
32
8
4
5
30
10-206

1. Hydraulic tank From SN WA470H20633

2. Oil filter up to SN WA470H21064
3. Breather
4. T.C. pump
5. Hydraulic pump
6. PPC, brake pump
7. Steering pump
8. Switch pump
9. Filter
11A. Accumulator for brake
11B. Accumulator for PPC
12. PPC valve
13. Orbit-roll
15. Steering valve
17. Relief valve
18. Steering spool
20. Cut-off valve
22. Relief valve
23. Bucket spool
26. Unload / suction valve
27. Boom spool
28. Boom cylinder
29. Bucket cylinder
30. Oil cooler
31. Security valve
33. Emerg. steering valve
34. Brake valve left
35. Brake valve right
36. Attachm. spool
37. Attachm. cylinder
10-207

STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
WORK EQUIPMENT HYDRAULIC DIAGRAM

Note: from SN WA470H21164 and up (Pos. 20H, 20 I added)
ALS
28
37
29
25
26
24
22
21
23
27
36
20
26A
20A
19
18
12
17
15
16
35
34
14
12
13
11A
10
1
3
11B
31
9
32A
8
LO S/W
32
S/T Pi
33
T/C
5
30
10-208

1. Hydraulic tank SN WA470H21065 and up

2. Oil filter
3. Breather
4. T.C. pump
5. Hydraulic pump
6. Switch pump
7. Steering pump
8. PPC, brake pump
9. Filter
11A. Accumulator for brake
11B. Accumulator for PPC
12. PPC valve
13. Orbit-roll
15. Steering valve
17. Relief valve
18. Steering spool
20. Cut-off valve
20A. 2-stage-Cut-off vavle / SN: WA470H21164
22. Relief valve
23. Bucket spool
26. Unload / suction valve
26A. Dam pressure valve (10 bar) / SN: WA470H21164
27. Boom spool
28. Boom cylinder
29. Bucket cylinder
30. Oil cooler
32A. Pressure relief valve (120 ± 7 bar)
34. Brake valve left
35. Brake valve right
36. Attachm. spool
37. Attachm. cylinder
10-209

STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. Boom lever 7. Attachment lever

2. Kick-down switch 8. Solenoid valve for bucket lever
3. Hold switch 9. Solenoid valve for boom lever
4. Not fitted in europe 10. Safety lever
5. Bucket lever 11. PPC valve
6. Not fitted in europe
10-210
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Oil filter 4. Filter suction valve

2. Breather 5. Oil filter
3. Sight gauge 6. Hydraulic tank
10-211
10-110-1
STRUCTURE AND FUNCTION HYDRAULIC TANK
BREATHER
1. Body
2. Filter element
3. Poppet
4. Sleeve
• Preventing negative pressure inside tank • Preventing rise in pressure inside tank
The tank is a pressurized sealed type, so if the If the pressure in the circuit rises above the set
oil level inside the hydraulic tank goes down, pressure during operations because of the
there will be negative pressure in the tank. If change in the oil level in the hydraulic cylinders
this happens, a poppet is opened by the differ- or the rise in the temperature, the sleeve is
ence between the pressure inside the tank and actuated to release the pressure inside the hy-
the atmospheric pressure, and air is let in to draulic tank.
prevent negative pressure from forming inside
the tank.
10-110-2
10-212
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
P. From PPC pump

P1. To bucket cylinder bottom end
P2. To boom cylinder head end
P3. To boom cylinder bottom end
P4. To bucket cylinder head end
T. Drain
10-211
1. Bolt
2. Piston
3. Plate
4. Collar
5. Retainer
6. Centering spring
7. Metering spring
8. Valve
9. Body
Function
• The PPC valve is installed at the bottom of the
work equipment control lever and is connected
by a linkage to the control lever.
• The oil from the PPC pump is supplied to the
end of each spool of the main control valve in
accordance with the movement of the control
lever, and this actuates the spool. For this rea-
son, the operating force of the control lever is
small and this helps to reduce operator fatigue.
10-212
PPC VALVE
P. From PPC pump

P1 . To bucket cylinder bottom end
P2 . To boom cylinder head end
P3 . To boom cylinder bottom end
P4 . To bucket cylinder head end
T. Drain
10-213
JOYSTICK, SERVO CONTROL VALVE

• Oil, from the brake/servo pump flows to the servo position.

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

connections 1 to 4 are connected through the
drillings in the servo pistons (16) to the return
channel T. This ensures that the control valves in
the main control valve block are also in the neutral
7
1. Lower
2. Tilt in
3. Lift
4. Tip out 8
5. Kick down switch
17
6. Joystick
9
7. Rubber cover
8. Universal joint 18
9. Rod with magnet 10
holding plate
10. Detent magnet for 19 11
connections 1 to 3
11. Rod pressure point 12
12. Pressure rod
13. Spring plate 13
14. Return spring
14
15. Control spring
16. Control piston 15
17. Rod
18. Rod guide
16
19. Detent ball 320_m c03
P. Servo oil pressure from the brake/servo pump
T. Oil return channel to the hydraulic tank
10-214

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

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

5. Kickdown
6. (-)
7. Hold
10-215
OPERATION OF PPC VALVE Schematic sketch only!

[At neutral]
• The oil from the pump enters port P. The circuit

is closed by spool (8), so the oil is drained from
relief valve (1).
At the same time, the oil at port PA1 of the main
control valve is drained from port f of spool (8).
In addition, the oil at port PB1 is drained from
port g of spool (10).
10-216

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

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

2):
When piston (2) starts to be pushed by plate
(10), retainer (5) is pushed. Valve (8) is also
pushed by spring (7) and moves down.
When this happens, fine control hole (f) is shut
off from drain chamber D. At almost the same
time it is connected to pump pressure chamber
PP, and the pilot pressure of the control valve is
sent through fine control hole (f) to port P4.
When the pressure at port P4 rises, valve (8) is
pushed back. Fine control hole (f) is shut off
from pump pressure chamber PP. At almost the
same time it is connected to drain chamber D,
so the pressure at port P4 escapes to drain
chamber D.
Valve (8) moves up and down until the force of
spring (7) is balanced with the pressure of port
P4.
The position of valve (8) and body (9) (when
fine control hold (f) is midway between drain
chamber D and pump pressure chamber PP)
does not change until the head of valve (8)
contacts the bottom of piston (2).
Therefore, spring (7) is compressed in propor-
tion to the travel of the control lever, so the
pressure at port P4 also rises in proportion to
the travel of the control lever. The spool of the
control valve moves to a position where the
pressure of port PA1 (same as pressure at port
P4) and the force of the return spring of the
control valve are balanced.
10-217

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

Plate (10) pushes piston (2) down, and piston
(2) forcibly pushes in valve (8).
Fine control hole (f) is shut off from drain cham-
ber D, and is connected to pump pressure cham-
ber PP.
Therefore, pressure oil from the charging pump
passes through fine control hole (f), and flows
from port P4 to chamber PA1 to push the spool
of the control valve.
The oil returning from chamber PB1 flows from
port P1 through fine control hole (f’) to drain
chamber D.
10-218

STRUCTURE AND FUNCTION PPC RELIEF VALVE
PPC RELIEF VALVE Up to SN WA470H20617
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Function
• The PPC relief valve is between the PPC, brake
pump and the PPC valve. When the PPC pump
is not being actuated, or when any abnormal
pressure is generated, the oil sent from the
pump is relieved from this valve to prevent any
damage to the pump or circuit.
Operation
• The relief valve is installed to the charge valve.
Port A is connected to the pump circuit and port
C is connected to the drain circuit.
The oil passes through the orifice in main valve
(1) and fills port B.
In addition, pilot poppet (4) is seated in valve
seat (3).
• When the pressure at port A and port B reaches
the set pressure, pilot poppet (4) opens and the
oil pressure at port B escapes from port D to
port C to lower the pressure at port B.
• When the pressure at port B goes down, a
difference in pressure is generated at ports A
and B by the orifice of main valve (1). Main
valve (1) is opened by the pressure at port A
and the oil at port A is drained to port C to
relieve the circuit.
10-219
STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC VALVE)
ACCUMULATOR (FOR PPC VALVE)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen gas
Gas amount: 500 cc
Max. actuation pressure: 3.4 MPa (35 bar)
Min. actuation pressure: 1.2 MPa (12 bar)
Function
• The accumulator is installed between the hy-
draulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under
their own weight by using the pressure of the
nitrogen gas compressed inside the accumula-
tor to send the pilot oil pressure to the main
control valve to actuate it.
Before operation After operation
Operation
• After the engine stops, if the PPC valve is at
hold, chamber A inside the bladder is com-
pressed by the oil pressure in chamber B.
• When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa (30 kg/
cm2). When this happens, the bladder is ex-
panded by the pressure of the nitrogen gas in
chamber A, and the oil inside chamber B is
used as the pilot pressure to actuate the main
control valve.
10-220
STRUCTURE AND FUNCTION CUT-OFF VALVE
CUT-OFF VALVE
Up to SN WA470H632
1. Unload valve Function

2. Check valve • The cut-off valve is installed between the switch
3. Cut-off relief valve pump and the main control valve. Depending
4. Screen on the operating condition, it switches the oil
C. Port C (from hydraulik pump) from the switch pump to the main control valve
P. Port P (from steering valve) or to the drain circuit.
T1 . Port T1 (to tank) • The cut-off valve is operated by hydraulic pres-
T2 . Port T2 (to tank) sure.
10-221
STRUCTURE AND FUNCTION CUT-OFF VALVE
CUT-OFF VALVE
SN WA470H633 and up
1. Port G
2. Port F
3. Port K
4. Port H
5. Cut-off pressure relief valve
G H
Ø 0 ,8
Ø 1,2
F. Pump pressure
K. Checkpoint
G. To main control valve
H. Drain
K F
10-222
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE Up to SN WA470H632
2-SPOOL
PA1. From PPC valve P4 A1. To bucket cylinder bottom end

PA2. From PPC valve P2 A2. To boom cylinder bottom end
PB1. From PPC valve P1 B1. To bucket cylinder head end
PB2. From PPC valve P3 B2. To boom cylinder head end
P. From pump D1. Drain port
P1. From PPC valve P2 D2. Drain port
P2. From PPC valve P3 T. Drain port
10-223
1. Main relief valve 6. Body

2. Bucket spool return spring 7. Suction valve
3. Boom spool return spring 8. Unload valve
4. Boom spool 9. Float selector valve
5. Bucket spool 10. Safety valve with suction
10-224
Up to SN WA470H632
3-spool
(if equipped)
MA1: From PPC valve A1: To bucket cylinder bottom end P: Pump port
MA2: From PPC valve A2: To boom cylinder bottom end T: Drain port
MA3: From PPC valve A3: To attachment cylinder (to hydraulic tank)
MB1: From PPC valve B1: To bucket cylinder head end D1: Drain port
MB2: From PPC valve B2: To boom cylinder head end D2: Drain port
MB3: From PPC valve B3: To attachment cylinder
10-225
1. Main relief valve 7. Safety valve

2. Attachment spool 8. Unload valve
3. Bucket spool 9. Suction valve
4. Boom spool 10. Safety valve with suction
5. Return spring 11. Float selector valve
6. Body
10-226
MAIN CONTROL VALVE SN WA470H633 and up
2-SPOOL
T
A2 B2
PA2 PB2
PA1 PB1
A1 B1
PA1. From PPC valve P4 A1. To bucket cylinder bottom end

PA2. From PPC valve P2 A2. To boom cylinder bottom end
PB1. From PPC valve P1 B1. To bucket cylinder head end
PB2. From PPC valve P3 B2. To boom cylinder head end
P. From pump T. Drain port
10-227
7 7
6 4
9 9
1 5

2. Bucket spool return spring 7. Unload / suction valve
3. Boom spool return spring 8. Float selector valve
4. Boom spool 9. Safety valve with suction
5. Bucket spool
10-228
SN WA470H633 and up
3-spool
(if equipped) T
A2 B2
PA3 PB3
A1
PA2 PB2
PB1
PA1 A3
B1
B3
PA1: From PPC valve A1: To bucket cylinder bottom end P: Pump port
PA2: From PPC valve A2: To boom cylinder bottom end T: Drain port
PA3: From PPC valve A3: To attachment cylinder (to hydraulic tank)
PB1: From PPC valve B1: To bucket cylinder head end
PB2: From PPC valve B2: To boom cylinder head end
PB3: From PPC valve B3: To attachment cylinder
10-229
7 7
6
8 8
3

2. Attachment spool 7. Unload / suction valve
3. Bucket spool 8. Safety valve with suction
4. Boom spool 9. Float selector valve
5. Return spring
10-230
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
6. Lock nut
Function
The relief valve is installed to the inlet portion of
the main control valve. If the oil goes above the
set pressure, the relief valve drains the oil to
the tank to set the maximum pressure for the
work equipment circuit, and to protect the cir-
cuit.
Operation
• Port A is connected to the pump circuit and port
C is connected to the drain circuit. The oil passes
through the orifice in main valve (1), and fills
port B. Pilot poppet (3) is seated in valve seat
(2).
• If the pressure inside ports A and B reaches the
set pressure of pilot poppet spring (4), pilot pop-
pet (3) opens and the oil pressure at port B
escapes from port D to port C, so the pressure
at port B drops.
• When the pressure at port B drops, a difference
in pressure between ports A and B is created
by the orifice of main valve (1). The main valve
is pushed open and the oil at port A passes
through port C, and the abnormal pressure is
released to the drain circuit.
• The set pressure can be changed by adjusting
the tension of pilot poppet spring (4). To change
the set pressure, remove the cap nut, loosen
the locknut, then turn adjustment screw (5) to
adjust the set pressure as follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
10-231
SAFETY VALVE (WITH SUCTION)

1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
Function
• The safety valve is in the bucket cylinder circuit
inside the main control valve. If any abnormal
pressure is generated by any shock to the cylin-
der when the main control valve is at the neu-
tral position, this valve relieves the abnormal
pressure to prevent damage to the cylinder.
Operation
Operation as safety valve
• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The oil
pressure at port A is sent to port D from the
hole in pilot piston (4). It is also sent to port C
by the orifice formed from main valve (2) and
pilot piston (4).
Pilot piston (4) is secured to the safety valve,
and the size of the cross-sectional surface
(cross-sectional area) has the following rela-
tionship: d2 > d1 > d3 > d4.
• If abnormal pressure is created at port A, suc-
tion valve (1) is not actuated because of rela-
tionship d2 > d1 >, but relationship between port
A and port C is d3 > d4, so main valve (2)
receives oil pressure equivalent to the differ-
ence between the areas of d3 and d4. If the
oil pressure reaches the force (set pressure) of
main valve spring (3), main valve (2) is actu-
ated, and the oil from port A flows to port B.
10-232
Operation as suction valve

• If any negative pressure is generated at port A,
port D is connected with port A, so there is also
negative pressure at port D. The tank pressure
of port B is applied to port E, so the safety valve
receives oil pressure a, which is equal to the
difference in the area of d2 and d1 because of
the tank pressure at port E. Therefore, oil pres-
sure e moves the valve in the direction of open- D
ing, and oil pressure a acts to move suction
valve (1) in the direction of closing.
When the pressure at port A drops (and comes
close to negative pressure), it becomes lower
than hydraulic pressure e. The relationship be-
comes oil pressure e > oil pressure a + force of
valve spring (5), and suction valve (1) opens to
let the oil from port B flow into port A and pre-
vent any negative pressure from forming at port
A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
Function
• This valve acts to prevent any negative pres-
sure from forming in the circuit.
Operation
• If any negative pressure is generated at port A
(boom cylinder rod end) (when a pressure lower
than tank circuit port B is generated), main pop-
pet (1) is opened because of the difference in
area between d1 and d2, and oil flows from port
B at the tank end to port A at the cylinder port
end.
10-233
OPERATION OF CUT-OFF VALVE
Function
• The cut-off valve is mounted between the switch
pump and work equipment valve. It switches
the oil flow from the switch pump between the
working equipment valve and the drain, accord-
ing to operating conditions, and controls the
speed of the work equipment.
• The cut-off valve is activated by oil pressure for
standard models, by electronic governor con-
troller on Hyper models.
• Cut-off operation conditions

• : Cut-off (drain)
x: Not actuated (to main control valve)
More than Less than

- 15.7 MPa 15.7 MPa
(160 bar) (160 bar)
Standard
specification – • x
machine
Operation
1. When the work equipment valve is held
The oil at the switch pump (the oil from the
steering valve) presses up check valve (1),
merges with the oil from the work equipment
pump and flows to the work equipment valve.
2. When the work equipment valve is activated

1) When the work equipment pump pres-
sure is lower than the cut-off pressure
As when the work equipment valve is
held, the oil at the switch pump (the oil
from the steering valve) presses up check
valve (1), merges with the oil from the
work equipment pump and flows to the
work equipment valve.
10-234
2) When the work equipment pump pres-
sure is higher than the cut-off pressure
When the cut-off pressure is reached, the
pressure of the oil in chamber a opens cut-
off valve (2), and the oil in unload valve (3)
chamber b passes through cut-off valve (2)
chamber c and is drained. The oil in unload
valve (3) chamber d passes through ori-
fices e and f, and into chamber b causing
the oil pressure in chamber d decrease,
and unload valve (3) to open. Thus, the oil
from the switch pump is drained.
10-235
FLOAT SELECTOR VALVE AND UNLOAD VALVE
Function
• The float selector valve and unload valve are inside
the main control valve. When the boom lever is
operated to the FLOAT position, the float selector
valve detects this, and it is actuated to actuate the
unload valve and set the boom to the FLOAT posi-
tion.
Operation
• If the boom lever is pushed further from the LOWER
position, it is set to the FLOAT position and the
PPC valve is set to the same condition as for the
LOWER position.
The pressure at port A becomes high pressure and
the pressure at port B becomes low pressure.
• The oil from the working pump fills chamber F and
chamber E.
• If the difference in pressure between port A and

port B becomes greater than the specified pres-
sure, float selector valve (2) is moved to the right,
and port C and port D open.
• When port C is opened, the oil pressure in chamber
E drops, unload valve (4) is moved up in the direc-
tion of the arrow, and the oil from the steering valve
flows to the drain circuit, and also flows to the rod
end of the lift cylinder.
The oil at the bottom end of the lift cylinder is con-
nected to the drain circuit and forms the FLOAT
position.
10-236

BOOM AND BUCKET SPOOL HOLD POSITION
Operation • The oil from the PPC pump passes through

• The oil enters port A from the pump, and the maxi- check valve (13), and enters port L of the
mum pressure is set by relief valve (11). PPC valve. However, the boom and bucket
• Bucket spool (1) is at the HOLD position, so the levers are at the HOLD position, so the oil
bypass circuit is open and the oil at port A passes returns to the hydraulic tank from PCC relief
around the spool and flows to port B. Boom spool valve (12).
(2) is also at HOLD, so the bypass circuit is open
and the oil at port B passes around the spool, en-
ters port C of the drain circuit, passes through the
filter, and returns to the tank.
10-237

BOOM SPOOL AT RAISE POSITION
Operation The bypass circuit is closed by the spool, so

• When boom lever (3) is pulled, the oil flows from the oil pushes open check valve (10). The
port L of the PPC valve to port N and port S. In oil flows from port H to port 1, and flows to
addition, the oil at port T passes through port M and the cylinder bottom.
flows to the drain circuit. • At the same time, the oil at the cylinder rod
The oil pressure at port S pushes boom spool (2) end enters drain port C from port K and re-
and moves it to the RAISE position. turns to the tank. Therefore, the boom rises.
• The oil from the pump passes through the bypass
circuit of the bucket spool and flows to the bypass
circuit of boom spool (2).
10-238

BOOM SPOOL AT LOWER POSITION
Operation The bypass circuit is closed by the spool, so

• When boom lever (3) is pushed, the oil flows from the oil pushes open check valve (10). The
port L of the PPC valve to port M and port T. In oil flows from port J to port K, and flows to
addition, the oil at port S flows to the drain circuit. the cylinder rod end.
Theoil pressure at port T pushes boom spool • At the same time, the oil at the cylinder bot-
(2) and moves it to the LOWER position. tom enters drain port C from port I and re-
• Theoil from the pump passes through the turns to the tank. Therefore, the boom goes
bypass circuit of the bucket spool and flows to the down.
bypass circuit of boom spool (2).
10-239

BOOM SPOOL AT FLOAT POSITION
Operation
• When boom lever (3) is pushed to the FLOAT posi- and connects to the drain circuit. When port
tion, the PPC valve spool moves beyond the LOWER C1 is connected to the drain circuit, unload
position to the FLOAT position. The pressure oil at valve (8) moves up and the oil from the pump
port L flows to port M, and at the same time, it also flows to the drain circuit.
flows to port T and port W. In addition, the pressu- • Therefore, the oil at the cylinder rod end
rized oil at port S flows to port N. passes from port K through unload valve (8)
• The pressurized oil at port T pushes boom spool (2) and flows to the drain circuit. The oil at the
to the LOWER position. cylinder bottom flows from port I to port C,
• If a difference in pressure greater than the specified and then flows to the drain circuit. There-
pressure is generated at port W and port X, valve fore, the boom is set to the FLOAT condition.
(7) moves to the right, opens port C1 and port C,
10-240

BUCKET SPOOL AT DUMP POSITION
Operation The oil from check valve (9) flows from port
• When bucket lever (4) is pushed, the pressure oil at F to port G, and then flows to the cylinder
port L of the PPC valve flows from port 0 to port V. rod end.
In addition, the oil at port R flows to the drain circuit. • At the same time, the oil at the cylinder bot-
The pressure oil at port V moves bucket spool (1) tom flows from port D to drain port C, and
to the DUMP position. returns to the tank, so the bucket is dumped.
• The bypass circuit is closed by bucket spool (1), so
the oil from port A pushes open check valve (9).
10-241

BUCKET SPOOL AT TILT POSITION
Operation
• When bucket lever (4) is pulled, the pressure oil at • The bypass circuit is closed by bucket spool
port L of the PPC valve flows from port P to port R. (1), so the oil from port A pushes open check
In addition, the oil at port V flows to the drain circuit. valve (9). The oil from check valve (9) flows
The pressure oil at port R moves bucket spool (1) from port D to port E, and then flows to the
to the TILT position. cylinder bottom.
• At the same time, the oil at the cylinder rod
end flows from port G to drain port C, and
returns to the tank, so the bucket is tilted.
10-242

AUFBAU UND FUNKTION HYDRAULIC SAFETY SYSTEM
HYDRAULIC SAFETY SYSTEM

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

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

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

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

the engine breaks down, or there is a hydraulic oil
leak and the oil level in the hydraulic tank drops to a
minimum.
Pressure in the pipe (4) drops, because the float valve
opens when the oil level in the hydraulic tank drops or
the pumps or the engine are not running. Because of
the drop in pressure in the pilot pipe (4) the safety
valve (5) switches over and the hydraulic oil is di-
rected through the safety valve, through the return
pipe (7) back to the hydraulic tank.
10-243

HYDRAULIC SAFETY SYSTEM LOCATION

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

2. Float valve 6. Main working hydraulic pipe
3. Restricted connection 7. Oil return pipe
4. Pilot pipe 8. Switch pump pressure pipe
10-244

HYDRAULIC SAFETY VALVE

1. Housing
2. Valve piston
3. Spring
Function:
• If a leak occurs between the safety valve and one
of the working cylinders in one of the pipes or the
main hydraulic valve, the safety valve directs the
main oil flow back to the hydraulic tank.
If the oil level in the hydraulic tank drops to a
minimum, so that the float valve opens, the safety
valve directs the oil flow from the main working
circuit back to the hydraulic tank.
Float valve
10-245

10-246
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
1. Bucket 4. Boom cylinder

2. Bellcrank 5. Boom
3. Bucket cylinder 6. Bucket link
10-251
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
10-252
STRUCTURE AND FUNCTION BUCKET
BUCKET
1. Bucket
2. Bolt-on cutting edge
3. Bucket tooth
10-253
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
1. Proximity switch
2. Proximity switch
3. Bucket cylinder rod
4. Lever
5. Plate
10-254
BUCKET POSITIONER
• The bucket positioner is an electrically actuated
system which is used to set the bucket to the
desired angle when the bucket is moved from
the DUMP position to the TILT position. When
the bucket reaches the desired position, the
bucket lever is returned from the TILT position
to the HOLD position, and the bucket is auto-
matically set to the suitable digging angle.
• Lever (4) is secured to bucket cylinder rod (3)
by bolts. In addition, proximity switch (1) fixed
to the cylinder by bolts.
• When the bucket is moved from the DUMP
position to the TILT position, the bucket cylin-
der rod moves to the left, and at the same time,
lever (4) also moves to the left. Proximity switch
(1) separates from lever (4) at the desired posi-
tion, and the bucket lever is returned to neutral.
BOOM KICK-OUT
• The boom kick-out is an electrically actuated
system. It acts to move the boom lever to the
HOLD position and stop the boom at the de-
sired position before the boom reaches the maxi-
mum height.
• Plate (5) is fixed to the boom. In addition, prox-
imity switch (2) is fixed to the frame.
When the boom is moved from the LOWER
position to the RAISE position, the boom rises,
and when it reaches the desired position, the
proximity switch and lever come together and
the system is actuated to return the boom lever
to the HOLD position.
10-255
Operation of proximity switch
Boom RAISE
• When the boom is lower than the set position
for the kick-out, the detector (steel plate) is not
above the detection surface of the proximity
switch, so the proximity switch load circuit is
shut off.
The relay switch is turned OFF and the current
for the solenoid is shut off.
• When the boom lever is moved to the RAISE

position, the boom spool is held at the RAISE
position by the cam follower and cam on the
lever, and the boom rises.
10-256
• When the boom rises and reaches the set posi-

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

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

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

(solenoid circuit)
10-257
Operation of proximity switch

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

position, the DUMP spool is held at the TILT
position by the cam follower and cam on the
lever, and the bucket tilts.
10-258
• When the bucket tilts and reaches the set posi-

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

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

(relay switch circuit)
Relay switch load circuit

Current is shut off Current flows
(solenoid circuit)
10-259
10-260
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Sensors:
1. Fuel level
2. Engine water level
3. Torque converter oil temperature
4. Engine water temperature
5. Engine oil level
6. Brake oil pressure
7. Engine oil pressure
8. Air cleaner clogging
Outline
• The machine monitor system uses the sensors • The displays can be broadly divided into the
and other devices installed to various parts of following: Cautions displayed on the monitors
the machine to observe the condition of the (abnormalities in the machine where an alarm
machine. It processes this information swiftly is given) and normal conditions which are al-
and displays it on the monitor panel to inform ways displayed on the instrument panel (pilot
the operator of the condition of the machine. lamps and readings for the gauges, speedom-
• The machine monitor system consists of the eter, and service meter).
main monitor, maintenance monitor, sensors, • There are also various switches built into the
switches, relays, alarm buzzer, and power monitor panel which function to operate the ma-
source. chine.
10-281
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
4H 4D 4E 4A 4C 4B 1 2
3A 4I
5A WORK MODE
5D
H S Ec
5E
MANUAL 5F
5C 5G
4J 4G
SDW0b228
1. CHECK lamp 5. Switches
2. CAUTION lamp 5A.** Work mode selection switch
3. Caution item 5C. ALS (if equipped)
3A. Emergency steering actuated 5D. Working lamp (front) switch
4. Pilot item 5E. Working lamp (rear) switch
4A. Turn signal (left) 5F. Transmission cut-off switch
4B. Turn signal (right) 5G.* Auto shift transmission pilot switch
4C. Hi beam
4D. Shift indicator ** Pos. 5A (added), Serial number: WA470H21164 and up
4E. Speedometer * Pos. 5G (added), Serial number: WA470H21104 and up
4F. Hold position
4G. Parking brake
4H. Emergency steering normal
4I. Preheating
4J. Failure action code
Outline
• The main motor has a display function for the • A liquid crystal display and LEDs are used for
speedometer and other gauges and a switch- the display. The switches are embossed sheet
ing function to control the electric components switches.
and controllers.
• There is one CPU (Central Processing Unit)
installed internally, and this processes the sig-
nals from the sensors and outputs the display.
10-282

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

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

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

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

specification When shift is held Display lights up
machine)
Digital display (display switches

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

failure and action by Digital display
Failure operator is needed, Buzzer sounds
action Failure action code CALL is displayed, (For details of the travel data
code or CALL and E oo display mode, see TROUBLE
(action code) are DATA DISPLAY MODE)
displayed in turn
10-283
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
E.C.S.S. function is actuated or Lights up E.C.S.S. function actuated

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

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

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

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

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

road driving (H, S) off High and standard mode
low fuel consumption stopped
** (added) Serial number: WA470H21164 and up

* (added) Serial number: WA470H21104 and up
10-284

TROUBLE DATA DISPLAY MODE
Item Switch operation Actuation
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and
trouble data display switch turned ON, press 2nd switch failure code is displayed on speedometer
mode from top on left side of main display and time elapsed since failure is
monitor (switch below emergency displayed on failure action code display.
steering display) and working lamp (1) Failure code is a two-digit display
(front) switch simultaneously given in numbers or letters.
for at least 5 seconds. The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item.
Clearing failure code Press working lamp (rear) switch Failure code and time elapsed since
for at least 2 seconds failure being displayed are cleared.
Failure code for problem now occurring
(flashing display) cannot be cleared.
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch
simultaneously for at least
5 seconds, or start the engine.
10-285
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
1. Check items (Checks before 3. Gauge items 6. Monitor module

starting) 3A. Fuel level 7. Switch module
1A. Engine water level 3B. Engine water tempera-
1B. Engine oil level ture
2. Caution items (warning 3C. Torque converter oil
items) temperature
2A. Engine oil pressure 5. Service meter
2B. Battery charge 5A. Service meter numeric
2C. Brake oil pressure display
2D. Air cleaner 5B. Service meter RUN pilot
(1A. Engine water level) lamp
Outline
• The maintenance monitor has a display function for • The monitor module has a built-in CPU (Cen-
the caution items and gauges, and switch functions tral Processing Unit). It processes the signal
to control the work equipment controller (if equipped). from the sensors, and carries out the display
• The maintenance monitor consists of the monitor and output.
module, switch module, service meter, case, and • A liquid crystal display and LEDs are used
other mechanisms. for the display portions. The switches are
embossed sheet switches.
10-286
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR DISPLAY FUNCTION
Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Check Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
CHECK lamp flashes
Engine water level Below low level Displays when engine is running
Display when normal: OFF
Display when abnormal: Flashes
Engine oil pressure Below specified CAUTION lamp flashes
pressure Buzzer sounds
Brake oil pressure Below specified

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

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

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

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

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

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

temperature applicable level
Flashes when level is 6 or 7
10-287
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
E.C.S.S. function is actuated or Lights up E.C.S.S. function actuated

E.C.S.S.
stopped each time switch is
(if equipped)
pressed Goes out E.C.S.S. function stopped
Front working lamp lights up

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

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

Transmission
actuated or stopped each time
cut-off
switch is pressed Goes out Cut-off function stopped
10-288
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
SYSTEM STRUCTURE DIAGRAM

A: Analog signal
No. Input No. Output
(D) (D)
1 Directional switch signal (1) F SOL
à (D) à
2 Range switch signal (D) (2) R SOL
à (D) à
3 Transmission cut-off signal (D) (3) HL SOL
à (D) à
4 Kick-down switch signal (D) (4) SP SOL
à (D) à
5 Hold switch signal Transmission (A) (5) Modulation valve solenoid
à (D) controller à
6 Neutralizer relay signal (P) (6) Engine speed signal
à (P) à
7 Travel speed signal (D) (7) Kick-down signal
à (P) à
8 Engine speed signal (D) (8) Alarm buzzer signal
à à
Model (engine) (D) (N) (9) Hold signal
9 à à
selection signal (N) (10) Buzzer signal
à
(N) (11) Failure code
à
D: Digital signal
P: Pulse signal
N: Network signal
CONTROL FUNCTION
Auto shift
Hold function
Kick-down function
Safety function
Troubleshooting
Model (engine) selection function
Outline
The auto-shift control system receives the position
signals from the directional lever and range lever,
the engine speed signal, travel speed signal, and
signals from other switches. The transmission con-
troller drives the speed solenoid valve and auto-
matically carries out shift control to select the opti-
mum speed range for the transmission.
10-289
SHIFT CONTROL SYSTEM FUNCTION

The F and R solenoids correspond to the F and
INPUT SIGNALS R positions of the directional lever.
1. Directional lever Positions 1 to 4 of the speed lever actuate the
This selects F (FORWARD), R (REVERSE), H-L solenoid and speed solenoid to select the
and N (Neutral). clutches to give the 1st to 4th transmission
2. Speed lever speeds. This combination is then output to the
This selects the optimum speed range when transmission. (See Table 1)
using auto-shift FORWARD or REVERSE. Nor-
mally, if the speed lever is at position 2 or above,
the transmission will be set to 2nd when the
machine starts. Table 1 Transmission solenoid output
When the auto shift used, and the gear shift
lever is moved 4 à 3 à 2 à 1 when the Speed
Solenoid Clutch
machine is traveling with the transmission in range
force, the transmission will also shift down im- F R HL SP F R 1 2 3 4
mediately 4 à 3 à 2 à 1. (Priority given to N ¡
speed lever!)
F1 ¡ ¡ ¡¡
3. Engine speed sensor
When the engine is running at low speed (less F2 ¡ ¡ ¡
than 1450 rpm), the auto shift is stopped. When F3 ¡ ¡ ¡ ¡
shifting between forward and reverse or when F4 ¡ ¡ ¡ ¡ ¡
coasting, the present speed range is maintained R1 ¡ ¡ ¡ ¡
and the shift shock is reduced.
R2 ¡ ¡ ¡
When the machine is traveling in 2nd, and the
engine speed changes from low speed (less R3 ¡ ¡ ¡ ¡
than 1450 rpm) to high speed (more than 1450 R4 ¡ ¡ ¡ ¡ ¡
rpm), the speed range is kept at 2nd to allow
the machine to accelerate more easily.
4. Travel speed sensor
The speed range is determined according to 2. Modulation output
the travel speed. In addition, the change in speed There is a data map for each shift pattern, and
is determined from the pulse count to decide the solenoid command current is controlled ac-
whether to shift up or down. cording to the data to reduce the shift shock
5. Neutralizer when engaging the clutches. (See Table 2)
The parking brake actuation signal is input to 3. Hold function (maintaining present speed range)
the controller and the transmission is shifted to When the hold switch is turned ON, the existing
neutral. speed range is held, and even if the travel speed
6. Transmission cut-off signal goes down, the transmission does not shift
When the controller receives the transmission down. However, if the direction of travel is shifted
cut-off signal, it shifts the transmission to neu- between forward and reverse, the transmission
tral. After the signal is canceled, it selects a shifts down, and then it shifts up to the speed
speed range that matches the travel speed at range according to the change in the condi-
that point. tions. (This prevents any unnecessary shift down
OUTPUT SIGNALS on level ground or unnecessary shift up when
1. Transmission solenoid output traveling downhill.) (See Table 2, Item 4)
10-290
4. Kick-down function Directional lever at R, speed lever at 4

If the operator wishes, he can override all the The transmission range is shifted according to
automatic conditions and shift down forcibly to the travel speed in the same way as for a).
1st (when traveling at below 13.1 km/h in 4th or 2. Changing direction (switching between forward
3rd, or when traveling at any speed in 2nd). and reverse)
(See Table 2, Item 5) (When the directional lever is shifted to the op-
When the travel speed increases, the transmis- posite direction from the direction of travel)
sion is shifted up in accordance with the auto If the travel speed and engine speed are in
shift up conditions, or it is shifted to 2nd when area I in Fig. 2, the transmission output shifts to
the direction is shifted between forward and re- 2nd speed in the same direction as the direc-
verse. tional lever regardless of the speed range. Fol-
This function is also available when holding the lowing this, the transmission shifts up to match
speed range (hold, engine at low speed). the travel speed. (See Table 2, Item 6)
SHIFT CHARACTERISTICS Example:
1. Auto shift (see Table 2, Item 1) Directional lever: F à N à R
When the engine speed is above 1450 rpm, the Transmission output:
transmission is shifted as follows according to F4 à N à R2 à R3 à R4
the travel speed. In area II in Fig. 2, the transmission output re-
a) FORWARD verses, but the speed range shifts down to 2nd
Directional lever at F, speed lever at 4 in accordance with the travel speed. Then, after
Shift up the actual direction of travel of the machine
(i) When starting, the transmission is set to changes to the same direction as the direc-
the F2 torque converter range. tional lever, the transmission shifts up in ac-
(ii) When the accelerator pedal is depressed, cordance with the travel speed. (To prevent dam-
the engine speed rises and the machine age to the clutch) (See Table 2, Item 7)
travels faster. If the engine speed contin- However, when the hold function is ON, the
ues to rise and the travel speed reaches transmission does not shift down.
9.4 km/h (10.0 km/h), the transmission is Example:
shifted up to F3. Directional lever: F à N à R
If there is insufficient acceleration, the trans- Transmission output:
mission shifts up when the travel speed F4 à N à R4 à R3 à R2
reaches the figure shown in ( ). (The transmission shifts down while the ma-
(iii) Immediately after the transmission shifts up, chine is coasting in forward)
the engine speed will drop momentarily, but R2 à R3 à R4
if the machine continues to travel faster and (The machine shifts up when traveling in
the travel speed reaches 18.6 km/h, the reverse)
transmission is shifted up to F4. However, if the speed lever is at 1, the trans-
mission remains in 1st.
Shift down 3. Switching F – N – F (R – N – R) (lever re-
(i) If the machine is traveling in F4 and the turned)
load increases, the transmission will shift A speed range that matches the speed is se-
down F3 if the travel speed drops below 16 lected. (See Table 2, Item 8)
km/h. 4. Skip shift
(ii) If the travel speed drops further to 10.0 km/ When the machine is coasting in 3rd or 4th
h (9.4 km/h), the transmission is shifted (engine speed below 1400 rpm), and the accel-
down to F2. erator pedal is depressed (engine speed above
If there is insufficient deceleration, the trans- 1400 rpm), the speed range is held if the travel
mission shifts down when the travel speed speed is more than 7.6 km/h in 3rd, or 8.7 km/
reaches the figure shown in ( ). h in 4th. If the travel speed is less than 7.6 km/
With the auto shift, the transmission does h in 3rd, or 8.7 km/h in 4th, the transmission is
not shift down to 1st even if the travel speed shifted down to 2nd to make it easier to accel-
drops. erate. (See following page: table 2, Item 3)
Normally, the transmission shifts to 1st only if
the speed lever is placed at 1 or if the kick-
down switch is pressed.
b) REVERSE
10-291
5. No-shift time Fig. 1 Automatic gear shift graph (High mode)

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

Kickdown has priority over gear hold. If shift
down from 4th, 3rd or 2nd is operated to 1st
gear by use of Kickdown then 1st gear is fixed
by using the gear hold switch. The machine will
select 1st or 2nd gear according to directional Fig. 3 Bidirectional change lever / gear position
change of lever`s position. Bidirectional change Gear Position:
lever position:
FàNàF F1àNàF1
RàNàR R1àNàR1
FàNàRàNàF F1àNàR2àNàF2
RàNàFàNàR R1àNàF2àNàR2
Table 2: Gear shift characteristics
Item Clutch Speed (km/h) No-shift time (sec)
1.Normal gear shift 1→2 Min. 5,5 (5,8) 2
2→3 Min. 9,4 (10,0) 2
3→4 Min. 18,6 1
4→3 Less than 16,5 1
3→2 Less than 10,0(9,4) 2
*(Economy / Standard mode) 2→3 Min. 7,0 2
2.Engine speed 4→2 Less than 1,1 0

(less than 1450 rpm) 3→2 Less than 1,1 0
3.Engine speed (less than 1450 rpm 4→2 Less than 8,7 2
→ more than 1450 rpm) 3→2 Less than 7,6 2
4.Shifting up when hold is ON 1→2 Min. 5,5 0

2→3 Min. 9,4 0
3→4 Min. 18,6 0
5.Kick-down 2→1 Whole range 5

OFF → ON 3→1 Less than 13,1 5
4→1 Less than 13,1 5
6.Directional lever 4→2 Note 1) 2
(Area I) (F →) N → R 3→2 ––– 2
(R →) N → F 1→2 2
7.Directional lever →4 Min. 18,6 0
(Area II) (F →) N → R →3 Less than 16,0 - 18,6 0
(R →) N → F Note 2) 0
8.Directional lever →4 Min. 18,6 0

F→N→F →3 Less than 9,4 - 18,6 0
R→N→ R →2 Less than 9,4 0
Note 1: Engine speed less than 2000 rpm and travel speed less than 16 km/h, or travel speed less
than13 km/h.
Note 2: When engine speed is more than 2000 rpm → 3 if travel speed is 13 km/h to 18.0 km/h
See Fig. 2, for details of Area I and Area II. * Serial number: WA470H21164 and up
10-292

SAFETY FUNCTION TROUBLESHOOTING

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

If the speed lever is shifted down when traveling
2016
downhill, the transmission is shifted down im-
mediately to make use of the braking force of
the engine.
MODEL SELECTION FUNCTION
5. Manual shift
If there should be any disconnection in the travel Model selection
speed sensor or any other failure, and the input
of the travel speed stops, the lever operation • The model is selected using the CN ENG
becomes manual. plug. This informs the transmission controller
of the type of engine. A dummy plug is lo-
Example: cated on this connection on the Komatsu
Directional lever F, speed lever 4 à F4 engine. This ensures that the correct data
Directional lever R, speed lever 2 à R2 records for switching control are activated in
the transmission controller.
10-293
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
1. Connector
CONNECTOR SIGNALS
CN1 CN2 CN3

1 NETWORK signal 1 Directional switch F 1
2 2 Range switch 2 2
3 Modulation valve, Sol (+) 3 Range switch 4 3
4 4 Neutralizer relay signal 4 Travel speed signal (+)
5 5 5 Engine speed signal
6 6 6 Kick-down signal output
7 7 Engine selection CN ENG 7
8 Power source input (+24V) 8 Engine selection CN ENG 8
9 GND 9 Signal GND output 9
10 HL, Sol 10 10
11 SP, Sol 11 Directional switch F 11
12 NETWORK signal 12 Directional switch R 12 Travel speed signal (–)
13 Sensor power source (+24V) 13 Range switch 1 13
14 Modulation valve, Sol (–) 14 Range switch 3 14 Engine speed signal output
15 15 15 Buzzer signal output
16 16 Transmission cut-off switch 16 Brake signal output
17 Solenoid power source input (+24V) 17 Kick-down switch
18 Power source input (+24V) 18 Hold switch
19 GND 19
20 R, Sol 20
21 F, Sol
10-294
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
COMBINED T/M AND ALS-CONTROLLER
CN1 Connector
CN2 Connector
CN3 Connector
CONNECTOR SIGNALS
CN1 (CNL29) CN2 (CNL30) CN3 (CNL31)

1 NETWORK signal 1 Directional switch F 1
2 2 Range switch 2 2
3 Modulation valve, Sol (+) 3 Range switch 4 3 ALS selected
4 4 Neutralizer relay signal 4 Travel speed signal (+)
5 5 Automatic OFF 5 Engine speed signal
6 6 ECSS-Switch 6
7 Sol. 3 (+) (Lo) 7 Engine select 7 Sol. 1 (+)
8 Power source input (+24V) 8 Engine select 8
9 GND 9 Signal GND output 9* Work mode input
10 HL, Sol 10* Work mode output 10
11 SP, Sol 11 Directional switch N 11
12 NETWORK signal 12 Directional switch R 12 Travel speed signal (–)
13 Sensor power source (+24V) 13 Range switch 1 13
14 Modulation valve, Sol (–) 14 Range switch 3 14 Engine speed signal output
15 15 Pressure switch (ALS off) 15 Buzzer signal output
16 Sol. 3 (-) (Lo) 16 Transmission cut-off switch 16 Sol. 2 (+) (Hi)
17 Solenoid power source input (+24V) 17 Kick-down switch * Serial number: WA470H21164
18 Power source input (+24V) (BR) 18 Hold switch
19 GND 19 ECSS select
20 R, Sol 20 20 km/h select
21 F, Sol * Serial number: WA470H21164
10-295

10-296
STRUCTURE AND FUNCTION E.C.S.S.
E.C.S.S. (Electronic Controlled

Suspension System)
1. E.C.S.S. (Electronic Controlled Suspension Sys-
tem)
• This system uses a combination of relieving the
hydraulic oil from the work equipment and
switching ON/OFF an accumulator which is
charged with high pressure gas. The controller
carries out automatic control of these in accord-
ance with the travel condition of the machine to
give resilience to the up and down movement
of the work equipment and to suppress the vi-
bration of the chassis when traveling at high
speed. In this way, it improves the ride for the
operator, prevents spillage of the load, and im-
proves the operating efficiency.
• Special solenoid valves (ON-OFF valves) are
used to control the ON-OFF switching of the
accumulator (high pressure, low pressure) and
the opening and closing of the relief valves.
• With this system, it is possible to handle all four
models with the same system simply by chang-
ing the connections of the model selection wir-
ing harness.
Serial communication
2. Structure of system Main-

monitor + 24V
• The E.C.S.S. consists of the following electronic
→
devices.
Solenoid
1) E.C.S.S controller (M type controller) Travel speed sensor (relief)
2) Input devices: E.C.S.S switch (system +
Solenoid
switch), pressure switch (boom cylinder bot-
tom pressure), travel speed sensor, model - E.C.S.S.
(High pressure accumulator)
Pressure switch
selection wiring harness, speed range se- Solenoid
controller
lection wiring harness (Low pressure
accumulator)
3) Output devices: solenoid valves (relief valve,
high pressure accumulator, low pressure ac- Speed range
selection
cumulator)
Serial communication
→ to main monitor
Model selection
wiring harness
10-311
3. Content of control
• In response to the input on the left side of the
table below, the controller carries out the output
on the right side to control the system.
¡: ON
Note 1: The E.C.S.S system is switched ON-OFF
x: OFF
Input Output
E.C.S.S switch Speed range [Note 2] Travel Solenoid Solenoid Solenoid
Pressure
(system ON-OFF) speed (1) (2) (high (3) (low
switch
[Note 1] H-L Speed [Note 3] (relief) pressure) pressure)
1 OFF – – – – x x x
ON ON
2 ON OFF Min. 5 km/h ON ¡ ¡ x

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

OFF OFF
4 OFF ON – – x x x
Min. 5 km/h
5 – –
[Note 4]
– x x x
by operating the E.C.S.S switch on the Note 3: Input pulse frequency when travel speed
main monitor. is 1 km/h
When the system is ON, the E.C.S.S LED Model Pulse frequency (Hz)
display on the main monitor lights up.
WA320-3 54.41
The ON-OFF condition of the system is
retained even after the engine stops or WA380-3 47.70
the starting switch is turned OFF. The next WA420-3 40.96
time that the starting switch is turned ON, WA470-3 44.46
the system is set to the same condition as
before it was turned OFF. Note 4: If the travel speed exceeds 5 km/h when
(Main monitor function) the output is OFF, the output is turned
Starting switch OFF à Machine stops à ON.
Starting switch ON When the output is ON, the output stays ON
When system is ON à System ON
[
When system is OFF à System OFF
] until the travel speed reaches 3 km/h, and
when the travel speed goes below 3 km/h,
Note 2: Relationship between speed range signal the output is turned OFF.
and shift position
Speed range
Shift position
H-L Speed
1st OFF ON
2nd OFF OFF
3rd ON OFF
4th ON ON
ON: +24V, OFF: OPEN
10-312
4. Self-diagnostic function
• This system always observes the condition of
the system, and displays the condition of the
system (LED code, see table below) in the con-
troller self-diagnostic display portion.
• If there is any abnormality in the controller itself
or in the input or output devices, the controller
carries out troubleshooting of the abnormality. It
turns all the output OFF and displays the error
code (failure code) in the self- diagnostic dis-
play portion and the main monitor.
LED codes
1) Displays on controller
LED Condition
Content
display of system
01 Selects model as WA320-3
Normal
Pressure switch ON
55
(displays only when ON)
Error in solenoid (relief)
d0
system
Error in solenoid
d1
(high pressure) system
Error Error in solenoid
d2 Abnormal
code (low pressure) system
Abnormality in travel speed
d3
sensor system
Abnormality in model
d4 selection (non-available
combination is selected)
• Error code displays [E] à [dx] (where x is a

numeral from 0 to 4 in the table above)
repeatedly in turn.
• If more than one abnormality occurs at the
same time, all the appropriate error codes
are displayed in turn.
• When the starting switch is turned OFF
(controller power OFF, the error codes are
reset and not written to memory.
• When checking the LED display, read the
code with the connector facing down.
2) Displays on main monitor
• For details, see MAIN MONITOR TROU-
BLE DATA DISPLAY.
10-313
5. Controller
1. ECSS-Controller
2. Self-diagnostic display
CN1 Connector
CN2 Connector
CN3 Connector
Input/output signals
CN1 CN2 CN3
Input/ Input/ Input/
No. Name of signal No. Name of signal No. Name of signal
output output output
1 Serial signal – 1 Model selection Input 1 – –
2 – – 2 Model selection Input 2 – –
3 – – 3 Model selection Input 3 – –
4 – – 4 Model selection (Parity) Input 4 Travel speed sensor (+) Input
5 – – 5 – – 5 – –
6 – – 6 – – 6 – –
7 – – 7 – 7 – –
8 Power source input (+24V) – 8 Pressure switch Input 8 – –
9 GND – 9 – – 9 – –
10 – – 10 – – 10 – –
11 Solenoid (low pressure) Output 11 – – 11 – –
12 Serial signal – 12 – – 12 Travel speed sensor (–) Input
13 – – 13 Travel speed H-L Input 13 – –
14 – – 14 Travel speed SPEED Input 14 – –
15 – – 15 SAS SW Input 15 – –
16 – – 16 – – 16 – –
Solenoid power source 17 – –
17 –
input (+24V) 18 – –
18 Power source input (+24V) – 19 – –
19 GND – 20 – –
20 Solenoid (high pressure) Output
21 Solenoid (relief) Output
Model selection table

CN2-1 CN2-2 CN2-3 CN2-4
WA320-3 x x x ¡
WA380-3 x x ¡ x
WA420-3 x ¡ x x ¡: GND
WA470-3 x ¡ ¡ ¡ x: OPEN
10-314
E.C.S.S.-SYSTEM
10-315
E.C.S.S.-SYSTEM (E.C.S.S.-PLUS)
SN WA470H20526 to WA470H20567
10-316
E.C.S.S.-ELECTRIC-CIRCUIT DIAGRAM
10-317
STRUCTURE AND FUNCTION ALS
ALS-CONTROL UNIT
Connections: 1. Two - way valve

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

accumulator assembly
10-318

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

2. Lift cylinde 2. Electrically controlled 3/2 valve
3. ALS-control unit with connections: 3. Electrically controlled 2/2 valve
A Lift cylinder piston side 4. Pressure reducing valve
B Lift cylinder piston rod side 5. Pressure cap, oil side
P Working hydraulic pressure 6. Check valve
T Return oil to the tank 7. Accumulator unit
M Pressure check point
Sp Connections for further accumulators
(1 accumulator for WA380-3H)
(2 accumulators for WA420-3/WA470-3)
10-319
10-320
STRUCTURE AND FUNCTION SENSORS
SENSORS
Function
• The sensors are a contact type sensor with one
end grounded to the chassis. The signal from
the sensor is input directly to the monitor panel,
and when the contacts are closed, the panel
judges the signal to be normal.
However, the engine oil pressure uses a relay
to reverse the sensor signal.
Sensor detection Sensor When When

item method normal abnormal
Electro-
Speed sensor magnetic
Engine oil level Contact ON OFF
Radiator water
level Contact ON OFF
Engine oil
pressure Contact OFF ON
Engine water
temperature Resistance
Torque converter
oil temperature Resistance
Engine speed Electro-

sensor magnetic
Fuel level sensor Resistance
SPEEDOMETER SENSOR
Function
• The speedometer sensor is installed to the trans-
mission output gear. A pulse voltage is gener-
ated by the rotation of the gear teeth, and the
signal is sent to the machine monitor to display
the travel speed.
1. Connector
2. Magnet
3. Case
10-331
ENGINE SPEED SENSOR
1. Magnet Function
2. Terminal • The engine speed sensor is installed to the ring
3. Case gear portion of the flywheel housing. A pulse
4. Boot voltage is generated by the rotation of the gear
5. Connector teeth, and a signal is sent to the controller and
monitor panel.
ENGINE OIL PRESSURE SENSOR
1. Plug Function
2. Contact ring • This sensor is installed to the engine block and
3. Contact the diaphragm detects the oil pressure. If the
4. Diaphragm pressure goes below the specified pressure, the
5. Spring switch is turned ON, and a relay is actuated to
6. Terminal turn the output OFF. This makes the mainte-
nance monitor flash to warn of the abnormality.
The caution lamp and alarm buzzer are also
actuated at the same time to warn of the abnor-
mality.
10-332
Fitting a new inductive rpm sender unit
All gear boxes for WA-3H, Cummins - engines in

WA 320/420
• Check that one gear tooth is in the centre of the sender

mounting opening.
• Screw in the new sender (hand tight) until it just touches

the gear tooth.
• Screw out 1 - 1.5 turns and lock.
Komatsu - engines S6 D125 and S6 D108 (WA380/470)
• The fly wheel of the Komatsu engine have 6 pins fitted

on the flywheel side around the circumfrence, on the
side of the flywheel seen from the starter motor side.
These are used to give the rpm signal to the inductive
rpm sender unit.
• To fit a new sender check that one of the pins is in the

middle of the sender unit mounting hole. Screw in the
new sender unit hand tight until it just touches the
pin.
• Screw out 1 - 1.5 turns and lock.
10-333
RADIATOR WATER LEVEL SENSOR
1. Float Function
2. Sensor • This sensor is installed to the top of the radia-
3. Connector tor. If the coolant goes below the specified level,
the float goes down and the switch is turned
OFF. The caution lamp and alarm buzzer are
also actuated at the same time to warn of the
abnormality.
ENGINE OIL LEVEL SENSOR
1. Connector Function
2. Bracket • This sensor is installed to the side face of the
3. Float oil pan. When the oil goes below the specified
4. Switch level, the float goes down and the switch is
turned OFF. This makes the maintenance moni-
tor flash to warn of the abnormality. The check
lamp also lights up at the same time to warn of
the abnormality.
10-334
FUEL LEVEL SENSOR
2. Float • The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down as the level of the fuel changes. As the
5. Spring float moves up and down, the arm actuates a
6. Contact variable resistance, and this sends a signal to
7. Spacer the sub monitor to display the fuel level. When
the display on the maintenance monitor reaches
the specified level, the warning lamp flashes.
10-335
ENGINE WATER TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR
2. Plug • These sensors are installed to the engine cylin-
3. Thermistor der block and transmission case. The change
in the temperature changes the resistance of
the thermistor, and a signal is sent to the main-
tenance monitor to display the temperature. If
the display on the sub monitor reaches the speci-
fied position, the lamp flashes and the buzzer
sounds to warn of the abnormality.
10-336
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT Up to SN WA470H20668
Function • When the motor rotates, terminal D also ro-

• There is neutral safety circuit which prevents the tates at the same time. When the non-con-
engine from being started if the directional lever is tinuous portion of terminal D reaches termi-
not at the N position. This is to ensure safety when nal B, the circuit from terminal A to B opens,
starting the engine. and the current from the battery to the motor
is shut off. The motor attempts to continue
Operation rotating under inertia, but when the continu-
• When the directional lever is placed at the N posi- ous portion of terminal D contacts terminal
tion, the neutral contacts of the directional lever B, both poles of the motor are connected to
switch are closed. In this condition, if the starting the ground, and the motor stops rotating.
switch is turned to the START position, electric cur- • In this condition, the stop motor cable is com-
rent flows in circuit from the battery + à starting pletely extended, and the fuel injection pump
switch terminal B à starting switch terminal C à lever is set to the FULL position to place it in
starting motor terminal C à starting motor terminal the operating condition.
E à directional lever switch terminal N à ground. • In addition, the current flows from starting
• In addition, electric current flows from starting switch switch terminal BR à battery relay coil à
terminal BR à stop motor relay terminal 1 - 2 à ground, and the battery relay switch is closed.
ground, and the relay coil is excited. • A circuit is formed from the battery à battery
• The electric current from the battery flows from en- relay à starting motor terminal B, so the
gine stop motor terminal A - B à relay terminal 5 engine starts. If the directional lever is not at
- 3 à terminal à 4 motor, and rotates the motor. the N position, circuit is not formed, so the
(The cable extends) engine does not start.
10-337
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT Up to SN WA470H20668
Function • When the motor rotates, terminal D also ro-

• The system is equipped with an electrical fuel cut tates at the same time. When the non-con-
device (engine stop motor) which makes it possible tinuous portion of terminal D reaches termi-
to start or stop the engine by turning the starting nal C, the circuit from terminal A to C opens,
switch ON or OFF. This improves the ease of and the current from the battery to the motor
operation. is shut off. The motor attempts to continue
rotating under inertia, but when the continu-
Operation ous portion of terminal D contacts terminal
• When the starting switch is turned OFF, starting C, both poles of the motor are connected to
switch terminals B, BR and C are opened. the ground, and the motor stops rotating.
• The current in the stop motor relay is shut off by the • In this condition, the stop motor cable is com-
starting switch, so the coil is not excited. There- pletely pulled in, and the fuel injection pump
fore, terminals 3 and 6 are closer. lever is set to the STOP position to stop the
• The current from the battery flows from engine stop engine.
motor terminals A - C à relay terminals 6 - 3 à
motor to rotate the motor. (The cable is pulled in)
10-338
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
PREHEATING CIRCUIT Up to SN WA470H20668
Outline Operation
• To improve the ease of starting in cold areas, an • When the starting switch is turned to the ON
automatic preheating system is installed. This sys- (ACC) position, a circuit is formed from start-
tem helps to reduce the preheating time and also ing switch terminal BR à controller inside
automatically sets the preheating time to match the main motor à preheating output ground.
engine water temperature when the starting switch The preheating relay coil is excited, so the
is operated. preheating relay is actuated to actuate the
• When the starting switch is turned to the ON (ACC) heater relay.
position, the preheating pilot lamp on the main moni- • Current flow from the battery à battery relay
tor lights up and preheating is carried out on the à heater relay à electrical intake air heater
intake air for the electric intake air heater. to carry out preheating. When the preheating
The engine water temperature is detected by the completion signal is sent from the controller,
water temperature sensor, and the preheating time the preheating relay and heater relay are
is set by the controller built into the main monitor. turned OFF and the preheating is completed.
• While the pilot lamp is lighted up, preheating is
being carried out, so the starting switch must be
kept at the ON position. If the starting switch is
turned to the START position while the pilot lamp is
ON, the preheating is canceled.
10-339
STRUCTURE AND FUNCTION ENGINE STARTING, STOP, PREHEATING CIRCUIT
ENGINE STARTING, STOP, PREHEATING CIRCUIT

SN WA470H20669 up to H20941
Ground
10-340

Sect. Sect.
6 S 43 Starting switch 6 G 10 Generator
10 S 58 Battery main switch 10 G 57 Battery
12 S 261 Switch gear selection 8 M9 Starting motor
3 P 426 Main monitor 4 H 76 Lamp pre-heating
3 R 12 Flame plug 3 Y 320 Solenoid engine stop
V Diode 4 B 14 Temp. sender pre-heating
V 118 Diode 5 x 6 K 208 Relay neutral position
7 K 106 Relay battery 2 K 282 Relay pre-heating
9 K158 Relay starting motor 2 K 283 Relay pre-heating
1 K 167 Time relay for Y 320
Connectors
XL Connector platform XT Connector transmission
XC Connector cab XR Connector rear frame
XF Connector front frame X FS Connector fuses
XM Connector engine
Fuses
F... Fuse
motor.tbl
Engine start Preheating
• Voltage flows in the following circuit: Starting mo- • Voltage flows in the following circuit: Start-
tor terminal 30, alternator terminal B+, battery re- ing motor terminal 30, alternator terminal
lay (K 106) terminal 30 and starting switch terminal B+, battery relay (K 106) terminal 30 and
30. starting switch terminal 30.
When the starting switch is turned (terminal 15), When the starting switch is turned (terminal
relay K106 is activated. Engine stop solenoid Y 15), relay K106 is activated. Engine stop
320 is activated, current flows in the preheating solenoid Y 320 is activated, current flows in
control circuit. the preheating control circuit.
• When the starting switch is turned further (terminal • Temperature switch B 14 is closed, ground
50a), relay neutral position (K 208) is activated, is connected to the main monitor and termi-
and current flows via terminal 30-87 if the gear nal 85 of the preheating relay K 282. Relay
lever is in neutral position. Current flows to the K282 and relay K 283 are activated. Current
starting motor relay K 158 and the starting motor flows to the preheating system. The lamp on
starts turning. the main monitor is activated via pin 15 of
connector XL 06. Preheating time depends
on the temperature and is controlled by the
Engine stop main monitor.
• If the starting switch is moved in the stop position,

current is interrupted on terminal 15, relay K 106
opens and the engine stop solenoid Y 320 moves
in stop position.
10-341
ENGINE STARTING, STOP, PREHEATING CIRCUIT

Ground
Maav_aa
10-342

Sect. Sect.
6 S 43 Starting switch 5 G 10 Generator
10 S 58 Battery main switch 10 G 57 Battery
12 S 261 Switch gear selection 8 M9 Starting motor
3 P 426 Main monitor 4 H 76 Lamp pre-heating
3 R 12 Flame plug 2 K 320 Engine stop motor relay
1 M 320 Engine stop motor 4 B 14 Temp. sender pre-heating
8 V 118.2 Diode 5 K 208 Relay neutral position
6 K 106 Relay battery 2 K 282 Relay pre-heating
8 K158 Relay starting motor 3 K 283 Relay pre-heating
Connectors
XM Connector engine
Fuses
F... Fuse
motor_a.tbl
Engine start Preheating
• Voltage flows in the following circuit: Starting mo- • Voltage flows in the following circuit: Start-
tor terminal 30, alternator terminal B+, battery re- ing motor terminal 30, alternator terminal
lay (K 106) terminal 30 and starting switch terminal B+, battery relay (K 106) terminal 30 and
30. starting switch terminal 30.
When the starting switch is turned (terminal 15), When the starting switch is turned (terminal
relay (K106) is activated. Engine stop motor 15), relay (K106) is activated. Engine stop
(M 320) is activated by the engine stop motor relay solenoid (Y 320) is activated, current flows
(K 320) (wire is being pulled out). in the preheating control circuit.
The preheating control circuit is activated. • Temperature switch (B 14) is closed, ground
• When the starting switch is turned further (terminal is connected to the main monitor and termi-
50a), relay neutral position (K 208) is activated, nal 85 of the preheating relay (K 282). Relay
and current flows via terminal 30-87 if the gear (K 282) and relay (K 283) are activated.
lever is in neutral position. Current flows to the Current flows to the preheating system. The
starting motor relay (K 158) and the starting motor lamp on the main monitor is activated via
starts turning. pin 15 of connector XL 06. Preheating time
depends on the temperature and is control-
led by the main monitor.
Engine stop
• If the starting switch is turned in the stop position,

current is interrupted on terminal 15, relay (K 106)
opens, engine stop motor relay (K 320) opens, en-
gine stop motor (M 320) stops (wire is being pulled
in).
10-343

STRUCTURE AND FUNCTION PREHEATING CIRCUIT
RIBBON HEATER
• The output of main monitor is different for quick

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

during pre-heating
Controller
reset
10-344
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION CONTROL
1. Transmission cut-off selector switch 8. Fuse boxes

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

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

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

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

• When the directional lever is set to the F posi-
tion, electric current flows from the battery (+)
or switched (+) à directional lever switch termi-
nal 1 – 2 à transmission controller FORWARD
terminal 1, and flows as the FORWARD output
signal from terminal 21 à FORWARD solenoid
(1) à ground, and the solenoid valve is actu-
ated.
2) Speed lever set to 2

• When the speed lever is at position 2, no elec-
tric current flows to H-L solenoid (3), R solenoid
(2) and speed solenoid (4). In this condition, the
transmission control valve is set to F2 by the
action of F solenoid (1).
• No current flows if the kick-down switch is not
pressed. Therefore, the kick-down is not actu-
ated, and the transmission is held in F2.
Solenoid actuation table
Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD (1) ¡ l ¡ ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
Speed select (4) ¡ ¡ ¡ ¡
10-366
Kick-down switch operated

(When operating in F2)
(When kick-down switch is pressed ON)
• When the kick-down switch is pressed, electric

current flows from the transmission controller
kick-down terminal (17) and enters the con-
troller. The kick-down circuit is formed inside
the controller, so the solenoid output signal flows
from terminals 21 and 11 to FORWARD sole-
noid (1) and speed solenoid (4). The solenoid
valves are actuated and the transmission is set
to F1.
• This kick-down circuit continues to be actuated
from this point even if the kick-down switch is
returned. (Self-hold circuit)
• In this way, when the speed lever is at F2, the
transmission is automatically shifted to F1 when
the kick- down switch is pressed. At the same
time, it will be held in F1 by the self-hold func-
tion of the kick-down relay even when the kick-
down switch is released. However many times
the kick-down switch is pressed, the transmis-
sion will stay in F1.
FORWARD (1) l ¡ ¡ ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
Speed select (4) l ¡ ¡ ¡
10-367
Canceling actuation of kick-down switch (Case I)

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

position, the F terminal contacts of the lever are
turned off, so the electric current stops flowing
from the battery (+) à speed lever switch ter-
minal 1 – 2 à transmission controller.
• The FORWARD circuit inside the transmission
controller is opened, so no electric current flows
to the kick-down circuit. In this way, the self-
hold circuit of the kick- down is canceled and
solenoid (4) is no longer actuated.
(When the directional lever is moved to N posi-
tion, the actuation is the same as above and the
kick-down circuit is canceled.)
In addition, the FORWARD circuit is also
opened, so solenoid (1) is no longer actuated.
• When the directional lever is moved the R posi-
tion, the REVERSE circuit is formed from the
battery (+) à speed lever terminal 1 – 4 à
transmission controller REVERSE terminal 12
à inside of controller. Current flows from the
output signal terminal (20) à REVERSE sole-
noid 2 à ground, and the REVERSE solenoid
valve is actuated. Therefore, only REVERSE
solenoid (2) is actuated, and the transmission is
set to R2.
FORWARD (1) ¡ ¡ ¡ ¡
REVERSE (2) ¡ l ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
10-368
Canceling actuation of kick-down switch (Case II)

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

other than 2, terminal contact 2 of the lever is
switched OFF, so the current stops flowing from
the battery (+) à speed lever switch terminal 1
– 6 à transmission controller.
• Therefore, the kick-down circuit connected to
the 2nd circuit is also shut off inside the trans-
mission controller, and solenoid (4) is no longer
actuated.
• When the speed lever is moved to position 3,
solenoid (3) is actuated. In addition, the direc-
tional lever is at the F position, so solenoid (1)
is actuated. Therefore, solenoids (1) a n d
(3) are actuated and the transmission is set to
F3.
FORWARD (1) ¡ ¡ l ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) l ¡ ¡ ¡
10-369
STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF SWITCH
TRANSMISSION CUT-OFF SWITCH
1. Case 5. Tube
2. Seal film 6. Connector
3. Disc 7. Cover
4. Vinyl tape (Red) 8. Spring
Outline Specifications
• When the left brake pedal is operated, the switch
detects the oil pressure in the brake circuit, WA470-3
shuts off the electric power to the solenoid valve
circuit for the directional clutch, and shifts the Voltage Min. 18 V
transmission to neutral. value Max. 30 V
Current Min. 5 mA
value Max. 0.1 A
10-370
STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF FUNCTION
TRANSMISSION CUT-OFF FUNCTION
(see page 10-365 for wiring diagram)
Outline
• If the transmission cut-off selector switch on the
main monitor is turned ON (pilot lamp lights up),
the transmission cut-off switch installed to the
left brake pedal is actuated. When the left brake
pedal is operated, the brakes are applied, and
the transmission is shifted to neutral at the same
time. If the transmission cut-off selector switch
is set to the OFF position (pilot lamp goes out),
the transmission is not shifted to neutral even
when the brake is operated, so the left brake
functions only as a brake in the same way as
the right brake.
Operation
1. Transmission cut-off selector switch ON
• If the transmission cut-off selector switch is turned
ON, the current from the transmission cut-off
switch (main monitor) is shut off, and current
flows only from the transmission cut-off switch
to terminal 16 of the transmission cut-off circuit
in the transmission controller. Voltage is applied
to transmission control valve solenoids F and R.
• When the left brake pedal is depressed, the
contacts of the transmission cut-off switch are
opened, so the voltage to solenoids R and F is
shut off. As a result, the brakes are applied as
normal, and the transmission is also shifted to
neutral at the same time.
2. Transmission cut-off selector switch OFF

• If the transmission cut-off selector switch is turned
OFF, the current flows from the transmission
cut-off switch (main monitor) to terminal 16 of
the transmission cut-off circuit in the transmis-
sion controller. In this condition, voltage is ap-
plied to transmission solenoids F and R regard-
less of the position of the transmission cut-off
switch. As a result, even when the left brake
pedal is depressed, the transmission is not shifted
to neutral.
10-371
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
ELECTRIC PARKING BRAKE CONTROL

Parking brake: Transmission neutralizer
Outline
• When the starting switch is turned ON and the • At the same time the parking brake warning
parking brake is applied, current flows from the light, in the main monitor, is connected to
main battery relay through the neutralizer relay, chassis through the parking brake switch
contacts 1. to 2. and over the parking brake and is switched ON.
switch to chassis.
• The neutralizer relay is now operated, contacts

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

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

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

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

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

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

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

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

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

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

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

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

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

8 9
9. Pipe to compressor
10-462
Installation: WA 320-3 / WA 380-3
1. Vent
2. Vent (Window)
3. Air conditioner condenser
4. Dry receiver
5. Compressor
6. Hot water inlet port
7. Hot water outlet port
8. Air conditioner unit
Installation: WA 420-3 / WA 470-3
1. Vent
2. Vent (Window)
3. Vent
4. Dry reciever
6. Compressor
8. Air conditioner unit
10-463
10-464
SAFETY
10-465
Handling coolants
When coolant circuits are opened, the contents may escape in liquid or vapour form. The
higher the pressure in the circuit, the more violently this will happen.
Wear safety goggles

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

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

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

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

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

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

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

2. Temperature control
3. Circulating air / Fresh air
4. Air distribution
5. Switch on lock
6. Switch ON / OUT
WA 320-3 / WA 380-3 / WA 420-3 / WA 470-3
Operating mode selector switch

for setting air direction or defrosting
Air recycling mode switch
Temperature
control Air conditioning system
step-free switch
Fan switch ON/OFF
and various stages Control panel for
temperatures
• The set temperature remains stored with the following exceptions:
- If the machine has not been operated for longer than 1 week
- If the battery voltage is extremely low
• It is possible to generate overpressure in the cab by running fan at high level and
switching to fresh air setting to prevent penetration by dust.
10-470
HINT
• Only operate the air-conditioning when the engine is running.

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

and press switch. The air-conditioning is now
switched on and the control lamp in the switch lights
up.
Maximum cooling is achieved with this setting; even

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

rear window via air jets (7 and 8). These air jets can
be opened and closed individually. The flow direction
can be adjusted by changing position of vanes.
10-471
Operation: WA 320-3 WA 380-3 WA 420-3 WA 470-3
Temperature level
indicator lamp
1. FAN SWITCH
Via these switches, the air flow can be set to four
various levels.
This switch also acts as the main switch for the air
conditioner.
When the switch is pressed, the indicator lamp above
the respective switch lights up to indicate the air flow.
2. AIR CONDITIONER SWITCH

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

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

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

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

being pressed. When the temperature reaches the desired
level, release the switch to set the temperature.
The settings for each mode are retained in memory even when be starting switch is turned OFF.
However, in the following cases, the settings must be made again:
• When the machine has been out of use for more than 7 days
• When the battery voltage is extremely low
• When there has been abnormal interference from outside
• When the fan switch is turned OFF (the setting is not kept in memory with only the air condi-
tioner switch active)
If the air conditioner is used together with the FRESH position, the inside of the cab will be pressu-
rized and this will prevent the entry of dust. The higher the position of the fan switch, the more
effective the pressurizing.
10-473
SETTINGS
Switch 1 2 3 4 5
Switch for air Operating mode Fresh/Circulating Temperature

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Single components must therefore be closed until they are installed.
5. Filling (see page 28).
10-481
Service operations
right wrong wrong

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

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

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

insert foldout from appendix.
(compare page number)
10-485

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

Pin Colour Connector
1 red (r) + Supply line (18-32 Volt)
2 brown (br) Ground
3 white/red (w/r) not used
4 white/black (w/b) Circulating air (24 Volt)
5 white (w) not used
6 blue (bl) not used
Page 35, Section K15
Connection for control of servomotor: warm air / cold air

Pin Colour Connector
1 red (r) not used
2 brown (br) Ground
3 white/red (w/r) + Supply line (18-32 Volt)
4 white/black (w/b) not used
5 white (w) Analogous entrance
6 blue (bl) not used
Page 35, Section K7
Connection for motor pins

Pin Colour Pin Colour
Connector
motor motor control control
1 green (g) 1 green (g) Poti ground
2 grey (gr) 2 grey (gr) Poti + 5 Volt
3 yellow (y) 3 yellow (y) Poti exit
4 NC 4 --- ---
5 brown (br) 5 brown (br) Motor
6 white (w) 6 white (w) Motor
Connector pins for the servomotors
10-487
Circuit diagram WA 270-3: Pin assignment
Section Name
39 Y 293 Solenoid valve, compressor
40 K 292 Relay
40 B 296.1 Press. switch, heat exchanger
41 S 54.2 Switch, cooling
41 M 296 Fan, heater / cooler
42 S 54.1 Switch, fan (heater / cooler)
43 S 293.1 Thermostat
44 M 297 Fan with thermostat
10-488
30
15
Masse
Signal
31
WA 270-3
31
39 40 41 42 43 44
Wiring Diagram
Air Conditioner
10-489
Technical data
Heating
Type Water / Air
Nominal voltage 24 Volt
Air flow rate max. 600 m³/h
Heat output Q 100 6.5 kW
Fan stages 4
Power consumption max. 10 amperes
Air conditioning unit

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

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

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

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

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

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

exchange
no
Relay fault? yes

exchange
no
Cable set faulty? yes

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

exchange
no
Control actuator yes

exchange
faulty?
no
yes repair, exchange

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

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

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

exchange
no
Control actuator yes

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

system repair and refill
no
Control faulty? yes

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

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

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

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

System leaking - O-ring connection leaking - Check pipe and line
- Compressor shaft seal connections
leaking - Check pipes and lines
- Hose/line leaking - Check whether magnetic
clutch belt pulley is oily
Cooling output too low - Vaporiser iced up - Check whether sensor lead
has been pushed into the
vaporiser correctly
lead is okay
Cooling output drops after a while - Compressor not switching off - Check whether compressor
- Thermostat not working switches on and off
- Check whether sensor lead
vaporiser correctly
lead is okay
Air conditioning system not - Power supply interrupted - Check electrical system
working - Not enough coolant in the - Check filling level
system - Check magnetic clutch,
- Magnetic clutch faulty replace if necessary
White smoke emerging from the - Vaporiser iced up - Check whether compressor
air vents - Thermostat set too cold switches on and off
- Check whether sensor lead
vaporiser correctly
lead is okay
Windows fogged up - Circulating air flaps not - Check whether the circulating
working or not working air system is working properly
properly - Check that the condensation
- Condensation unable to drain drain hose is not blocked and
away is correctly laid
Bad smell coming from air - Condensation not draining - Check that the condensation
conditioning system away drain hose is not blocked and
is correctly laid
10-503
10-504
STRUCTURE AND FUNCTION WIRING DIAGRAMS

10-601

10-603

10-605

10-607
Wiring Diagrams
10-609
Wiring diagram (Fig. 1) is according from Serial Number: WA470H20669 up to H20941
WA470-3 Wiring diagram

active Fig. 1
Sect. Sect.
20 STDSW Switch emergency contr. transm. 109 K 385 Relay back-up alarm
6 S 43 Starting switch 21 KTDR 1 Relay emergen. contr. transm. 1
10 S 58 Battery main switch 16 KTDR 2 Relay emergen. contr. transm. 2
14 S 127 Switch parking brake 25 XOP 6 Option 20 km/h
23 S 260.1 Switch transmission cut-off 27 XOP 7 Option automatic "OFF"
24 S 260.2 Footswitch transmission cut-off 26 XRPM Option engine rpm
12 S 261 Switch gear selection 6 G 10 Generator
25 S 417.1 Kick-down switch 10 G 57 Battery
25 S 417.2 Hold switch 8 M9 Starting motor
22 A1 Transmission controller 4 H 76 Lamp pre-heating
28 P 384 Speed display 14 H 126 Lamp parking brake
18 P 425 Gear display 23 H 260 Lamp transmission cut-off
3 P 426 Main monitor 24 YH Solenoid High
3 R 12 Flame plug 23 YS Solenoid Speed
V Diode 20 YM Solenoid Modulation
V 118 Diode 5 x 16 Y 236 Solenoid Forward
7 K 106 Relay battery 18 Y 237 Solenoid Reverse
9 K158 Relay starting motor 3 Y 320 Solenoid engine stop
1 K 167 Time relay for Y 320 28 B2 Sender speed
6 K 208 Relay neutral position 26 B 228 Engine rpm sender
2 K 282 Relay pre-heating 4 B 14 Temp. sender pre-heating
2 K 283 Relay pre-heating 66 B 398. Sender engine oil
14 K 200 Relay parking brake
Connectors
XM Connector engine XMFS Connector multifunction-lever
Fuses
F... Fuse
470EL1.tbl
10-610


10-611

10-612

active Fig. 2
Sect. Sect.
44 S8 Horn switch 55 H 100.2 Lamp lamp working light
48 S 51.1 Switch working light front 34 H 318 Lamp ALS
52 S 51.2 Switch working light rear 38 M7 Front wiper motor
31 S 117.1 Proximity switch lift cut-off 41 M 182.1 Front washer motor
30 S 117.2 Proximity switch return to dig 43 M 182.2 Rear washer motor
34 S 316 Switch ALS 40 M 248 Rear wiper motor
38 S 331.3 Switch front wiper / washer 49 E3 Working lamp front left
40 S 331.4 Switch rear wiper / washer 50 E4 Working lamp front tright
29 Y 214 Detent magnet Float 53 E 60 Working lamp rear left
32 Y 217 Detent magnet Lift 54 E 61 Working lamp rear right
34,36 Y 315... Solenoid ALS
45 B 8.1 Horn left
46 B 8.2 Horn right
46 K8 Relay Horn
32 K 139 Relay lift cut-off
30 K 209 Relay return to dig
42 K 337 Relay wiper interval
49 K 432 Relay front working light
53 K 433 Relay rear working light
V 118... Diode 5 x
X ALS Option ALS
51 H 100.1 Lamp front working light
Connectors
XL Connector platform XR Connector transmission
XC Connector cab XK Connector air-conditioner
XM Connector engine XH Connector engine hood
Fuses
F... Main fuse electric
470EL2.tbl
10-613

active Fig. 3
Sect. Sect.
60 B 13 Sender engine water temp. 65 H 30 Lamp engine oil press.
65 B 19 Sender engine oil pressure 58 H 98 Lamp fuel level
63 B 255 Sender engine water level 61 H 109 Lamp T/C temp.
68 B 262 Sender air filter control 78 H 111 Lamp steering oil press.
62 B 304 Sender brake pressure 60 H 170 Lamp engine water temp.
79 B 305 Flow indicator emergen. steering 63 H 259 Lamp engine water level
78 B 307 Sender air pressure 69 H 263 Lamp air filter
61 B 323 Sender T/C temp. 62 H 288 Lamp brake press.
72 B 335 Warner Sub-, Main Monitor 79 H 306 Lamp emergency steering
66 B 398 Sender engine oil level 80 H 334.1 Central warning lamp
58 R 97 Sender fuel level 81 H 334.2 Central check lamp
70 G 10 Generator 66 H 399 Lampe engine oil level
64 K 19.1 Relay engine oil level
66 K 262.1 Relay air filter control
76 E 35.1 Lumination Main Monitor
75 E 35.2 Lumination Sub Monitor
74 P 21 Working hour gauge
59 P 25 Engine water temp. gauge
61 P 26 T/C oil temp. gauge
58 P 96 Fuel level gauge
76 P 426 Main Monitor
75 P 427 Sub Monitor
70 H 28 Lamp Generator
Connectors
XL Connector platform X TL Connector transmission
XM Connector engine
Fuses
F... Fuse
470EL3.tbl
10-614

10-615

10-616

active Fig. 4
Sect. Sect.
105 S 70 Switch brake light 85 E 243 Turning signal left
87 S 101 Switch waring lamp 91 E 244 Turning signal right
99 S 331.1 Switch headlights 96 K 67.1 Indicator relay 2+1
87 S 331.2 Switch turning signal 94 K 67.2 Indicator relay 3+1
110 B 279 Horn back off alarm 93 K 101 Relay waring lamp
V 118.. Diode 91,93 K 163... Relay turning signal
100 H 29 Lamp main head light 109 K 385 Relay back off alarm
89 H 31.1 Lamp turning signal right
86 H 31.2 Lamp turning signal left
94 E1 Headlight left
97 E2 Headlight right
85 E5 Turning signal front left
91 E6 Turning signal front right
101 E 68.1 Rear light left
100 E 69.1 Rear light right
86 E 68.2 Turning signal rear left
89 E 69.2 Turning signal rear right
105 E 68.3 Brake light left
106 E 69.3 Brake light right
108 E 68.4 Reversing light left
109 E 69.4 Reversing light right
103 E 71 Number plate light left
104 E 72 Number plate light right
Connectors
XC Connector cab
Fuses
F... Fuse
470EL4.tbl
10-617

active Fig. 5
Sect. Sect.
116 S 195 Switch rotating warning light
121 M 405 Motor pump centr. grasing
121 A 407 Controller centr. grasing
115 R 246 Cigarette lighter
113 E 123 Cab light
116 E 130 Rotating warning light
119 T 250 Transformer 24V-12V
119 A 249 Casette radio
118 W 309 Ariel with booster
118 B 245.1 Speaker, left
119 B 245.2 Speaker, right
Connectors
XC Connector cab XR Connector raer frame
X GR Connector back off alarm X RA Connector radio
XM Connector engine X LGRE Connector centr. grasing
X LOP Connector options
Fuses
F... Fuse
470EL5.tbl
Wiring colour
Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour
W ws white G gn green Gr gr gray Ch an anthrazit
B sw black L bl blue P rs pink O or orange
R rt red Br br brown Sb hbl light blue V vi violett
Y ge yellow Lg hgn light green Dg dgn dark green
270EL6.tbl
10-618

10-619

10-620
Wiring Diagrams
From SN WA470H20942
10-621

active Fig. 1
Sect. Sect.
20 STDSW Switch emergency contr. transm. 109 K 385 Relay back-up alarm
6 S 43 Starting switch 21 KTDR 1 Relay emergen. contr. transm. 1
14 S 127 Switch parking brake 25 XOP 6 Option 20 km/h
22 S 260.1 Switch transmission cut-off 27 XOP 7 Option automatic "OFF"
23 S 260.2 Footswitch transmission cut-off 26 XRPM Option engine rpm
12 S 261 Switch gear selection 5 G 10 Generator
25 S 417.1 Kick-down switch 10 G 57 Battery
25 S 417.2 Hold switch 8 M9 Starting motor
22 A1 Transmission controller 1 M 320 Engine stop motor
27 P 384 Speed display 4 H 76 Lamp pre-heating
18 P 425 Gear display 14 H 126 Lamp parking brake
3 P 426 Main monitor 23 H 260 Lamp transmission cut-off
17 P 442 Error code display 24 YH Solenoid High
3 R 12 Flame plug 23 YS Solenoid Speed
73 K 109 Relay test emerg. steering pump 17 Y 237 Solenoid Reverse
6 K 106 Relay battery 3 Y 320 Solenoid engine stop
8 K 158 Relay starting motor 26 B2 Sender speed
5 K 208 Relay neutral position 27 B 228 Engine rpm sender
2 K 282 Relay pre-heating 4 B 14 Temp. sender pre-heating
3 K 283 Relay pre-heating 66 B 398 Sender engine oil
14 K 200 Relay parking brake
2 K 320 Relay Motorstop
Connectors
XM Connector engine XMFS Connector multifunction-lever
Fuses
F... Fuse
470EL1a.tbl
Remark: The wiring diagrams (Fig. 2 up to 5) are identical with those

from Serial Number: WA470H20669 and up
10-622


10-623

10-624
Wiring Diagrams
Notice:
The electrical emergency steering pump has already been installed from Serial number
WA470H21065 and up. Alterations in connection with the wiring diagram are marked with (*)
in the legend.
The same is valid for the use of the auto transmission pilot switch from Serial number
WA470H21104 and up. Alterations in the wiring diagram are marked with (**) in the legend.
10-625


active plus Fig. 1
Sect. Sect.
20 STDSW Switch emergency contr. transm. 2 K 320 Relay Motorstop
6 S 43 Starting switch 109 K 385 Relay back-up alarm
14 S 127 Switch parking brake 16 KTDR 2 Relay emergen. contr. transm. 2
22 S 260.1 Switch transmission cut-off 8 K 109 Relay test emergency steering
23 S 260.2 Footswitch transmission cut-off 25 XOP 6 Option 20 km/h
12 S 261 Switch gear selection 26 XRPM Option engine rpm
25 S 417.1 Kick-down switch 5 G 10 Generator
25 S 417.2 Hold switch 10 G 57 Battery
26 SOP 7 Switch manual shift ** 8 M9 Starting motor
22 A1 Transmission controller 1 M 320 Engine stop motor
27 P 384 Speed display 4 H 76 Lamp pre-heating
18 P 425 Gear display 14 H 126 Lamp parking brake
3 P 426 Main monitor 23 H 260 Lamp transmission cut-off
17 P 442 Error code display 26 HOP 7 Lamp manual shift **
3 R 12 Flame plug 23 YH Solenoid High
RES 1 Resistor manual shift ** 22 YS Solenoid Speed
6 K 106 Relay battery 17 Y 237 Solenoid Reverse
8 K 158 Relay starting motor 26 B2 Sender speed
14 K 200 Relay parking brake 27 B 228 Engine rpm sender
5 K 208 Relay neutral position 4 B 14 Temp. sender pre-heating
2 K 282 Relay pre-heating 66 B 398 Sender engine oil
3 K 283 Relay pre-heating
Connectors
XM Connector engine
Fuses
F... Fuse
470EL1b.tbl
** SN WA470H21104 and up
10-626


10-627


10-628


active plus Fig. 2
Sect. Sect.
44 S8 Horn switch 55 H 100.2 Lamp lamp working light
48 S 51.1 Switch working light front 34 H 318 Lamp ALS
52 S 51.2 Switch working light rear 38 M7 Front wiper motor
31 S 117.1 Proximity switch lift cut-off 41 M 182.1 Front washer motor
30 S 117.2 Proximity switch return to dig 43 M 182.2 Rear washer motor
34 S 316 Switch ALS 40 M 248 Rear wiper motor
38 S 331.3 Switch front wiper / washer 49 E3 Working lamp front left
40 S 331.4 Switch rear wiper / washer 50 E4 Working lamp front tright
29 Y 214 Detent magnet Float 53 E 60 Working lamp rear left
32 Y 217 Detent magnet Lift 54 E 61 Working lamp rear right
34,36 Y 315... Solenoid ALS
45 B 8.1 Horn left
46 B 8.2 Horn right
46 K8 Relay Horn
32 K 139 Relay lift cut-off
30 K 209 Relay return to dig
42 K 337 Relay wiper interval
49 K 432 Relay front working light
53 K 433 Relay rear working light
V 118... Diode 5 x
X ALS Option ALS
51 H 100.1 Lamp front working light
Connectors
XC Connector cab XK Connector air-conditioner
Fuses
F... Main fuse electric
420EL2b.tbl
10-629


active plus Fig. 3
Sect. Sect.
59 B 13 Sender engine water temp. 77 P 426 Main Monitor
64 B 19 Sender engine oil pressure 73 P 427 Sub Monitor
63 B 255 Sender engine water level 74 M 160 Emergency steering pump *
66 B 262 Sender air filter control 70 G 10 Generator
62 B 304 Sender brake pressure 68 H 28 Lamp Generator
78 B 305 Sender emerg. steering pump * 64 H 30 Lamp engine oil press.
77 B 307 Sender air pressure * 58 H 98 Lamp fuel level
60 B 323 Sender T/C temp. 60 H 109 Lamp T/C temp.
70 B 335 Warner Sub-, Main Monitor 77 H 111 Lamp steering oil press.
65 B 398 Sender engine oil level 59 H 170 Lamp engine water temp.
58 R 97 Sender fuel level 63 H 259 Lamp engine water level
64 K 19 Relay engine oil level 67 H 263 Lamp air filter
74 K 159 Relay test emergency steering * 62 H 288 Lamp brake press.
74,75 K 161... Relay emerg. steering * 78 H 306 Lamp emergency steering
66 K 262 Relay air filter control 81 H 334.1 Central warning lamp
73 K 414 Rpm sensor emerg. steerg. pump * 82 H 334.2 Central check lamp
72 P 21 Working hour gauge 65 H 399 Lampe engine oil level
59 P 25 Engine water temp. gauge 79 E 35.1 Lumination Main Monitor
60 P 26 T/C oil temp. gauge 73 E 35.2 Lumination Sub Monitor
58 P 96 Fuel level gauge V 118... Diode
Connectors
XM Connector engine
Fuses
F... Fuse
470EL3b.tbl
* SN WA470H21065 and up
10-630


10-631


10-632


active plus Fig. 4
Sect. Sect.
105 S 70 Switch brake light 85 E 243 Turning signal left
87 S 101 Switch waring lamp 91 E 244 Turning signal right
99 S 331.1 Switch headlights 96 K 67 Indicator relay
87 S 331.2 Switch turning signal 93 K 101 Relay waring lamp
110 B 279 Horn back off alarm 104 K 165 Relay brake light
V 118.. Diode 109 K 385 Relay back off alarm
100 H 29 Lamp main head light
89 H 31.1 Lamp turning signal right
86 H 31.2 Lamp turning signal left
94 E1 Headlight left
97 E2 Headlight right
85 E5 Turning signal front left
91 E6 Turning signal front right
101 E 68.1 Rear light left
100 E 69.1 Rear light right
86 E 68.2 Turning signal rear left
89 E 69.2 Turning signal rear right
105 E 68.3 Brake light left
106 E 69.3 Brake light right
108 E 68.4 Reversing light left
109 E 69.4 Reversing light right
103 E 71 Number plate light left
104 E 72 Number plate light right
Connectors
XC Connector cab X FS Connector fuses
XF Connector front frame XH Connector engine hood
XM Connector engine
Fuses
F... Fuse
470EL4b.tbl
10-633


active plus Fig. 5
Sect. Sect.
117 K 442 Relay accelerator pedal 125 T 250 Transformer 24V-12V
117 K 443 Relay work mode 125 A 249 Casette radio
115 Y 218 Way valve 123 W 309 Ariel with booster
119 Y 442 Solenoid accelerator pedal 123 B 245.1 Speaker, left
122 S 195 Switch rotating warning light 125 B 245.2 Speaker, right
116 S 219 Switch work mode
127 M 405 Motor pump centr. grasing
116 A1 Transmission controller
127 A 407 Controller centr. grasing
120 R 246 Cigarette lighter
116 HS Lamp Standard mode
117 HH Lamp High mode
117 HE Lamp Economy mode
121 H 195 Lamp rotating warning light
113 E 123 Cab light
122 E 130 Rotating warning light
Connectors
XL Connector platform XR Connector raer frame
XC Connector cab X FS Connector fuses
XF Connector front frame X RA Connector radio
X GR Connector back off alarm X LGRE Connector centr. grasing
XM Connector engine X LOP Connector options
X TL Connector transmission
Fuses
F... Fuse
470EL5b.tbl
Wiring colour
Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour
W ws white G gn green Gr gr gray Ch an anthrazit
B sw black L bl blue P rs pink O or orange
R rt red Br br brown Sb hbl light blue V vi violett
Y ge yellow Lg hgn light green Dg dgn dark green
270EL6.tbl
10-634


10-635


10-636

20 TESTING AND ADJUSTING
Standard value table for engine ............................ 20-2 Testing and adjusting fan belt tension ............... 20-131
Standard value table for chassis .......................... 20-5 Measuring accelerator pedal ............................ 20-132
Test certificate ...................................................... 20-8 Basic adjustment of accelerator pedal ........... 20-133-1
Standard value tables for electrical parts ............ 20-13 Measuring operating force,
Tools for testing, adjusting travel of speed lever ......................................... 20-134
and troubleshooting .......................................... 20-101 Measuring stall speed....................................... 20-135
From SN WA470H20669 Measuring torque converter, transmission,
up to SN WA470H20941: MTA11 (STC) parking brake oil pressure ............................... 20-137
Measuring engine speed .................................. 20-103 Method of operating emergency manual spool . 20-139
Measuring intake air pressure .......................... 20-104 Measuring clearance between tire and wheel ... 20-141
Testing and adjusting valves and injectors......... 20-105 Measuring steering oil pressure ....................... 20-144
Measuring blow-by pressure ............................ 20-112 Measuring brake performance ......................... 20-147
Measuring engine oil pressure ......................... 20-113 Testing brake oil pressure ................................ 20-148
Testing and adjusting fan belt tension ............... 20-114 Measuring brake disc wear .............................. 20-149
Measuring stall speed....................................... 20-116 Bleeding air from brake system........................ 20-150
Up to SN WA470H20668: S6D125-1 Measuring parking brake performance ............ 20-151
SN WA470H20942 and up: SA6D125E-2 Method for manual release of parking brake .... 20-152
Measuring engine speed .................................. 20-119 Testing wear of parking brake disc ................... 20-153
Measuring intake air pressure Measuring work equipment control lever .......... 20-154
(boost pressure) .............................................. 20-120 Measuring work equipment
Adjusting valve clearance ................................. 20-121 hydraulic pressure ........................................... 20-156
Measuring exhaust colour ................................ 20-122 Measuring PPC valve pressure ........................ 20-160
Measuring exhaust gas temperature ................. 20-123 Measuring work equipment .............................. 20-162
Measuring blow-by pressure ............................ 20-124 Testing and adjusting bucket positioner ............ 20-164
Measuring compression pressure .................... 20-125 Testing and adjusting boom kick-out ................. 20-165
Measuring engine oil pressure ......................... 20-126 Adjusting main monitor (speedometer module) . 20-167
Testing and adjusting fuel injection timing ......... 20-127 Checking for abnormality in fuel level sensor ... 20-168
Method for adjusting engine motor stop cable .. 20-129
« When using the standard value table to make judgement for testing and adjusting, and troubleshooting, the following
precautions are necessary.
1. The standard values in the table are the values for a new machine and are given as reference values for the time when
the machine is shipped from the factory. These values should be used as a guide when estimating wear and tear after
the machine is operated, and when carrying out repairs.
2. The permissible values given in the table are values estimated based on the results of various tests carried out on the
machines shipped from the factory, so they should be used together with the information on the repair condition and
other information such as the operating history of the machine when judging the condition of the machine.
3. These standard values do not form a basis for judging claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety pins
and blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unauthorized people near
the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the
water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE


Engine S6D125-1
Item Measurement conditions Unit Standard value Permissible value
High idling 2,400 ± 50 2,400 ±100

Engine Speed Low idling rpm 725 ± 25 725 ± 50
Rated speed 2,200 –
At sudden acceleration Max. 6.0 8.0
Exhaust gas color Bosch
At high idling index Max. 1.0 2.0
Valve clearance Intake valve 0.33 –

(cold) mm
Exhaust valve 0.71 –
Compression pressure Oil temperature:

(SAE 30 oil) 40-60°C bar 32 22
(engine speed:
250-300 rpm)
At rated output
Blowby pressure
(SAE 30 oil) mmH2O Max. 80 160
(Water temperature:
Operating range)
(Water temperature:
Operating range)
At high idling 3.0 - 5.0 2.1

(SAE 30) (bar)
Oil pressure At low idling 1.5 0.7

(SAE 30)

(SAE 10W)
At low idling 1.0 0.7

(SAE 10W)
Whole speed range

Oil temperature (inside oil pan) °C 80 -110 120
°
Fuel injection timing Before top dead center (degree) 24 ± 1 24 ± 1
Deflection when pressed

with finger force of
Fan betlt tension approx. 6kg mm 10 7 - 13
(alternator pulley -
Fan pulley)
20-2

From SN WA470H20669 up to H20941

Engine MTA 11 (STC)
High idling 2,200 - 2,300 –

Engine Speed Low idling rpm 750 - 780 –
Rated speed 2,200 –
Exhaust gas color At sudden acceleration Bosch Max. 7.0 –

index

(cold) mm
At rated output
Blowby pressure
(SAE 30 oil) mmH2O 305 460
(Water temperature:
Operating range)
(Water temperature:
Operating range)
At high idling min. 2,1 –

(15W40) (bar)
Oil pressure At low idling min. 0,7 –

(15W40)
Whole speed range

Use tool for deflection

testing
Fan betlt tension ST-1293 N 670 –
20-3



Engine SA6D125E-2
High idling 2,350 – 2,450 –

Engine Speed Low idling rpm 700 – 750 –
At sudden acceleration Max. 5.5 7.5

Exhaust gas color Bosch
At high idling index Max. 1.0 2.0

(cold) mm
Compression pressure Oil temperature:

(SAE30 or SAE15W-40 oil) 40-60°C bar 30 20
(engine speed:
200-250 rpm)
At rated output
Blowby pressure
(SAE30 or SAE15W-40 oil) mmH2O Max. 100 200
(Water temperature:
Min. 70°C)
(Water temperature:
Operating range)

(SAE30 or SAE15W-40) (bar)
Oil pressure At low idling 1.2 0.7

(SAE30 or SAE15W-40)

(SAE10W)
At low idling 1.0 0.7

(SAE10W)
Whole speed range

°
Fuel injection timing Before top dead center (degree) 15.25 – 16.75 –
Deflection when pressed

with finger force of
Fan betlt tension approx. 6kg mm 8 6 - 10
(alternator pulley -
Fan pulley)
20-4

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

gory value
Operating force N 68.6 – 73.6 Max. 112.8

(kg) (7 – 7.5) (Max. 11.5)
Accelerator pedal
a1 48 —
Operating angle deg.
a2 30 —
Stopper height L mm 49.5 ± 5 —

Directional lever
Operating N – FORWARD N 5.9 +5 +0.5

–3 (0.6 –0.3) Max. 16.7 (Max.1.7)
force (kg)
N – REVERSE 5.9 +5 +0.5
–3 (0.6 –0.3) Max. 16.7 (Max.1.7)
N – FORWARD 35 ± 10 35 ± 20
Travel mm
N – REVERSE 35 ± 10 35 ± 20
1st – 2nd 5.9 +5

–3 (0.6 +0.5
–0.3) Max. 16.7 (Max.1.7)
Operating Engine stopped N
force 2nd – 3rd Torque converter oil (kg) 5.9 +5 +0.5
–3 (0.6 –0.3) Max. 16.7 (Max.1.7)
Speed lever
temperature: 60 – 80°C
3rd – 4th 5.9 +5
–3 (0.6 +0.5
–0.3) Max. 16.7 (Max.1.7)
1st – 2nd 35 ± 10 35 ± 20
Travel 2nd – 3rd mm 35 ± 10 35 ± 20
3rd – 4th 35 ± 10 35 ± 20
Engine water temperature
Torque converter stall gauge: Green range 2,180 - 2,280 –
Engine
Torque converter oil

Hydraulic stall temperature: 60 – 80°C rpm 2,160 - 2,260 –
Hydraulic oil
Full stall temperature: 45 – 55°C 1,770 - 2,050 –
2.8 ± 0.15
Priority Rated speed (29 ± 1.5) 2.8 +0.15 +1.5
–0.44 (29 –4.5 )
pressure 2.5 ± 0.15
Low idling (25 ± 1.5) 2.5 +0.15 +1.5
–0.39 (25 –4.0 )
Transmission valve
Torque 0.44 ± 0.05

converter Rated speed (4.5 ± 0.5) 0.44 +0.05 +0.5
–0.1 (4.5–1.0 )
outlet port 0.34 ± 0.05
pressure Low idling Torque converter oil MPa (3.5 ± 0.5) 0.34 +0.05 +0.5
–0.09 (3.5 –0.9 )
temperature: 60 – 80°C (bar) 1.0 ± 0.1 +0.1 (10.0 +1.0 )
Pilot pressure Work mode selector switch (10.0 ± 1.0) 1.0 –0.2 –2.0
on High mode (from 2.3 ± 0.2 +0.2 (23 +2.0 )
Clutch pressure (25 ± 3.0) 2.3 –0.39 –4.5
SN WA470H21164 and up)
2.8 ± 0.15
Parking Rated speed (29 ± 1.5) 2.8 +0.15 +1.5
–0.44 (29 –4.5 )
brake 2.5 ± 0.15
pressure Low idling +0.15 (25 +1.5 )
2.5 –0.39
(25 ± 1.5) –4.0
Tire inflation pressure:
A Specified pressure Max. 2.5 —
Fitting of wheel
lock ring
Tire
B mm Max. 4.0 —
Clearance of wheel C 2 – 10 —
lock ring
20-5

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Cate- Permissible
gory Item Measurement conditions Unit Standard value value
Engine stopped, machine
Play facing straight to front mm 30 – 70 30 – 100
Steering wheel
Flat, horizontal, straight, N 9.8 – 14.7 Max. 22.6

Operating force dry paved road surface (kg) (1.0 – 1.5) (Max. 2.3)
Hydraulic oil temp.: 45 –55°C
Low idling Work mode selector switch Max. 3.7 Max. 5.6
Operating on High mode (from
Sec.
time SN WA470H21164 and up)
High idling Max. 2.5 Max. 3.8
valve Frame
Clearance between front Hydraulic oil

frame and rear frame temperature: 45 – 55°C mm 25 ± 2 —
Engine speed: 1200 rpm
Engine speed: High idling
Steering
MPa +1.0 +10 +1.0 10

Relief pressure Hydraulic oil (bar) 20.58–0.7 (210 –7 ) 20.58–1.7 (210 –17 )
Work mode selector switch
on High mode (from
Engine speed: Low idling N 294.2 ± 29.4 Max. 421.7
Operating force Hydraulic oil temp.: 45 – 55°C (kg) (30 ± 3) (Max. 43)
on High mode (from
a1 45 —
Operating angle
a2 deg. 15+1 —
–0
Brakes
Play a3 5 ± 0.5 —
Flat, horizontal, straight, dry

paved road surface
Speed when applying brake:
20 km/h, braking delay: 0.1 sec.
Performance Brake pedal operating force: m Max. 5 Max. 5
Specified operating force
Specified pressure
MPa Max. 0.5 Max. 0.5

Drop in hydraulic pressure 50 kg/cm2 in 5 minutes (bar) (Max. 5) (Max. 5)
Disc wear Piston stroke mm 1.2 – 4.7 Max. 6.2

Specified pressure
Parking brake
Performance Flat paved road — Stopped —

with 1/5 (11°20’) grade
Dry road surface
Machine at operating condition
Disc thickness mm 3.2 ± 0.08 Max. 2.83
Max. 23.5 Max. 35.3

Work equipment control lever
HOLD • RAISE
(Max. 2.4) (Max. 3.6)
Max. 15.7 Max. 23.5
RAISE • HOLD (Max. 1.6) (Max. 2.4)
Operating force
HOLD • LOWER Engine speed: Low idling Max. 24.5 Max. 37.3
Boom Hydraulic oil N (Max. 2.5) (Max. 3.8)
temperature: 45 – 55°C (kg)
LOWER • HOLD — —
LOWER • FLOAT Max. 34.3 Max. 60.0

(Max. 3.5) (Max. 5.3)
Max. 14.7 Max. 22.6
FLOAT • HOLD (Max. 1.5) (Max. 2.3)
20-6

Cate- Item Measurement conditions Unit Standard value Permissible

gory value
HOLD à DUMP Max. 23.5 Max. 35.3
(Max. 2.4) (Max. 3.6)
Operating
Max. 23.5 Max. 35.3

force
Work equipment control lever
Bucket HOLD à TILT N

(kg) (Max. 2.4) (Max. 3.6)
TILT à HOLD Max. 14.7 Max. 22.6

(Max. 1.5) (Max. 2.3)
HOLD à RAISE 67 ± 15 67 ± 30
Engine speed: Low idling
Boom HOLD à LOWER Hydraulic oil 53 ± 15 53 ± 30
Travel
HOLD à FLOAT 67 ± 15 67 ± 30
mm
HOLD à DUMP 60 ± 15 60 ± 30
Bucket
HOLD à TILT 60 ± 15 60 ± 30
PPC Maincontrolvalve
Hydraulic oil MPa +1.0

Relief pressure temperature: 45 – 55°C 20.58–0.7 (210+10
–7 )
+1.0
20.58–1.7 (210+10
–17)
Engine speed: High idling (bar)
valve
PPC pressure 1*) on High mode (from MPa 3.7 +0.39

(38 +4
) 3.7 +0.39
(38 +4
(bar) –0.19 –0.19 –2 )
Hydraulic oil
Work equipment speed
Boom lifting time 5.5 ± 0.3 Max. 7.0

Boom lowering time Engine speed: High idling 3.7 ± 0.5 Max. 5.1
Steering valve: Neutral
Bucket dumping time Sec. 1.4 ± 0.3 Max. 2.1
Bucket At full stroke on High mode (from 1.9 ± 0.3 Max. 2.7
Boom
tilting SN WA470H21164 and up)

time Bucket horizontal 1.2 ± 0.3 Max. 1.8
No load
Hydraulic drift
Retraction of boom Hydraulic oil temperature: 45 – 55°C

cylinder rod Leave for 5 minutes after stopping Max. 30 Max. 36
engine then measure for next 15 minutes
Retraction of bucket Bucket empty, boom, bucket horizontal mm Max. 20 Max. 24
cylinder rod
Clearance of bucket
Proximity
switch
positioner switch 3–5 —

Hydraulic oil
Clearance of boom temperature: 45 – 55°C mm 3–5 —
kick-out switch
Accumulator 20 14
ALS
• Hydraulic oil
bar
Working pressure temperature: 45 – 55°C 98 +5 103
+0,39 +0,4
1)* Serial No WA470H20618 and up: Standard: 2,94 0 (30 0 )
Permiss.: 2,94 +0,39 (30 +4 )
- 0,19 -2
20-7

TESTING AND ADJUSTING TEST CERTIFICATE
Test certificate WA 470 - 3

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

1 Rated output ( kW / HP ) 194 / 264
2 Low idle speed 700-750
3 High idle speed, no load 2350-2450
4 Stall speed against torque converter 2200-2300
5 Stall speed against hydraulics 2160-2360
6 Stall speed against torque converter and hydraulics 1770-2170
Operating temp ° C Nominal Actual

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

10 Working hydraulic pressure (max) 203 - 220
11 Cut-off pressure 160 - 165
12 PPC pressure 38 + 4
13 Steering pressure 207 - 220
14 Torque converter outlet pressure 4.0 - 5.0
15 Clutch pressure 25 ± 3
16 Accumulator gas press., operating / parking brake 35 / 15
Working times in sec. At high idling Nominal Actual

17 Lift, bucket empty 5.2 - 5.8
18 Bucket dump, boom highest position 1.1 - 1.7
19 Tilt back, boom highest position 1.6 - 2.2
20 Lower, bucket empty, to ground 3.2 - 4.2
21 Lower, bucket empty, to ground in float position 3.1 - 4.1
22 Steering, end to end, at high idling max. 2.5
Gear change speeds ( km / h )

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

27 Lift cyl. (15 min) max. 30mm
28 Bucket cyl.(15 min) max. 20mm
All pressures and timings to be measured with the machine at working temp. July 96
20-8
From SN WA470H20669 up to H20941




15 Clutch pressure 25 ± 3


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

All pressures and timings to be measured with the machine at working temp. January 98
20-9

From SN WA470H20942




15 Clutch pressure 22 - 28


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

All pressures and timings to be measured with the machine at working temp. March 1999
20-10
!
TEST CERTIFICATE WA 470 - 3H


1 Rated output ( kW / HP) 194 / 264
2 Low idle speed 750 - 800
3 High idle speed, (no load) High mode 2290 - 2390
4 Economy mode 2085 - 2115
5 Stall speed against torque converter (High mode) 2230 - 2330
6 Stall speed against hydraulics (High mode) 2230 - 2330
7 Stall speed against torque converter and hydraulics (High mode) 1670 - 2070
Operating temp ° C
8 Engine (in operating temperature)
Operating pressure bar. / at high idling

12 Cut-off pressure High mode 160 - 165
13 Standard / Economy mode max. 20
16 Torque converter outlet pressure 4-5
17 Clutch pressure 22 - 28
Working times in sec. / at high idling (High mode)

23 Lower, bucket empty, to ground (in float position) 3.1 - 4.1

25 Up (2 - 3) / High mode 8 - 12
26 Up (2 - 3) / Economy mode 5-9
27 Up (3 - 4) / High mode 14 - 20
28 Down (4 - 3) / High mode 12 - 18
29 Down (3 - 2) / High mode 8 - 12
Final speed (Tires 26.5-25) ( km / h )

30 1. Gear / High mode 6-8
31 2. Gear / High mode 10 - 12

32 Lift cylinder (15 min) (measured at piston rod) max. 30 mm
33 Bucket cylinder (15 min) (measured at piston rod) max. 20 mm
All pressures and timings to be measured with the machine at working temperature. November 1999
20-11

20-12
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLES FOR ELECTRICAL PARTS

Connector Inspection Measurement

Name of component Judgment table
No. method conditions
If the condition is as shown in the table Turn starting
Short connector
below, the sensor is defective. switch ON.
Short connector Monitor goes off
connected
CN R06
disconnected Monitor lights up
Radiator water level CN R06
sensor If the condition is as shown in the table Turn starting
Check continuity
below, the sensor is normal. switch OFF.

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

chassis ground

Connect to
Chassis ground Monitor goes off

connected
CN E10
Engine oil level sensor CN E10

Check continuity

Engine oil level Continuity
normal
Engine oil level
abnormal No continuity

resistance
Measure

temperature sensor CN T07 Normal temperature Approx. 38 – 48 kΩ
(25°C)
Engine water CN E06
temperature sensor 100°C Approx. 3.6 – 3.9 kΩ

resistance

Measure
+1
Fuel level sensor CN R07 Full Approx. 10 – 3Ω
Empty Approx. 85 – 95 KΩ
When engine is running Start engine

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

Alternator — « If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
20-13


chassis ground
Connect to
Terminal wiring Monitor goes off
harness disconnected
Connected to
chassis ground Monitor lights up
Engine oil pressure
sensor CNE 11 If the condition is as shown in the table Start engine.
Check continuity
below, the sensor is normal.

Oil pressure above No continuity
70 KPa (0.7 bar)
Oil pressure below
30 KPa (0.3 bar) Continuity

Short connector

connected
CN T08
Parking brake sensor CN T08
Check continuity

Oil pressure above Continuity
0.6 MPa (6.1 bar)
Oil pressure below
0.34 MPa (3.5 bar) No continuity

Short connector

connected
CN B08, CN B13
Brake ACC CN B08
Low pressure switch CN B13 If the condition is as shown in the table Turn starting
Check continuity

Oil pressure above Continuity
5.9 MPa (60 bar)
Oil pressure below
3.9 MPa (40 bar) No continuity
20-14
Sys- Name of Connector Inspection Measurement

Judgment table
tem component No. method conditions
Between When engine is running 1) Start engine.
Measure
voltage
Alternator alternator (half throttle or above) à 27.5 – 29.5 V
terminal R If the battery is old, or after starting in cold
and chassis areas, the voltage may not rise for some time.
If the condition is as shown in the table 1) Turn starting

Measure resist- below, it is normal. switch OFF.
Main monitor
2) Disconnect
Engine water CNE 05
ance Normal tem- Approx. 2 kΩ CNE05.
temperature sensor (male) perature (25°C) Between CNE05
(male) – GND
Pre-heating 5°C Approx. 4 kΩ
resistance

Measure
below, it is normal. switch OFF.

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

resistance
in the table below, it is normal. switch OFF.

Measure
2) Disconnect
F solenoid CNT01 connector.
(male) Between (1) – (2) 46 – 58 kΩ
Between (1) – chassis Min. 1 MΩ

resistance
Measure
2) Disconnect
R solenoid CNT02 connector.
(male) Between (1) – (2) 46 – 58 kΩ

Transmission controller

resistance

Measure
2) Disconnect
H-L solenoid CNT03 connector.
(male) Between (1) – (2) 46 – 58 kΩ

resistance
Measure
2) Disconnect
Speed solenoid CNT04 connector.
(male) Between (1) – (2) 46 – 58 kΩ

resistance
Measure
2) Disconnect
Modulation valve CNT12
solenoid (male) Between (1) – (2) 12 – 15 Ω connector.
20-15

Judgment table
resistance
Measure
Relief solenoid for CNAF4 2) Disconnect
(male)
cylinder rod Between (1) – (2) 20 – 40 Ω CNAF4.
resistance
Measure
High pressure CNAF5 2) Disconnect
solenoid (male)
E.C.S.S. controller (if equipped)
Between (1) – (2) 20 – 40 Ω CNAF5.

resistance
Measure

Low pressure CNAF6 2) Disconnect
solenoid (male)
Between (1) – (2) 20 – 40 Ω CNAF6.

resistance
Measure
2) Disconnect
Pressure switch CNAF7 Oil pressure above CNAF7.
(male) Continuity
5.4 MPa (55 kg/cm2) Between
Oil pressure below (1) – (2)
4.4 MPa (45 kg/cm2) No continuity
resistance

Measure

Speed sensor CNT06 2) Disconnect
(male)
Between (1) – (2) 500 – 1000 Ω CNT06.
20-16
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

Name of component Connector Inspection Judgment table Measurement

Short connector
Short connector
connected Monitor goes off
CN R06 Monitor lights up

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

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

water level abnormal

chassis ground

Connect to
Chassis ground
connected Monitor goes off
CN E10 Monitor lights up

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

Engine oil level
normal Continuity
Engine oil level No continuity

abnormal

resistance

Measure
XT07 Normal temperature

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

resistance

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

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

« If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
20-17

chassis ground
Connect to
Terminal wiring Monitor goes off
harness disconnected
Connected to
chassis ground Monitor lights up
Engine oil pressure
sensor XB19 If the condition is as shown in the table Start engine.
Check continuity
below, the sensor is normal.

Oil pressure above No continuity
70 KPa (0.7 bar)
Oil pressure below
30 KPa (0.3 bar) Continuity
Check continuity

Brake ACC XB304 below, the sensor is normal. switch OFF.
Disconnect
Oil pressure above Continuity connector.
60 bar
Oil pressure below
40 bar No continuity
20-18

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

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

Measure

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

resistance

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

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

Transmission controller

resistance

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

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

resistance
Measure
2) Disconnect
Modulation valve XT12
solenoid Between (1) – (2) 12 – 15 Ω connector.
20-19

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

Measure

Speed sensor XE228 2) Disconnect
Between (1) – (2) 500 – 1000 Ω CN06.
20-20
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

Check or measurement item Symbol Part No. Part Name Remarks
Digital display
Engine speed A 799-203-9000 Multi-tachometer L: 60 – 2,000 rpm
H: 60 – 19,999 rpm
1 799-101-1502 Digital temperature gauge ––

Coolant, oil, and exhaust B
temperatures
2 799-201-1110 Wiring harness Measure exhaust temperature
Pressure gauge
799-101-5002 Analog hydraulic tester 2.45, 5.88, 39.2, 58.8 MPa
(25, 60, 400, 600 bar)
Oil pressure C
Pressure gauge
790-261-1203 Digital hydraulic tester 49.0 MPa (500 bar)
799-401-2320 Hydraulic gauge 1.0 MPa (10 bar)
0 – 6.9 MPa (0 – 70bar)
1 795-502-1590 Compression gauge
Compression pressure D Kit Part No. 795-502-1205
2 795-502-1360 Adapter ––
1 799-201-1511 Tool
2 799-201-1541 Gauge
Blowby pressure E Kit Part No.
3 799-201-1571 Tube 799-201-1504
4 799-201-1450 Adapter
Valve clearance F Commercially Feeler gauge

available
Discoloration 0 – 70% (with
standard color)
1 799-201-9000 Handy smoke checker (Discoloration % x 1/10 =
Exhaust color G
Bosch index)
2 Commercially Smoke meter ––
available
Intake air pressure H 799-401-2310 Pressure gauge 1,500 mmHg
1 79A-264-0090 Push-pull scale 0 – 490 N (0 – 50 kg)

Operating force I
2 79A-264-0020 Push-pull scale 0 – 294 N (0 – 30 kg)
J Commercially Scale ––
Stroke, hydraulic drift available
Commercially
Work equipment speed K available Stop watch ––
Troubleshooting of wiring
harnesses and sensors L 799-601-7400 T-adapter ––
Measuring voltage and Commercially
resistance values M available Tester ––
Commercially
Clearance O available Feeler gauge
Wear of parking brake P Commercially Calipers

available
1 793-520-1803 Brake test kit
Brake oil pressure Q
2 170-21-11190 Nipple
Boom drop prevention tool R 793-463-1100 Stopper
SN WA470H20669 and up:

Tools for testing and adjusting the Cummins MTA 11 engine are specified on the following pages.
20-101
20-102
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

From SN WA470H20669
When removing or installing the measuring equip-
ment, be careful not to touch any high temperature
or rotating parts.
« Measure the engine speed under the following condi-

tions.
1) Coolant temperature: Within operating range
2) Engine oil temperature: 70 – 90°C
3) Hydraulic oil temperature: 45 – 55°C
1. Attach a reflective marker to the fan pulley.
2. Start the engine, and measure the engine speed

when the engine is at low idling and high idling.
3. Check engine speed using the digital optical ta-

chometer.
Cummins-Part No. 3377462 Tachometer
« When measuring items other than the above

(during torque converter stall), see the proce-
dure for each item.
20-103

TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR

PRESSURE
From SN WA470H20669
parts.
1. Remove intake air pressure measurement plug.
2. Install pressure gauge kit (0 - 160 psi).

Cummins-Part No. 3375275 Pressure gauge
When measuring, be careful not to touch any rotat-

ing or high temperature parts.
Note:
Intake manifold pressure (turbocharger boost) must
be corrected for variations due to intake air tem-
perature. Use the 'Boost Pressure Correction Fac-
tor' explained in Engine Testing - General Informa-
tion'.
20-104

TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS

VALVES AND INJECTORS
From SN WA470H20669
Valve and injector
Valves and injectors must be correctly adjusted for adjustment limits
the engine to operate efficiently. Valve and injector
adjustment must be performed using the values listed "Top stop" injector preload: 0,6 - 0,7 Nm
in this section. The accompanying table gives the
adjustment limits for STC engines. mm
1. Adjust the valves and the injectors at each 1,500 Intake valve 0,35
hour maintenance interval. If the valves and injectors Exhaust valve 0,68
have been adjusted during troubleshooting or before
the 1,500 hour scheduled maintenance interval, ad-
justment is not required at this time.
« All overhead, valve and injector, adjustments must

be made when the engine is cold, any stabilized
coolant temperature at 60°C or below.
2. Remove the crankcase breather tube from the crank-

case breather outlet. Remove the 16 capscrews,
isolators, and spacers from the cover.
3. Remove the valve cover and gasket.
« Each cylinder has three rocker levers:

• The long rocker lever (E) is the exhaust lever.
• The center rocker lever is the injector lever.
• The short rocker lever (1) is the intake lever.
Refer to the accompanying chart for valve rocker

lever locations.
20-105

« The crankshaft rotation is clockwise when viewed

from the front of the engine.
The cylinders are numbered from the front gear

cover end of the engine.
The engine firing order is 1-5-3-6-2-4.
« The valves and injectors on the same cylinders are

not adjusted at the same index mark on the acces- Valve and injector
sory drive pulley on STC engines. adjustment sequence
Bar engine
One pair of valves and one injector are adjusted at in direction Pulley Set cylinder
each pulley index mark before rotating the acces- of rotation position Injector Valve
sory drive to the next index mark. Start A 3 5
advance to B 6 3
advance to C 2 6
Two crankshaft revolutions are required to adjust all advance to A 4 2
the valves and injectors. advance to B 1 4
advance to C 5 1
Do not pull or pry on the fan to manually rotate the

crankshaft. To do so can damage the fan blades.
Damaged fan blades can cause premature fan fail-
ures which can result in serious personal injury or
property damage.
« The valve set marks are located on the accessory

drive pulley. The marks align with a pointer on the
gear cover.
4. Use the accessory drive shaft to rotate the crank-

shaft.
The adjustment can begin on any valve set mark. In

the following example the adjustment will begin on
the "A" valve set mark with cylinder number five
valves closed and cylinder number three injector
ready for adjustment.
5. Rotate the accessory drive shaft clockwise until the

“A" valve set mark on the accessory drive pulley is
aligned with the pointer on the gear cover.
20-106
When the “A’ mark is aligned with the pointer, the

intake and exhaust valves for cyilnder number five
must be closed. If these conditions are not correct,
cylinder number four injector and cylinder number
two valves must be ready to set.
« Both valves are closed when both rocker levers are

loose and can be moved from side to side.
6. Loosen the injector adjusting screw locknut on cylin-

der number three. Tighten the adjusting screw until
all the clearance is removed from the injector train.
7. Tighten the adjusting screw one additional turn to

correctly seat the link.
8. Loosen the injector adjusting screw until the STC

tappet touches the top-cap of the injector.
9. Make sure to loosen the adjusting screw enough, so

there is no preload on the injector. This will be
accomplished when e rocker lever is loose enough
to move.
10. Place the STC tappet adjusting tool on the upper

surface of the STC injector top-cap.
Cummins-Part No. 3823348 Adjusting tool
11. Rotate the tool around the tappet until the tool’s
locating pin is inserted into one of the four holes in
the top of the tappet.
20-107
Apply thumb pressure to the tool handle to hold the

tappet in the maximum upward position.
Apply only enough force to the tool to hold the

tappet in the maximum upward position. Excess force
will cause the tool to break
An overtightened setting on the injector adjusting

screw will produce increased stress on the injector
train and the camshaft injector lobe which can result
in engine damage.
12. Use a torque wrench to tighten the adjusting screw

while holding the tappet in the maximum upward
position.
Adjusting screw: 0,6 - 0,7 Nm
Cummins-Part No. 3376592 Torque wrench
13. Hold the adjusting screw in this position. The adjust-

ing screw must not turn when the locknut is tight-
ened.
Locknut: 61 Nm
(without torque wrench adapter)
Locknut: 47 Nm
(with torque wrench adapter (1))
The tappet tool must be removed before rotating the

crankshaft to prevent damage to the tappet.
14. Remove the tappet adjusting tool.
15. Check to make sure the injector push rod can be

rotated by hand. If it can’t, the setting is too tight.
20-108
16. Adjust the valves on the appropriate cylinder ac-

cording to the sequence chart before rotating the Valve and injector
accessory drive to the next valve set mark. adjustment sequence
Bar engine
in direction Pulley Set cylinder
of rotation position Injector Valve
Start A 3 5
advance to B 6 3
advance to C 2 6
advance to A 4 2
advance to B 1 4
advance to C 5 1
Select a feeler gauge for the correct valve lash

specification.
Valve Lash Specification
mm
Intake valve 0,36
Exhaust valve 0,69
17. Insert the feeler gauge between the top of the

crosshead and the rocker lever pad.
« Two different methods for establishing valve lash

clearance are described below. Either method can
be used; however, the torque wrench method has
proven to be the most consistent. It eliminates the
need to feel the drag on the feeler gauge.
Torque Wrench Method: Use the torque wrench.

and tighten the adjusting screw.
Adjusting screw: 0,7 Nm
Cummins-Part No. 3376592 Torque wrench
Touch Method: Tighten the adjusting screw until a

light drag is felt on the feeler gauge.
20-109
18. Hold the adjusting screw in this position. The adjust-

ing screw must not turn when the locknut is tight-
ened.
Locknut: 61 Nm
(without torque wrench adapter)
Locknut: 47 Nm
(with torque wrench adapter (1))
19. After tightening the locknut to the correct torque

value, check to make sure the feeler gauge will slide
backward and forward between the crosshead and
the rocker lever with only a slight drag.
20. If using the touch method, attempt to insert a feeler

gauge that is 0.03 mm thicker between the crosshead
and the rocker lever pad. The valve lash is not
correct when a thicker feeler gauge will fit.
21. After adjusting the valves, rotate the accessory drive

and align the next valve set mark on the accessory
drive pulley with the pointer on the gear cover.
20-110
22. Adjust the appropriate injector and valves following

the injector and valve adjustment sequence chart. Valve and injector
adjustment sequence
23. Repeat the process to adjust all injectors and valves. Bar engine
in direction Pulley Set cylinder
24. After adjusting all the injectors and valves, check the of rotation position Injector Valve
torque ie adjusting screw locknuts to make sure Start A 3 5
none were overlooked. advance to B 6 3
advance to C 2 6
advance to A 4 2
advance to B 1 4
advance to C 5 1
If the valve cover gasket was not damaged, it can be

used again. If the gasket was damaged, it must be
discarded and a new one used.
25. Install the cover on the rocker lever housing.
26. Install the 16 isolators, spacers and capscrews in

the cover. Tighten the capscrews in the sequence
shown.
Screws: 15 Nm
20-111
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
From SN WA470H20669
« Raise the coolant temperature to the operating range

before measuring the blow-by pressure.
1. Install testing tool to the tip of engine breather hose.
Cummins-Part No. 3822566 Testing tool
2. Install manometer to the testing tool.
Cummins-Part No. ST-1111-3 Manometer
3. Run the engine at the rated output and measure the

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

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

gine running at rated output.
• When measuring in the field, a similar value can
be obtained at stall speed.
• If it is impossible to check at rated output or stall
speed, measure at high idling. In this case, the
blow-by value will be about 80% of the value at
rated output.
« Blow-by varies greatly according to the condi-
tion of the engine. Therefore, if the blow-by
value is considered abnormal, check for prob-
lems connected with defective blow-by, such as
excessive oil consumption, defective exhaust gas
color, and prematurely dirty or deteriorated oil.
20-112

TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
From SN WA470H20669
When measuring, be careful not to let your clothes

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

any oil pressure sensor or oil pressure gauge.
« When measuring the oil pressure, always measure
at the specified oil temperature.
1. Remove plug at cylinder block.
2. Install oil pressure gauge (Range: 0-160 psi).

Cummins-Part No. 3375275 Pressure gauge
3. Start the engine and measure the oil pressure.
20-113

TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION

FAN BELT TENSION
From SN WA470H20669
DRIVE BELT, COOLING FAN
1. Measure the belt tension in the center span of the

pulleys.
Cummins Part-No. ST-1293 Belt tension gauge
New Used
Fan belt tension (N) 1330 530 to 1070
Do not adjust belt tension to full value with the

adjusting screw. Belt tension can increase when the
locknut is tightened and cause reduced belt and
bearing life.
2. Adjustment
1) Loosen the idler pulley shaft locknut and adjust belt

tension.
2) Tighten the idler pulley shaft locknut.
3. Check the belt tension again to make sure the belt is

not too tight.
20-114

DRIVE BELT, ALTERNATOR FAN

From SN WA470H20669
1. Measure the belt tension in the center span of the
pulleys.
Cummins Part-No. ST-1293 Belt tension gauge
New Used
Drive belt tension (N) 670 270 to 530
NOTE:
A belt is considered used if it has been in operation
for 10 minutes or longer.
2. Adjustment
1) Loosen the adjusting screw locknut (1).
2) Loosen the adjustment link locking capscrew (2).
3) Loosen the alternator mounting capscrew (3).
4) Turn the adjusting screw (4) clockwise to increase

tension.
5) Tighten the adjusting screw locknut (2) against the

retainer.
6) Tighten the adjustment link locking

capscrew (3).
Locking capscrew: 80 Nm
7) Tighten screw (4) and nut (5).

Screw: 47 Nm
Nut: 47 Nm
20-115

TESTING AND ADJUSTING MEASURING STALL SPEED
MEASURING STALL SPEED

From SN WA470H20669
« Measurement conditions
• Engine water temperature: Within green range on

engine water temperature gauge
• Hydraulic oil temperature: 45 – 55°C
• Engine speed: High idling
• Torque converter oil temperature: 60 – 80°C
« Check that low idling and high idling are the stand-
ard values.
« Check that the engine speed is the standard value.

If it is not within the standard range, check for loose
linkage or play.
Apply the parking brake and put blocks under the

tires.
When measuring, be careful not to touch any rotat-

ing or high temperature parts.
Check stall speed together with a second person.
TORQUE CONVERTER STALL SPEED
« Before carrying out the measurement, always dis-

connect the connector from the speedometer sen-
sor wiring.
Person A:
1. Attach a reflective marker to the fan pulley.
Person B:
2. Start the engine and run at low idling.
3. Release the parking brake.
4. Place the speed lever at the highest position for

FORWARD or REVERSE.
20-116

5. Use the brakes to stop the machine.

« Turn transmission cut-off selector switch (2) OFF
and use the left brake.
(Check that the pilot lamp goes out.)
« Do not keep the stall condition for more than 20
seconds. Make sure that the torque converter oil
temperature does not exceed 120°C.
Person B:
6. Check engine speed at high idling, using the digital
optical tachometer.
HYDRAULIC STALL SPEED
Person A:
1. Start the engine and run at high idling.
2. Operate the lever to the DUMP or LIFT position to

operate the cylinder to the end of its stroke and
actuate the relief valve in the main control valve.

seconds. Operate the control lever quickly
T E W _ 00 74
Person B:
3. Check engine speed at high idling, using the digital
optical tachometer.
20-117
FULL STALL SPEED

connect connector from speedometer sensor wiring.
• Measure the engine speed when the torque con-

verter stall and hydraulic stall are both carried out at
the same time.
« Before measuring the full stall, check that the
torque converter stall and hydraulic stall speeds
are normal.
If either of the stall speeds are abnormal, cor-
rect the problem and measure again.
20-118
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

parts.
« Measure the engine speed under the following condi-

tions.
1) Coolant temperature: Within operating range
2) Torque converter oil temperature : 60 – 80°C
3) Hydraulic oil temperature : 45 – 55°C
4) Work mode selector switch on High mode
(from SN WA470H21164 and up)
1. Remove cap (1) from speed pick-up port, then in-

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

cable.
When carrying out the measurement, be careful

not to touch any high temperature parts or rotat-
ing parts.
3. Start the engine, and measure the engine speed

when the engine is at low idling and high idling.
« When measuring items other than the above (dur-
ing torque converter stall), see the procedure for
each item.
20-119
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRES-

SURE (BOOST PRESSURE)

parts.
1. Remove intake air pressure measurement plug (1)

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

pler (2) and pressure gauge C (1500 mmHg).
When carrying out the measurement, be careful

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

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

pressure indicated by the gauge.
20-120

ADJUSTING VALVE CLEARANCE ADJSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

« When adjusting the valve clearance, use the follow-
ing procedure to adjust the clearance between the
valve and and rocker lever to the value.
1. Remove valve cover (1).
2. Rotate the crankshaft in the normal direction to align

the "1.6TOP" line (6) on the crankshaft pulley with
the pointer (2) when No.1 cylinder is at top dead
center. When rotating, check the movement of the
valves.
6. When No.1 cylinder is at compression top dead

center, adjust the valves marked "l"; when No.6
cylinder is at compression top dead center, adjust
the valves marked "¡".
« Valve arrangement
Cylinder no. 1 2 3 4 5 6
Intake valve l l ¡ l ¡ ¡
Exhaust valve l ¡ l ¡ l ¡
4. To adjust the valve clearance, loosen locknut (6),

then insert feeler gauge D between rocker lever (3)
and crosshead (4), and turn adjustment screw (5)
until the clearance is a sliding fit.
Then tighten locknut (6) to hold the adjustment screw
in position.
Locknut : 66.7 ± 7.9 Nm (6.8 ± 0.8 kgm)
5. Next, rotate the crankshaft one turn (360°) in the

normal direction and adjust the valve clearance of
the remaining valves marked "¡".
« After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 120° each time and adjust the valve
clearance of each cylinder according to the firing
order.
• Firing order : 1 à 5 à 3 à 6 à 2 à 4
« After tightening the locknut, check the valve clear-
ance again.
20-121

TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOUR

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

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

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

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

measuring the exhaust gas color.
1) Insert the probe into the outlet port of the ex-
haust pipe, then tighten the clip to secure it to
the exhaust pipe.
2) Connect the probe hose, accelerator switch plug,
and air hose to tool G2.
« The pressure of the air supply should be
less than 1.5 MPa (15 kg/cm2).
3) Connect the power cord to the AC100V outlet.
« When connecting the cord, check first that
the power switch is OFF.
4) Loosen the cap nut of the suction pump, then fit
the filter paper.
« Fit the filter paper securely so that the ex-
haust gas does not leak.
5) Turn the power switch.
6) Accelerate the engine suddenly, and at the same
time, depress the accelerator pedal and 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 value.
20-122
TESTING AND ADJUSTING MEASURING EXHAUST GAS TEMPERATURE
MEASURING EXHAUST GAS

TEMPERATURE
The temperature sensor is installed to the exhaust
manifold, so if the machine has been operated, wait
for the manifold to cool down before installing the
sensor.

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

install temperature sensor (2).
• Temperature sensor : 6215-11-8180 (cable length:
610 mm), or 6215-11-8170 (cable length: 490
mm)
2. Connect to digital temperature gauge F1 with wiring

harness F2.
Measurement procedure
1. Measuring at torque converter stall
« If the exhaust gas temperature is measured only
at torque converter stall, and this is continued
until the sensor core heats up and a stable value
is obtained, the torque converter will overheat.
1) Use the full stall (torque converter stall + hydrau-
lic relief) to raise the exhaust gas temperature .
2) From the above condition, cancel the hydraulic
relief, and carry out only torque converter stall.
(The temperature will start to go down. If it does
not go down and continues to go up, make the
temperature setting at 1) higher.)
3) When the temperature starts to go down, record
the stable temperature.
2. When measuring maximum value for exhaust gas
temperature
Carry out actual work and measure the maximum
value when operating.
« Use the PEAK mode function (the maximum
value can be recorded) of the temperature gauge.
20-123
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRES-

SURE
before measuring the blow-by pressure.
1. Install tools G4 and G1 to the tip of engine breather

hose (1), then connect tools G3 and G2.
2. Run the engine at the rated output and measure the

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

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

gine running at rated output.
• When measuring in the field, a similar value can
be obtained at stall speed.
• If it is impossible to check at rated output or
stall speed, measure at high idling. In this case,
the blow-by value will be about 80% of the value
at rated output.
« Blow-by varies greatly according to the condition
of the engine. Therefore, if the blow-by value is
considered abnormal, check for problems con-
nected with defective blow-by, such as exces-
sive oil consumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
20-124

ADJUSTING VALVE CLEARANCE MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
When measuring the compression pressure, be careful
not to touch the exhaust manifold or muffler, or to
get your clothes caught in the fan, fan belt or other
rotating parts.
« Warm up the engine (oil temperature: 40 - 60’C)

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

For details, see ADJUSTING VALVE CLEARANCE.
2. Remove spill tube (1) and disconnect fuel injection
pipe (2).
3. Remove nozzle holder assembly (3) from each cylin-

der to be measured.
« When removing nozzle holder assembly (3),
assemble bolt to the spill tube mount and
twist with bar to remove.
« Be careful not to let dirt or dust get in.
4. Install adapter H2 in the mount of the nozzle holder

of the cylinder to be measured, and tighten to the
specified torque.
Torque : 21.6 :t 2.9 Nm (2.2 :c 0.3 kgm)
5. Connect compression gauge H1 to adapter H2.
6. Disconnect connector (5) of stop motor (4), set to

the NO INJECTION position, then crank the engine
with the starting motor and measure the compres-
sion pressure at the point where the pressure gauge
indicator remains steady.
6A. Disconnect the manual emergency engine stop ca-

ble, place the governor lever of the injection pump in
the NO INJECTION position, then crank the engine
with the starting motor and measure the compres-
sion pressure at the point where the ressure au e
indicator remains stead .
20-125

TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL

PRESSURE
When measuring, be careful not to let your clothes

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

any oil pressure sensor or oil pressure gauge.
« When measuring the oil pressure, always measure
at the specified oil temperature.
1. Remove oil pressure sensor.

2. Install tool B (gauge: 1.0 MPa (10 bar)).
3. Start the engine and measure the oil pressure.
20-126

TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
The following methods can be used for testing and

adusting the fuel injection timing of the injection
pump.
• Match mark alignment method
This method is used when assembling the injection
pump to the original engine without making any re-
pairs.
• Delivery valve method
This method is used when assembling and injection
pump that has been repaired or replaced.
« Set the No. 1 cylinder to the compression top dead
center position before carrying out testing and ad-
justing.
For details, see ADJUSTING VALVE CLEARANCE.
Testing and adjusting using match mark alignment

method
1. Rotate the crankshaft 30 - 40° in the reverse direc-

tion from the No. 1 cylinder TOP position.
2. Rotate the crankshaft slowly in the normal direction

to align pointer (2) with the injection timing line on
crankshaft damper (1).
3. Check that line a on the injection pump and line b on

the coupling are aligned.
If tile lines are not aligned, loosen nut (3), move the
coupling to align the lines, then tighten the nut.
Nut: 60.8 ± 2 Nm (6.2 ± 0.2 kgm)
20-127

TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
3. Take out delivery valve stopper spring (6) and deliv-

ery valve (7) from the delivery valve holder, then in-
stall the delivery valve holder again.
4. Place the fuel control lever at the FULL position,

then rotate the crankshaft in the normal direction
while operating the priming pump, and stop at the
point where the fuel stops flowing from the delivery
valve holder.
5. Check that the pointer and the injection timing line

on the crankshaft damper are aligned at the point
where the fuel stops flowing.
« Beyond injection timing line: Injection timing is
retarded
« Before injection timing line: Injection timing is
advanced
« If the check shows that the injection timing is not

correct, adjust the fuel injection timing as follows.
« After testing and adjusting, do not forget to assemble

the spring and delivery valve again.
1) Rotate the crankshaft 30 - 401 in the reverse direc-

tion from the No. 1 cylinder TOP position.
2) Rotate the crankshaft slowly in the normal direction

to align pointer (2) with the injection timing line on
crankshaft damper (1).
3) Loosen nut (3) in the oblong hole of the injection

pump mounting flange, then rotate the flange at the
pump end a little at a time while operating the prim-
ing pump, and stop at the point where the fuel stops
flowing from the delivery valve holder.
4) Tighten the nut in the oblong hole of the injection

pump mount flange.
Check the injection timing again to confirm that the in-
jection timing is correctly adjusted.
Nut: 60.8 ± 2 Nm (6.2 ± 0.2 kgm)
5) Align match mark a with match mark b and cut a

line.
20-128
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
METHOD FOR ADJUSTING

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

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

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

stopper at the stop end so that clearance a is 1 – 2
mm.
Adjust with nut (6) which secures the cable to the
bracket or carry out fine adjustment by changing the
depth that ball joint (3) is screwed in.
20-129

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

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

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

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

stop motor, and this absorbs the error in the
stop motor when the engine is stopped.
However, if this is absorbed by the loose
spring in the engine stop motor, force is
brought to bear on the injection pump, so
depending on the machine model, this sys-
tem may not be possible to use.
With such models, there is a danger of prob-
lems arising with the injection pump if the
clearance between the stop lever and the
stopper at the STOP end is set to 0 when
the engine is stopped.
20-130

FAN BELT TENSION
1. Testing fan belt tension

Measure the deflection of the belt when it is pushed
with a finger force (approx. 58.8 N (6 kg)) at point a
midway between the fan pulley and the alternator
pulley.
« Deflection of V-belt: Approx. 10 mm
2. Adjusting belt
1) Loosen alternator mount bolt (1) and adjust plate
mounting bolt (2).
2) Loosen the locknut, then tighten adjustment nut (3)
to adjust the tension of the belt.
3) After adjusting the belt tension to the standard value,
tighten the locknut, then tighten adjust plate mount-
ing bolt (2) and alternator mount bolt (1).
20-131

TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR
PEDAL
OPERATING FORCE OF ACCELERATOR PEDAL
Measuring
1. Set push-pull scale I2 at a position 150 mm from
pedal fulcrum a.
« Put the center of push-pull scale I2 in contact
with a point 150 mm from the pedal fulcrum.
2. Start the engine, then measure the maximum value

when the pedal is moved from the pushed position
(low idling) to the end of its travel (high idling).
Testing and adjusting

1. Stop the engine.
2. Remove cable (1) at the bottom of the accelerator

pedal, and check that there is no stiffness in plate
(2) or any other part under the pedal.
3. Connect cable (1) at the bottom of the pedal, dis-

connect it again at the injection pump connection,
and check that there is no stiffness in rod (3) or ball
joint (4).
« Carry out the above inspection, and adjust or
replace parts if necessary. Then carry out the
measurement of the operating force again to
check that it is within the standard value.
20-132
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
OPERATING ANGLE OF ACCELERATOR PEDAL
1. Measuring
1) Stop the engine.
2) Put angle gauge in contact with the accelera-

tor pedal, and measure operating angle a (a =
a1 – a2) when the pedal is operated from low
idling position a1 to high idling position a2.
2. Adjusting
1) Remove the cover at the bottom of the cab, and
open the inspection cover of the engine hood.
2) Loosen nut (1), and adjust bolt (2) so that in-

stalled height L of the accelerator pedal stopper
is within a range of 49.5 ± 5 mm.
3) Loosen locknut (3) and adjust the length of the

cable so that the injection pump governor lever
contacts the high idling stopper when the accel-
erator pedal is depressed (high idling).
« Check that the injection pump governor con-
tacts the low idling stopper when the accel-
erator pedal is let back to the low idling
position.
« Adjust the travel of the governor lever with
joint (4).
Cable joint nut: 13.7 ± 1 Nm
(1.4 ± 0.1 kgm)
« After carrying out the above adjustment,
measure each part again and check that it
is within the standard value.
20-133
TESTING AND ADJUSTING BASIC ADJUSTMENT OF ACCELERATOR PEDAL
BASIC ADJUSTMENT
OF ACCELERATOR PEDAL SN WA470H21164 and up
(5)
• Engine water temperature: Within green range
on engine water temperature gauge
• Torque converter oil temperature: 60 – 80°C ‘A’
• When the work mode selector switch is on high or

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

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

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

2100 ±15 rpm. If the maximum engine speed is not
within the tolerance, the height of the accelerator
pedal stop (2) must be adjusted.
5. Loosen the lock-nut (6) and turn the accelerator

pedal stop (2) at least 180° to the left or right until
the engine speed stands by 2100 ±15 rpm.
6. Tighten the lock-nut (6).
7. Switch to the work mode "standard" or "high" and

check the maximum engine speed. It must be about
2290 - 2390 rpm.
NOTE:
With full speed (accelerator pedal on stop), the
lever on the injection pump must not be connected
to the stop.
20-134
20-133-1

20-135
20-133-2

TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER
• Engine stopped
OPERATING FORCE OF SPEED LEVER
• Install push-pull scale I2 or a spring balance to the

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

knob, and measure the travel when the lever is
operated in the direction of operation.
20-134
MEASURING STALL SPEED


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

tires.
TORQUE CONVERTER STALL SPEED

connect the connector from the speedometer sen-
sor wiring.
2. Release the parking brake.
3. Place the speed lever at the highest position for

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

tachometer A to measure the speed when the en-
gine is run at high idling.
« Turn transmission cut-off selector switch (2) OFF
(Check that the pilot lamp goes out.)
seconds. Make sure that the torque converter oil
temperature does not exceed 120°C.
20-135
HYDRAULIC STALL SPEED
1. Start the engine and run at high idling.
2. Operate the lever to the DUMP or LIFT position to

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

seconds. Operate the control lever quickly.
FULL STALL SPEED

connect connector (2) from speedometer sensor
wiring (1).
• Measure the engine speed when the torque con-

verter stall and hydraulic stall are both carried out at
the same time.
« Before measuring the full stall, check that the
torque converter stall and hydraulic stall speeds
are normal.
If either of the stall speeds are abnormal, cor-
rect the problem and measure again.
20-136
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
MEASURING TORQUE CON-

VERTER, TRANSMISSION,
PARKING BRAKE OIL PRES-
SURE


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

measuring all oil pressures.
• Remove cover (1) on the left side of the rear
frame.
• Turn transmission cut-off selector switch (2) OFF
(Check that the pilot lamp is OFF.)
• Remove the plug from the measurement port of
the transmission valve.
• Install hydraulic tester kit B to the measurement
port, extend the gauge to the operator’s com-
partment, then start the engine and measure the
pressure.
« Check that no oil is leaking from any connection.
Measurement method
1. Priority pressure
1) Measurement port (P1, PT 1/8)
2) Start the engine, run at low idling, and measure
the pressure at the rated speed.
2. Torque converter outlet port pressure

2) Start the engine, run at low idling, and measure
the pressure at the rated speed.
20-137
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
Measurement method
1. Priority pressure
2) Start the engine,run at low idling,and meas-
ure the pressure at the rated speed.
2. Torque converter outlet port pressure

2) Start the engine, run at low idling, and
measure the pressure at the rated speed.
3. Pilot pressure
2) Start the engine and measure the pressure.
4. Clutch pressure
1) Measurement part (P4, PT 1/8)
2) Start the engine.
3) Release the parking brake.
4) Place the directional lever at neutral, and meas-
ure the pressure when the speed lever is op-
erated.
5. Parking brake pressure

2) Start the engine, and measure the pressure
when the parking brake is released.
20-138
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
METHOD OF OPERATING
EMERGENCY MANUAL SPOOL
Outline
The transmission valve is controlled electrically, but if

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

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

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

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

frame.
2. Remove lock plate (3) from emergency manual spool

(2) of the transmission valve.
« The lock plate can be removed simply by loos-
ening the mounting bolts.
3. Operate emergency spool (2) to the operating posi-

tion according to the direction of movement of the
machine (forward or reverse).
• REVERSE: Push in the spool until it enters the
detent. (Approx. 8 mm)
• FORWARD: Pull the spool until it enters the
detent. (Approx. 8 mm)
4. Check that the area around the machine is safe,

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

pedal fully.
20-139
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
6. Start the engine, then release the parking brake and

slowly let the brake pedal out to start the machine.
When the engine is started, the transmission is also

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

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

install the lock plate.
20-140
TESTING AND ADJUSTING MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
MEASURING CLEARANCE BE-

TWEEN TIRE AND WHEEL
• Tire inflation pressure: Specified pressure
Method of measuring
1. Fitting of wheel lock ring
Using feeler gauge O, measure dimensions a and b
at four places around the circumference.
2. Clearance of wheel lock ring

Measure dimension c.
20-141
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
MEASURING OPERATING FORCE OF STEER-

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

• Engine speed: Low idling or high idling (bucket empty)
Measurement method
1. Install push-pull scale I2 to the steering wheel knob.
2. Start the engine.

« After starting the engine, raise the bucket approx.
400 mm and remove the safety bar.
3. Pull push-pull scale I2 in the tangential direction and

measure the value when the steering wheel moves
smoothly.
« Avoid measuring when the steering wheel starts
to move.
20-142

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

WHEEL

• Engine speed: Low and high idling
Measurement method

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

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

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

2. Operate the steering wheel to the end of its stroke to
turn the machine to the left or right.
3. Stop the engine.
4. Turn the stop travel bolt until the head of the bolt
touches the top of the valve.
5. Start the engine und turn the steering wheel until the
machine sets in a straight line.
6. Stop the engine; loosen stop travel bolt 8,5 turns
(approx. 15mm) and lock bolt.
7. Carry out the measurements to both the left and
right side.
20-143
TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
MEASURING STEERING OIL

PRESSURE
• Hydraulic oil: 45 – 55°C

METHOD OF MEASURING MAIN RELIEF PRES-

SURE
Loosen the oil filler cap to release the pressure

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

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

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

turn the steering wheel to the right and measure the
pressure when the relief valve is actuated.
« To measure the pressure when turning the steer-
ing wheel to the left, remove the plug for the left
turn steering circuit.
20-144

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

sure.
1. Stop the engine.
2. Loosen locknut (3), then turn adjustment screw (4)

to adjust.
« Pressure adjustment for one turn of adjustment

screw: Approx. 14.8 MPa (151 bar)
« Turn the adjustment screw to adjust the set
pressure as follows.
« Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
20-145
TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER

• Engine speed: Low idling
Operating force of pedal
1. Install push gauge to the operator’s foot.

« Align the center of the push gauge with the
center of the pedal.
2. Start the engine, run at low idling, and measure the
operating force when the pedal is depressed.
Travel of pedal
1. Install push gauge to the operator’s foot.

« Align the center of the push gauge with the
center of the pedal.
2. Start the engine, and measure pedal angle a1 when
running at low idling, and pedal angel a 2 when the
pedal is depressed with a force of 30 kg.
« Install angle gauge to the brake pedal when
measuring.
Pedal play

2. Push the brake pedal lightly by hand, and measure
pedal angle a3 when the pedal starts to become
heavy.
20-146
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
MEASURING BRAKE
PERFORMANCE
• Travel speed: 20 km/h when brakes are applied
• Delay in applying brakes: 0.1 sec
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position

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

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

brakes were applied to the point where the machine
stopped.
« Repeat this measurement three times and take
the average.
20-147
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
TESTING BRAKE OIL

PRESSURE
• Brake oil pressure: 4.9MPa (50 bar)
Put blocks securely under the tires.
Testing
1. Remove bleeder screw (1) and nipple (3), then
install tool Q2, nipple (3), and tool Q1 in order in the
mount of bleeder screw (1).
2. Start the engine and bleed the air.

« This operation is carried out with two workers.
One worker operates the brake pedal while the
other worker bleeds the air from bleeder screw
(2).
« Turn the transmission cut-off switch ON.
3. Depress the left brake, set the gauge reading to 4.9

MPa (50 bar), then leave for 5 minutes and measure
the drop in the pressure.
4. After measuring, stop the engine, loosen the bleeder

screw to lower the pressure, then remove tool Q1.
« Remove tool Q2 also.
« After completing the operation, bleed the air
from the brake circuit again.
20-148
TESTING AND ADJUSTING MEASURING BRAKE DISC WEAR
MEASURING BRAKE DISC

WEAR
• Brake oil pressure:
Specified (4.9 MPa (50 bar))
Park the machine on horizontal ground and put

blocks securely under the tires.
Measurement method
1. Remove plug (1).
2. Depress the brake pedal fully.
3. Use calipers P to measure depth a from the end

face of the housing to the spring guide.
« When measuring, keep the brake pedal de-
pressed.
4. Install a vinyl hose to bleeder (2), then loosen the

bleeder and drain the brake oil.
« After draining the brake oil, check that the brake
piston has returned to the end of its stroke.
5. Measure depth b from the end face of the housing

to the spring guide pin.
Calculating piston stroke

• S=a–b S = Max. 6.2 mm
20-149
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE SYSTEM
BLEEDING AIR FROM BRAKE

SYSTEM
Put blocks securely under the tires.
1. Remove cap (1) of the bleeder screw, insert a vinyl

hose into the screw, and insert the other end in a
container.
3. Depress the brake pedal, then loosen the bleeder

screw and bleed the air.
« This operation is carried out with two workers.
One worker operates the brake pedal while the
other worker bleeds the air from the bleeder
screw.
« When depressing the brake pedal, use the left
pedal.
4. When no more bubbles come out with the fluid from

the hose, depress the pedal fully and tighten the
bleeder screw while the oil is still flowing.
« Repeat the operation to bleed the air from the
other cylinders, and after completing the opera-
tion, check the level in the oil tank and add more
oil if necessary.
« To bleed the air completely, bleed the air first
from the cylinder which is farthest from the
brake pedal.
20-150
TESTING AND ADJUSTING MEASURING PARKING BRAKE PERFORMANCE
MEASURING PARKING BRAKE

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

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

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

release the brake pedal and check that the machine
is held in position.
« When the engine is stopped, the parking brake
is automatically switched ON.
« Carry out the measurement in two ways: Once
with the machine facing uphill, and once more
with the machine facing downhill.
20-151
TESTING AND ADJUSTING METHOD FOR MANUAL RELEASE OF PARKING BRAKE
METHOD FOR MANUAL RE-

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

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

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

procedure.
1. Loosen bolt (1), then remove lock plate (2) from bolt
(3) (3 places).
2. Tighten bolts (3) at 3 places in turn as far as the

mounting position for the plate at portion ”a”, then
install lock plate (2) at portion ”a”.
« Tighten all three bolts uniformly a little at a time.
« Bolt (3) pushes piston (4) and (5) and releases
the parking brake.
3. Tighten bolt (1) to secure lock plate (2) in position.
20-152
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
TESTING WEAR OF PARKING

BRAKE DISC
« If the parking brake becomes weak, measure the
piston stroke as follows.

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

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

parking brake manual release bolt (3) (3 places).
2. Measure dimension “a” with the three manual re-

lease bolts (3) in contact lightly with brake pistons
(4).
3. Tighten the three manual release bolts (3) in turn

and measure dimension “b” when the release bolts
(3) are tightened fully.
« Piston stroke (L) = a – b
L = Max. 9.9
« If the piston stroke is greater than 9.9 mm,

check thickness W of brake disc (6). For
details, see DISASSEMBLY AND ASSEMBLY,
REMOVAL OF PARKING BRAKE DISC.
• Dimension W: Min 2.83 mm
20-153
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
MEASURING WORK EQUIP-

MENT CONTROL LEVER
• Engine speed: Low idling
Install the safety bar to the frame.
Measurement method
1. Operating force of work equipment control lever
Install push-pull scale I2 to the work equipment con-
trol lever and measure the operating force.
« Install the push-pull scale to the center of the
knob.
« Operate the control lever at the same speed as
for normal operations, and measure the mini-
mum value for the force needed to operate the
knob.
2. Travel of work equipment control lever

Measure travel L at each position when operating
the work equipment control lever.
« Mark the lever knob and use scale J to meas-
ure.
20-154
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
Adjusting
1. Remove cover (1).
2. With solenoid (6) pulled, fix the solenoid in position

so that the clearance between cam (3) and roller (4)
is dimension a.
Dimension a: 0 – 0.5 mm
« Set the bucket lever and lift lever at the HOLD
position.
« If cam (3), roller (4), or spring (5) are broken,
replace them before adjusting.
3. Boom lever
Operate the boom lever and adjust the length of rod
(2) so that roller (4) is dimension b at the notch at
both ends of cam (3).
Dimension b: 0 – 1 mm
4. Bucket lever
Operate the lift lever and adjust the length of rod (2)
so that roller (4) is dimension C at the notch at both
ends of cam (3).
Dimension C: 0 – 1 mm
20-155
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASURING WORK EQUIP-

MENT HYDRAULIC PRESSURE
Up to Serial number: WA470H20617

tires.
1. PPC relief valve pressure
Measuring
1) Raise boom (1), set support (2) or stopper R in
position under the lift arm, then remove cover
(3).

inside the hydraulic tank, then operate the bucket
control lever at least 40 times between TILT and
HOLD to completely release the pressure in the
accumulator.
« After operating the bucket lever, operate the

bucket lever to the DUMP position and check
that the bucket does not dump.
« Always stop the engine before operating the
lever.
2) Remove plug (4) for measuring the hydraulic

pressure in the dump cylinder circuit of the
main control valve.
3) Install hydraulic tester kit B to the measurement

port.
« Install the 90° elbow in the hydraulic tester
kit to the measurement port, then connect
the hose.
« Check that there is no oil leakage from any
joint.
« Use a hose which is long enough to reach
the operator’s compartment.
4) Start the engine, raise the lift arm approx. 400

mm, then operate the control lever to tilt back
the bucket, and measure the pressure when the
relief valve is actuated.
« Be careful not to apply pressure suddenly
to the oil pressure gauge.
When removing the oil pressure gauge, release

the pressure inside the circuit in the same way
as when installing the gauge.
20-156
Adjusting
Always stop the engine when adjusting the oil pres-

sure.
1) Stop the engine and remove cover (1).
2) Loosen locknut (2), then turn adjustment screw

(3) to adjust.
« Pressure adjustment for one turn of adjust-
ment screw:
Approx. 1.79 MPa (18.3 bar)
20-157
2. Work equipment relief valve pressure
Measurement method

inside the hydraulic tank, then operate the control
lever several times to release the remaining pres-
sure inside the piping.
« When operating each lever, set the bucket so that

portion a is raised 30 mm – 50 mm, then lower
portion b to the ground and stop the engine.
« After operating each lever, check that both bottom

surfaces of the bucket (portions a and b) contact
the ground surface.
1) Remove oil pressure measurement plug (1) from

the bucket cylinder circuit.
2) Install hydraulic tester kit B to the measurement

port.
« Install 90° elbow in the hydraulic tester kit
to the measurement port, then connect the
hose.
« Check that there is no oil leakage from any
joint.
« Use a hose which is long enough to reach
the operator’s compartment.
3) Start the engine, raise the lift arm approx. 400

mm, then operate the control lever to tilt back
the bucket, and measure the pressure when the
relief valve is actuated.
« Be careful not to apply pressure suddenly

to the oil pressure gauge.
When removing the oil pressure gauge, release

the pressure inside the circuit in the same way
as when installing the gauge.
20-158
Adjusting

sure.
1) Raise boom (1), set support (2) or stopper R in

position under the boom, then remove cover (3).
2) Remove locknut (4) of the relief valve.
3) Turn adjustment screw (5) to adjust.

« Pressure adjustment for one turn of adjust-
ment screw: Approx. 5,18MPa (52 bar)
20-159
TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
MEASURING PPC VALVE

PRESSURE
Serial number: WA470H20618 and up
Ports:
T M22 x 1,5
P, VA, HA, PPC, Orbitrol M16 x 1,5
Me1, Me2 M14 x 1,5
Me3 G 1/4
max. flow 62 l/min
max. pressure 110 bar
Pressure regulating valve:

Switch on press. 70 +8 bar
Switch off press. 100 -8 bar
2. Decal
3. Strainer
J. Pressure regulating valve
• Engine water temperature: Within engine water tem-
perature gauge green range
• Hydraulic oil temperature: 45 to 55°C
• Engine speed: High idle
Apply the parking brake and blocks the tires.
Measuring
1. Install the safety bar (4) to the frame.
2. Stop the engine, loosen the oil supply cap to release
the pressure inside the hydraulic oil tank and oper-
ate the bucket lever at least 40 times to release
accumulator pressure completly.
« Be sure to stop the engine before operating the
lever.
« After the accumulator pressure is completely re-
leased, set the bucket lever to the dump position and
check that the bucket does not dump.
3. Remove plug at measuring port (Me3).
4. Install hydraulic test kit to the measuring port (Me3).
« Check that there is no oil leakage from any joints.
« Use a hose which is long enough to reach the
operator's seat.
20-160

TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
5. Start the engine and measure.

• Be careful not to apply any sudden pressure to the
pressure gauge.
When removing the hydraulic pressure gauge, re-
lease the pressure inside the circuit in the same
way as when it was installed.
Adjusting

sure.
« The PPC relief valve is installed near the articulation

center at the rear frame.
1. Loosen locknut and turn adjustment screw to adjust.

« Adjust pressure at pressure regulating valve.
« Turn the adjustment screw to adjust the set pressure
as follows.
LOOSEN to DECREASE pressure.
20-161
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
MEASURING WORK
EQUIPMENT
• Steering position: Neutral
Measurement method
1. Boom RAISE time
Set the bucket at the lowest position from the ground
with the bucket tilted back fully, then raise it and
measure the time taken for the bucket to reach the
maximum boom height.
2. Boom LOWER time

Set the bucket horizontal, then lower the boom from
the maximum height and measure the time taken for
the bucket to reach the lowest position from the
ground.
3. Bucket DUMP time

Raise the boom to the maximum height, and meas-
ure the time taken to move the bucket from the tilt
position (bucket fully tilted back) to the dump posi-
tion (bucket fully tipped forward).
4. Bucket TILT time
1) Raise the boom to the maximum height, and

measure the time taken to move the bucket to
the tilt position (bucket fully tilted back).
2) Set the bucket horizontal to the ground and
measure the time taken to move the bucket from
the horizontal position to the tilt position (bucket
fully tilted back).
20-162

TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
MEASURING HYDRAULIC DRIFT WORK EQUIP-

MENT
• Stop the engine, leave for 5 minutes, then measure
for 15 minutes.
• Boom: Horizontal
• Bucket: Horizontal
• No load
Apply the safety lock to the work equipment control

levers.
Never go under the work equipment.
Measurement method
1. Set the boom and bucket in a horizontal position,
then stop the engine.
2. Leave for 5 minutes, then start the measurement.

3. Wait for 15 minutes, then measure retraction amount
A of the bucket cylinder rod and retraction amount
B of the boom cylinder rod.
20-163
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER

BUCKET POSITIONER
Testing
1. Stop the engine and check that the clearance be-
tween switch (1) and angle (2) is the standard value.
2. Start the engine, run at idling and check the actua-

tion position.
(Check three times and take the average value.)
Adjusting
1. Lower the bucket to the ground, operate the bucket
to the desired digging angle, then return the lever to
HOLD and stop the engine.
2. Adjust nut (6) of switch (1) so that clearance a from

the tip of switch protector (3) to the switch sensing
surface is the standard value, then secure the switch
in position.
« Clearance a: 0.5 – 1.0 mm
Switch mounting nut: 17.7 ± 2 Nm
(1.8 ± 0.2 kgm)
3. Using shims, adjust clearance b between the sens-

ing surface of switch (1) and angle (2) to the stand-
ard value, then secure in position.
« Use shims to adjust the angle so that the clear-
ance between the switch sensing surface and
the angle is within the standard value for the
whole stroke of the angle, then secure in posi-
tion.
« Check that the center of the switch sensing
surface and the angle do not move, then secure
in position.
« After adjusting, operate the bucket lever, check
that the positioner is actuated at the desired
position, then secure in position.
« Clearance b: 3 – 5 mm
20-164
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT

BOOM KICK-OUT
Testing
1. Stop the engine, and check that the clearance be-
tween switch (1) and plate (2) is the standard value.
2. Start the engine, run at high idling, and check the

actuation position.
(Check three times and take the average value.)
Adjusting
1. Raise the boom to the desired height, return the
boom lever to the HOLD position, then stop the
engine.
Always apply the safety lock to the work equipment

control lever.
2. Adjust the position of the plate so that the center of

switch (1) is aligned with the top of plate (2), then
secure in position.
3. Secure the switch in position so that clearance a

between the sensing surface of the switch and plate
(2) is the standard value.
« Clearance a: 3 – 5 mm
Switch mounting nut: 17.7 ± 2 Nm
(1.8 ± 0.2 kgm)
« After adjusting, operate the boom lever and
check that the kick-out is actuated at the de-
sired position.
20-165
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT
Proximity switch actuation pilot lamp (red)

The proximity switch is equipped with a pilot lamp which
shows when it is being actuated, so use this when
adjusting.
Proximity switch
actuation Lights up Goes out
pilot lamp
When detector is positioned at detection When detector has moved away from
Detectorposition
surface of proximity switch detection surface of proximity switch
Bucket
positioner
Boom kick-out
20-166
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
ADJUSTING MAIN MONITOR

(SPEEDOMETER MODULE)
• The speedometer on the main monitor is a common
part for all machines, and the input signal for the
travel speed differs according to the machine, so it
is necessary to adjust the monitor for use with the
particular model.
• In addition, the tire diameter also differs according
to the type of tire fitted, so it is necessary to adjust
to give the correct travel speed.
• It is also necessary to change the switches if the
optional E.C.S.S. (Electronically Controlled Suspen-
sion System) is installed.
Adjustment procedure
• Turn off the power, then remove the main monitor
and adjust the switches at the back of the speedom-
eter.
1. Setting machine model
1) Remove the rubber caps from dipswitches (1),
(2), (3), and (4) at the back of the speedometer.
2) When the rubber cap is removed, a rotary switch
can be seen inside. Using a flat-headed screw-
driver, turn this switch to adjust it to the settings
in the table below.
Tire size
Switch 23,5 x 25 26,5 x 25
1 4 4
2 C (2)** 7
3 0 0
** SN WA470H21164 and up
3) When the cap is removed from dipswitch (4) at

the back of the speedometer, an ON/OFF switch
can be seen.
Adjust the setting if the E.C.S.S. (Electronically
Controlled Suspension System) is installed. S1 - Model selection
S2 - Tire correction
S3 - km/h or MpH
Switch 4 S4 - Attachment
WA470
Switch
Reference: Amount of correction for switch (2)
No. without with with manual with work
attachment ECSS / ALS gear shift mode Switch posi-
tion 0 1 2 3 4 5 6 7
selector
1 ON ON ON OFF Amount of
2 ON ON ON ON correction (%) +14 +12 +10 +8 + 6 +4 +2 +0
3 ON OFF ON ON
4 ON ON OFF ON Switch posi-
tion 8 9 A B C D E F
4) After completing the adjustment, fit the rubber caps Amount of

correction (%) 0 –2 –4 –6 –8 –10 –12 –14
securely and install the main monitor.
20-167

TESTING AND ADJUSTING CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
CHECKING FOR ABNORMAL-

ITY IN FUEL LEVEL SENSOR
• If there is a marked difference between the actual
amount of fuel remaining in the fuel tank and the
display on the fuel gauge (the fuel tank is full but the
fuel gauge does not indicate FULL), check the fuel
level sensor as an individual part and measure the
resistance at the three positions for the float.
Measurement method
• Connect one end of the probe of terminal (1), con-
tact the other probe with terminal (2), and measure
the resistance.
Resistance for fuel level sensor at each point

Unit: Ω
FULL (top) 1/2 (horizontal) EMPTY (bottom)
10 +–13 32 85+100
« The resistance values are only given as a guideline.
20-168
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC SYSTEM
GAS SIDE TEST AND TOPPING UP THE GAS PRESSURE
Note:
If a filling unit, as shown ,

DFM (9), and a pressure
table are available, then
the test can be carried out
in the machine. To carry
out this care must be taken
to check that there is no
hydraulic pressure on the
hydraulic side of the
accumulators. If the accumulators are to be
checked out off the machine , then there is no
need for the special mounting tool (2).
Accumulator pressure test, gas side:
Follow the following instructions :
a) Remove the protection cap (10) from the gas

connector M28 X 1.5 on the accumulator (1)
and check that the connector is clean.
b) Release the gas fill screw (11) using a 6mm

allen key approx. ¼ turn.
c) Close the release screw (12), on the filling

unit, fully.
d) Fit the filling unit (9) without the hose (13) to

the gas connection. Check that the O-ring
(14) is in position and sitting correctly in the
grove. Attention ! The check valve (15) only
works when the hose (13) is fitted in position.
e) After fitting the filling unit (9), feed the key

(16) by turning the handle (17) back and fore
into the gas fill screw (11). Open the release
screw slowly by turning clockwise, so that gas
from the accumulator can enter the filling unit.
The gas pressure can be read on the pres-
sure gauge. At ambient temp, the pressure
read is the gas pressure.
f) If the pressure, read at ambient temp., is more g) Remove the filling unit (9) from the accumu-
than 17 bar, close the gas fill screw (11) using lator. Tighten the gas filling screw (11) using
the handle (17) and the key (16). Open the an allen key to 20 +5 Nm.. Fit the protection
release screw (12) and release the gas pres- cap back on the gas connector (10) M28 x
sure in the fill unit. 1.5mm.
20-169

TOPPING UP THE GAS PRESSURE
• Use only dry, technically clean nitrogen from stand-

ard nitrogen gas bottles.
Important safety note:

• Do not fill directly from the gas bottle with DFM
filling unit. The use of improvised adapters is not
allowed. When using the DMF filling unit always use
a purpose built pressure reducing valve set (bottle
pressure to 200 bar, regulating pressure 20 bar).
h) As in a) to c)
i) Connect the filling unit (9) to the hose (13), M28 x

1.5. Check that the O-ring (14) is correctly fitted in
its grove. Connect the hose, connector (19), to the
gas bottle pressure reducing valve((21), connector
(20). The gas bottle valve (22) and the pressure
reducing valve out-let (23) are closed.
j) Slowly open the gas bottle valve (22) and allow the
gas to flow at the desired pressure (adjusting valve
(24)). Pressure gauge (25) shows the filling pres-
sure, pressure gauge (26) the gas bottle pressure.
The pressure reducing valve out-let (23) is open.
k) Feed the key (16) by turning the handle (17) back

and fore into the gas fill screw (11) and then open
slowly in clockwise direction. Keep the pressure
reducing valve out-let (23) open until the Pressure
gauge (18) on the filling unit (9) shows the desired
pressure. Allow time for the temp. to stabilise. Close
the pressure reducing valve out-let (23) and the
gas bottle valve (22). If the pressure drops because
of temp. equalising, repeat the topping up opera-
tion. Allow an extended stabilising time.
l) As in f) and g).
Renewing the Usit-ring (27)
• The Usit-ring seals the gas fill screw (11). If it is

suspected that the Usit-ring is leaking or as a pre- as in steps h) to l).
ventive measure (long life) it is to be changed, then
the gas pressure in the accumulator has to be Pressure warning system
dropped to zero by following steps a) to e) and
opening the release screw (12).Now remove the • The gas fill screw (11) is provided with a
filling unit (19) and remove the gas fill screw (11). release grove. If the screw is opened, gas
Renew the Usit-ring (27) making sure that the con- flows out and causes a hissing noise as a
nector and surrounding is clean and not damaged. warning that gas pressure is present.
After fitting a new Usit-ring to the accumulator gas
fill screw (11), renew the accumulator gas pressure
20-170

HYDRAULIC ACCUMULATOR
Service:
• Service of the ALS accumulators should be carried

out every 1000 hrs or once a year. The service
consists of checking the gas pressure and eventu-
ally topping up. Also regular checks for leaks and
condition of the mountings should be carried out. If
the gas pressure is found to be under 17 bar (at
ambient temp.), see also the table opposite, then
the pressure must be topped-up, according to the
following instructions, to 20 bar, or the hydraulic
accumulator must be changed completly.
Gas pressure check from the hydraulic side
Note:
• With a gas pressure check, from the hydraulic
side, with two or more accumulators, it is not pos-
sible to check the condition of individual accumula-
tors. If one accumulator losses all its gas pressure
it will not show up in this check as long as the other
accumulators have gas pressure. Because of this it
is only recommended to carry out this type of test
with individual accumulators that have been removed
from the system. The position nos., in brackets
refer to the fig. on the next page.
Press.
• The individual accumulators (1) should be mounted

in the special holder (2), 206-1036-011-001, and
secured with 4 screws (3) M8 x 80. Care should be
taken to check that one of the 2 SAE ¾” standard
connections (4) is sealed with plug (5) M20 x 1.5. A
When filling: a full off in pressure rise speed
test pump (7) (hand pump) should be fitted to the
other SAE connector (6) along with a pressure test
When releasing: a sudden drop in pressure to
gauge (8). When the test pump is operated oil will
zero
enter the accumulator. Because oil can not be
compressed the pressure on the gauge will rise
rapidly, see graph diagram. When the gas pres- Accumulated volume
sure is reached, the pressure rise speed, in the
accumulator, falls off to a slower curve. This is seen
as an almost constant pressure on the pressure
gauge. When this point is reached the gas pres-
sure in the accumulator is the same as that shown
on the gauge. The pressure is equivalent to gas
pressure P0ϑ at a test temp ϑ in ° C.
• If the test temp. ϑ is different to the ambient temp. Safety note:

(20°C = 293 K) then the read gas pressure P0ϑ Damaged hydraulic accumulators must be
must be calculated (pressure absolute). exchanged completly!
20-171

MEMO:
20-172

TROUBLESHOOTING
Points to remember when troubleshooting ............................................................................................. 20-202

Sequence of events in troubleshooting .................................................................................................. 20-203
Precautions when carrying out maintenance ......................................................................................... 20-204
Handling connectors ............................................................................................................................... 20-211
Checks before troubleshooting ............................................................................................................... 20-212
Method of using troubleshooting charts ................................................................................................. 20-213
Connector types and mounting locations, connector pin arrangement diagrams ................................... 20-222
Mounting location of diodes ..................................................................................................................... 20-230
Troubleshooting of engine (S mode)...................................................................................................... 20-251
Troubleshooting of main monitor system (M mode) ............................................................................... 20-351
Troubleshooting of maintenance monitor system (K mode) ................................................................... 20-401
Troubleshooting of electrical system (E mode) ...................................................................................... 20-451
Troubleshooting of transmission controller (A mode) ............................................................................. 20-501
Troubleshooting of hydraulic and mechanical system (Chassis related) (T mode) ............................... 20-551
Troubleshooting of ECSS (Electronically Controlled Suspension System) (D mode) ........................... 20-601
20-201

TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any
unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for the engine to
cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal
pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible
causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to 4) Check the stroke of the control valve spool.
disassemble the components. 5) Other maintenance items can be checked exter-
If components are disassembled immediately any fail- nally, so check any item that is considered to be
ure occurs: necessary.
• Parts that have no connection with the failure or 4. Confirming failure
other unnecessary parts will be disassembled. • Confirm the extent of the failure yourself, and judge
• It will become impossible to find the cause of the whether to handle it as a real failure or as a prob-
failure. lem with the method of operation, etc.
It will also cause a waste of manhours, parts, or oil or « When operating the machine to reenact the
grease, and at the same time, will also lose the confi- troubleshooting symptoms, do not carry out
dence of the user or operator. any investigation or measurement that may
For this reason, when carrying out troubleshooting, it make the problem worse.
is necessary to carry out thorough prior investigation 5. Troubleshooting
and to carry out troubleshooting in accordance with • Use the results of the investigation and inspec-
the fixed procedure. tion in Items 2 – 4 to narrow down the causes of
2. Points to ask user or operator failure, then use the troubleshooting flowchart to
1) Have any other problems occurred apart from the locate the position of the failure exactly.
problem that has been reported? « The basic procedure for troubleshooting is
2) Was there anything strange about the machine as follows.
before the failure occurred? 1) Start from the simple points.
3) Did the failure occur suddenly, or were there prob- 2) Start from the most likely points.
lems with the machine condition before this? 3) Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the fail- 6. Measures to remove root cause of failure
ure? • Even if the failure is repaired, if the root cause of
When were these repairs carried out? the failure is not repaired, the same failure will
6) Has the same kind of failure occurred before? occur again.
3. Check before troubleshooting To prevent this, always investigate why the prob-
1) Check the oil level lem occurred. Then, remove the root cause.
2) Check for any external leakage of oil from the
piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

TEW00180 TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first Ring Ring

ask the following points.
• Name of customer
• Type, serial number of machine
• Details of jobsite, etc.
2) Ask questions to gain an outline of the problem.
• Condition of failure
• Work being carried out at the time of the TEW00182
failure
• Operating environment
• Past history, details of maintenance, etc. Breakdown
Step 2 TEW00183
Determining probable location of cause
Step
1) Look at the troubleshooting section of the shop
manual to find locations of possible causes. Repair at jobsite
Hurray !
It's repaired
TEW00184
Step 3 TEW00185
Preparation of troubleshooting tools
1) Look at the table of troubleshooting tools in the

shop manual and prepare the necessary tools. Step 7
• T-adapter • Pinpoint locations of failure (carry out
• Hydraulic pressure gauge kit, etc. troubleshooting)
2) Look in the parts book and prepare the neces- • Decide action to take
sary replacement parts.
TEW00186
1) Before starting troubleshooting, locate and re-
pair simple failures.
• Check before starting items
• Other check items
Step 8 2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart that
Repair at workshop matches the symptoms, and carry out trouble-
shooting.
TEW00187
Machine Step 6
volume Re-enacting failure
• Drive and operate the machine to confirm the

Shop manual condition and judge if there is really a failure.
TEW00188
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of fail-
ure.
• Was there anything strange about the machine

before the failure occurred?
• Did the failure occur suddenly?
• Had any repairs been carried out before the
TEW00189 failure?
TEW00190
20-203
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a
long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance
and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with
correct repair procedures for mechatronics and is
aimed at improving the quality of repairs. For this
purpose, it gives sections on “Handling electric equip-
ment” and “Handling hydraulic equipment”
(particlularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLING ELECTRIC

EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connect-ing
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protector or tubes
used for protecting the wiring. Compared with
other electrical components fitted in boxes or
cases, wiring harnesses are more likely to be
affected by the direct effects of rain, water,
heat, or vibration. Furthermore, during inspec-
tion and repair operations they are frequently
removed and installed again, so they are likely
to suffer deformation or damage. For this rea-
son, it is necessary to be extremely careful
when handling wiring harnesses.
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to TEW00191
occur because the male connector is not Improper insertion
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
TEW00192
20-204
(2) Defective compression or soldering of con-

nectors
The pins of the male and female connectors
Improper compression
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 correction or breakage.
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a TEW00193
heavy object hits the wiring, the compres-
sion of the connector may be lost, or the
soldering may be damaged, or the wiring
may be broken.
(4) High pressure water entering connector

The connector is disigned to make it difficult
for water to enter (drip-proof structure), but
if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector depending on the direction of the
water jet.
The connector is designed to prevent water
from entering, but at the same time, if the TEW00194
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-circuited
by the water, so if any water gets in, imme-
diately dry the connector or take other ap-
propriate action before passing electricity
through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating
surface between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. TEW00195
If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or
blow dry with air, and spray it with a contact
restorer.
« When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
« If there is water or oil in the air, it will
increase the contamination of the points,
so clean with air from which all the
water and oil has been removed.
TEW00196
20-205
2) Removing, installing, and drying connectors and

wiring harnesses
Disconnecting connectors
(1) Hold the connectors when disconnecting. Press lightly
When disconnecting the connectors, hold when removing
the connectors and not the wires. Lock stopper
For connectors held by a screw, loosen the
screw fully, then hold the male and female
connectors in each hand and pull apart. For
connectors which have a lock stopper, press
TEW00197
down the stopper with your thumb and pull
the connectors apart.
(2) Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
Connecting connectors
(1) Check the connector visually.
a. Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
b. Check that there is no deformation, de-
TEW00198
fective contact, corrosion, or damage to
the connector pins.
c. Check that there is no damage or break-
age to the outside of the connector.
« If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has got inside the
connector, warm the inside of the wir-
ing with a dryer, but be careful not to
make it too hot as this will cause short
circuits.
« If there is any damage or breakage,
replace the connector.
20-206
(2) Fix the connector securely.

Align the position of the connector cor-rectly,
then insert it securely.
For connectors with lock stopper
Push in the connector until the stopper clicks
into position. Cliks into position
TEW00199
(3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct
any protrusion or the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct
position.
« When blowing with dry air, there is dan-
ger that the oil in the air may cause
improper contact, so clean with air from
which all the water and oil has been
removed. TEW00200
Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connec-tor must be
washed in water, do not use high pressure
water or steam directly on the wiring harness. If
water gets directly on the connector, do as
follows.
(1) Disconnect the connector and wipe off the
water with a dry cloth.
« If the connector is blown dry with air,
there is the risk that oil in the air may
cause defective contact, so avoid blow- TEW00196
ing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
« Hot air from the dryer can be used, but
be careful not to make the con-nector
or related parts too hot, as this will cause
deformation or damage to the connec-
tor.
TEW00202
20-207
(3) Carry out a continuity test on the connec-

tor.
After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
« After completely drying the connector,
blow it with contact restorer and reas- T-adapter
semble.
TEW00203
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits.
These control all of the electronic circuits
on the machine, so be extremely careful
when handling the control box.
(2) Do not open the cover of the control box
unless necessary.
(3) Do not place objects on top of the control
box.
(4) Cover the control connectors with tape or a
vinyl bag. TEW00204
(5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
(6) Do not place the control box on oil, water,
or soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand)
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
TEW00205
TEW00206
20-208
2. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is nec-
essary 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 re-
pairs, so it is desirable to use unit exchange.
Disassembly and main-tenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perform-
ance should be confirmed with special test equip-
ment. TEW00207
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking
oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling TEW00208

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
TEW00209
20-209
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the hy-
draulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil Flushing oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and
secondary flushing is carried out with the speci-
fied hydraulic oil.
TEW00210
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEW00211
20-210
TROUBLESHOOTING HANDLING CONNECTORS
HANDLING CONNECTORS
1. When removing the connectors from the clips, pull
the connector in a parallel direction to the clip.
« If the connector is twisted to the left and right or
up and down, the housing may break.
TBW00484
Stopper
TBW00485
2. When disconnecting male and female connectors,

release the lock and pull in parallel with both hands.
« Never try to pull out with one hand.
TBW00486
3. When the wiring harness clamp of the connector

has been removed, always return it to its original
condition and check that there is no looseness of
the clamp.
TBW00487
20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Remedy

standard
1. Check fuel level, type of fuel — Add fuel
2. Check for dirt or water in fuel — Clean, drain
Lubricant, coolant
3. Check hydraulic oil level — Add oil

4. Check filter (hydraulic, transmission, torque converter) — Replace
Checks before starting
5. Check oil level — Add oil

6. Check engine oil — Add oil
7. Check coolant level — Add water
8. Check clogging of dust indicator — Clean or check
Electrical components
9. Check for loose or corroded battery terminals or wiring — Tighten or replace

10. Check for loose or corroded alternator terminals or wiring — Tighten or replace
11. Check for loose or corroded starting motor terminals or wiring — Repair or replace
12. Check operation of gauges — Repair or replace
Hydraulic, mechanical
13. Check for abnormal noise or smell — Repair

14. Check for oil leakage — Repair
components
15. Bleed air from system — Bleed air

16. Check effect of brakes — Adjust or repair
17. Check battery voltage (engine stopped) 24 – 26V Repair or replace
18. Check battery electrolyte level — Add electrolyte or
replace
Other check items
19. Check for discolored, burned, or bare wiring — Replace

Electrical components
20. Check for missing wiring clamps, hanging wires — Repair

21. Check for water on wiring — Dry place affected by
(check carefully for water at connectors and terminals) water
22. Check for broken or corroded fuses — Replace
23. Check alternator voltage (engine running at over half throttle) — Replace
(If the battery charge is low, it may reach approx. 25 V 28.5 – 29.5V Repair or check
immediately after starting)
24. Noise when battery relay is operated — Replace
(turn starting switch ON-OFF)
20-212
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting code No. Component
S-OO Troubleshooting of engine
M-OO Troubleshooting of main monitor
K-OO Troubleshooting of maintenance monitor
E-OO Troubleshooting of electrical system
A-OO Troubleshooting of transmission controller
T-OO Troubleshooting of hydraulic and mechanical system
D-OO Troubleshooting of ECSS (Electronically Controlled Suspension System)
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem
The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode
(problem with the machine). (See Example (1))
2) Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ according to the
model, component, or problem. In such cases, the failure mode (problem) is further divided into
sections marked with small letters (for example, (a)), so go to the appropriate section to carry out
troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item
in the failure mode. (See Example (2))
3) Method of following troubleshooting chart Y E S
• Check or measure the item inside , and according to the answer follow either the YES line
2016
N O
or the NO line to go to the next . (Note: The number written at the top right corner of
the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally
to the Cause column. Check the cause and take the action given in the Remedy column on the
right. (See Example (3))
• Below the [ ] there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the are correct or the answer to the question inside the is
YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO,
follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is
mistaken, there is danger that it may cause mistaken judgement, or the equipment may be
damaged. Therefore, before starting inspection or measurement, always read the instructions
carefully, and start the work in order from Item 1).
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items
are given at the top of the page and marked with «. (See Example (4))
The precautions marked « are not given in the , but must always be followed when carrying out
the check inside the .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number
connection. When carrying out troubleshooting, see this chart for details of the connector pin number
and location for inspection and measurement of the wiring connector number appearing in the
troubleshooting flow chart for each failure mode (problem).
20-213
< Example >

(1) M-15 Abnormality in buzzer
(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check)
(3)
2016
(4)
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
20-214
2016
20-215
3. Using troubleshooting chart for engine-related failure
This troubleshooting chart is divided into three sec-

tions: questions, check items, and troubleshooting. The
questions and check items are used to pinpoint high
probability causes that can be located from the failure
symptoms or simple inspeciton without using trouble-
shooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final
confirmation.
[Questions]
Sections + in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under in the
chart on the right correspond to this.
The serviceman narrows down the causes from in-
formation that he has obtained from the user and
the results of that he has obtained from his own
inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of prob-
ability, starting with the causes that have been marked
as having the highest probability from information
gained from [Questions] and [Check items].
20-216
The basic method of using the troubleshooting chart is

as follows.
Items listed for [Questions] and [Check items] that have
a relationship with the Cause items are marked with ¡,
and of these, causes that have a high probability are
marked with .
Check each of the [Questions] and [Check items] in
turn, and marked the ¡ or in the chart for items where
the problem appeared. The vertical column (Causes)
that has the highest number of points is the most prob-
able cause, so start troubleshooting for that item to make
final confirmation of the cause.
1. For [Confirm recent repair history] in the [Ques-
tions] Section, ask the user, and mark the Cause
column with ∆ to use as reference for locating
the cause of the failure. However, do not use
this when making calculations to narrow down
the causes.
2. Use the ∆ in the Cause column as reference for
[Degree of use (Operated for long period)] in
the [Questions] section as reference. As a rule,
do not use it when calculating the points for
locating the cause, but it can be included if
necessary to determine the order for trouble-
shooting.
20-217
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
20-218
Five causes
Step 1
Clarify the relaitionship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of ¡ and marks where the hori-

zontal lines for the three symptoms and the vertical
columns for the causes intersect.
(1) Clogged air cleaner element: ¡
(2) Air leakage between turbocharger
and head: ¡¡
(3) Clogged, seized injection nozzle: ¡
(4) Defective contact of valve, valve seat: ¡
(5) Worn piston ring, cylinder: ¡
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting area
and carry out the troubleshooting item marked l.
The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return
to normal.
20-219
4. Method of using matrix troubleshooting tables

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate
the causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the
main components, such as the steering system and work equipment hydraulic system. Follow the
procedure given below and carry out troubleshooting to locate the problems accurately and swiftly.
Step 1. Questioning the operator

The questions to ask the operator are given
below the failure symptom. If the answers to the 1. Steering does not work ¨ Symptom [Example]
questions match the information given, follow
the arrow to reach the probable cause of the Ask the operator about the following points.
failure. • Did the steering suddenly stop working? à
Consider the contents of the questions and con- Breakage in steering equipment
sult the table while proceeding to Steps 2 and 3 • Had the steering gradually been becoming
to grasp the true cause. heavy? à Internal wear of steering equip-
ment, defective seal
Step 2. Checks before troubleshooting
Before starting the main troubleshooting and Checks before starting [Example]
measuring the hydraulic pressure, first check
the Checks before Starting items, and check for • Is the oil level and type of oil in the hy-
oil leakage and loose bolts. These checks may draulic tank correct?
avoid time wasted on unnecessary troubleshoot- • Is there any leakage of oil from the steer-
ing. ing control valve?
The items given under Checks before Starting
are items which must be considered particularly
for that symptom before starting troubleshoot-
ing. [Example 1]
Step 3. Using cross-reference table

1) Operate the machine to carry out the checks
in the troubleshooting item column.
Mark the items where the results match the
symptom.
« It is not necessary to follow the trouble-
shooting checks in order; follow an or-
der which is easiest to carry out trou-
bleshooting.
2) Find the appropriate cause from the cause
column. If the symptom appears, the ! marks
on that line indicate the possible causes. [Example 2]
(For item No. 2 in the table on the right, the
possible causes are c or e.)
If there is only one o:
Carry out the other troubleshooting items
(where the same cause is marked with !),
check if the symptom appears, then repair.
If there are two o's:
Go on to Step 3) to narrow down the possi-
ble causes.
20-220
3) Operate the machine and check the trouble-

shooting items other than those in 1).
Operate the machine and check the items in the
same way as in 1), and if the symptom appears,
mark that item. (In the chart on the right, the
symptom appears again for item 5).
4) Find the appropriate cause from the cause col-
umn. In the same way as in Step 2), if the
symptom appears, the ¡ marks on that line
indicate the possible causes. (For item No.5 in
the table on the right, the possible causes are b
or e.)
5) Narrow down the possible causes.

There is one common cause among the causes
located in Steps 2) and 4). (One cause marked
¡ appears on the line for both items.) This
cause is common to both the symptoms in trou-
bleshooting Steps 1) and 3).
« The causes which are not common to both
troubleshooting items (items which are not
marked ¡ for both symptoms) are unlikely
causes, so ignore them.
(In the example given on the right, the causes
for Troubleshooting Item 2 are c or e, and
the causes for Troubleshooting Item 5 are b
or e, so cause e is common to both.)
6) Repeat the operations in Steps 3), 4) and 5)
until one cause (one common cause) remains.
« If the causes cannot be narrowed down to
one cause, narrow the causes down as far
as possible.
7) Remedy
If the causes are narrowed down to one com-
mon cause, take the aciton given in the remedy
column.
The symbols given in the remedy column indi-
cate the following:
X: Replace, ∆: Repair, A; Adjust, C: Clean
20-221
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATION

(1/3)
Con- Con- Con- Con-
nector nector Mounting location nector nector Mounting location
No. Type No. Type
CNA18 SWtype Servo motor left CNGR1 M type Intermediate connector
CNB01 X type Condenser motor left CNGW1 M type Working lamp
CNLR1 S type Floor wiring harness
CNB03 (Con- Front washer motor
nector) SWP Floor wiring harness
CNLR2
type
CNB04 (Con- Rear washer motor
nector) SWP Floor wiring harness
CNLR3
CNB07 X type Condenser motor right type
SWP CNLR4 SWP Floor wiring harness
CNBR1 Bulkhead wiring harness
type type
CNC01 M type Front wiper motor CNLR5 X type Floor wiring harness
CNC02 M type Radio CNLR6 L type Floor wiring harness
CNC03 M type Working lamp right CNR05 X type Brake pressure
CNC04 M type Working lamp left CNR06 X type Radiator level sensor
CNR07 X type Fuel level sensor
CNC05 (Con- Warning lamp
nector) Combination lamp
CNR08 M type
rear left
CNC06 (Con- Room lamp
nector) Combination lamp
CNR09 M type
CNC07 M type Rear wiper motor rear right
CNCL1 S type Instrument wiring harness
CNR18 (Con- Reverse light
CNCL2 S type Air condenser nector)
CNCL3 S type Air condenser
CNR19 (Con- Reverse light
SWP nector)
CNE03 Engine stop motor
type CNR25 X type Brake oil pressure
Engine water temp. sensor CNT01 X type F solenoid
CNE06 X type
CNT02 X type R solenoid
CNE08 — Pre-heating CNT03 X type Hi-Lo solenoid
CNE09 — Pre-heating CNT04 X type Speed solenoid
SWP CNT06 X type Speed sensor (kmh)
CNER1 Engine wiring harness
type Torque converter oil
CNT07 X type
temperature sensor
CNER2 SWP Engine wiring harness
type CNT10 X type Pressure switch
CNF01 M type Head lamp right Flow control
CNT11 X type
CNF02 M type Combination lamp
front right SWP
CNTL1 Floor wiring harness
Combination lamp type
CNF03 M type
front left SWP
CNTL2 Floor wiring harness
CNF04 M type Head lamp left type
CNF05 X type Bucket positioner CNT12 X type Proportional solenoid
CNF06 X type Boom kick-out CNT08 X type Pressure switch parking brake
CNFR1 S type Wiring harness
front frame
CNFR2 X type Wiring harness

front frame
20-222
20-223
Connector Pin Arrangement Diagram (2/3)

Con- Con- Con- Con-

No . Type No . Type
CNA5 M type Thermistor
MIC
SWP CNL29 type Transmission controller
CNA6 Air mix servo motor
type
CNA7 M type Blower motor
AMP040
CNA8 S type Air conditioner CNL30 Transmission controller
connector
CNA9 — Ventilator relay (MAIN)
CNA10 — Ventilator relay (Hi) AMP040
CNL31 Transmission controller
connector
CNA11 — Ventilator relay (M2)
CNA12 — Condenser relay (Hi) CNL48 — Bucket relay
CNA13 — Ventilator relay (M1) CNL49 — Boom relay
CNA14 — Condenser relay CNL52 — Warning relay
CNA15 — Air condit. compress. relay CNL53 — Brake light relay
CNCL1 S type Floor wiring harness CNL55 — Horn relay
CNCL2 S type Air conditioner CNL56 — Pre-heating relay
CNCL3 S type Air conditioner CNL57 — Neutral relay
CNFS1 L type Fuse box CNL60 — Front working lamp relay
CNFS2 S type Fuse box CNL61 — Rear working lamp relay
CNFS3 M type Fuse box CNL62 — Engine stop relay
CNFS4 L type Fuse box CNL63 — Horn switch
CNFS5 M type Fuse box CNL64 — Engine oil pressure relay
CNFS6 M type Fuse box CNL67 — Reverse lights
CNL09 — Starting switch CNL80 — Air clogging relay
SWP Transmission combination CNL200 — Parking brake neutral
CNL02
type switch TDR1 — Transmission control
CNL03 SWP Transmission combination TDR2 — Transmission control
type switch
TD1-4 — Diode
CNL04 SWP Transmission combination
type switch K67.1 — Flasher 2+1
K67.2 — Flasher 3+1
CNL05 AMP040 Main monitor
connector K163.1 — Turn signal indicat.
K163.2 — Turn signal indicat.
connector TD5-8 — Diode
connector

connector
CNL18 AMP040 Maintenance monitor

connector

connector
CNL21 (Con- Maintenance monitor

nector)

nector)
20-224

Up to SN WA470H20487: SN WA470H20488 - H20668: SN WA470H20669 - H21163
C N L6 7
C N L52 C N L 52
CNL60 K 163.1 TDR2 K 163 .1 TD R 2
C N L2 0 0 C N L 61 TDR1 TDR1
C N L200 C N L200
C N L 55 K1 63 .2 K163.2
C N L4 9 C N L49
TDR 1 C N L 56 C N L67.1 C N L48 K 67.1 C N L48
C N L6 4 C N L67.2 C N L53 K67.2 C N L53
TD R2 C N L57 C N L60 C N L57 C N L60
C N L67 C N L56 C N L67 C N L56

C N L5 7
CNL62
C N L55 C N L55
C N L8 0 C N L62 C N L62
T D 1-T D 4 T D 1-TD 4
C N L5 2
C N L4 9
Z Z
Z C N L61 C N L61
F orw ard Forwa rd
F orw a rd
CNL48 C N L44 C N L44 T D 5-T D 8
C N L 53 C N L64 C N L64
C N L80 C N L80
CNFS1
CNFS2
C NL22 CNFS3
C NL18 Z CNFS4
C NL19
C NL21 CNFS5
CNFS6
C N L3 1
C N L3 0 CNA8
CNL29
C N A 14
CNL03 CNA9
CNL09
C N A 11
CNL02
CNL06 CNA10
CNL07
CNA13
CNL08
CNA12
CNL05
CN A15
CNL63
CNA5
CN CL1 CNA7
CNCL2 CNA6
CNCL3 re l_ m c
C NL04
20-225

Connector Pin Arrangement Diagram (2/3)

Con- Con- Con- Con-

No . Type No . Type
CNA5 M type Thermistor
MIC
SWP CNL29 type Transmission controller
CNA6 Air mix servo motor
type
CNA7 M type Blower motor
AMP040
CNA8 S type Air conditioner CNL30 Transmission controller
connector
CNA9 — Ventilator relay (MAIN)
CNA10 — Ventilator relay (Hi) AMP040
connector
CNA11 — Ventilator relay (M2)
CNA12 — Condenser relay (Hi) K443 — Selection work mode
CNA13 — Ventilator relay (M1) K414 — Rpm sensor emergency steering
CNA14 — Condenser relay K161.1 — Emergency steering
CNA15 — Air condit. compress. relay K67 — Indicator
CNCL1 S type Floor wiring harness K101 — Warning lamp
CNCL2 S type Air conditioner K385 — Back off alarm
CNCL3 S type Air conditioner K208 — Neutral position
CNFS1 L type Fuse box K200 — Parking brake
CNFS2 S type Fuse box KTDR2 — Emergency control transmission
CNFS3 M type Fuse box KTDR1 — Emergency control transmission
CNFS4 L type Fuse box V118.1 — Diode
CNFS5 M type Fuse box K8 — Horn
CNFS6 M type Fuse box K165 — Brake light
CNL09 — Starting switch K139 — Lift cut-off
SWP Transmission combination K209 — Return to dig
CNL02
type switch —
K337 Wiper interval
CNL03 SWP Transmission combination —
type switch K19 Engine oil pressure
K262 — Air filter
CNL04 SWP Transmission combination
type switch K433 — Rear working light
K432 — Front working light
connector V118.2 — Diode
CNL06 AMP040 Main monitor V118.3 — Diode
connector
K159 — Test emergency steering
CNL07 AMP040 Main monitor K282 — Pre-heating
connector

connector

connector

connector

nector)

nector)
20-226

K101
K67 KTDR2
K161.1 KTDR1
K200
K414 K139
K209
(K218) K432
K443
K208 K282
K385
K8 K159
V118.1 K433
K165
Z V118.3
K337 K262
Forward K19 V118.2
(Fahrtrichtung)
CNFS1
CNFS2
CNL18 CNL22 Z CNFS3
CNL19 CNFS4
CNL21 CNFS5
CNFS6
CNL31
CNL30 CNA8
CNL29
CNA14
CNL03 CNA9
CNL09
CNA11
CNL02
CNL06 CNA10
CNL07
CNA13
CNL08
CNA12
CNL05
CNA15
CNL63
CNA5
CNCL1 CNA7
CNCL2 CNCL3 CNA6 Rel_m2
CNL04
20-227

Connector pin arrangement diagram (3/3)
(3/3)
Con- Con-
nector nector Mounting location
No . Type
CNE04 X type RPM sensor
CNE05 (Con- Water temperature

nector) sensor (pre-heating)
CNE06 X type Water temperature

sensor (Display)
CNE08 — Pre-heating (WA 380-3H)
CNE09 X type Pre-heating (WA 380-3H)
CNE09 X type Pre-heating (WA 470-3H)
CNE10 X type Engine oil level sensor
CNE11 — Engine oil pressure sensor
CNE12 X type Compressor clutch
CNE13 X type Starting motor
CNE15 — Alternator B
CNE16 — Alternator R
CNE17 — Alternator E
CNE19 (Con- Dust indicator

nector)
CNE20 (Con- Dust indicator

nector)

type

type
20-228
20-229
TROUBLESHOOTING MOUNTING LOCATION OF DIODES
MOUNTING LOCATION OF DIODES

• The column "See page" shows monting location of diodes (3-dimensional drawings)
Add-
Diode - No. See page:
ress:
CNTD 1 20-230 Q6
CNTD 2 20-230 Q6
CNTD 3 20-230 Q6
CNTD 4 20-230 Q6
CNR 01 20-229 B3
CNR 02 20-229 B3
CNR 03 20-229 B3
CNR 04 20-229 B3
CNB 05 20-228 G6
CNB 06 20-228 G6
CNF 23 20-228 H7
F 12 20-228 E3
CNT 15 20-228 G4
CNT 16 20-228 G4
CNT 17 20-228 G4
CN 203 20-230 R3
CN 100 20-230 (WA-380 only) Q7
20-230
MOUNTING LOCATION OF DIODES (1/3)
20-231
20-232
20-233
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

« The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
No. X type connector

of
pins Male (female housing) Female (male housing)
TEW00219 TEW00220
1
1
2
2
TEW00221 TEW00222
1 3 3 1
2 2
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-234
No. AMP040 type connector

of
1 5 8 4
4 8 5 1
TEW00237 TEW00228
6 12
12 6
12
1 7 7 1
TEW00229 TEW00230
8 16 16 8
16
1 9 9 1
TEW00231 TEW00232
10 20 20 10
20
1 11 11 1
TEW00233 TEW00234
20-235
No. SWP type connector

of
1 4 4 1
3 6 6 3
TEW00235 TEW00236
1 5 5 1
4 8 8 4
TEW00237 TEW00238
1 4 8 11 11 8 4 1
14
3 7 10 14 14 10 7 3
TEW00239 TEW00240
20-236
No. M type connector

of
1 1
2 2
TEW00241 TEW00242
2 3 3 2
1 1
TEW00243 TEW00244
1 3
3 1
2 4 4 2
TEW00245 TEW00246
1 4 4 1
3 6 6 3
TEW00247 TEW00248
20-237
No. S type connector

of
1 5 5 1
4 8 8 4
TEW00249 TEW00250
1 6 6 1
10
5 10 10 5
TEW00251 TEW00252
12 5 6 1
12
6 1 TEW00253 12 5 TEW00254
16 7 8 1
16
8 1 TEW00255 16 7 TEW00256
20-238
No. L type connector

of
pins Male (male housing) Female (female housing)
1 1
6
2 2
TEW00257 TEW00258
No. MIC type connector

of
1 11
11 1
12 21
21 21 12
TEW00259 TEW00260
No. Diode type connector

of
1 1
2
2
2
TEW00261 TEW00262
20-239
No. Simple connector (ring connector)

of
TEW00263 TEW00264
TEW00263 TEW00265
20-240
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
S- 1 Starting performance is poor (Starting always takes time) ........................................................ 20-253

S- 2 Engine does not start ................................................................................................................. 20-254
(1) Engine does not turn ........................................................................................................... 20-254
(2) Engine turns but to exhaust gas comes out (Fuel is not being injected) ........................... 20-255
(3) Exhaust gas comes out but engine does not start (Fuel is being injected) ........................ 20-256
S- 3 Engine does not pick up smoothly (Follow-up is poor) ............................................................. 20-257
S- 4 Engine stops during operations .................................................................................................. 20-258
S- 5 Engine does not rotate smoothly (hunting) ................................................................................ 20-259
S- 6 Engine lacks output(no power) ................................................................................................... 20-260
S- 7 Exhaust gas is black (incomplete combustion) .......................................................................... 20-261
S- 8 Oil consumption is excessive (or exhaust gas is blue) .............................................................. 20-262
S- 9 Oil becomes contaminated quickly ............................................................................................. 20-263
S-10 Fuel consumption is excessive ................................................................................................... 20-264
S-11 Oil is in cooling water, or spurts back, or water level goes down ............................................ 20-265
S-12 Oil pressure lamp lights up (drop in oil pressure) ..................................................................... 20-266
S-13 Oil level rises .............................................................................................................................. 20-267
S-14 Water temprautre becomes too high (overheating) ................................................................... 20-268
S-15 Abnormal noise is made ............................................................................................................. 20-269
S-16 Vibration is excessive ................................................................................................................. 20-270
20-251
20-252
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)

General causes why starting performance is poor
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of – 10°C or below, use ASTM D975
No. 1, and – 10°C or above, use ASTM D975 No. 2 diesel fuel.) Causes
« Battery charging rate.
Charging rate
ck)
Ambient 100% 90% 80% 75% 70%
er
ath syste er stu

temperature
ain
20°C 1.28 1.26 1.24 1.23 1.22
ine p str
g
eat
m
fue , plun
0°C 1.29 1.27 1.25 1.24 1.23
ole
es
y
tter
r
er h
pu
alv
–10°C 1.30 1.28 1.26 1.25 1.24
ck
l
inje ion no ed ba
el t ng, a p (ra
r el lve, v
mg
tra
t
• The specific gravity should exceed the value for the charging rate
De ctive l filter emen

cle t of va r
e
e, c jection iming
tac ylinde
ir in
d p primi
ps
bre
zzl
m
of 70% in the above table.
at
u
tive gula ug
um
fec e inje terior
air
p
• In cold weather the specific gravity must exceed the value for the
tor
t
alte tor
,
c
pl
n
ane
ank
rna
ng,
ctio
charging rate of 75% in the above table.
ow
gi
e
ct
fee
or d
log
n ri
gge e con
l
ue
g
Legend
re
in
air
isto
d fu
tive
df
De ctive
: Possible causes (judging from Questions and check items)
tive
tive
Lea ctive
v
tiv
d
e
kag
: Most probable causes (judging from Questions and Check items)
rn p
gge
t
fec
gg
fec
fec
fec
fec
fe
fe
: Possible causes due to length of use (used for a long period)
fe
Clo
Wo
Clo
De
De
De
De
De
De
De
clo
: Items to confirm the cause
Confirm recent repair history
Degree of use Operated for long period
Gradually became worse
Ease of starting Starts when warm
Questions
Indicator lamp does not light up

Engine oil must be added more frequently
Replacement of filters has not been carried out according to
operation manual
Dust indicator is red
Non-specified fuel has been used
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
Blow-by gas is excessive
Match marks on fuel injection pump are out of alignment
Check items
Mud is stuck to fuel tank cap

When engine is cranked with starting motor
1) Little fuel comes out even when injection pump sleeve
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
Leakage from fuel piping
When compression pressure is measured, it is found to be low

When air element is inspected directly, it is found to be
clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to
Troubleshooting
be clogged
Heater mount does not become warm
Voltage is 26 - 30V betweem alternator terminal B and Yes
terminal E with engine at low idling No
Either specific gravity of electrolyte or voltage of battery is low
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
When control rack is pushed, it is found to be heavy or does
not return (when blind plug at rear of pump is removed, it
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-253
TROUBLESHOOTING S-2
S-2 Engine does not start Causes
(1) Engine does not turn
ire
rw
General causes why engine does not turn
oto
• Internal parts of engine seized
itch
n
pm
it
ctio
« If internal parts of the engine are seized,
ircu
sw
o
nne
ry
t
es
carry out troubleshooting for “Engine
fety
gc
atte
gin
l co
stops during operations”.
rtin
r sa
tor
db
f en
ch
ina
mo
• Failure in power train
sta
yo
rate
wit
oto
nt o
erm
e la
• Defective electrical system
top
ela
of
gs
erio
gm
ry r
me
ry t
s
ty r
ing
rtin
ne
r
et
rtin
ust
a tte
gea
atte
Legend
afe
wir
or d
ngi
sta
sta
adj
b
s
ring
e
tive
tive
tiv e
tive
tive
tive
tive
tive
tive
ken
fec
fec
fec
fec
fec
fec
fec
fec
fec
Bro
De
De
De
De
: Items to confirm the cause.
De
De
De
De
De
Questions
Condition of horn when starting Horn does not sound
switch is turned ON Horn sound level is low
Rotating speed is slow
Makes grating noise

When starting switch is turned to
START, pinion moves out, but Soon disengages again
Makes rattling noise and
does not turn
When starting switch is turned to START, pinion does not
move out
Check items
When starting switch is turned to ON, there is no clicking sound

Carry out troubleshooting for defective wiring of starting circuit
Battery terminal is loose
When starting switch is turned to ON, linkage does not move
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low
For the following conditions 1) - 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are

Troubleshooting
3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of
starting motor are connected, engine starts
5) There is no 24V voltage between battery relay terminal B
and terminal E
When ring gear is inspected directly, tooth surface is found
to be chipped
Does not move even when engine stop motor linkage is
disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
–
20-254
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust gas comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust gas comes out
• Supply of fuel impossible
• Supply of fuel is extremely small Causes
• Improper selection of fuel (particularly in winter)
)
zed
Standards for use of fuel
sei
Ambient temprature
ger
Type of fuel
ey
–22 –4 14 32 50 68 86 104 122°F
ole
ft, k
n
–30 –20 –10 0 10 20 30 40 50°C
plu
rh
n
sha
isto
ck,
the
ASTM D975 No.2
r
a
g
rive
pp
r
rea
r
pin
ain
oto
(
ine
Diesel fuel
mp
pum
pd
l pi
b
pm
r
stra
ASTM D975 No.1
, st
u
air
um
fue
np
sto
eed
ter
d
ank
np
um
ctio
use
ing
l fil
ine
rn f
Legend
ctio
el t
dp
eak
inje
fue
eng
uel
rok
el
e
inje
d fu
f fu
d fe
d, l
er f
tive
d, b
ed
tive
gge
ken
ko
gge
rop
gge
gg
fec
fec
ize
Lac
Imp
Clo
Bro
Clo
Clo
Clo
De
De
Se
Exhaust gas suddenly stops coming out (when starting again)

Questions
operation manual
Fuel tank is found to be empty
There is leakage from fuel piping
When starting switch is turned ON, linkage does not move
When fuel filter is drained, fuel does not come out
When engine is cranked with starting motor,
1) Injection pump coupling does not rotate

Check items
2) No fuel comes out even when fuel filter air bleed plug is
loosened
3) No fuel spurts out even when injection pipe sleeve is

loosened
Rust and water are found when fuel is drained
Check injection pump directly
When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
Check feed pump directly
When fuel filter, strainer are inspected directly, they are found
to be clogged
be clogged
Does not move even when engine stop motor linkage is
disconnected
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
20-255
TROUBLESHOOTING S-2
Causes
(3) Exhaust gas comes out but engine does not start
.)
etc
(Fuel is being injected)
k)
ver
tuc
r , le
ay
rs
General causes why exhaust gas comes out but engine does
spr
cke
ge
m
not start
lun
e
, ro
ste
ve
hol
k, p
lve
i
• Lack of rotating force due to defective electrical system
l sy
ect
her
(va
tery
rac
f
r
fue
, de
r
ine
nt
de
eat
m
ner
bat
me
e
ir in
a
mp
zle
ylin
yst
r
str
ir b
trai
ele
ed
es
noz
pu
• Improper selection of fuel
g, a
c
ps
a
ter,
riat
valv
ner
lug
g,
tion
d
ank
gin
tion
pum
use
rin
eto
l fil
wp
lea
ken
Legend
log
el t
jec
inje
or d
fue
ton
uel
ir c
glo
ed
ro
e, c
d fu
d in
,b
d fe
er f
da
pis
tive
ed
tive
tive
tive
kag
gge
gge
gge
rop
gge
gg
fec
rn
fec
fec
fec
Lea
Wo
Clo
Imp
Clo
Clo
Clo
Clo
De
De
De
De
Suddenly failed to start
When engine is cranked, abnormal noise is heard from
around head
Questions

operation manual
Rust is found when fuel is drained
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not
contact stopper
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve
Check items
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
starting engine, temperature of some cylinder is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
Troubleshooting
found to be clogged
be clogged
When air element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or pump
is heavy
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Clean
Clean
Clean
Remedy
–
20-256
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)

General causes why engine does not pick up
smoothly
• Insufficient intake of air Causes
y
• Improper fuel used
pra
t
es
sea
e
ctiv
hol
nce
ve
efe
val
her
ere
ger
r
g
ne
e, d
nt
ipin
ve,
eat
terf
lun
ner
r
rai
me
nde
ce
val
el p
zzl
r
pp
r, in
trai
ir b
, st
ele
ran
i
o
c yl
um
t of
ps
g fu
a
rge
ter
n
ner
lea
ank
tion
ng,
np
pum
tac
l fil
cha
kin
lea
ec
Legend
n ri
ctio
el t
jec
con
fue
a
alv
ir c
rbo
ed
e
d fu
d in
isto
inje
d, l
er v
d fe
da
tive
d tu
ed
rn p
gge
gge
gge
gge
zed
gge
rop
gg
fec
ize
Clo
Imp
Clo
Clo
Wo
Clo
Clo
Sei
Clo
De
Se
operation manual
Questions

Noise of interference is heard from around turbocharger
Engine pick-up suddenly became poor
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
There is hunting from engine (rotation is irregular)

When fuel filter, strainer are inspected directry, they are
found to be clogged
be clogged
Troubleshooting

not return
does
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-257
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during opera-
tions
• Seized parts inside engine
Causes
• Overheating
« If there is overheating and insufficient
ck)
tc)
output, carry out troubleshooting for over-
stu
er e
heating.
ger
lev
• Failure in power train
lun
rod
er,
ole
« If the engine stops because of a failure
k, p
ring
ey
ock
pum ther h
ing
n
ft, k
t
in the power train, carry out troubleshoot-
isto
in
bea
rac
e, r
ect
me
tra
g
ne
sha
pp
ing for the chassis.
pin
p(
rea
v
onn
ner
aft
rai
qui
er
( va
pum
l pi
trai
trai
ir b
ive
ksh
ow
nc
, st
ry e
fue
tem
ps
sp
isto
ear
ran
pd
ter
ed
a
tion
ank
i
pum
uxil
ing
sys
ssi
d fe
dg
dc
l fil
um
dp
Legend
c
el t
pa
eak
nje
cha
ize
ize
fue
ize
el p
ize
ve
ed
el
pum
d fu
i
, se
, se
, se
val
, se
d fe
d, l
f fu
tive
u
e in
ed
f
gge
gge
ken
ken
ken
ken
ken
ken
gge
ko
ken
gg
fec
ilur
Clo
Lac
Bro
Clo
Bro
Bro
Bro
Bro
Clo
Bro
Bro
Clo
De
Fa
Abnormal noise was heard
and engine stopped suddenly
Condition when engine Engine overheated and stopped
stopped Engine stopped slowly
Questions
There was hunting and

engine stopped
Fuel gauge lamp lights up
operation manual
When feed pump is operated, there is no response or it is heavy
Engine turns, but stops when transmission control lever is
operated
Does not turn at all
Check items
Carry out troubleshooting in chassis volume
Try to turn by hand using Turns in opposite direction

barring tool Moves amount of backlash
Shaft does not turn
Metal particles are found when oil is drained
Remove oil pan and check directly

Troubleshooting
When gear train is inspected, it does not turn

Turns when pump auxiliary equipment is removed
found to be clogged
be clogged
Check feed pump directly
When control rack is pushed, it is fond to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
Remedy
–
Add
20-258
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
smoothly
• Air in fuel system
• Defective governor mechanism Causes
• Defective engine throttle controller mecha-
p
um
zle
nism
dp
noz
fee
(engine throttle controller type)
nd
and
pa
e
pum
ck
hol
nk
l ra
l ta
or
er
r
ern
rno
fee
fue
ntro
ath
r
ine
gov
ove
en
en
ner
bre
f co
tra
we
we
of g
trai
f
nt o
bet
bet
no
r, s
air
low
ps
on
me
uit
atio
uit
e
ank
pum
t
rati
irc
o
circ
l fil
ust
o
Legend
per
el t
in c
is t
ope
fue
ir in
adj
ed
el
d fu
o
, air
ed
d fe
f fu
d, a
tive
ed
tive
tive
spe
gge
eed
ko
gge
ge
gee
fec
fec
fec
g
Low
Clo
Lac
Clo
Clo
Clo
Clo
De
De
De
Occurs at certain speed range
Occurs at low idling
Condition of hunting Ocuurs even when speed is

Questions
raised
Ocuurs on slopes
operation manual
Rust is found when fuel is drained
When feed pump is operated,
1) No response, light, return is quick

Check items
1) No response, light, return is normal

Engine speed sometimes rises too high
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor lever is moved it is found to be stiff
When injection pump is tested, governor is found to be
improperly adjusted
Troubleshooting
does not return
be clogged
found to be clogged
Adjust
Adjust
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Remedy
Add
20-259
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

General causes why engine lacks output Causes
ent
stm
y
pra
• Improper fuel used
dju
eat
es
(if non-specified fuel is used, output drops)
ole
ea
es
ctiv
e
er h
ctiv
alv
• Lack of output due to overheating
enc
efe
ger
er
« If there is overheating and insufficient
e, v
efe
ath
g
rfer
ent
e, d
ain
pin
ner
lun
er
e, d
alv
bre
inte
output, carry out troubleshooting for over-
em
ce
ind
l pi
r
zzl
trai
pp
, st
of v
ran
kag
r el
air
heating.
fue
cyl
o
er,
ps
um
ter
l ea
ane
arg
ank
act
r lin
pum
tion
ng,
np
ing
l fil
ec
Legend
och
ont
cle
n ri
el t
ctio
eak
e
jec
fue
al v
ed
lev
c
turb
ir
d fu
isto
d in
inje
d fe
d, l
er v
da
tive
ed
uel
rn p
gge
gge
gge
gge
zed
gge
zed
rop
gg
fec
nt f
Clo
Imp
Wo
Clo
Clo
Clo
Clo
Sei
Clo
Sei
De
Be
Suddenly
Power was lost
Gradually
Questions

operation manual
Black
Engine pickup is poor and combustion is irregular
High idling speed under no load is normal, but speed
Check items
suddenly drops when load is applied

There is hunting from engine (rotation is irregular)
High idling speed of engine is low

When trubocharger is rotated by hand, it is found to be heavy
found to be clogged
Troubleshooting
When feed pump strainer are inspected directly, it is found

to be clogged
dose not return
When lever is placed at FULL position, it does not contact
stopper
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-260
TROUBLESHOOTING S-7
S-7 Exhaust gas is black

(incomplete combustion)
General causes why exhaust gas is black
• Insufficient intake of air Causes
e d)
)
tion
eiz
ead
jec
er s
dh
e in
t
ung
r an
sea
siv
rge
, pl
nce
ve
ce s
le
cha
ack
val
ozz
ere
(ex
rbo
p (r
nt
ve,
nn
terf
ce
er
me
g
mp
u
min
val
um
r
lind
ctio
ran
t
ffle
r, in
ele
en
u
np
np
t of
n ti
lea
mu
y
inje
twe
rge
c
ner
ctio
ctio
ng,
ctio
ec
tac
ged
r be
cha
ed
lea
Legend
n ri
alv
con
inje
inje
nje
eiz
log
f ai
ir c
rbo
er v
isto
d, s
er i
d, c
eo
da
tive
tive
tive
d tu
rn p
rop
rop
gge
kag
gge
she
fec
fec
fec
ize
Imp
Imp
Lea
Cru
Wo
Clo
Clo
De
De
De
Se
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Suddenly
Power was lost
Gradually
Check items

Match marks on fuel injection pump are out of alignment
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
Troubleshooting
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
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy, or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-261
TROUBLESHOOTING S-8
S-8 Oil consumption is

excessive (or exhaust gas is
blue)
« Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is exces-
sive
• Abnormal combustion of oil
• External leakage of oil
• Wear of lubrication system
Causes
ger
har
boc
c.
, et
Tur
eal
ead
ce
ler
urfa
tem
ns
ose
er h
r
oo
line
oke
sys
al s
er h
il c
lind
er
lug
), b
r, o
, se
ke
ath
lind
, cy
end
in p
ide
nta
d
ing
bre
filte
eal
r en
pan
, cy
, gu
mi
dra
pip
ine
ar s
r or
e
oil
ring
o
ring
low
tern
urb
ler
oil
oil
oil
r
n re
the
Legend
in f
m
coo
at b
om
om
at t
ton
om
e (s
fro
rea
ton
e
ed
rok
e fr
e fr
pis
e fr
oil
eal
db
eal
alv
uck
pis
ge
b
kag
kag
kag
ken
ken
rn s
rn v
rn s
gge
aka
st s
rn,
rn

Lea
Lea
Lea
Wo
Bro
Bro
Wo
Wo
Wo
Wo
Clo
Du
Le

Questions

Oil consumption suddenly increased
Engine oil becomes contaminated quickly
Exhaust gas is blue under light load
Abnormally excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty

with oil
Inside of turbocharger intake pipe is dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
Troubleshooting
clogged with dirty oil

There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Check rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty
with oil
Replace
Replace
Replace
Repalce
Repalce
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
20-262
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
• Intake of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper combustion
• Improper oil used Causes
• Operation under excessive load
end
ine
urb
er t
e
ube
pip
arg
er t
ain
er
och
ath
ind
r dr
e
ve
uid
turb
bre
cyl
age
ck
val
eg
er
r
bla
ng,
er,
filte
l at
chr
Legend
fety
ool
alv
ath
s is
n ri
sea
rbo
e, v
il c
oil
a
re
s
t ga
isto
d tu
do
db
alv
tive
tive
ed
rn p
aus
gge
gge
gge
rn v
gg
fec
fec
Exh
Clo
Wo
Clo
Clo
Clo
Wo
De
De
Questions

Black
Abnormally excessive
Carry out troubleshooting for "Exhaust is black"
Amount of blow-by gas

None
Check items
Oil filter caution lamp stays on even when oil pressure rises
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
When breather element is inspected directly, it is found to be clogged with

Troubleshooting
dirty oil, or hose is broken
When oil filter is inspected directly, it is found to be clogged
When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be catching or
broken
Replace
Replace
Replace
Repalce
Repalce
Clean
Clean
Clean
Remedy
20-263
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

Causes
General causes why fuel consumption is excessive
• Leakage of fuel
r
filte
)
tion
)
ton
e
uel
jec
kag
(pis
e in
g, f
r lin
mp
pin
ssiv
r
ove
eve
r
u
nge
y
l pi
dp
xce
pra
min
dc
el l
plu
fue
fee
p (e
le s
hea
f fu
n ti
mp
om
ide
ozz
nt o
um
ctio
de
u
s
e fr
np
np
nsi
l in
me
inje
n
ctio
kag
ctio
ctio
el i
sea
ust
Legend
l
fue
f fu
inje
inje
inje
adj
lea
oil
eo
er
tive
tive
tive
tive
tive
nal
rop
kag
fec
fec
fec
ter
fec
fec
Imp
Lea
De
De
De
Ex
De
Confirm recent repair history De

Questions
More than for other machines of
same model
Condition of fuel consumption
Gradually increased
Suddenly increased
Black
Exhaust gas color
White
There is irregular combustion
When exhaust manifold is touched immediately after starting engine,

Check items
temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
Injection pump test shows that injection amount is excessive
Speed of some cylinders does not change when operating on reduced

Troubleshooting
cylinders
When control rack is pushed, it is found to be heavy, or does not return
When check is made using delivery method, injection timing is found to be
incorrect
Remove feed pump and check directly
When engine speed is measured, low idling speed is found to be high

Replace
Replace
Adjust
Adjust
Adjust
Repair
Repair
Repair
Remedy
20-264
S-11 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
• Internal leakage in lubrication system
• Internal leakage in cooling system
Causes
ing
pitt
by
ed
ain
ck
aus
r
line
blo
g
r
er t
-rin
sc
er
of
pow
ole
e, O
ind
ket
on
g, h
cyl
gas
usi
cor
for
-rin
s in
r
ad
ler
ler
rot
Legend
, he
rO
coo
coo
ack
p
nt
line
d
hea
l cr
oil
oil
icie
ken
ken
rna
ken
ken
uff
Inte
Bro
Bro
Bro
Ins
Bro

Questions
Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white

Check items
Excessive air bubbles inside radiator, spurts back
Hydraulic oil, torque converter transmission oil is cloudy white
When hydraulic oil, torque converter transmission oil is drained, water

is
found
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage
Remove cylinder head and check directly

Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-265
S-12 Oil pressure lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Standards for engine oil selection

Selection of oil SAE number according
to ambient temperature
Type of oil
–22 –4 14 32 50 68 86 104 122°F
–30 –20 –10 0 10 20 30 40 50°C
Causes
SAE 30
SAE 10W
Diesel fuel
pan
SAE 10W-30
oil
ing
ide
pan
pip
or
SAE 15W-40
ins
ens
g
oil
lic
zin
an
or
e
ipe
rau
re s
alv
ens
ide
bra
il p
e
il p
hyd
alv
v
ins
l
ssu
el s
rna
in o
ipe
tor
no
oil
p
ef v
r
hed
ner
filte
pum
jou
pre
ula
p
lev
Legend
oke
in
oil
on
reli
trai
reg
rus
ing
oil
oil
el
oil
i
oil
r
nt
t
d, b
suc
, fu
ds
ear
g, c
tive
tive
tive
cie
tive
ed
tive
gge
gge
rn b
ter
ken
kin
gg
fec
uff
fec
fec
fec
fec
Wa
Lea
Clo
Clo
Clo
Bro
Ins
Wo
De
De
De
De
De

Dregree of use Operated for long period
Questions
Replacement of filter has not been carried out according to

operation manual
Caution lamp lights up
Lights up at low idling
Condition when oil pressure Lights up at low, high idling
lamp lights up Lights up on sloes
Sometimes lights up
There is clogging, leakage from hydraulic piping (external)
Check items
Oil level sensor lamp lights up

When oil level in oil pan is checked, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Carry out troubleshooting for
When oil filter is inspected directly, it is found to be clogged

Troubleshooting

Oil pump rotation is heavy, there is play
There is catching of relief valve, regulator valve, spring, or
"Oil level rises"
valve guide is broken

When oil level sensor is replaced, oil pressure sensor lamp
goes out
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
Add
20-266
S-13 Oil level rises

« If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
• Water in oil (cloudy white)
• Fuel in oil (diluted, and smells of diesel fuel) Cause
er)
• Entry of oil from other component
al
e)
mb
typ
es
ent
er
cha
ing
cov
ctiv
ipm
ge
ion
pitt
e
flan
t
ead
bus
equ
f
, de
by
com
eh
p(
ade
y
ole
m
xilia
pre
sid
ve
er h
sm
u
rfac
g
g in
ing
np
lee
r au
-rin
k
ath
loc
ole
lud
ipin
ctio
er s
eat
e, O
al s
po
(inc
er b
g, h
bre
at s
r se
inje
old
pum
ket
cor
rom
-rin
mp
ind
le h
gas
t
a
s
ide
r pu
d re
cyl
rO
ler
rmo
el f
l of
Legend
ead
ozz
coo
ins
line
ide
age
f fu
ea
ate
the
d, h
n
es
ins
eo
dw
tive
oil
dam
ged
tive
tive
hea
ctiv
kag
ken
cks
gge
fec
ma
fec
fec
ken
rn,
efe
Cra
Lea
Bro

Clo
De
Wo
De
Da
De
Bro
D
Questions
There is oil in radiator cooling water

Exhaust gas is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an
abnormal number of bubbles appear, or water spurts back
Water pump breather hole is clogged with mud
When water pump breather hole is clean, water comes out
Check items
Oil level goes down in clutch, TORQFLOW transmission, or

damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Remove water pump and check directly

Check rear seal directly
When pump auxiliary equipment is removed, seal is found
to be broken
Remove injection pump and check directly
There is improper contact of thermostat seat valve
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
20-267
Causes
S-14 Water temperature becomes too high
(overheating)
ing
pitt
re
General causes why water temperature becomes too high
n)
atu
by
ope
• Lack of cooling water (deformation, damage of fan)
per
ley
ade
e
aug
not
• Drop in heat dissipation efficiency
tem
pul
sm
fan
re g
• Defective cooling circulation system
oes
fan
oil
ole
ter
er
tor
atu
ool
• Rise in oil temperature of power train
t
e
ter
t (d
wa
e
g, h
dia
orn
alv
k
per
gas
il c
« Carry out troubleshooting for chassis.
ver
e
sta
d ra
g, w
re v
cor
-rin
ing
tem
no
con
ead
rmo
p
rO
ool
she
ssu
um
tor
pin
Legend
oke
ter
d, h
ue
dia
line
er p
the
nt c
pre
u
slip
wa
r
r
torq
d, b
d, c
d ra
hea
wat
tive
ged
cie
tive
tive
elt
gge
gge
gge
e in
ken
uffi
ken
fec
nb
ma
fec
fec
Clo
Clo
Clo
Ris
Bro
Ins
Bro
De
Da
De
Fa
De
Suddenly overheated
Condition of overheating
Questions
Always tends to overheat
Rises quickly
Water temperature gauge Does not go down from red
range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
There is play when fan pulley is rotated

Check items
Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through

Water is leaking because of cracks in hose or loose clamps
Belt tension is found to be slack
Power train oil temperature enters red range before engine
water temperature
Carry out troubleshooting for chassis
Temperature difference between top and bottom radiator

tank is excessive
Temperature difference between top and bottom radiator
tank is slight
Troubleshooting
When water filler port is inspected, the core is found to be clogged
When a function test is carried out on the thermostat, it does
not open even at the cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set

pressure is found to be low

Replace
Replace
Repalce
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
–
Add
20-268
Causes
S-15 Abnormal noise is made
.)
)
n)
ion
etc
d)
sitio
ize
d
jec
er,
hea
f po
« Judge if the noise is an internal noise or an
r se
lev
e in
ut o
and
external noise.
nge
e
t
bel
er
siv
c
ran
do
ock
General causes why abnormal noise is made
r
plu
rge
ces
an
ce
oar
le
lea
r
• Abnormality due to defective parts
e, r
n
of f
a
ozz
ck,
line
x
ere
och
ec
gb
e
ash
• Abnormal combustion noise
(ra
alv
p(
nn
ce
alv
idin
terf
er
turb
l
n
v
pum
p
k
• Air sucked in from intake system
lind
ctio
of v
(
ere
div
r, in
bac
um
g
tem
en
hin
, cy
er (
inje
terf
np
ent
twe
rge
tion
rain
bus
sys
uffl
ring
ctio
, in
m
cha
r be
ed
jec
ar t
Legend
t
ed
em
jus
fan
eiz
ve
inje
rbo
f ai
ton
eiz
e
d
val
sid
i
d, s
er g
er a
ed
eo
tive
g, s
d tu
tive
pis
t in
ken
form
gge
rop
kag
rop
sin
fec
fec
ize
rn
fec
Imp
Bro
Imp
Lea
Wo
Clo
Mis
De
De
De
Se
De

Questions
Gradually occurred
Condition of abnormal noise
Suddenly occurred

Color or exhaust gas
Black
Metal particles are found in oil filter


Check items
Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler

When trubocharger is rotated by hand, it is found to be heavy
Remove gear cover and check directly

Troubleshooting
When control rack is pushed, it is found to be heavy or does not return
Fan is deformed, or belt is loose
Remove cylinder head cover and check directly
When muffer is removed, abnormal noise disappers

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Repair
Remedy
20-269
S-16 Vibration is excessive

« If there is abnormal noise together with the
vibration, carry out troubleshooting for “Ab-
normal noise is made”.
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion
Causes
n)
k
ctio
tuc
rain
inje
n
c) s
r)
hio
e
er t
mp
cus
, et
ive
pow
(da
ess
ver
ken
ring
and
r le
aft
exc
bro
bea
t sh
h
cke
e
p(
ts,
las
gin
g
ain
tpu
bol
hin
um
, ro
ack
e n
,m
bus
u
ing
np
lve
een
nb
o
rod
unt
e
am
ctio
(va
ilot
trai
w
sid
mo
ing
bet
Legend
r, c
rt p
t in
inje
tem
ear
ect
ine
nce
ent
o
par
er g
upp
onn
sys
tive
eng
nm
ala
ken
rn s
rop
rn c

rn b
alig
fec
se
lve
Imp
Bro
Loo
Mis
Wo
Wo
Wo
De
Va

Questions
Suddenly increased
Condition of vibration
Gradually increased

Metal particles are found in oil filter
Check items
Oil pressure is low at low idling
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust gas is black

Remove oil pan and check directly?

Remove side cover and check directly
Troubleshooting
Check directly for worn support pilot, play

Check directly for loose engine mounting bolts, broken cushion
Check inside of output shaft (damper) directly

When radial runout, face runout are measured, they are
found to be outside standard value
Remove front cover and check directly

Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Remedy
20-270
TROUBLESHOOTING OF
MAIN MONITOR SYSTEM
(M MODE)
Trouble data display ................................................................................................................................ 20-353
M- 1 Main monitor does not work ....................................................................................................... 20-357

M- 2 When starting switch is turned ON and engine is started immediately,
all lamps stay lighted up ............................................................................................................. 20-358
M- 3 Speedometer display does not work properly ............................................................................ 20-359
M- 4 Abnormality in shift indicator
(a) Stays at N even when directional lever is at F ................................................................... 20-360
(b) Stays at N even when directional lever is at R ................................................................... 20-360
(c) Does not display N even when directional lever is at N and displays R when
directional lever is at F ........................................................................................................ 20-360
(d) Does not display N even when directional lever is at N and displays F when
directional lever is at R ........................................................................................................ 20-361
(e) Does not display 1st, 4th ..................................................................................................... 20-361
(f) Does not display 3rd, 4th .................................................................................................... 20-362
(g) Does not display 2nd, 3rd ................................................................................................... 20-362
(h) Does not display 1st, 2nd .................................................................................................... 20-363
M- 5 High beam does not light up ...................................................................................................... 20-364
M- 6 Turn signal display does not light up
(a) L.H. turn signal does not light up ........................................................................................ 20-365
(b) R.H. turn signal does not light up ........................................................................................ 20-365
M- 8 Abnormality in preheating system (QGS)
(a) Does not carry out preheating ............................................................................................ 20-366
(b) Always carries out preheating for 1 minute ........................................................................ 20-367
(c) Preheating stays on ............................................................................................................. 20-367
(d) Preheating time becomes shorter, or is unstable ................................................................ 20-368
M- 9 Night lighting does not light up ................................................................................................... 20-369
M-10 Abnormality in front working lamp
(a) Neither monitor display nor front working lamp light up ...................................................... 20-370
(b) Working lamp lights up but monitor display does not light up ............................................ 20-370
(c) Monitor lights up but working lamp does not light up .......................................................... 20-370
M-11 Abnormality in rear working lamp
(a) Neither monitor display nor rear working lamp light up ...................................................... 20-371
(b) Working lamp lights up but monitor display does not light up ............................................ 20-371
(c) Monitor lights up but working lamp does not light up .......................................................... 20-371
M-12A Abnormality in transmission cut-off (WA320-3H manual gear shift)
(a) When monitor switch is pressed, cut-off function is not switched and
display is not given .............................................................................................................. 20-373
(b) Monitor display goes out but cut-off stays on ..................................................................... 20-373
(c) Monitor display lights up but cut-off function is not actuated ............................................. 20-374
M-12B Abnormality in transmission cut-off (WA-3H automatic transmission)
(a) When monitor switch is pressed, cut-off function is not switched and
display is not given .............................................................................................................. 20-375
(b) Monitor display goes out but cut-off function is actuated when pedal
is depressed ......................................................................................................................... 20-375
(c) When monitor display is turned off, cut-off function is always actuated ............................ 20-375
(d) Cut-off function is always actuated regardless of monitor display ...................................... 20-375
(e) Monitor display lights up but cut-off function does not work .............................................. 20-376
20-351
M-13 Abnormality in parking brake dragging warning
(a) When parking brake is applied, buzzer sounds (intermittently) even when
directional lever is at N, and caution lamp flashes ............................................................. 20-377
(b) When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N .......................... 20-377
M-14 When parking brake dragging warning is given, buzzer and caution lamp
are actuated continuously, or they are not actuated
(a) Actuated continuously .......................................................................................................... 20-378
(b) Not actuated ......................................................................................................................... 20-378
M-15 Abnormality in buzzer
(a) Buzzer does not sound when starting switch is turned ON (during self-check) ................. 20-379
(b) Buzzer always sounds ......................................................................................................... 20-379
M-17 Abnormality in failure display mode
(a) Does not enter failure display mode ................................................................................... 20-381
(b) Time for time elapsed since failure on failure display mode does not advance ................ 20-281
M-20 Buzzer does not sound because of transmission controller ...................................................... 20-382
M-21 Abnormality in emergency steering normal display
(a) Emergency steering normal display does not light up ........................................................ 20-383
(b) Emergency steering normal display stays lighted up .......................................................... 20-383
M-22 Abnormality in emergency steering actuation display
(a) Emergency steering actuation display does not light up ..................................................... 20-384
(b) Emergency steering actuation display stays lighted up ...................................................... 20-384
M-23 Abnormality in auto greasing system (KOMATSU auto greasing system only)
(a) Forced greasing cannot be carried out ............................................................................... 20-385
(b) Monitor display flashes rapidly ............................................................................................ 20-385
(c) When no more grease remains, monitor display flashes rapidly ........................................ 20-385
(d) Monitor display flashes slowly .............................................................................................. 20-386
(e) Monitor display goes out ...................................................................................................... 20-386
M-24 Abnormality in ECSS system
(a) Display does not change when switch is pressed .............................................................. 20-387
(b) Monitor display lights up but ECSS function does not work ............................................... 20-387
M-26B Failure code is not sent to main monitor (abnormality in network) ........................................... 20-388
20-352
TROUBLESHOOTING TROUBLE DATA DISPLAY
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main monitor is
used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2. Abnormality in failure action code

This code informs the operator directly of the Example: When action code CALL is displayed
abnormality, and takes action, such as stopping

the machine immediately. SPEED
There are four types of action code: E00,

E01+CALL (E01 and CALL are displayed alter- km/h Action code
nately), E03+CALL, and CALL. If a failure
occurs suddenly, one of these codes is shown
on the action code display.
For details of the action taken by operator for TDW00283
the action codes, see Item 4.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible Example: When failure code "41" has occurred
27 hours before
to tell from this code which system in which
controller has failed, so carry out troubleshoot- Failure code
SPEED
ing for the applicable controller.
For failures that have occurred, the failure code
and the time elapsed since failure are displayed Time elapsed
since failure
to make it easy to check failures that are not
occurring at present.
The failure codes for failures that are now oc-
TDW00283
curring flash, and the codes for failures that are
not occurring light up.
For details of the method of operating and trans-
ferring data to the trouble data display mode,
see STRUCTURE AND FUNCTION for the main
monitor.
Note: If the engine is not stopped, it is impos-
sible to switch to the trouble data dis-
play mode, so the codes for failures
which can only be detected when the
engine is operating light up.
For the correspondence between the failure
codes for each controller and the failed system,
see Item 5.
20-353
4. Action code table
Action code: "Epp+ CALL" means that Epp and CALL are displayed alternatly
Transmission control system

Action Alarm Action by
code Problem system Action of maschine Buzzer operator
Speed sensor Does not shift gear Normal operation

system automatically (gear possible using
E00 No
(disconnection) must be shifted manually) manual gear
shifting
H-L solenoid, Transmission range fixed Travel under own

speed solenoid (1st - 3rd, depending power possible,
system on case) call for service after
E01 + Yes moving to a
CALL safe place

Shift lever system Neutral (F,R solenoids Actuate emergency

output OFF) manual spool, open
modulation solenoid
Directional solenoid Neutral (F,R solenoids, manually. This action
E03 + system modulation solenoids Yes makes it possible to
CALL output OFF) travel under own
Moulation solenoid Neutral (F,R solenoids, power. Call for service
system modulation solenoids
output OFF)
Wiring harness on return Neutral (F,R solenoids, Stop machine imme-

side of modulation solenoid modulation solenoids diately, turn starting
CALL short circuit with output OFF), possible Yes switch OFF, then call
power source that controller is burnt out for service
20-354
5. Failure code chart
Transmission control system ECSS control system
10 Modulation solenoid system d0 Relief solenoid system
11 Modulation solenoid system High pressure solenoid

d1 system
12 F solenoid valve system Low pressure solenoid

d2 system
13 R solenoid valve system d3 Speed sensor system
14 H-L solenoid valve system Abnormality in model

d4 selection
16 Speed solenoid system
Directional lever input

20
system
21 Speed lever input system
22 Speed sensor input system
23 Engine speed input system
20-355
WA320-3H Automatic
4. Action code table

Action code: "Epp+ CALL" means that Epp and CALL are displayde alternatly
Transmission control system

Action Alarm Action by
code Problem system Action of maschine Buzzer operator
Speed sensor Does not shift gear Normal operation

E00 system automatically (gear No possible using
(disconnection) must be shifted manually) manual gear shifting
H-L solenoid, Transmission range fixed Travel under own

E01 +
speed solenoid (1st - 3rd, depending Yes power possible,
CALL
system on case) call for service
Actuate emergency
Shift lever system Neutral (F,R OFF)
manual spool.
E03 +
Yes Possible to travel
CALL
Directional system Neutral (F,R OFF) under own power.
Call for service
Stop machine imme-
CALL Neutral (F,R OFF), possible
Short circuit Yes diately, starting switch
that controller is burnt out
OFF, call service
5. Failure code chart
Transmission control system ECSS control system

12 F solenoid valve system
d0 Relief solenoid valve
13 R solenoid valve system
d1 High pressure solenoid system
14 H-L solenoid valve system
d2 Low pressure solenoid system
16 Speed solenoid system
d3 Speed sensor system
20 Directional lever input system
d4 Abnormality in model selection
21 Speed lever input system
22 Speed sensor input system
23 Engine speed input system
20-356
TROUBLESHOOTING M-1
M-1 Main monitor does not work

Cause Remedy
YES Defective main monitor Replace

1
Is voltage between Defective contact, or
CNL05 (1), (2) and disconnection in wiring
(3) normal ? 2 YES After inspection,
harness between CNL05
repair or replace
Is there continuity (female) (1), (2) and
1) 20 - 30 V between CNL05 CNFS2 (9)
2) Turn starting NO (female) (3) and
switch ON. chassis ground? Defective contact, or
disconnection in wiring After inspection,
1) Turn starting NO harness between CNL05 repair or replace
switch OFF. (female) (3) and CNLR2 (11)
2) Disconnect
CNL05.
Power source
Maintenance monitor Buzzer
Battery relay
CNL05
1 CNFS2 CNFS1 CNLR6

Fuse Slow blow fuse
2 9 2 1
CNE02
3
CNLR5
3
CNL06
16
CNL07 CNLR11
12
20-357
TROUBLESHOOTING M-2
M-2 When starting switch is turned ON and engine is started

immediately, all lamps stay lighted up
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (4) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
NO harness between CNL05 repair or replace
1) 20 - 30 V
(female) (4) and CNL57 (3)
2) Turn starting
switch START.
Neutral relay
Start signal,
neutral signal
Starting motor
CNL57
1 2 3 5 6 CNL04
CNL05
3 N Speed lever
Starting
4
CNLR5
8
Neutral
2
CNR10
Rear frame GND
CNL09
3
Starting switch
20-358
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly

« Check that the gap between the speed sensor and gear is normal.
Cause Remedy
2 YES
Is resistance
YES between CNL07
(female) (1) and Defective contact, or
1 (2) normal ? disconnection in wiring
After inspection,
Is resistance harness between CNL07
1) 500Ω - 1 kΩ NO repair or replace
between CNT06 (female) (1), (2) - CNTL2
(male) (1) and (2) 2) Turn starting (1), (2) - CNT06 (1), (2)
normal? switch OFF.
3) Disconnect
1) 500Ω - 1 kΩ CNL07.
2) Turn starting Defective speed sensor Replace
NO
switch OFF.
3) Disconnect
CNL06.
Speedometer
CNL07 CNTL2 CNT06 Speed sensor
1 1 1
2 2 2
20-359
TROUBLESHOOTING M-4
M-4 Abnormality in shift indicator

« Check that the transmission shifts.
Cause Remedy
(a) Stays at N even when directional lever is at F
1 YES
Is voltage between
CNL08 (7) and
1) 20 - 30 V
2) Turn starting
switch ON.
3) Directional
lever: F
(b) Stays at N even when directional lever is at R
1 YES
Is voltage between
CNL08 (8) and
1) 20 - 30 V (female) (8) and CNL04 (4)
2) Turn starting
switch ON.
3) Directional
lever: R
(c) Does not display N even when directional lever is

at N and displays R when directional lever is at F
1 YES
Is voltage between
CNL08 (8) and
chassis ground Contact of power source with
normal? wiring harness between
After inspection,
CNL08 (female) (8) and
1) 0 - 5 V NO repair or replace
CNL04 (4), or defective
control lever
2) Turn starting
switch ON.
3) Directional
lever: N
20-360
TROUBLESHOOTING M-4
(d) Does not display N even when directional lever

Cause Remedy
at N and displays F when directional lever is at R
1 YES
Is voltage between
CNL08 (7) and
chassis ground Contact of power source
normal? with wiring harness between
After inspection,
control lever
2) Turn starting
switch ON.
3) Directional
lever: N
(e) Does not display 1st, 4th

(WA320-3H with manual gear shift)
1 YES
Is voltage between
CNL05 (12) and
1) 20 - 30 V NO harness between CNL05 repair or replace
2) Turn starting
switch ON.
3) Speed lever: 1
WA-3H with automatic transmission

1 YES
Is resistance between
CNL05 (female) (12)
and chassis ground Defective contact, or
harness between CNL05 repair or replace
1) Disconnect NO (female) (12) and CNL29
CNL05. (11)
2) 50 - 70 Ω
20-361
TROUBLESHOOTING M-4
Cause Remedy
(f) Does not display 3rd, 4th
1 YES
Is voltage between
CNL05 (13) and
1) 20 - 30 V NO harness between CNL05 repair or replace
2) Turn starting (female) (13) and CNL04 (7)
switch ON.
3) Speed lever: 3
1 YES
CNL05 (female) (13)
1) Disconnect NO (female) (13) and CNL29
CNL05. (10)
2) 50 - 70Ω
(g) Does not display 2nd, 3rd

1 YES
Is voltage between
CNL05 (12) and
chassis ground Contact of power source
normal? with wiring harness between
After inspection,
2) Turn starting control lever
switch ON.
3) Speed lever: 2
Relationship between monitor H : 20 30 V

input signal and display L : 0V
CNL05(12) CNL05(13) Display
H L 1
L L 2
L H 3
H H 4
20-362
TROUBLESHOOTING M-4
Cause Remedy
(h) Does not display 1st, 2nd
1 YES
Is voltage between
CNL05 (13) and Contact of power source
chassis ground with wiring harness between
normal? CNL05 (female) (13) and After inspection,
CNL04 (7), or defective repair or replace
1) 0 - 5 V NO
transmission lever
2) Turn starting
switch ON.
3) Speed lever: 2
Transmission lever
WA320-3H with manual gear shift CNL04
Transmission range
2 F
CNL05 4 R
12 5 1ST
13 7 3RD
CNL08 CNTL1 CNT03

Hi-Lo
7 5 1
8 6 2
FORWARD relay REVERSE relay CNT04

SPEED
CNL66 CNL67
1
5 5
2

CNL29 CNL30
Transmission lever
10 11 1 12 CNL04
Transmission range
2 F
CNL05 4 R
12 1ST
13 3RD
CNL08 CNTL1 CNT03

Hi-Lo
7 5 1
8 6 2
Buckup lamp relay CNT04

SPEED
CNL54
1
20-363
TROUBLESHOOTING M-5
M-5 High beam does not light up

« Before starting troubleshooting, check that the lamp bulb is not blown.
Cause Remedy
2 YES
Is there continuity
YES between CNL06
(female) Defective contact, or
1 chassis ground? disconnection in wiring After inspection,
Is voltage between 1) Turn starting NO harness between CNL06 repair or replace
CNL06 (12) and switch OFF. (female) (13) and CNL02 (3)
chassis ground 2) Disconnect
normal? CNL06.
3) Dimmer switch:
1) 20 - 30 V Defective contact, or
H beam
2)Turn starting disconnection in wiring After inspection,
switch ON. NO harness between CNL06 repair or replace
(female) (12) and CNFS2
(2)
Hi beam
CNL06 CNFS2
12 2
13 1
CNL02
2 Lamp switch
Dimmer switch
CNLR1 CNFR1 CNF01
10 4 2
R.H. head lamp
8 2 3
20-364
TROUBLESHOOTING M-6
M-6 Turn signal display does not light up

« Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not
blown.
Cause Remedy
(a) L.H. turn signal does not light up

1 YES
Is voltage between
CNL06 (14) and
1) Repeat 0V and NO harness between CNL06 repair or replace
20 - 30 V. (female) (14) and CNL03 (4)
2) Turn starting
switch ON.
(b) R.H. turn signal does not light up

1 YES
Is voltage between
CNL06 (15) and
1) Repeat 0V and
(female) (15) and CNL03
20 - 30 V.
(3)
2) Turn starting
switch ON.
To turn signal lamp
Turn signal
CNL06 CNL03 Turn signal switch

L
14 4
B
15 3
CNL12
B
Hazard switch
E
Turn signal unit
20-365
TROUBLESHOOTING M-8
M-8 Abnormality in preheating system (QGS) (WA380-3H)

(a) Does not carry out preheating

« Check that the water temperature is below 5°C. Cause Remedy
(1) Monitor display also does not light up
2 YES
Defective monitor panel Replace
YES CNL05 (female) (7)
and chassis ground Wiring harness between
1
normal? CNL05 (female) (7) - CNLR4
After inspection,
Is resistance (2) - CNER1 (8) - CNE05
between CNE05 1) Disconnect NO repair or replace
(female) short circuiting with
(male) and chassis CNL05.
chassis ground
ground normal? 2) Turn starting
switch OFF.
1) Disconnect 3) Min. 4kΩ Defective engine water
CNE05. temperature sensor Replace
NO
2) Turn starting
switch OFF.
3) Min. 4kΩ
(2) Only monitor display lights up

YES
Defective glow plug Replace
2
Is voltage between
YES CNE07 and
chassis ground 3 YES
normal? Defective heater relay Replace
Is voltage between
1) 20 - 30 V CNE08 and
1
NO chassis ground Defective contact, or
Is voltage between normal? disconnection in wiring After inspection,
2) Turn starting
CNE09 (1) and (2) harness between CNE08 repair or replace
switch ON. 1) 20 - 30 V NO
normal? and slow blow fuse
2) Turn starting Defective contact, or
1) 20 - 30 V switch ON. disconnection in wiring
harness between CNL56 (3)
2) Turn starting
- CNLR4 (7) - CNER1 (4) - After inspection,
switch ON.
NO CNE09 (female) (1), or repair or replace
between CNE09 (female)
(2) - CNER2 (5) - chassis
ground
20-366
TROUBLESHOOTING M-8
(b) Always carries out preheating for 1 minute Cause Remedy

« Check that the water temperature is below 10°C.
2 YES
1
normal? disconnection in wiring
Is resistance
After inspection,
between CNE05 1) Max. 8 kΩ NO repair or replace
(female) (7) - CNLR4 (2) -
(male) and chassis 2) Turn starting CNER1 (8) - CNE05 (female)
ground normal? switch OFF.
3) Disconnect
1) Max. 8 kΩ CNE05. Defective engine water
temperature sensor Replace
NO
2) Turn starting
switch OFF.
3) Disconnect
CNE05.
(c) Preheating stays on

YES
1
3 YES
Does preheating Defective preheating relay Replace
stop? Is voltage between
YES CNL06 (4) and
2 chassis ground Wiring harness between
1) Turn starting normal? CNL06 (female) (4) and After inspection,
switch ON.
Does preheating 1) 20 - 30 V NO CNL56 (2) short circuiting repair or replace
NO stop? 2) Turn starting with chassis ground
2) Disconnect
CNL06. switch ON. Contact of power source
1) Turn starting with wiring harness between After inspection,
switch ON. NO CNL56 (3) - CNLR4 (7), repair or replace
CNL05 (19)
2) Remove
preheating
relay.
20-367
TROUBLESHOOTING M-8
Cause Remedy
(d) Preheating time becomes shorter, or there is variation
3 YES
Is voltage between
YES CNL05 (3) and
2 chassis ground Defective contact of wiring
normal? harness between CNL05 (3) After inspection,
1) Max. 0.1 V NO - CNLR5 (3) - CNR11 - repair or replace
and chassis ground 2) Turn starting chassis ground
1 normal? switch ON. Defective contact of wiring
Is resistance harness between CNL05
1) Are temperature After inspection,
between CNE05 (female) (7) - CNLR4 (2) -
and resistance repair or replace
(male) and chassis value as shown
NO CNER1 (8) - CNE05, or
ground normal? in table below? leak from chassis ground
2) Turn starting
1) Are temperature switch OFF. Defective engine water
and resistance temperature sensor Replace
value as shown NO
in table below?
2) Turn starting
switch OFF.
Table (Tolerance ± 0.5 kΩ)
Temperature(°C) 10 8 6 4 2 0 2 4
Resistance value(kΩ) 7.7 7.1 6.5 6.0 5.5 5.1 4.7 4.3
Starting motor SWR2 signal

Preheating
CNL05 CNLR4 CNER1 CNE09

Slow blow fuse
19 7 4 1 + 24 V
CNE08
2
CNL06 CNER2
CNE09
4
CNL56 Glow plug
5
1 2 3 5 6
Preheating relay
Starting switch
CNL09
2 BR
Water temperature signal CNLR5 Battery ⊕

CNL05 3
3 CNLR4 CNER1 CNE05

7 2 8
Engine water
temperature sensor
20-368
TROUBLESHOOTING M-9
M-9 Night lighting does not light up

« Before starting troubleshooting, check that the lamp bulb is not blown.
Cause Remedy
1 YES
Is voltage between
CNL05 (16) and
1) 20 - 30 V
(female) (16) and CNFS2
(5)
2) Turn starting
switch ON.
3) Turn side lamp

switch ON.
Side lamp (right)
Side
CNL05 CNFS2
16 5
Lighting switch
CNL02
5
20-369
TROUBLESHOOTING M-10
M-10 Abnormality in front working lamp

« Before starting troubleshooting, check that the monitor lighting is lighted up.
Cause Remedy
(a) Neither monitor display nor front working lamp light up
Defective contact, or
YES disconnection in wiring After inspection,
harness between CNL60 (1) repair or replace
- CNL05 (17), CNCL1 (7)
1 YES Defective front working lamp

Is voltage between Replace
3 relay
CNL60 (1) and Is voltage between
chassis ground YES CNL60 (6) and Defective contact, or
normal? chassis ground 4 YES disconnection in wiring After inspection,
1) 0 - 3 V normal? Is voltage between harness between CNL06 (1) repair or replace
2) Turn starting 2 CNL06 (1) and and CNL60 (6)
1) 0 - 3 V
switch ON. Is voltage between
2) Turn starting NO chassis ground
CNL60 (2), (5) and normal?
switch ON.
NO chassis ground Defective main monitor Replace
normal? 1) 0 - 3 V NO
2) Turn starting
1) 20 - 30 V switch ON. Defective contact, or
2) Turn starting disconnection in wiring After inspection,
switch ON. harness between CNL60 repair or replace
NO
(2), (5) - CNFS5 (1)
(b) Working lamp lights up but monitor display does not light up
1 YES
Is voltage between
CNL05 (17) and
1) 20 - 30 V
2) Turn starting
switch ON.
(c) Monitor lights up but working lamp does not light up

disconnection in wiring
harness between CNL60 (1) After inspection,
- CNCL1 (7) - front working repair or replace
lamp, or blown working lamp
bulb
20-370
M-11 Abnormality in rear working lamp

« Before starting troubleshooting, check that the monitor lighting is lighted up.
Cause Remedy
(a) Neither monitor display nor rear working lamp light up
YES After inspection,
harness between CNL61 (1)
- CNL05 (18), CNLR1 (12) repair or replace
1 YES Defective rear working lamp

Is voltage between relay Replace
3
CNL61 (1) and
Is voltage between
chassis ground YES CNL61 (6) and Defective contact, or
normal?
chassis ground 4 YES disconnection in wiring After inspection,
1) 20 - 30 V normal? Is voltage between harness between CNL06 (2) repair or replace
2) Turn starting
2 and CNL61 (6)
1) 0 - 3 V CNL06 (2) and
switch ON. Is voltage between
CNL61 (2), (5) and 2) Turn starting NO chassis ground
switch ON. normal?
NO chassis ground Defective main monitor Replace
normal? 1) 0 - 3 V NO
2) Turn starting
switch ON. Defective contact, or
(2), (5) - CNFS5 (2)
(b) Working lamp lights up but monitor display does not light up
1 YES
Is voltage between
CNL05 (18) and
harness between CNL05 After inspection,
1) 20 - 30 V NO (female) (18) and CNL61 repair or replace
2) Turn starting (1)
switch ON.
(c) Monitor lights up but working lamp does not light up Defective contact, or
- CNLR1 (12) - rear repair or replace
working lamp, or blown
working lamp bulb
20-371
F Working lamp relay

CNL60
Working lamp F
CNL05 5 6 1 2 3 4 CNCL1
to front working lamp
17 7
CNL06 CNFS5
1 1 + 24 V
R Working lamp relay

CNL61
Working lamp R
CNL05 5 6 1 2 3 4 CNLR1
To rear working lamp
18 12
CNL06 CNFS5
2 2 + 24 V
20-372
TROUBLESHOOTING M-12A
M-12A Abnormality in transmission cut-off

(a) When monitor switch is pressed, cut-off function is Cause Remedy

not switched and display is not given
(b) Monitor display goes out but cut-off function stays

on
3 YES
A
Is voltage between
YES CNL65 (1) and
2 chassis ground Defective contact, or
YES CNL65 (2) and NO harness between CNL65 (1) repair or replace
1) 20 - 30 V
chassis ground and CNFS2 (8)
1 normal? 2) Turn starting Defective contact, or
Is voltage between
1) 0 - 3 V switch ON. disconnection in wiring After inspection,
CNL06 (3) and
chassis ground
2) Turn starting (female) (3) and CNL65 (2)
normal?
switch ON.
1) 0 - 3 V
NO
2) Turn starting
switch ON.
5 YES Defective transmission cut-
Replace
Is voltage between off relay
YES CNL65 (5) and
1) 20 - 30 V NO harness between CNL65 (5) repair or replace
4 2) Turn starting and CNL12 (female) (2)
Is voltage between switch ON.
CNL65 (3) and 3) Turn parking
A chassis ground switch OFF.
normal? 4) Remove cut - off
relay.
1) 20 - 30 V 5) Stop machine
cut - off function.
2) Turn starting Defective contact, or
switch ON. disconnection in wiring After inspection,
NO harness between CNL65 (3) repair or replace
3) Turn parking and CNL12 (female) (1)
switch OFF.
20-373
TROUBLESHOOTING M-12A
(c) Monitor display lights up but cut-off function is not actuated Cause Remedy
YES
Defective cut-off relay Replace
2
Is voltage between
YES CNL65 (2) and
chassis ground 3 YES
normal? Defective main monitor Replace
1
1) 20 - 30 V Does cut-off
Does cut-off
NO function work? Wiring harness between
function work? 2) Turn starting CNL06 (female) (3) and After inspection,
switch ON. 1) Turn starting NO CNL65 (2) short circuiting repair or replace
switch ON. with chassis ground
1) Turn starting 2) Disconnect Contact of wiring harness
switch ON. CNL06. between CNL65 (3) and (5), After inspection,
NO or defective cut-off switch repair or replace
2) Remove cut - off
relay.
Transmission cut-off relay CNL65
Transmission cut-off
CNFS2
CNL06 +24V
CNL04 Transmission lever
CNL08
CNL12 Transmission cut-off switch
Parking
brake
switch CNTL1
F solenoid
R solenoid
Neutralizer relay FORWARD relay REVERSE relay

CNL58 CNL66 CNL67
TDW00297
20-374
TROUBLESHOOTING M-12B
M-12B Abnormality in transmission cut-off

(WA-3H with automatic transmission)
(a) When monitor switch is pressed, cut-off function is not Cause Remedy
switched and display is not given
(b) Monitor display goes out but cut-off function is actuated

when pedal is depressed Defective contact, or
1 YES After inspection,
Is voltage between repair or replace
CNL06 (3) and (female) (16)
chassis ground
normal?
1) 0 - 3 V NO
2) Turn starting
switch ON.
3) Disconnect
CNL12.
(c) When monitor display is turned off, cut-off function is

always actuated Defective contact, or
2 harness between CNL12
repair or replace
Is there continuity
YES between CNL12 (female) (16)
1
chassis ground? disconnection in wiring
Is there continuity After inspection,
between CNL12 1) Disconnect harness between CNL12
NO repair or replace
(male) (1) and CNL12. (female) (2) and chassis
(2) ? ground
1) Disconnect Defective transmission cut-

Replace
CNL12. NO off switch
(d) Cut-off function is always actuated regardless of

monitor display
1 YES Defective transmission
Replace
Is voltage between controller
CNL30 (16) and Defective contact, or
chassis ground disconnection in wiring
normal? harness between CNL30 After inspection,
1) 0 - 3 V NO (female) (16) - CNL06 repair or replace
(female) (3), CNL12
(female) (1)
20-375
Cause Remedy
(e) Monitor display lights up but cut-off function does not work
YES Defective transmission cut-

Replace
off switch
1
Does cut-off YES

function work? Defective main monitor Replace
2
1) Disconnect Does cut-off

CNL12.
NO function work? 3 YES Defective transmission
Replace
2) Turn starting
Is voltage between controller
switch ON.
1) Disconnect CNL30 (16) and Wiring harness between
CNL06. NO chassis ground CNL06 (female) (3) -
2) Turn starting normal? CNL30 (female) (16) - After inspection,
switch ON. 1) Disconnect NO CNL12 (female) (1) short repair or replace
CNL 12. circuiting with chassis
2) Disconnect ground
CNL06.
3) Turn starting
switch ON.
4) 20 - 30 V
CNL30
16
Cut-off signal
CNL06 CNL12 Transmission cut-off switch
3 1
20-376
M-13 Abnormality in parking brake dragging warning

(a) When parking brake is applied, buzzer sounds Cause Remedy

(intermittently) even when directional lever is at N, and
caution lamp flashes
1 YES
Is voltage between
CNL05 (8) and
1) 20 - 30 V
2) Turn starting
switch ON.
(b) When parking brake is applied, buzzer does not sound

and caution lamp does not light up even when
directional lever is at position other than N
« Check that the synchronous flash signal is normal.
YES
1
Is voltage between
CNL05 (8) and Contact of power source with
chassis ground 2 YES wiring harness between After inspection,
normal? CNL05 (female) (8) and repair or replace
Is resistance
between CNL05 CNL04 (female) (3)
1) 0 - 5 V
2) Turn starting NO (male) (8) and (3)
switch ON. normal?
1) 3 kΩ - 4 kΩ NO
2) Turn starting
switch OFF.
3) Disconnect Neutral relay
CNL05.
Start signal,
neutral signal
Starting motor
CNL57
1 2 3 5 6 CNL04
CNL05
3 N Speed lever
Starting
4
CNLR5
8
Neutral
2
CNR10
Rear frame GND
CNL09
3
Starting switch
20-377
M-14 When parking brake dragging warning is given, buzzer and

caution lamp are actuated continuously, or they are not actuated
Cause Remedy
(a) Actuated continuously
2 YES Defective maintenance

monitor Replace
YES Does buzzer stop
and lamp go out? Defective contact, or
1 disconnection in wiring
After inspection,
1) Turn starting NO repair or replace
Does buzzer stop switch ON. (female) (5)
and lamp go out? 2) Connect CNL19
(female) (5) to
chassis ground.
1) Turn starting
switch ON. Defective main monitor Replace
2) Connect CNL07 NO
(6) to chassis
ground.
(b) Not actuated

Replace
monitor
YES Do buzzer and
1 lamp work? Wiring harness between
CNHL19 (female) (5) short After inspection,
Do buzzer and 1) Turn starting NO repair or replace
circuiting with chassis
lamp work? switch ON. ground
2) Disconnect
1) Turn starting CNL19.
switch ON. NO
2) Disconnect
CNL07.
Synchronous flashing signal
CNL07 CNL19
6 5
20-378
M-15 Abnormality in buzzer

Cause Remedy
(a) Buzzer does not sound when starting switch is turned
ON (during self-check)
YES
1 (female) (8) and CNL43
(male)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
1) Turn starting CNL42 (female) and
switch ON. NO chassis ground Defective contact, or
2) Contact CNL43 normal? disconnection in wiring After inspection,
(female) to 1) 20 - 30 V NO harness between CNL42 repair or replace
chassis ground. 2) Turn starting (female) and CNFS2 (9)
switch ON.
(b) Buzzer always sounds
YES
Defective main monitor. Replace
1
Does buzzer stop? YES Go to Troubleshooting for

-
2 maintenance monitor
1) Turn starting Does buzzer stop? Wiring harness between

switch ON. 3 YES CNL06 (female) (8) and
NO After inspection,
2) Disconnect CNL43 (male) short
repair or replace
CNL06. circuiting with chassis
1) Turn starting Does buzzer stop? ground
switch ON. NO
2) Disconnect
CNL19. Defective buzzer Replace
1) Turn starting NO
switch ON.
2) Disconnect
CNL43.
CNL19 CNL42
CNFS2 9
Buzzer output 4 Buzzer
+ 24 V
CNL06 Maintenance monitor CNL43

8
20-379
20-380
M-17 Abnormality in failure display mode

Cause Remedy
(a) Does not enter failure display mode
1 YES
Is voltage between
CNL05 (5) and Contact of power source
chassis ground with wiring harness between
normal? CNL05 (female) (5) - After inspection,
1) 0 - 5 V NO CNLR4 (6) - CNER1 (9) - repair or replace
2) Turn starting alternator terminal R, or
switch ON. defective alternator
(b) Time for time elapsed since failure on failure

display mode does not advance
1 YES
Is voltage between
CNL05 (5) and Defective contact, or
chassis ground disconnection in wiring
normal? harness between CNL05
After inspection,
(female) (5) - CNLR4 (6) -
CNER1 (9) - alternator
2) Start engine. terminal R, or defective
alternator
Charge
Alternator
CNL05 CNLR4 CNER1
5 6 9 R
CNE16
20-381
TROUBLESHOOTING M-19, M-20
M-20 Buzzer does not sound because of transmission controller
Cause Remedy
Go to
2 YES Defective transmission Troubleshooting
Is resistance between controller for transmission
YES CNL31 (female) (15) controller
1 and chassis ground Defective contact, or
Does buzzer 1) 1kΩ - 2kΩ NO repair or replace
sound? 2) Turn starting (female) (15)
switch ON.
1) 0 - 3 V
2) Turn starting Defective main monitor Replace
switch ON. NO
CNL34
Transmission controller buzzer 7
CNL08 CNL31
6 15
3.3 K
20-382
M-21 Abnormality in emergency steering normal display

Cause Remedy
(a) Emergency steering normal display does not light up
YES Defective emergency

steering normal sensor Replace
1
Is there continuity
between CNT10
(male) (1) and 2 YES
(2)? Defective main monitor Replace
Is voltage between
1) Disconnect CNL05 (10) and
Wiring harness between
CNT10. NO chassis ground
normal? CNL05 (female) (10) -
2) Turn starting After inspection,
CNTL1 (2) - CNT10 (female)
switch ON. 1) 20 - 30 V NO repair or replace
(1) short circuiting with
2) Turn starting chassis ground
switch ON.
(b) Emergency steering normal display stays lighted up
3 YES
Is voltage between
YES CNL05 (10) and
2 normal? disconnection in wiring After inspection,
Is there continuity harness between CNL05 repair or replace
1) 0 - 2 V NO (female) (10) - CNTL1 (2) -
YES between CNT10
(female) (2) and 2) Turn starting CNT10 (female) (1)
1 chassis ground? switch ON.
Is there continuity 1) Disconnect disconnection in wiring
between CNT10 After inspection,
CNT10. harness between CNT10
(male) (1) and NO repair or replace
(female) (2) - CNTL1 (8) -
(2)? chassis ground
1) Disconnect
Defective emergency
CNT10. Replace
NO steering normal sensor
2) Turn starting
switch ON.
Emergency steering normal
CNL05 CNTL1 CNT10 Emergency steering

normal sensor
10 2 1
8 2
20-383
M-22 Abnormality in emergency steering actuation display

Cause Remedy
(a) Emergency steering actuation display does not light up
YES Defective emergency

Replace
1 steering function sensor
Is there continuity
between CNT11
(male) (1) and 2 YES
(2)? Defective main monitor Replace
Is voltage between
1) Disconnect CNL05 (11) and
Wiring harness between
CNT11. NO chassis ground
normal? CNL05 (female) (11) -
CNTL1 (1) - CNT11 (female)
switch ON. 1) 20 - 30 V NO repair or replace
switch ON.
(b) Emergency steering actuation display stays lighted up
3 YES
Is voltage between
YES CNL05 (11) and
chassis ground Wiring harness between
2 normal? CNL05 (female) (11) -
After inspection,
Is there continuity CNTL1 (1) - CNT11 (female)
YES between CNT11 (1) short circuiting with
(female) (2) and
switch ON.
1 chassis ground?
Is there continuity 1) Disconnect disconnection in wiring
between CNT11 After inspection,
CNT11. harness between CNT11
(male) (1) and NO repair or replace
(female) (2) - CNTL1 (8) -
(2)? chassis ground
1) Disconnect
Defective emergency
CNT11. Replace
NO steering actuation sensor
2) Turn starting
switch ON.
Emergency steering actuation
CNL05 CNTL1 CNT11 Emergency steering

actuation sensor
11 1 1
8 2
20-384
M-23 Abnormality in auto-greasing system

(KOMATSU auto-greasing system only)
Cause Remedy
(a) Forced greasing cannot be carried out

Go to
2 YES operation maintenance
manual for handling –
Is voltage
auto-greasing system
YES between CNGRE
(1) and chassis
1 ground normal ? disconnection in wiring After inspection,
Is voltage NO harness between CNL06 repair or replace
1) 0 - 3 V
between CNL06 (female) (5) and CNGRE (1)
2) Turn starting
(6) and chassis switch ON
ground normal ? 3) Turn auto-greasing
1) 0 - 3 V switch ON
switch ON NO
3) Turn auto-greasing
switch ON
(b) Monitor display flashes rapidly (2 times/sec)
YES
1
Is voltage
between CNL08 Defective contact, or
(5) and chassis 2 YES disconnection in wiring After inspection,
ground normal ? harness between CNL08 repair or replace
Is voltage
between CNGRE (female) (5) and CNGRE (3)
1) 0 - 30 V
2) Turn starting NO (3) and chassis Go to
switch ON ground normal ? operation maintenance
NO manual for handling –
1) 0 - 30 V
2) Turn starting auto-greasing system
switch ON
(c) When no more grease remains, monitor display flashes

rapidly (2 times/sec)
YES
1
Is voltage
between CNL07 Defective contact, or
(11) and chassis disconnection in wiring
ground normal ? harness between CNL07
Is voltage repair or replace
(female) (11) and CNGRE
1) 20 - 30 V between CNGRE (2)
2) Turn starting NO (2) and chassis
Go to
switch ON ground normal ?
operation maintenance
1) 20 - 30 V NO manual for handling –
switch ON
20-385
Cause Remedy
(d) Monitor display flashes slowly (1 time/sec)

Go to
operation maintenance
manual for handling –
auto-greasing system
(e) Monitor display goes out

YES
1
Is voltage
between CNL07 Contact of power source
(11) and chassis 2 YES with wiring harness After inspection,
ground normal ? between CNL07 (female) repair or replace
Is voltage
between CNGRE (11) and CNGRE (female) (2)
1) 0 - 3 V
2) Turn starting NO (2) and chassis Go to
switch ON ground normal ? operation maintenance
NO manual for handling –
1) 0 - 3 V
switch ON
Relationship between input signal

and display
CNL07(11) CNL08(5) Display

Rapid flashing
L L (2 times/sec)
Slow flashing
H L (1 time/sec)
H H OFF
L H ON
Auto-greasing
CNL06 CNGRE
CNL07
A 11
CNL08
P
20-386
M-24 Abnormality in ECSS system

Cause Remedy
(a) Display does not change when switch is pressed
(b) Monitor display lights up but ECSS function does not

work
Go to
2 YES Troubleshooting
Defective ECSS controller
Is voltage between for ECSS
YES CNDP2 (1) and controller
1 chassis ground Defective contact, or
CNL06 (7) and 1) 0 - 3 V NO harness between CNL06 (7) repair or replace
chassis ground 2) Turn starting and CNDP2 (1)
normal? switch ON.
1) 0 - 3 V
2) Turn starting NO
switch ON.
ECSS
CNL06 CNDP2
7 1
20-387
M-26B Failure code is not sent to main monitor

(abnormality in network)
« Set dipswitch 3 at the rear of the main monitor to F.
Cause Remedy
2 YES Applicable controller is

Replace
Is voltage normal defective
YES between pins of Defective contact, or
connectors in disconnection in wiring
table below? harness between CNL08 After inspection,
1
1) Repeat 0 V and NO (female) (1)(3), CNL08 repair or replace
Is voltage (female)(2)(4) - applicable
between CNL08 12 V
2) Turn starting connector pins
(male) (1) and (2)
normal ? switch ON
3) Disconnect connector
1) Repeat 0 V and to be measured
12 V
switch ON NO
3) Disconnect
CNL08
Table
Connector Pin No.
CNL29 CNL30 Between (1) (9)
CNL29
CNL08 CNDP2
ECSS
20-388
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor does not work ..................................................... 20-402
(a) All lamps on maintenance monitor do not light up for 3 seconds ....................................... 20-402
(b) Some lamps do not light up ................................................................................................. 20-403
K- 2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out ........................................................................................................................ 20-403
K- 3 When engine is started immediately after starting switch is turned ON
(within 3 seconds), all lamps on maintenance monitor do not go out ....................................... 20-404
K- 4 When starting switch is turned ON (engine stopped), CHECK items flash ............................... 20-405
(a) Engine oil level display flashes ............................................................................................ 20-405
(b) Engine water level display flashes ....................................................................................... 20-406
K- 5 When starting switch is turned ON (engine started), CAUTION items flash ............................. 20-407
(a) Engine oil pressure display flashes ..................................................................................... 20-407
(b) Battery charge level display flashes .................................................................................... 20-408
(c) Brake oil pressure display flashes ....................................................................................... 20-409
(d) Air cleaner display flashes ................................................................................................... 20-410
K- 6 CAUTION items are flashing but alarm buzzer does not sound ............................................... 20-411
K- 7 There is no abnormality in monitor display but alarm buzzer sounds ....................................... 20-412
K- 8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp)
does not light up ........................................................................................................................ 20-413
(a) CHECK lamp ....................................................................................................................... 20-413
(b) CAUTION lamp .................................................................................................................... 20-413
K- 9 There is no abnormality in maintenance monitor display but
warning lamp (CHECK lamp, CAUTION lamp) lights up ........................................................... 20-414
(a) CHECK lamp ....................................................................................................................... 20-414
(b) CAUTION lamp .................................................................................................................... 20-414
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up) ........................................................... 20-415
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays
lighted up .................................................................................................................................... 20-416
K-12 Service meter does not work ..................................................................................................... 20-417
K-13 Service meter is running even when engine is stopped ............................................................ 20-417
K-14 Abnormality in gauge items ........................................................................................................ 20-418
(a) Abnormality in fuel gauge .................................................................................................... 20-418
(b) Abnormality in engine water temperature gauge ................................................................. 20-419
(c) Abnormality in torque converter oil temperature gauge ...................................................... 20-420
20-401
TROUBLESHOOTING K-1
K-1 When starting switch is turned ON, all lamps on maintenance

monitor do not light up for 3 seconds, maintenance monitor does
not work
« Always connect any disconnected connectors before go-

ing on the next step.
(a) All lamps on maintenance monitor do not light up for 3 Cause Remedy
seconds
YES Defective maintenance Replace
monitor module
disconnection in wiring Repair wiring
YES harness between CNL18 harness,
1 3 (female) (1), (2) - CNFS2 replace or
Is voltage Is voltage between (9) - fuse box - CNFS1 replace fuse
between CNL18 YES CNFS1 (female) (2) (male) (2), or blow fuse
(1),(2) - (3) and chassis
normal? ground normal?
2 1) 20 - 30 V harness between CNFS1 harness,
1) 20 - 30 V
Is there continuity 2) Disconnect (female) (2) - CNLR6 (1) - replace or
2) Turn starting NO
between CNL18 CNFS1. slow blow fuse - battery replace fuse
switch ON.
(female) (3) and 3) Turn starting relay, or blow fuse
NO
chassis ground? switch ON.
1) Turn starting disconnection in wiring Repair wiring
switch ON. harness between CNL18 harness or
2) Disconnect NO (3) - CNLR4 (12) - chassis replace
CNL18. ground
Battery relay
CNL18 Fuse box Slow blow fuse
1 CNFS2 10A CNFS1 CNLR6 80A

2 9 2 1
3
CNLR4 Battery terminal
12
20-402
TROUBLESHOOTING K-1, K-2
Cause Remedy
(b) Some lamps do not light up
Defective maintenance
monitor module Relace
K-2 When starting switch is turned ON, all lamps on maintenance

monitor light up but do not go out
Cause Remedy
Go to troubleshooting of –
main monitor
20-403
TROUBLESHOOTING K-3
K-3 When engine is started immediately after starting switch is turned

ON (within 3 seconds), all lamps on maintenance monitor do not
go out
Cause Remedy
1
YES
When starting Defective maintenace Replace
engine, is voltage monitor module
between CNL19
(female (1) and Defective contact, or
chassis ground disconnection in wiring Repair wiring
normal? harness between CNL19 harness or
NO replace
1) 20 - 30 V (female) (1) and neutral
2) Disconnect relay
CNL19.
3) Start engine.
4) Measure when
starting motor is
turning.
CNL09
CNL19 3
1
C
Starting switch
6 5 3 2 1
CNL04
CNL57 3 N Speed lever
Neutral relay
20-404
TROUBLESHOOTING K-4
K-4 When starting switch is turned ON (engine stopped), CHECK items

flash
(a) Engine oil level display flashes Cause Remedy

« Before starting troubleshooting, check the engine oil level again.

Replace
Is there continuity monitor module
YES between CNL18
1 (female) (13) and Defective conact, or
chassis ground? disconnection in wiring Repair wiring
Is there continuity
harness between CNL18 harness or
between CNE10 1) Turn starting NO (female) (13) - CNLR4 (4) - replace
(male) (1) and switch off. CNER1 (3) - CNE10
chassis ground? 2) Disconnect (female) (1)
CNL18.
Defective engine oil lever Replace
1) Turn starting NO sensor
switch off.
2) Disconnect
CNE10.
CNL18 CNLR4 CNER1 CNE10 Engine oil lever sensor
13 4 3 1
20-405
TROUBLESHOOTING K-4
(b) Engine water level display flashes Cause Remedy

« Before starting troubleshooting, check the engine
water level again.

Replace
YES between CNL18
2 chassis ground disconnection in wiring Repair wiring
Is there continuity NO harness between CNL18 harness or
YES between CNR06 1) Turn starting
(female) (8) - CNLR3 (2) - replace
(female) (1) and switch OFF.
CNR06 (female) (1)
1 chassis ground 2) Disconnect
CNL18. Defective contact, or
Is there continuity Repair wiring
1) Turn starting disconnection in wiring
between CNR06 harness or
switch OFF. harness between CNR06
(male) (2) and NO replace
(1)? 2) Disconnect (female) (2) and chassis
CNR06. ground
1) Turn starting
switch OFF. Defective radiator water Replace
2) Disconnect NO level sensor
CNR06.
CNL18 CNLR3 CNR06 Radiator water level sensor
8 2 1
20-406
TROUBLESHOOTING K-5
K-5 When starting switch is turned ON (engine started), CAUTION

items flash
Cause Remedy
(a) Engine oil pressure display flashes
YES Defective engine oil Replace

pressure sensor
1
Does display go 3 YES Defective maintenance
monitor module Replace
out when ring Is there continuity
terminal is YES between CNL18
removed? (female) (10) and
chassis ground?
1) Start engine. 2 harness between CNL18 harness,
Is voltage between
1) Disconnect NO (female) (10) - engine oil replace, or
ring terminal and CNL18. pressure relay - chassis replace relay
2) Turn starting ground, or defective relay
NO chassis ground switch OFF.
removed?
Contact off ground with
1) 20 - 30 V
wiring harness between Repair wiring
2) Remove ring
terminal. ring terminal - CNER1 (2) harness,
3) Start engine. NO - CNLR4 (3) - engine oil replace, or
pressure relay, or replace relay
defective relay
CNL18 CNLR4 CNER1 Ring terminal

10 3 2
Engine oil pressure sensor
+24V
6 5 3 2 1
Enginge oil pressure relay

CNL64
20-407
TROUBLESHOOTING K-5
Cause Remedy
(b) Battery charge level display flashes

Replace
Is voltage between monitor module
YES CNL18 (female)
1 (12) and chassis Disconnection in wiring
ground normal? harness between CNL18 Repair wiring
Is voltage between (female) (12) - CNLR4 (6) - harness or
alternator terminal R 1)20-30V NO CNER1 (9) - alternator replace
and chassis
2)Startengine. terminal R
ground normal?
1)20-30V Defective alternator Replace

2)Startengine. NO

12 6 9 2 R Starting motor
R Alternator
CNR04
2 CNR12
1 1
Battery relay
20-408
TROUBLESHOOTING K-5
Cause Remedy
(c) Brake oil pressure display flashes
YES Defective maintenance

4 Replace
monitor module
Is voltage
YES between CNL18 Defective contact, or
ground normal? harness between CNL18 Repair wiring
(female) (11) and CN41 harness,
replace, or
3 1) Start engine. NO (female) (2), or between replace diode
Is there continuity 2) 0 - 3 V CN41 (female) - CNLR2
YES between CNB13 (8) - CNBR1 (6) - CNB13
(female) (2) and (female) (1), or defective
chassis ground? diode
1) Turn starting
2
switch OFF. Defective contact, or
Is there continuity 2) Disconnect
YES between CNB08 disconnection in wiring Repair wiring
CNB13. harness between CNB13 harness or
(male) (1) and
(2)?
NO (female) (2) and CNB08 replace
(female) (1), or between
1
1) Start engine. CNB08 (female) (2) -
Is there continuity 2) Disconnect CNBR1 (1) - chassis ground
between CNB13 CNB08.
(male) (1) and Defective brake
(2)? accumulator charge oil Replace
NO
pressure switch (CNB08
1) Start engine. end)
2) Disconnect
CNB13. Defective brake Replace
accumulator charge oil
NO
pressure switch (CNB13
end)
CN41
CNL18 2 1 CNLR2 CNBR1 CNB13
11 8 6 1
4 2
Brake accumulator oil

CNB08 pressure switch
20-409
TROUBLESHOOTING K-5
Cause Remedy
(d) Air cleaner display flashes
YES Defective dust indicator Replace

sensor
1 YES
Defective maintenance Replace
3
monitor
Does display go Is there continuity
YES between CNL18
out? Defective contact, or
(female) (15) and disconnection in wiring
chassis ground? harness between CNL18 Repair wiring
1) Start engine. 1) Turn starting (female) (15) and CNL80 harness,
2
2) Disconnect switch OFF. NO (female) (3), or between replace, or
CNE19. Is voltage between 2) Disconnect CNL80 (female) (6) - CNLR5 replace relay
CNE19 (female) (1) CNL18. (2) - chassis ground, or
NO and chassis ground defective dust indicator
normal? relay
1) Turn starting
switch ON. Short circuit, or contact of
Repair wiring
2) Disconnect wiring harness between
harness,
CNE19. CNE19 (female) (1) - CNER1
replace, or
3) 20 - 30 V NO (5) - CNLR4 (5) - CNL80
replace relay
(female) (2) with chassis
ground, or defective dust
indicator relay
+24V
CNL18 CNLR4 CNER1 CNE19 Dust indicator
15 5 5 1
CNER2 CNE20
5 1
6 5 3 2 1
CNLR5
2
Dust indicator relay

CNL80
20-410
TROUBLESHOOTING K-6
K-6 CAUTION items are flashing but alarm buzzer does not sound
« The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
Cause Remedy

2 monitor module
YES Does buzzer sound

when CNL19 (female) Defective contact, or
pin (4) is connected 3 YES disconnection in wiring Replace
to chassis ground? Does buzzer sound harness between CNL19
1
when CNL43 (female) (female) (4) and CNL43
Is voltage between 1) Turn starting pin (1) is connected (male) (1)
switch ON. NO
CNL42 (female) (1) to chassis ground?
and chassis Defective buzzer Replace
ground normal? 1) Turn starting NO
switch ON.
1) 20 - 30 V Defective contact, or Repair wiring
2) Disconnect disconnection in wiring harness or
CNL42. harness between CNL42 replace
NO
3) Turn starting (female) (1) - CNFS2 (9) -
switch ON. +24V
+24V
CNFS2 CNL42 Alarm buzzer
9 1
Maintenace monitor
CNL19 CNL43
4 1
Main monitor
CNL06
8
20-411
TROUBLESHOOTING K-7
K-7 There is no abnormality in monitor display but alarm buzzer

sounds
« Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause Remedy
YES Defective buzzer Replace

1
Is there continuity
between CNL43 Contact of chassis ground Repair wiring
(female) (1) and 2 YES with wiring harness harness or
chassis ground?
Is there continuity between CNL19 (female) replace
1) Turn starting between CNL19 (4) and CNL43 (male) (1)
switch OFF. NO (female) (4) and
2) Disconnect chassis ground?
CNL43. Defective maintenance Replace
1) Turn starting NO monitor module
switch OFF.
2) Disconnect
CNL19.
+24V
CNFS2 CNL42 Alarm buzzer
9 1
Maintenace monitor
CNL19 CNL43
4 1
Main monitor
CNL06
8
20-412
TROUBLESHOOTING K-8
K-8 CAUTION items are flashing but warning lamp (CHECK lamp,
CAUTION lamp) does not light up
« Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause Remedy
(a) CHECK lamp
YES Defective maintenance

1 Replace
monitor module
Does check lamp
light up when
CNL19 (female) pin Defective contact, or
2 YES Repair wiring
(2) is connected to disconnection in wiring
chassis ground? Does check lamp harness or
light up when replace
1) Disconnect CNL06 (male) pin
CNL19. NO (female) (10)
(10) is connected to
2) Turn staring chassis ground?
1) Disconnect
NO
CNL06.
2) Turn staring
switch ON.
(b) CAUTION lamp

1
Does check lamp
monitor module
light up when
CNL19 (female) pin Defective contact, or Repair wiring
(3) is connected to
2 YES
disconnection in wiring harness or
chassis ground? Does check lamp harness between CNL19
light up when replace
1) Disconnect (female) (3) and CNL06
CNL06 (male) pin
CNL19. NO (9) is connected to
(female) (10)
2) Turn staring chassis ground?
1) Disconnect NO
CNL06.
2) Turn staring
switch ON.
Maintenace monitor Main monitor

CNL19 CNL06
2 10
3 9
20-413
TROUBLESHOOTING K-9
K-9 There is no abnormality in maintenance monitor display but

warning lamp (CHECK lamp, CAUTION lamp) lights up
« Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Cause Remedy
(a) CHECK lamp
Contact of chassis ground Repair wiring
1 YES with wiring harness harness or
between CNL19 (female) replace
Is there conitnuity
between CNL 19 (2) and CNL06 (female)
(female) (2) and (10)
chassis ground?
Defective maintenance Replace
NO monitor module
1) Turn starting
switch OFF.
2) Disconnect
CNL19.
(b) CAUTION lamp
Contact of chassis ground Repair wiring

1 YES harness or
with wiring harness
Is there conitnuity between CNL19 (female) replace
between CNL 19
(3) and CNL06 (female) (9)
(female) (3) and
chassis ground?
NO Defective maintenance Replace

1) Turn starting monitor module
switch OFF.
2) Disconnect
CNL19.
Maintenace monitor Main monitor

CNL19 CNL06
2 10
3 9
20-414
TROUBLESHOOTING K-10
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up)
« Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause Remedy
1 YES Disconnection in wiring Replace

Is voltage harness of lamp holder
between CNL21
(female) (1) and Defective contact, or Repair wiring
(2) normal? disconnection in wiring harness or
1) 20 - 30 V NO harness between CNL21 replace
2) Diconnect (female) (1) and CNFS2 (5)
CNL21.
3) Turn starting
switch ON.
4) Turn lamp
switch ON.
Fuse box
Lighting +24V
CNL21 CNFS2 10A
1 5 CNL02 Lamp switch
2 2 4 1
5
CNLR5
20-415
K-11 Night lighting lights up even when lamp switch is OFF, night
lighting stays lighted up
Cause Remedy
Contact of +24V with

wiring harness between Repair wiring
2 YES CNFS2 (male) (4) - fuse harness or
Is voltage between box - CNFS2 (5) - CNL21 replace
YES CNFS2 (female) (4) (female) (1)
and chassis
Contact of +24V with
ground normal? Repair wiring
1 wiring harness between
1) 0 V CNL02 (female) (5) and harness or
NO replace
Is lamp switch 2) Disconnect CNFS2 (female) (4)
normal? CNFS2.
3) Turn lamp
switch ON.
1) Turn starting 4) Turn starting
switch OFF. switch ON.
Defective lamp switch Replace
2) Disconnect NO
CNL02.
3) Check that
continuity
between CNL02
(male) (1) and
(5) is as shown
in table below
when lamp
switch is turned
ON-OFF.
Switch Continuity
ON Continuity
OFF NO continuity
Fuse box
Lighting +24V
CNL21 CNFS2 10A
1 5 CNL02 Lamp switch
2 2 4 1
5
CNLR5
20-416
TROUBLESHOOTING K-12, K-13
K-12 Service meter does not work

Cause Remedy
YES Defective service Replace

meter
1 Defective contact, or
YES disconnection in wiring Repair wiring
Is voltage harness or
between CNL22 3 harness between CNL22
(female) (2) - CNLR4 (6) - replace
(female) (2) and Is there continuity
(1) normal? YES between CNL22 CNER1 (9) - alternator
(female) (1) and terminal R
1) 20 - 30 V 2 chassis ground? Defective contact, or
2) Start engine. Is voltage between disconnection in wiring Repair wiring
1) Turn starting
3) Disconnect alternator terminal harness between CNL22 harness or
switch ON. NO
CNL22. NO R and chassis (female) (1) - CNLR5 (2) - replace
ground normal? 2) Disconnect
chassis ground
CNL22.
1) 20 - 30 V Defective alternator Replace
2) Start engine. NO
K-13 Service meter is running even when engine is stopped

Cause Remedy
1 YES
Defective service meter Replace
Is voltage
between CNL22
(female) (2) and Defective alternator, or Replace
(1) normal? contact of wiring harness alternator, or
NO between CNL22 (female) repair, replace
1) 0 -4 V (2) - CNLR4 (6) - CNER1 wiring harness
2) Turn starting (9) alternator terminal R
switch ON. with +24V
3) Disconnect
CNL22.

2 6 9 2 R Starting motor
1
CNLR5
service meter
2 R Alternator
20-417
K-14 Abnormality in gauge items

(a) Abnormality in fuel gauge

« Before carrying out troubleshooting, check the fuel
Cause Remedy
level again.
(1) Little or nothing is displayed in the display area
YES
Defective fuel sensor Replace
1
Does fuel gauge monitor module Replace
Is there continuity
show FULL? YES between CNL18
1) Disconnect
2 chassis ground? disconnection in wiring Repair wiring
CNR07. Is there continuity harness between CNR07 harness or
2) Connect short between CNR07 1) Turn starting NO (female) (1) - CNLR4 (10) - replace
connector to switch OFF. CNL18 (female) (6)
(female) (2) and
CNR07 (female). NO 2) Connect short
3) Turn starting chassis ground? connector to
switch ON. CNR07 (female).
1) Turn starting 3) Disconnect
switch OFF. CNL18.
2) Disconnect Defective contact, or
CNR07. Repair wiring
harness or
NO harness between CNR07
replace
(female) (2) and chassis
ground
(2) Display always shows FULL and does not move
YES
Defective fuel sensor Replace
1
Do all display Contact of chassis ground
areas on fuel with wiring harness Repair wiring
gauge go out? 2 YES between CNR07 (female) harness or
Is there continuity (1) - CNLR4 (10) - CNL18 replace
1) Disconnect between CNR07 (female) (6)
CNR07. (female) (1) and
2) Turn starting
NO
chassis ground?
switch ON. Defective maintenance
Replace
switch OFF.
2) Disconnect
CNR07.
Fuel sensor
CNL18 CNLR4 CNR07

6 10 1
20-418
(b) Abnormality in engine water temperature gauge

Cause Remedy
(1) Nothing is displayed in the display area
YES Defective engine water

Replace
1 temperatur sensor
Does engine water
temperature gauge Contact of chassis ground
with wiring harness Repair wiring
display minimum 2 YES
between CNE06 (female) harness or
level? Is there continuity
(1) - CNER1 (6) - CNLR4 replace
1) Disconnect between CNE06
(female) (1) and (1) - CNL18 (female) (4)
CNE06. NO
2) Turn starting chassis ground?
switch ON. Defective maintenance Replace
1) Trun starting NO monitor module
switch OFF.
2) Disconnect
CNE06.
(2) Display shows lowest level and does not move
YES Defective engine water

temperatur sensor Replace
1
Do all display 3 YES Defective maintenance
areas on engine Replace
water temperature YES between CNL18
gauge go out? (female) (4) and Defective contact, or
2 chassis ground? Repair wiring
1) Disconnect Is there continuity harness between CNE06 harness or
CNE06. 1) Trun starting NO replace
between CNE06 (female) (1) - CNER1 (6) -
2) Connect short switch OFF.
connector to NO (female) (2) and CNLR4 (1) - CNL18
CNE06 (female). chassis ground? 2) Connect short
(female) (4)
3) Turn starting connector to
switch ON. 1) Trun starting CNE06 (female).
switch OFF. 3) Disconnect Defective contact, or
2) Disconnect CNL18. disconnection in wiring Repair wiring
CNE06. harness between CNE06 harness or
NO (female) (2) - CNER1 (7) - replace
chassis ground
CNL18 CNLR4 CNER1 CNE08 Water temperature sensor
4 1 6 1
7 2
20-419
(c) Abnormality in torque converter oil temperature gauge

Cause Remedy
(1) Nothing is displayed in the display area
YES Defective torque converter Replcae

1 oil temperature sensor
Does torque converter
oil temperature gauge Contact of chassis ground
display minimum with wiring harness Repair wiring
2 YES
level? between CNT07 (female) harness or
Is there continuity replace
(1) - CNTL2 (4) - CNL18
1) Disconnect between CNT07
(female) (5)
CNT07. NO (female) (1) and
2) Turn starting chassis ground? Defective maintenance
switch ON. Relace
switch OFF.
2) Disconnect
CNT07.
(2) Display shows lowest level and does not move
YES Defective torque converter

Replace
oil temperature sensor
1
Do all display areas 3 YES Defective maintenance
on torque converter Replace
oil temperature YES between CNL18
gauge go out? (female) (5) and Defective contact, or
2 chassis ground? disconnection in wiring Repair wiring
1) Disconnect
CNT07. Is there continuity harness between CNT07 harness or
2) Connect short 1) Turn starting NO (female) (1) - CNTL2 (4) - replace
between CNT07
connector to switch OFF. CNL18 (female) (5)
CNT07 (female). NO (female) (2) and 2) Connect short
3) Turn starting chassis ground? connector to
switch ON. CNT07 (female).
1) Turn starting 3) Disconnect
switch OFF. CNL18.
2) Disconnect Defective contact, or
CNT07. disconnection in wiring Repair wiring
harness between CNT07 harness or
NO (female) (2) - CNTL2 (5) - replace
CNLR4 (12) - chassis
ground
CNT02 CNT07 Torque converter oil

CNL18 temperature sensor
5 4 1
12 5 2
CNLR4
20-420
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
E- 1 Engine does not start ................................................................................................................. 20-452

(a) Starting motor does not turn ................................................................................................ 20-452
(b) Starting motor turns ............................................................................................................... 20-456
E- 2 Engine does not stop ................................................................................................................... 20-458
E- 3 Engine stops when machine is traveling .................................................................................... 20-458
WA320-3H with manual transmission only:

E- 8 Transmission does not work normally ........................................................................................ 20-459
(a) Problem in common circuit for transmission (always stays in 2nd) ................................... 20-461
(b) Problem in H-L circuit .......................................................................................................... 20-461
(c) Problem in speed circuit ...................................................................................................... 20-462
(d) Problem in 4th circuit (does not enter 4th) ......................................................................... 20-462
(e) Contact in H-L circuit .......................................................................................................... 20-464
(f) Contact in speed circuit ....................................................................................................... 20-466
(g) Contact in 4th circuit (always stays in 4th) ......................................................................... 20-468
(h) Problem in FORWARD circuit (REVERSE is normal) ........................................................ 20-470
(i) Problem in REVERSE circuit (FORWARD is normal) ........................................................ 20-472
(j) Problem in common circuit for FORWARD and REVERSE
(does not travel forward, parking brake is normal) ............................................................. 20-474
(k) Contact in FORWARD circuit .............................................................................................. 20-476
(l) Contact in REVERSE circuit ............................................................................................... 20-478
(m) Problem in common circuit for FORWARD and REVERSE ............................................... 20-480
E- 9 Kick-down switch does not work ................................................................................................ 20-482
E-10 Kick-down works only when kick-down switch is ON ................................................................ 20-484
E-11 Kick-down operation cannot be canceled .................................................................................. 20-484
(a) Not canceled even when directional lever is moved from F to N or R ............................... 20-484
(b) Not canceled even when speed lever is moved from 2nd to other position
(becomes 4th) ............................................................................................................................ 20-486
E-12 Kick-down switch is actuated by mistake when traveling in 2nd ............................................... 20-488
20-451
TROUBLESHOOTING E-1
E-1 Engine does not start

« When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out
checks, always turn the starting switch OFF before starting.
« When connecting the T-adapter (or socket adapter), connect to the connector specified as CN¡∆( ).
« After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return
to the original condition before going on to the next check.
(a) Starting motor does not turn
YES
YES
3
5
Is voltage between
YES starting motor Is voltage between
YES both battery relay
terminal (E) and
chassis 20 - 30 V? terminals and
chassis 20 - 30 V?
1) Turn starting
1) Turn starting
switch ON 4 NO
switch ON
Is actuating sound
2) Check voltage
heard from battery
NO relay ? between chassis
and both YES
terminals
2 1) Turn starting connected by
Is there continuity switch thick cable 6
YES between starting ON OFF Is voltage 20 - 30V
motor terminal (E) between both
and chassis? connection terminals of
NO CNR12 and CNR13 of
B battery relay?
1) Turn starting
switch OFF 1) Turn starting
1 switch ON
NO
Is voltage between
CNE13 (female)
(1) and chassis
20 - 30 V ?
1) Disconnect
CNE13
NO
2) Directional
lever: Neutral
Go to A on next page
3) Turn starting NO
switch to
START
20-452
TROUBLESHOOTING E-1
Cause Remedy
Defective starting motor

assembly Replace
disconnection in cable After inspection,
between battery relay and repair or replace
starting motor
• If answer is NO for both

terminals: Defective
contact or disconnection After inspection,
in wiring harness repair or replace
between battery and
battery relay
• If answer is NO for one
terminal: Defective Replace
battery relay
Defective battery relay Replace
harness between starting
switch terminal BR-CNL09
YES (2) - CNLR4 (9) - CNR03 After inspection,
7 (diode) - CNR12 (female) repair or replace
Is voltage between or defective contact, or
starting switch disconnection in wiring
terminal BR and harness between CNR13
chassis 20 - 30 V ? and chassis ground
Defective starting switch Replace

1) Turn starting NO
switch ON.
After inspection,
disconnection in starting
repair or replace
motor ground cable
20-453
TROUBLESHOOTING E-1
YES
YES
3
Is voltage between
YES CNL57 (female)
(5) and chassis 5 YES
1
20 - 30 V? YES Is voltage between
Does starting 4 starting switch
motor turn when 1) Disconnect terminal C and
A Is voltage between
CNL57 chassis 20 - 30 V?
relay is replaced? starting switch
NO terminal B and 1) Turn starting NO
1) Replace neutral 2) Turn starting chassis 20 - 30 V? switch to
relay (CNL57) switch to START START
with stop lamp 1) Turn starting
relay (CNL53) switch OFF
NO
2) Directional lever:
Neutral
3) Turn starting 2
switch to START Is voltage between
CNL57 (female) 8 YES
NO (1) and (2) Is voltage between
20 - 30 V ?
YES CNL04 (3) and
chassis 20 ? 30 V?
1) Disconnect
CNL57
NO
1) Connect T-
2) Directional lever: 7 adapter to
Neutral
Is voltage between CNL04
YES CNL04 (female) 2) Directional lever:
3) Turn starting
(1) and chassis Neutral
switch to START
20 - 30 V? 3) Turn starting
switch ON
1) Disconnect
CNL04 9 YES
6
2) Turn starting Is actuating sound
Is there continuity heard from battery
between CNL57 switch ON NO relay?
Go to B on
NO (female) (2) and
chassis? previous
1) Turn starting NO page
1) Turn starting switch ON OFF
switch OFF
2) Disconnect
CNL57
NO
20-454
TROUBLESHOOTING E-1
Cause Remedy
Defective neutral relay Replace
(female) (3) - CNLR4 (8) - repair or replace
CNR01, 02 (diode) - CNER1
(10) - CNE13 (female) (1)
harness between starting After inspection,
switch terminal C - CNL09 repair or replace
(3) - CNL57 (female) (5)
Defective starting switch Replace
harness between starting
switch terminal B - CNL09 After inspection,
(1) - CNFS3 (4) - fuse - repair or replace
CNFS3 (6) - CNLR5 (1) -
CNR17 - slow blow fuse
30A - battery relay
(female) (3) and CNL57 repair or replace
(female) (1)
Defective directional lever

Replace
switch
harness between battery
relay - slow blow fuse 80A -
repair or replace
CNR15 - CNLR6 (1) -
10
CNFS1 (2) - fuse - CNFS2
Is voltage between (8) - CML04 (female) (1)
both battery relay
terminals and • If answer is NO for both
chassis 20 - 30 V? terminals: Defective contact
or disconnection in wiring
1) Turn starting harness between battery After inspection,
switch ON and battery relay repair or replace
2) Check valtage NO
• If answer is NO for one
between chassis terminal: Defective battery
and both relay
terminals
connected by Defective contact, or
thick cable. disconnection in wiring
After inspection,
repair or replace
(female) and chassis ground
ground
20-455
TROUBLESHOOTING E-1
(b) Starting motor turns
YES
YES
3 YES
1
YES Is voltage between
CNE03 (7) and
Does engine stop
chassis 20 - 30 V ?
motor work ?
1) Connect T-
1) Turn starting adapter to 4
CNE03 YES
switch ON
OFF and check Does engine stop
2) Turn starting
visually. switch ON motor work when
NO relay is replaced ? 6
Is there continuity
1) Replace engine YES between CNL62
2 stop relay (female) (2) and
(CNL62) with
Is voltage between Stop lamp relay chassis?
CNE03 (female) (CNL53) 5 1) Turn starting
NO (4) and chassis 2) Turn starting Is voltage between switch OFF
20 - 30 V ? switch ON CNL62 (female)
OFF and check 2) Disconnect
1) Turn starting visually NO (1) and chassis CNL62 NO
switch OFF 20 - 30V ?
2) Disconnect 1) Disconnect
CNE03 CNL62
2) Turn starting
switch ON NO
NO
20-456
TROUBLESHOOTING E-1
Cause Remedy
Defective adjustment of wire

between engine stop motor Adjust
and lever
Defective engine stop motor,

or defective contact, or
harness between CNE03 repair or replace
(female) (8) - CNER2 (5) -
chassis ground
Defective engine stop relay Replace
YES
Defective engine stop motor Replace
7
Is there continuity
between CNE03 Defective contact, or
(female) (5) and disconnection in wiring
(7) ? harness between CNE03
(female) (5) - CNER2 (3) -
1) Disconnect CNLR3 (5) - CNL62 (female) After inspection,
CNE03 NO (5), or between CNE03 repair or replace
(female) (7) - CNER2 (4) -
2) Turn starting CNLR3 (6) - CNL62 (female)
switch ON (3)
(female) (2) and chassis repair or replace
ground
(female) (2)
Blown fuse, or defective

contact, or disconnection in
wiring harness between After inspection,
CNF2 (female) (11) - CNLR repair or replace
(3) - CNER2 (1) - CNE03
(female) (4)
20-457
TROUBLESHOOTING E-2, E3
E-2 Engine does not stop
Cause Remedy
Defective adjustment
YES
and stop lever
1
YES
Does engine stop Defective engine stop motor Replace
motor work?
2 disconnection in wiring
1) Turn starting harness between CNE03
Is voltage between
switch ON (female) (3) - CNER2 (2) -
CNE03 (7) and (8)
OFF and check CNLR3 (4) - CNL62
visually NO 20 - 30 V ? YES After inspection,
(female), or between
CNL62 (female) (3) - repair or replace
1) Connect 3 CNLR3 (6) - CNER2 (4) -
T-adapter to CNE03 (female) (7)
CNE03 (engine Is voltage between
or defective relay
stop motor CNE03 (3) and (8)
(CNL62)
connector) NO 20 - 30 V ?
pin) 4 YES Defective engine stop motor Replace
1) Connect Is voltage between
2) Turn starting T-adapter to
switch OFF CNE03 (4) and (8) Defective contact, or
CNE03
NO 20 - 30 V ? disconnection in wiring
harness between CNE03
(female) (4) - CNER2 (2) -
switch OFF 1) Connect NO CNLR3 (3) - CNFS2 repair or replace
T-adapter to
(female) 11, or blown fuse
CNE03
E-3 Engine stops when machine is traveling
« Check if the starting motor turns. If it does not turn, check

E-1(a) (Engine does not start).
Defective adjustment
YES
1 and stop lever
Does engine stop YES

motor work ? Defective engine stop motor Replace
2
Does voltage between
1) Turn starting CNE03 (7) and (8)
switch ON NO switch between 0V and 3 YES
OFF and check 20 - 30 V ? Defective engine stop relay Replace
Is voltage between
visually
CNL62 (female) (2) Defective contact, or
1) Connect
T-adapter to NO and (female) (1) 20 disconnection in wiring
- 30 V ? harness between starting After inspection,
CNE03
NO switch terminal BR - CNL09 repair or replace
1) Disconnect
2) Turn starting (2) - CNL62 (female) (1)
CNL62 (engine
switch ON stop relay)
OFF
2) Turn starting
switch ON
20-458
TROUBLESHOOTING E-8
E-8 Transmission does not work normally

(WA320-3H manual gear shift)
« When carrying out troubleshooting of the transmission system, stop the machine on flat ground.
Cause Remedy
If condition is as shown in
Table 2 - 1 (transmission is
always in 2nd) Problem in common circuit
Go to E-8(a)
for transmission
Table 1 or Table 2 - 2
Problem in H-L circuit Go to E-8(b)
2 Table 1 or Table 2 - 3
Problem in speed circuit Go to E-8(c)
Travels in both Check voltage If condition is as shown in Table
FORWARD and between CNT03 (1) 2 - 4 or Table 2 - 5 or Table 2 -
REVERSE. (female) and chassis 6 (does not enter 4th)
and between CNT04 Problem in 4th circuit Go to E-8(d)
(1) (female) and
chassis. If condition is as shown in
Table 2 - 7
1) Disconnect Contact in H - L circuit Go to E-8(e)
CNT03 and
CNT04 If condition is as shown in
2) Turn parking Table 2 - 8
switch ON Contact in speed circuit Go to E-8(f)
3) Turn parking If condition is as shown in
1 switch ON Table 2 - 9 (transmission is
OFF always in 4th)
Does machine 4) Operate speed Contact in 4th circuit Go to E-8(g)
?
travel forward and lever with
directional lever If condition is as shown in
in reverse? at FORWARD, Table 3 or Table 4 - 1
NEUTRAL, and (REVERSE is normal) Problem in FORWARD
REVERSE to circuit Go to E-8(h)
1) Start engine
check condition If condition is as shown in
2) Turn parking Table 3 or Table 4 - 2
switch ON Travels in only (FORWARD is normal) Problem in REVERSE
OFF circuit Go to E-8(i)
FORWARD or
REVERSE, or 3 If condition is as shown in
3) Operate directional does not travel Table 4 - 3 (does not travel in Problem in common circuit
lever FORWARD Check voltage either direction)
REVERSE in either between CNT01 (1) for FORWARD and Go to E-8(j)
direction. (female) and chassis REVERSE
and between CNT02 Table 4 - 4 (REVERSE is
(1) (female) and normal) Contact in FORWARD
chassis. circuit Go to E-8(k)
1) Disconnect Table 4 - 5 (FORWARD is
CNT01 and normal) Contact in REVERSE circuit
CNT02 Go to E-8(l)
2) Turn parking If condition is as shown in
switch ON Table 4 - 6 (does not travel in
3) Turn parking either direction) Problem in common circuit
switch ON for FORWARD and Go to E-8(m)
OFF REVERSE
4) Operate directional lever with speed lever
in all positions (1st to 4th) to check condition
Go to applicable item.
20-459
TROUBLESHOOTING E-8

¡: 0 0.5 V
l: 20 30 V
(H L) (Speed)
Between Between Between Between Between Between Between Between
CNT03 CNT04 CNT03 CNT04 CNT03 CNT04 CNT03 CNT04
Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1)
mission chassis chassis mission chassis chassis mission chassis chassis mission chassis chassis
range ground ground range ground ground range ground ground range ground ground
1 ¡ l 1 ¡ ¡ 1 ¡ l 1 ¡ ¡
2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡
3 l ¡ 3 ¡ ¡ 3 ¡ ¡ 3 l ¡
4 l l 4 ¡ ¡ 4 ¡ l 4 l ¡
Table 1 (normal) Table 2-1 (abnormal) Table 2-2 (abnormal) Table 2-3 (abnormal)
Between Between Between Between Between Between

CNT03 CNT04 CNT03 CNT04 CNT03 CNT04
Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1)
mission chassis chassis mission chassis chassis mission chassis chassis
range ground ground range ground ground range ground ground
1 ¡ l 1 ¡ l 1 ¡ l
2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡
3 l ¡ 3 l ¡ 3 l ¡
4 ¡ ¡ 4 l ¡ 4 ¡ l
Table 2-4 (abnormal) Table 2-5 (abnormal) Table 2-6 (abnormal)

Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1) Trans- (female) (1) (female) (1)
mission chassis chassis mission chassis chassis mission chassis chassis
range ground ground range ground ground range ground ground
1 l l 1 ¡ l 1 l l
2 l ¡ 2 ¡ l 2 l l
3 l ¡ 3 l l 3 l l
4 l l 4 l l 4 l l
(F) (R)
Between Between Between Between Between Between Between Between
CNT01 CNT02 CNT01 CNT02 CNT01 CNT02 CNT01 CNT02
Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1)
tional chassis chassis tional chassis chassis tional chassis chassis tional chassis chassis
lever ground ground lever ground ground lever ground ground lever ground ground
FORWARD l ¡ FORWARD ¡ ¡ FORWARD l ¡ FORWARD ¡ ¡

REVERSE ¡ l REVERSE ¡ l REVERSE ¡ ¡ REVERSE ¡ ¡
Table 3 (normal) Table 4-1 (abnormal) Table 4-2 (abnormal) Table 4-3 (abnormal)

Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1)
tional chassis chassis tional chassis chassis tional chassis chassis
lever ground ground lever ground ground lever ground ground
FORWARD l l FORWARD l ¡ FORWARD l l

REVERSE ¡ l REVERSE l l REVERSE l l
20-460
TROUBLESHOOTING E-8

(a) Problem in common circuit for transmission (always stays in 2nd)
Cause Remedy
Problem in H-L circuit and

1 YES
speed circuit –
Is voltage between • Go to E-8 (b), E-8 (c)
CNL04 (5)(6)(7)(8)
and chassis as
shown in table?
Defective speed lever switch Replace
1) Connect NO
T-adapter to
CNL04
2) Turn starting switch ON

3) Shift speed lever and check
l: 20 30 V
¡: 0 0.5 V
Transmission
Between Between Between Between
range CN04(5) chassis CN04(6) chassis CN04(7) chassis CN04(8) chassis
1 l ¡ ¡ ¡
2 ¡ l ¡ ¡
3 ¡ ¡ l ¡
4 ¡ ¡ ¡ l
(b) Problem in H-L circuit
Cause Remedy
YES
Defective H - L solenoid Replace
2
Is voltage between
YES CNT03 (female) Defective contact, or
(1) and chassis 3 YES After inspection,
20 - 30 V ? repair or replace
Is voltage between (female) (7) - CNTL1 (5) -
1 1) Disconnect CNL04 (7) and CNT03 (female) (1)
CNT03 NO chassis 20 - 30V?
Is there continuity
between CNT03 2) Turn starting Defective speed lever switch Replace
(female) (2) and switch OFF 1) Connect NO
T-adapter to
chassis ? CNL04
2) Turn starting
1) Disconnect switch ON
CNT03 3) Speed lever: 3rd Defective contact, or
2) Turn starting disconnection in wiring
harness between CNT03 After inspection,
switch OFF
NO (female) (2) and chassis repair
ground
20-461
TROUBLESHOOTING E-8

(c) Problem in speed circuit
Cause Remedy
YES
Defective speed solenoid Replace
2
Is voltage between
YES CNT04 (female) Defective contact, or
(1) and chassis 3 YES disconnection in wiring
After inspection,
20 - 30 V ? harness between CNL04
repair or replace
1 Is voltage between (female) (5) - CNTL1 (6) -
Is there continuity 1) Disconnect CNL04 (5) and CNT04 (female) (1)
CNT04 NO chassis 20 - 30 V?
between CNT04
(female) (2) 2) Turn starting Defective speed lever switch Replace
chassis ? switch ON 1) Connect NO
T-adapter to CNL04
1) Disconnect 3) Speed lever: 1st 2) Turn starting switch ON Defective contact, or
CNT04 3) Speed lever: 1st disconnection in wiring
After inspection,
harness between CNT04
2) Turn starting NO repair or replace
switch OFF (female) (2) and chassis
ground
(d) Problem in 4th circuit (does not enter 4th)
1 YES
After inspection,
(female) (8) - CN37 -
repair or replace
Is voltage between CNTL1 (male) (6) or CNL04
CNL04 (8) and (female) (8) - CN38 -
chassis ground 20 CNTL1 (male) (5)
- 30V?
1) Connect Defective speed lever switch Replace
NO
T-adapter
to CNL04
2) Turn starting
switch ON
3) Speed lever: 4th
20-462
20-463
TROUBLESHOOTING E-8

(e) Contact in H-L circuit
YES
1
Is voltage between
CNT03 (female) YES
(1) and chassis
20 - 30 V ?
1) Disconnect
CNT03
2) Disconnect 2
CNTL1
Is there continuity
3) Turn starting between CNTL1 YES
switch ON NO (female) (5) and
(3)(4)(6)?
1) Turn starting
switch OFF
2) Disconnect 3
CNT03 Is voltage between
CNTL1 (male) (5) YES
3) Disconnect
CNTL1 NO and chassis 20 -
30 V ?
1) Disconnect
CNTL1
2) Disconnect
4
CNL04 Is there continuity
between CNTL1
3) Turn starting
switch ON NO (male) (5) and
(3)(4)(6)?
1) Turn starting YES

switch OFF
2) Disconnect 5
CNTL1 Is there continuity
3) Disconnect between CNL04
CNL04 NO (female) (7) and
(1)(2)(3)(4)(6)?
1) Turn starting
switch OFF
NO
2) Disconnect
CNTL1
3) Disconnect
CNL04
4) Disconnect
CNL66
20-464
TROUBLESHOOTING E-8
(WA320-3H manual gear shift) Cause Remedy
Abnormal contact of wiring

After inspection,
(female) (1) and CNTL1
repair or replace
(female) (5) with +24 V
wiring harness

harness between CNTL1
(female) (5) and CNT03
(female) (1) with wiring harn.
between CNTL1 (female) (3) After inspection,
- CNT01 (female) (1), CNTL1 repair or replace
(female) (4) - CNT02 (female)
(1),
CNTL1 (female) (6) - CNT04
(female) (1)

harness between CNTL1 After inspection,
(male) (5) and CNL04 (male) repair or replace
(7) with +24 V wiring harness

(male) (5) and CNL04
between CNTL1 (male) (3) - After inspection,
CNL66 (female) (2), CNTL1 repair or replace
(male) (6) - CNL04
(female) (5)

(male) (5) with wiring
(male) (1) - CNFS2 (female)
(8) or CNL04 (female) (2) After inspection,
CNL66 (female) (5) or repair or replace
CNL04 (female) (3) - CNL57
(female) (1) or CNL04
(female) (4) - CNL67 (female)
(5) or CNL04 (female) (6) -
CNL66 (3)
Defective transmission
control switch Replace
20-465
TROUBLESHOOTING E-8

(f) Contact in speed circuit
YES
1
Is voltage between
CNT04 (female) YES
(1) and chassis
20 - 30 V ?
1) Disconnect
CNT04
2) Disconnect 2
CNTL1
Is there continuity
switch ON NO (female) (6) and
(3)(4)(5)?
1) Turn starting
switch OFF
2) Disconnect 3
CNT04 Is voltage between
CNTL1 (male) (6) YES
3) Disconnect
CNTL1 NO and chassis 20 -
30 V ?
1) Disconnect
CNTL1
2) Disconnect
4
between CNTL1
3) Disconnect
CNL04 NO (male) (6) and
(3)(4)(5)?
4) Turn starting
switch ON 1) Turn starting YES
switch OFF
2) Disconnect 5
CNTL1 Is there continuity
(1)(2)(3)(4)(6)?
4) Disconnect
CNL04
1) Turn starting
switch OFF
NO
2) Disconnect
CNTL1
3) Disconnect
CNL68
4) Disconnect
CNL04
5) Disconnect
CNL66
20-466
TROUBLESHOOTING E-8
(WA320-3H manual gear shift) Cause Remedy

After inspection,
repair or replace
(female) (6) with +24 V
wiring harness

(female) (4) - CNT02 (female)
(1),
(female) (1)
(male) (6) and CNL04 repair or replace
(female) (5), CNL68 (female)
(4) with +24 V wiring harness

(male) (6) and CNL04 After inspection,
(female) (5) with wiring harn. repair or replace
between CNTL1 (male) (3) -
CNL66 (female) (2), CNTL1
(male) (4) - CNL04
(female) (7)

(male) (6) with wiring
(female) (1) - CNFS2 (female)
(8) or CNL04 (female) (2) After inspection,
CNL66 (female) (5) or repair or replace
(5) or CNL04 (female) (6) -
CNL66 (3)
After inspection,
control switch, or abnormal
repair or replace
contact of CNL68 (3) (4)
(male)
20-467
TROUBLESHOOTING E-8

(g) Contact in 4th circuit (always stays in 4th)
Cause Remedy
Abnormal contact of CNL04

1 YES (female) (8) - CN37 (female)
After inspection,
(2), CN38 (female) (2) with
+24 V wiring harness
CNL04 (female)
(8) and chassis
20 - 30 V ?
Defective speed lever switch Replace
NO
1) Disconnect
CNL04
2) Turn starting
switch ON
20-468
20-469
TROUBLESHOOTING E-8

(h) Problem in FORWARD circuit (REVERSE is normal)
2 YES
Is there continuity
YES between CNT01
(female) (2) and
chassis ?
1) Disconnect NO
CNT01
2) Turn starting
1 switch OFF YES
Is voltage between
CNT01 (female)
(1) and chassis
20 - 30V? 7 YES
1) Disconnect Is voltage between
CNT01 YES CNL66 (female) (5)
and chassis 20 -
2) Turn starting 3
switch ON 6 30V?
Is problem Is there continuity 1) Disconnect NO
3) Turn parking
switch ON removed when YES between CNL66 CNL66
OFF NO relay is replaced ? (female) (6) 2) Turn starting
switch ON
chassis? 3) Directional lever:
4) Dirctional 5
lever: 1) Replace FORWARD
FORWARD Is there continuity 1) Disconnect
FORWARD CNL66
solenoid relay YES between CNL66
(CNL66) with NO
REVERSE (female) (2) and 2) Turn starting
solenoid relay chassis? switch OFF
(CNL67) 4
1) Disconnect
2) Start engine Is voltage between CNL66
CNL66 (female)
3) Turn parking 2) Turn starting NO
switch ON NO (1) and chassis switch OFF
OFF 20 - 30V?
4) Dirctional 1) Disconnect
lever: FORWARD CNL66
2) Turn starting
switch ON NO
3) Turn parking
switch ON
OFF
20-470
TROUBLESHOOTING E-8
Cause Remedy
harness between CNT01 repair or replace
Defective FORWARD
solenoid Replace
Defective FORWARD relay Replace
After inspection,
repair or replace
(female) (5)

Replace
switch
After inspection,
repair or replace
(female) (2) - CNTL1 (3) -
CNT01 (female) (1)
After inspection,
repair or replace
(female) (1)
20-471
TROUBLESHOOTING E-8

(i) Problem in REVERSE circuit (FORWARD is normal)
2 YES
Is there continuity
YES between CNT02
(female) (2) and
chassis ?
1) Disconnect NO
CNT02
2) Turn starting
1 switch OFF YES
Is voltage between
CNT02 (female)
(1) and chassis
20 - 30V? 7 YES
1) Disconnect Is voltage between
CNT02 YES CNL67 (female) (5)
and chassis 20 -
2) Turn starting 3
switch ON 6 30V?
Is problem Is there continuity 1) Disconnect NO
3) Turn parking
switch ON removed when YES between CNL67 CNL67
OFF NO relay is replaced ? (female) (6) 2) Turn starting
switch ON
chassis? 3) Directional lever:
4) Dirctional 5
lever: 1) Replace REVERSE
REVERSE Is there continuity 1) Disconnect
REVERSE CNL67
solenoid relay YES between CNL67
(CNL67) with NO
FORWARD (female) (2) and 2) Turn starting
solenoid relay chassis? switch OFF
(CNL66) 4
1) Disconnect
2) Start engine Is voltage between CNL67
CNL67 (female)
3) Turn parking 2) Turn starting NO
switch ON NO (1) and chassis switch OFF
OFF 20 - 30V?
4) Dirctional 1) Disconnect
lever: REVERSE CNL67
2) Turn starting
switch ON NO
3) Turn parking
switch ON
OFF
20-472
TROUBLESHOOTING E-8
Cause Remedy
harness between CNT02 repair or replace
Defective REVERSE
solenoid Replace
Defective REVERSE relay Replace
After inspection,
repair or replace
(female) (5)

Replace
switch
After inspection,
repair or replace
(female) (2) - CNTL1 (4) -
CNT02 (female) (1)
After inspection,
repair or replace
(female) (1)
20-473
TROUBLESHOOTING E-8

(j) Problem in common circuit for FORWARD and REVERSE
(does not travel forward, parking brake is normal)
YES
2
Is voltage between
YES CNL04 (2), (4) -
chassis as shown in 3 YES
table? Is voltage between
CNL04 (female)
1) Connect
T-adapter to NO (1) and chassis
CNL04 20 - 30 V ?
2) Turn starting 1) Disconnect NO
1 switch ON CNL04
Is voltage between 3) Directional lever: 2) Turn starting

CNL66 (female) F N R switch ON YES
5
(1) and chassis Is problem removed
20 - 30 V? YES when short connector is
connected instead of
1) Disconnect transmission cut-off
CNL66 switch?
2) Turn starting 1) Connect short NO
switch ON connector to
4 CNL12 (female)
3) Turn parking
brake switch Is problem removed 2) Start engine YES
ON OFF
when transmission
3) Turn transmission
NO cut-off switch is cut-off selector
turned OFF? switch ON
1) Start engine
YES
6 9
Is voltage between
Is problem YES CNL58 (female)
removed when (3) and chassis
NO relay is replaced?
8 20 - 30 V?
1) Replace Is there continuity 1) Disconnect

neutralizer relay YES between CNL58 CNL58
NO
(CNL58) with (female) (2) and
stop lamp relay 2) Turn starting
(CNL53) chassis? switch ON
7
2) Start engine Is voltage between 1) Disconnect
CNL58 (female) CNL58
NO (1) and chassis NO
2) Turn starting
20 - 30 V? switch OFF
1) Disconnect
CNL58
2) Turn starting NO
switch ON
3) Turn parking
brake switch
ON OFF
l: 20 30 V
¡: 0 0.5 V
Divectional
Between Between
lever CN04(2) chassis CN04(4) chassis
F l ¡
N ¡ ¡
R ¡ l
20-474
TROUBLESHOOTING E-8
Cause Remedy
Go to E-8 (h) and (i) –

switch Replace
harness between CNFS2 After inspection,
(female) (1)
Defective transmission cut-

off switch Replace
After inspection,
repair or replace
(female) (1), or between
CNL65 (female) (5)
Defective neutralizer relay Replace
(female) (5) and CNL12 After inspection,
(female) (1), or between repair or replace
CNL12 (female) (2) -
CNL66 (female) (1), CNL67
(female) (1)
(female) (3) - CNFS2 (8) - repair or replace
fuse - CNFS1 (male) (2)
(female) (2)
20-475
TROUBLESHOOTING E-8

(k) Contact in FORWARD circuit
YES
1 YES
Is problem
removed when
relay is replaced?
1) Replace
FORWARD relay 2
(CNL66) with F
working lamp Is voltage between
relay (CNL60) CNT01 (female) YES
NO (1) and chassis
2) Start engine 20 - 30 V ?
3) Turn parking 1) Disconnect
brake switch ON CNT01
OFF
2) Disconnect 3
4) Directional lever: CNTL1
FORWARD Is there continuity
switch ON
NO (female) (3) and
(4)(5)(6)?
1) Turn starting
switch OFF
2) Disconnect 4
CNT01
Is voltage between YES
3) Disconnect CNTL1 (male) (3)
CNTL1
NO and chassis
20 - 30 V?
1) Disconnect
CNTL1
2) Disconnect
CNL66 5
Is there continuity
3) Turn starting
switch ON between CNTL1
NO (male) (3) and
(4)(5)(6)?

switch OFF
2) Disconnect
CNTL1 6
3) Disconnect Is there continuity
CNL66 between CNL04
NO (female) (2) and (1)
(3)(4)(5)(6)(7)(8)?
1) Turn starting
switch OFF
2) Disconnect NO
CNL66
3) Disconnect
CNL04
20-476
TROUBLESHOOTING E-8

Cause Remedy
Defective FORWARD relay Replace

After inspection,
repair or replace
(female) (3) with +24V
wiring harness

(female) (5) - CNT03
(female) (1),
(female) (5)

After inspection,
repair or replace
wiring harness

(female) (2) with wiring
(male) (4) - CNL67 (female) repair or replace
(2),CNTL1 (male) (6) -
CNL04 (female) (5)

between CNL04 (female) (1) -
CNFS2 (female) (8), CNL04
(female) (3) - CNL57
(female) (1), After inspection,
repair or replace
(5) - CNTL1 (male) (6),
(7) - CNTL1 (male) (5),
CNL04 (female) (6) - CN37
(2) or CN38 (2)
Replace
control switch
20-477
TROUBLESHOOTING E-8

(l) Contact in REVERSE circuit
YES
1 YES
Is problem
removed when
relay is replaced?
1) Replace
REVERSE relay 2
(CNL67) with F
working lamp Is voltage between
relay (CNL60) CNT02 (female) YES
NO (1) and chassis
2) Start engine 20 - 30 V ?
3) Turn parking 1) Disconnect
brake switch ON CNT02
OFF
2) Disconnect 3
4) Directional lever: CNTL1
REVERSE Is there continuity
switch ON
NO (female) (4) and
(3)(5)(6)?
1) Turn starting
switch OFF
2) Disconnect 4
CNT02
Is voltage between YES
3) Disconnect CNTL1 (male) (4)
CNTL1
NO and chassis
20 - 30 V?
1) Disconnect
CNTL1
2) Disconnect
CNL67 5
Is there continuity
3) Turn starting
switch ON between CNTL1
NO (male) (4) and
(3)(5)(6)?

switch OFF
2) Disconnect
CNTL1 6
CNL67 between CNL04
NO (female) (4) and (1)
(2)(3)(5)(6)(7)(8)?
1) Turn starting
switch OFF
2) Disconnect NO
CNL67
3) Disconnect
CNL04
20-478
TROUBLESHOOTING E-8

Cause Remedy
Defective REVERSE relay Replace

After inspection,
repair or replace
wiring harness

(female) (5) - CNT03
(female) (1),
(female) (1)

After inspection,
repair or replace
wiring harness

(female) (2) with wiring
(male) (3) - CNL66 (female) repair or replace
(2),CNTL1 (male) (6) -
CNL04 (female) (5)

between CNL04 (female) (1) -
CNFS2 (female) (8), CNL04
(female) (1), After inspection,
repair or replace
(5) - CNTL1 (male) (6),
(7) - CNTL1 (male) (5),
CNL04 (female) (6) - CN37
(2) or CN38 (2)
Replace
control switch
20-479
TROUBLESHOOTING E-9

(m) Problem in common circuit for FORWARD and REVERSE
Cause Remedy
Contact of wiring harness

between CNT01 (female) (1)
YES and CNL66 (female) (2) with After inspection,
wiring harness between repair or replace
1 CNT02 (female) (1) and
CNL67 (female) (2)
Is there continuity
between CNT01 Contact of wiring harness
(female) (1) and between CNL04 (female) (2)
CNT02 (female) (1)? 2 YES and CNL66 (female) (5) with After inspection,
wiring harness between repair or replace
1) Turn starting Is there continuity
switch OFF between CNL04
CNL67 (female) (5)
NO (female) (2) and
2) Disconnect CNL04 (female) (4)?
CNT01 and Defective transmission
CNT02 NO control switch Replace
1) Turn starting
switch OFF
2) Disconnect
CNL04
20-480
20-481
TROUBLESHOOTING E-9
E-9 Kick-down switch does not work

(the regular F1 to F4 shifts normally)
YES
YES
2
Is problem
YES
removed when
relay is replaced?
1) Replace kick-
down realy
(CNL68) with
REVERSE
solenoid relay
(CNL67) 3 YES
2) Start engine
Is problem
removed when
NO relay is replaced? 6
Is there continuity
1) Replace YES between CNL15
FORWARD (female) 1)
1 soleniod realy CNL66 (female) (4)?
(CNL66) with
Is there continuity REVERSE 5
solenoid relay 1) Disconnect
between CNL15 CNL15 and
(CNL67) Is there continuity
YES between CNL68
(male) (2) ? 2) Start engine
(female) (5) 2) Turn starting
switch OFF NO
1) Disconnect CNL15 (female) (2)?
CNL15
4 1) Disconnect
2) Press kick-down CNL68 and
switch Is there continuity CNL15
3) Turn starting between CNL68
switch OFF 2) Turn starting
NO (female) (6) and switch OFF
NO
chassis ground?
1) Disconnect
CNL68
2) Turn starting
switch OFF NO
NO
20-482
TROUBLESHOOTING E-9
Cause Remedy
Defective kick-down relay Replace
Defective FORWARD
solenoid relay Replace
YES disconnection in wiring
After inspection,
repair or replace
Is voltage between
YES CNL68 (female) (female) (5)
(3) and chassis Defective contact, or
20 - 30V ? disconnection in wiring
7 After inspection,
1) Disconnect harness between CNL68
Is voltage between CNL68 (female) (3) and CNFS2
CNL66 (female) (female) (3)
2) Turn starting
(3) and chassis switch ON
20 - 30V ? Defective contact, or
1) Disconnect 9 YES After inspection,
CNL66 Is voltage between repair or replace
2) Speed lever: CNL04 (6) and (female) (6)
2nd NO chassis 20 - 30V?
3) Turn starting Defective speed lever switch Replace
switch ON 1) Connect NO
T-adapter to CNL04
2) Speed lever: 2nd Defective contact, or
3) Turn starting switch ON disconnection in wiring
(female) (4)
(female) (2)
After inspection,
repair or replace
ground
Defective kick-down switch Replace
20-483
TROUBLESHOOTING E-10, E-11
E-10 Kick-down works only when kick-down switch is ON (Kick-down

switch relay does not hold in position (self-holding function) )
Cause Remedy
1 YES
Defective kick-down relay Replace
Is problem Defective contact, or
removed when disconnection in wiring
relay is replaced? harness between CNL66
After inspection,
1) Replace kick- NO repair or replace
down relay
(CNL68) with (female) (2) - CNL68
REVERSE (female) (5)
solenoid relay
(CNL67)
2) Start engine
E-11 Kick-down operation cannot be canceled

(a) Not canceled even when directional lever is moved from F to N or R
Cause Remedy
1 YES Defective FORWARD Replace

solenoid relay
Is problem
removed when
relay is replaced? Contact of wiring harness
After inspection,
between CNL66 (female) (3)
1) Replace and (4)
FORWARD
solenoid relay
(CNL66) with
REVERSE
solenoid relay
(CNL67)
2) Start engine
20-484
20-485
TROUBLESHOOTING E-11

(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th)
YES
1
Is there continuity YES
between CNL04
(female) (1) and
CNL04 (female) (6)?
2
1) Turn starting
switch OFF Is there continuity
between CNL04
YES
2) Disconnect
CNL04 (female) (6)?
3) Disconnect 3
CNL66 1) Turn starting
switch OFF Is voltage between
CNL66 (female) YES
2) Disconnect
CNL04 NO (3) and chassis
20 - 30 V ?
3) Disconnect
CNL66 1) Disconnect 4
CNL66 Is voltage between
2) Disconnect CNL66 (female)
CNL04 NO (4) and chassis YES
20 - 30 V?
3) Turn starting
switch ON 1) Disconnect 5
CNL66
Is voltage between
2) Disconnect CNL68 (female) YES
CNL68 NO (2) and chassis
3) Disconnect
20 - 30 V?
6
CNL15
1) Disconnect
4) Turn starting between CNL04
switch ON
2) Disconnect NO (female) (1) and
CNL15 CNL04 (female) (5)?
3) Turn starting
switch ON 1) Turn starting
switch OFF
2) Disconnect NO
CNL04
3) Disconnect
CNFT1
20-486

Cause Remedy

After inspection,
repair or replace
(female) (1) (6)

(female) (2) (6), or defective repair or replace
speed lever switch

and CNL66 (3) with +24V repair or replace
wiring harness

(female) (4) - CNL68 (female) After inspection,
(1) , CNL15 (female) (1) with repair or replace
+24 V wiring harness

(female) (2) - CNL68 (female) After inspection,
(5) - CNL15 (female) (2) with repair or replace
+24V wiring harness

(female) (1) (5) repair or replace

YES (4), CN37 (female) (1), After inspection,
7 CNTL1 (male) (6) with repair or replace
+24V wiring harness, or
Is voltage between
defective speed lever switch
CNL68 (female)
(4) and chassis
20 - 30V ? Abnormal contact of wiring
1) Disconnect harness between CNTL1 (6) After inspection,
CNL68. NO and CNT04 (1) with +24V repair or replace
2) Disconnect wiring harness
CNTL1.
3) Disconnect
CNL04.
4) Turn starting
switch ON
20-487
E-12 Kick-down switch is actuated by mistake when traveling in 2nd

« When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks,
always turn the starting switch OFF before starting.
Cause Remedy
YES
Defective kick-down switch Replace
1
Is there continuity
between CNL15 YES
(male) (1) and Defective kick-down relay Replace
CNL15 (male) (2) ? 2
CNL15 between CNL68 YES Contact of wiring harness
After inspection,
NO (male) (1) - (2) 3
repair or replace
2) Turn starting and (3) - (4) ? (2)
switch OFF
Is there continuity
3) Do not press
4 YES Contact of wiring harness
kick-down relay
kick-down (CNL68) NO (female) (1) and After inspection,
switch CNL15 (female) (2) ?
Is there continuity
repair or replace
2) Turn starting (2)
switch OFF 1) Disconnect between CNL68
CNL68 (female) (2) ? Contact of wiring harness
After inspection,
2) Turn starting between CNL68 (female) (3)
switch OFF NO (4) repair or replace
1) Disconnect
CNL68
3) Directional
lever: N 2) Turn starting
switch OFF
3) Directional
lever: N
20-488
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(A MODE)
OUTLINE .................................................................................................................................................. 20-502

1 Function ............................................................................................................................................... 20-502
2 When carrying out troubleshooting ..................................................................................................... 20-502
3 Failure code table ................................................................................................................................ 20-502
4 Table of troubleshooting modes and causes ....................................................................................... 20-503
A- 1 Troubleshooting code [10] Modulation valve solenoid system

(disconnection, short circuit) ...................................................................................................... 20-504
A- 2 Troubleshooting code [11] Short circuit in power source for
modulation valve solenoid system ............................................................................................... 20-505
A- 3 Troubleshooting code [12] F solenoid signal system ................................................................. 20-506
A- 4 Troubleshooting code [13] R solenoid signal system ................................................................. 20-506
A- 5 Troubleshooting code [14] Abnormality in H-L solenoid signal system ..................................... 20-507
A- 6 Troubleshooting code [16] Abnormality in speed solenoid signal system .................................. 20-508
A- 8 Troubleshooting code [20] Abnormality in directional lever signal system ................................ 20-510
A- 9 Troubleshooting code [21] Abnormality in speed lever signal system ....................................... 20-511
A-10 Troubleshooting code [22] Abnormality in travel speed signal system ...................................... 20-512
A-11 Troubleshooting code [23] Abnormality in engine speed signal ................................................ 20-513
A-12 Hold switch system ..................................................................................................................... 20-514
A-13 Kick-down switch system ........................................................................................................... 20-514
A-14 Kick-down output signal system ................................................................................................. 20-515
A-15 Transmission cut-off signal system ............................................................................................ 20-516
A-17 Buzzer signal system ................................................................................................................. 20-518
A-18 Network signal system ................................................................................................................ 20-519
A-19 Controller power source system ................................................................................................. 20-520
20-501
TROUBLESHOOTING OUTLINE
OUTLINE
1. Function
The control mechanism of the transmission con-
troller consists of the controller, sensors, input
switch, solenoid output, and buzzer output. The
controller receives the input signal, processes it,
and carries out the auto-shift control by control-
ling the solenoid to a transmission range that
matches the travel speed.
2. When carrying out troubleshooting

The controller has a troubleshooting function,
and when a failure is detected, the alarm buzzer
soands to warn the operator that there has been
a failure, and the display also shows the failure
code on the main monitor. However, failure
codes number A-12 to A-20 are no function to
display in the display area but are abnormality
in the control.
3. Failure code table
No. Failure code Failure No. Failure code Failure

Abnormality in modulation Abnormality in engine speed
A-1 10 A-11 23
solenoid signal system sensor signal system
Abnormality in modulation
A-2 11 A-12 Hold switch signal system
solenoid signal system
Abnormality in F solenoid Kick-down switch signal
A-3 12 A-13
signal system system
Abnormality in R solenoid Kick-down output signal
A-4 13 A-14
Abnormality in H-L solenoid Transmission cut-off signal
A-5 14 A-15
Abnormality in speed
A-6 16 A-16 Neutralizer signal system
solenoid signal system
A-17 Alarm buzzer signal system
Abnormality in directional
A-8 20 A-18 Network signal system
lever signal system
Abnormality in speed Abnormality in controller
A-9 21 A-19
lever signal system power source voltage
Abnormality in travel speed Abnormality in model
A10 22 A-20
sensor signal system selection wiring harness
20-502
TROUBLESHOOTING OUTLINE
4. Table of troubleshooting modes and causes
Cause of failure Related equipment
Engine speed sensor signal system

Travel speed sensor signal system
Controller power source voltage system

Model selection wiring harness system
Modulation valve solenoid system
Directional lever signal system
Transmission cut-off system
Alarm buzzer signal system

Speed lever signal system
Hold switch signal system
Neutralizer signal system

Kick-down signal system
Speed solenoid system
Network signal system

H-L solenoid system
R solenoid system
F solenoid system
Failure mode
Main monitor display failure code 12 13 14 16 10
11 20 21 22 23
Impossible to travel ¡¡ ¡¡ ¡¡ ¡
Auto-shift does not work ¡¡ ¡¡
Position of directional lever and
direction of travel do not match ¡
Machine travels forward when
directional lever is not at F position ¡
Machine travels in reverse when
directional lever is not at R position ¡
Transmission does not shift down in
accordance with travel speed ¡¡ ¡
Transmission does not shift up in
accordance with travel speed ¡¡
Transmission stays in same range as
speed lever regardless of travel speed ¡
There is excessive shock when shifting gear ¡ ¡ ¡
There is shift hunting when traveling ¡
There is shift hunting when shifting gear ¡ ¡
Transmission range cannot be
controlled with speed lever
¡
Shift cannot be held ¡

Transmission does not shift to 1st with ¡
kick-down switch
No power for scooping operations
when kick-down switch is ON
¡
Transmission is not cut off when left

brake is operated ¡
Machine can travel when parking brake

is applied ¡
Alarm buzzer does not sound when
travel direction is switched between ¡
forward and reverse when traveling at
high speed
Alarm buzzer does not stop ¡
Main monitor does not display
transmission controller information ¡
(alarm buzzer, failure code, etc.)
Model selection cannot be carried out ¡
20-503
TROUBLESHOOTING A-1
A-1 Troubleshooting code [10] Modulation valve solenoid system

(disconnection, short circuit)
« When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting
switch OFF.
Cause Remedy
2 YES
Defective controller Replace
Is insulation
YES between CNL29 Wiring harness between Repair wiring
3 YES CNL29 (female) (3), (14), harness, or
(female) (3) and
chassis normal ? CNTL2 (7), (8) - CNT12 replace
s insulation (19), (2) short circuiting
between CNT12 with chassis ground.
1) Disconnect
(male) (1) and
1 CNL29. NO chassis normal ?
2) Min. 1MΩ Defective modulation Replace
Is resistance 1) Disconnect NO solenoid valve
between CNL29 CNT12.
(female) (3) and (14) 4 YES 2) Min. 1MΩ Defective contact, Repair wiring
disconnection, or short harness, or
normal? Is resistance circuit in wiring harness replace
between CNT12 between CNL29 (female)
1) Disconnect (male) (1) and (2) (13), (14) - CNTL2 (7), (8)
NO
CNL29. normal? - CNT12 (1), (2)
2) 12 - 15 Ω
NO Defective modulation Replace
1) Disconnect
solenoid valve
CNT12.
2) 12 - 15 Ω
CNL 29 CNTL 2 CNTL 12 Modulation solenoid

Modulation solenoid (+)
Modulation solenoid (-) 14
20-504
TROUBLESHOOTING A-2
A-2 Troubleshooting code [11] Short circuit in power source for

modulation valve solenoid system
switch OFF.
Cause Remedy
3 YES
Is voltage between
2 YES CNT12 (male) (1) and
chassis normal?
Is voltage between Short circuit of solenoid Replace
YES
CNL29 (female) (14) power source
1) Disconnect NO
and chassis normal?
CNT12.
2) Max. 1V
1) Disconnect
3) Turn starting switch ON. Wiring harness between Repair wiring
CNL29 and
1 CNL29 (female) (14) - harness or
CNT12. CNTL2 (8) - CNT12 (2) - replace
Is voltage between NO
2) Max. 1V solenoid short circuiting
CNL29 (female) (3) and 3) Turn starting with power source
chassis normal? switch ON.
Wiring harness between Repair wiring

1) Disconnect CNL29 (female) (3) - harness or
CNL29 and NO
CNTL2 (7) - CNT12 (1) replace
CNT12. solenoid short circuiting
2) Max. 1V with power source
3) Turn starting switch ON.
CNL 29 CNTL 2 CNTL 12 Modulation solenoid

Modulation solenoid (+)
Modulation solenoid (-) 14
20-505
TROUBLESHOOTING A-3, A-4
A-3 Troubleshooting code [12] F solenoid signal system

switch OFF.
Cause Remedy
YES
· Defective contact, or
(female) (21) - CNTL1 (3)
Is resistance
- CNT01 (female) (1) or
between CNL29
short circuit with ground Repair wiring
(female) (21) and 2 YES
· Disconnection in wiring harness or
(19) normal? Is resistance harness between CNT01 replace
1) Disconnect between CNT01 (female) (2) and chassis
NO (male) (1) and (2)
CNL29 and
normal?
CNT1R Defective F solenoid Replace
(if equipped). 1) Disconnect NO
2) 46 - 58 Ω CNT01.
2) 46 - 58 Ω
A-4 Troubleshooting code [13] R solenoid signal system

Cause Remedy
YES
· Defective contact, or
Is resistance between (female) (20) - CNTL1 (4)
CNL29 (female) (20) - CNT02 (female) (1) or
Repair wiring
and (19) normal? 2 YES short circuit with ground
harness or
· Disconnection in wiring
Is resistance between replace
CNT02 (male) (1) and (female) (2) and chassis
1) Disconnect
NO (2) normal?
CNL29
(If equipped). Defective R solenoid Replace
2) 46 - 58 Ω 1) Disconnect CNT02. NO
2) 46 - 58 Ω
CNL 29
GND 19
R - solenoid CNTL 1 CNT02 R - solenoid
20
F - solenoid
21
CNT01 F - solenoid
CNTIR
F - solenoid
20-506
TROUBLESHOOTING A-5
A-5 Troubleshooting code [14] Abnormality in H-L solenoid signal

system
switch OFF.
Cause Remedy
YES
3 YES chassis ground and harness or
CNL29 (female) (10), replace
CNTL1 (male) (5),
Is resistance CNL05 (female) (13) short
YES between CNTL1 circuiting with chassis
(female) (5) and ground, or disconnection,
1 chassis normal ? defective contact
Repair wiring
· Wiring harness harness or
Is resistance NO between CNTL1 (female)
1) Disconnect replace
between CNL29 (5) and CNT03 (female)
(female) (10) and 2 CNTL1. (1) short circuiting with
(19) normal? 2) 46 - 58 Ω chassis ground, or
Is resistance disconnection, defective
between CNT03 contact
1) Disconnect · Disconnection in wiring
NO (male) (1) and (2)
CNL29, CNT1R harness between CNT03
(if equipped). normal? (female) (2) and chassis
2) 46 - 58 Ω 1) Disconnect
Defective H solenoid Replace
CNT03.
NO
2) 46 - 58 Ω
CNL29
GND
CNTL1 CNT03 H-L solenoid
H-L solenoid
Speed solenoid 11
GND 19 CNT04 Speed - solenoid
CNTIR
Speed solenoid
H-Lsolenoid
CNL05
12 Transmission range 1
20-507
TROUBLESHOOTING A-6
A-6 Troubleshooting code [16] Abnormality in speed solenoid signal

system
switch OFF.
Cause Remedy
YES
3 YES CNL29 (female) (11) - harness or
CNTL1 (female) (6), replace
Is resistance between CNL05 (female) (12) short
YES CNTL1 (female) (6) circuiting with chassis
ground, or disconnection,
and chassis normal ?
defective contact
1 Repair wiring
· Wiring harness harness or
Is resistance between NO between CNTL1 (female)
1) Disconnect replace
CNL29 (female) (11) (6) and CNT04 (female)
and (19) normal? 2 CNTL1.
2) 46 - 58 Ω chassis ground, or
disconnection, defective
CNT04 (male) (1) and contact
1) Disconnect
CNL29, CNT1R NO (2) normal? · Disconnection in wiring
(if equiped) harness between CNT04
and CNL05. (female) (2) and chassis
1) Disconnect
2) 46 - 58 Ω
CNT04. Defective speed solenoid Replace
NO
2) 46 - 58 Ω
CNL29
GND
CNTL1 CNT03 H-L solenoid
H-L solenoid
Speed solenoid 11
GND 19 CNT04 Speed - solenoid
CNTIR
Speed solenoid
H-Lsolenoid
CNL05
20-508
20-509
TROUBLESHOOTING A-8
A-8 Troubleshooting code [20] Abnormality in directional lever signal

system
« Check that there is no abnormality in the combination
switch for the directional and speed levers.
« Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
« Always connect any disconnected connectors before going
on the next step. Cause Remedy
« When disconnecting connectors to connect 3 YES
the T-adapter (or socket adapter), Is voltage between
always turn the starting · Wiring harness between
2 YES CNL30 (12) and (9) CNL30 (female) (12) -
switch OFF. normal? CNL04 (4) directional,
Is voltage between Repair wiring
YES CNL30 (1) and (9) speed lever switch short
harness or
normal? 1) Directional lever NO replace
ground or disconnection,
at R: 20 - 30 V defective contact
Other than R: 0 V · Wiring harness between
1) Directional lever 2) Turn starting CNL30 (female) (1) -
at F: 20 - 30 V CNL08 (female) (8) short
1 switch ON.
Other than F: 0 V circuiting with chassis
Is voltage between 2) Turn starting ground
CNL30 (11) and (9) switch ON.
normal?
· Wiring harness between
CNL30 (female) (1) - Repair wiring
1) Directional lever CNL04 (2) directional, harness or
at N: 20 - 30 V speed lever switch short replace
Other than N: 0 V circuiting with chassis
2) Turn starting ground or disconnection,
NO defective contact
switch ON.
CNL08 (female) (7) short
ground

Fuse 24 V CNL30 (female) (11) -
CNL04 (3) directional,
speed lever switch short Repair wiring
circuiting with chassis harness or
NO ground or disconnection,
replace
CNFS2 defective contact
Directional CNL05 (female) (8) short
CNL04 lever switch
ground
CNL30
Directional lever F
Speed lever 2 Main monitor
Speed lever 4
CNL08
Signal ground Transmission
Directional lever N 11 signal F input
Transmission
Directional lever R 12
signal R input
Speed lever 1 13
14
Speed lever 3 CNL05
Neutral
20-510
TROUBLESHOOTING A-9
A-9 Troubleshooting code [21] Abnormality in speed lever signal

system
Cause Remedy
YES
4
Is voltage
YES
between CNL30 Wiring harness between
(3) and (9) CNL30 (female) (3) -
Repair wiring
3 normal? CNL04 (8) - directional
harness or
speed lever switch short
Is voltage NO replace
YES between CNL30 circuiting with chassis
1) Speed lever
(14) and 4th: 20 - 30 V
defective contact
(9)normal? Other than 4th:
2
0V Wiring harness between
Is voltage 1) Speed lever 2) Turn starting
YES between CNL30 CNL30 (female) (14) - Repair wiring
3rd: 20 - 30 V swtich ON. CNL04 (7) - directional
(2) and (9) harness or
Other than 3rd: speed lever switch short replace
normal? 0V NO circuiting with chassis
2) Turn starting ground, or disconnection,
1) Speed lever
swtich ON. defective contact
2nd: 20 - 30 V
1
Other than 2nd:
Is voltage 0V
between CNL30 Wiring harness between
2) Turn starting CNL30 (female) (2) -
(13) and (9) swtich ON. Repair wiring
CNL04 (6) - directional harness or
normal?
speed lever switch short replace
1) Speed lever NO circuiting with chassis
1st: 20 - 30 V ground, or disconnection,
Other than 1st: defective contact
0V
2) Turn starting Wiring harness between
swtich ON. CNL30 (female) (13) -
CNL04 (5) - directional Repair wiring
speed lever switch short harness or
NO circuiting with chassis replace
Fuse 24 V ground, or disconnection,
defective contact
CNFS2
Directional
CNL04 lever switch
CNL30
Directional lever F
Speed lever 2 Main monitor
Speed lever 4
CNL08
Signal ground Transmission
Directional lever N 11 signal F input
Transmission
Directional lever R 12
signal R input
Speed lever 1 13
14
Speed lever 3 CNL05
Neutral
20-511
TROUBLESHOOTING A-10
A-10 Troubleshooting code [22] Abnormality in travel speed signal

system
switch OFF.
Cause Remedy
YES
YES Defective speed sensor Replace

1
Is resistance between Defective contact, or Repair wiring
CNL31 (female) (5) YES disconnection in wiring harness or
and (12) normal? 2 harness between CNL31 replace
(female) (4), (12) - CNTL2
Is resistance between (1), (2) - CNT06 (female)
CNT06 (male) (1) and (1), (2)
1) Disconnect CNL31
(2) normal? 3
2) 0.5 - 1 ΚΩ NO
Is insulation between
CNL31 (female) (4)
1) Disconnect CNT06 and (12) normal ? Wiring harness between Repair wiring
2) 0.5 - 1 ΚΩ NO CNL31 (female) (4), (12) harness or
- CNTL2 (1), (2) - CNT06 replace
NO (female) (1), (2) short
1) Disconnect CNL31
ciruiting with chassis
and CNT06
ground, short circuit
CNL31 Speed sensor

CNTL2 CNT06
Speed signal (+)
Engine speed siganl (+)
Speed signal (-) 12
To engine throttle controller

floor wiring harness
CNL07
14 Engine speed (+)
15 Engine speed (-)
Main monitor
CNL07
Speedometer (+)
Speedometer (-)
Tachometer (+)
20-512
A-11 Troubleshooting code [23] Abnormality in engine speed signal

« Check that there is no error message for the engine speed signal for the engine throttle controller.
switch OFF.
Cause Remedy
2 YES
Is continuity between
and (12) normal?
Defective contact, or Repair wiring
1 disconnection in wiring harness or
1) Disconnect CNL31, NO harness between CNL31 replace
Is insulation between
CNLGL and CNL07. (female) (5) and CNLGL
CNL31 (female) (5),
2) Short circuiting CNLGL (female) (14), (15). (female) (14)
(12) and chassis
normal?
1) Disconnect Wiring harness between Repair wiring

CNL31, CNLGL CNL31 (female) (5), (12) harness or
and CNL07. NO - CNL07 (female) (3), (2), replace
2) Min. 1 ΜΩ between CNL31 (female)
(5), (12) - CNLGL
(female) (14), (15) short
ground
CNL31 Speed sensor

CNTL2 CNT06
Speed signal (+)
Engine speed siganl (+)
Speed signal (-) 12

CNL07
14 Engine speed (+)
15 Engine speed (-)
Main monitor
CNL07
Speedometer (+)
Speedometer (-)
Tachometer (+)
20-513
TROUBLESHOOTING A-12, A-13
A-12 Hold switch system

switch OFF.
Cause Remedy
YES
1
Is continuity between Wiring harness between Repair wiring
CNL30 (female) (18) CNL30 (female) (18) and harness or
and chassis normal? 2 YES CNL15 (female) (3) short replace
CNL15 (male) (3) and
1) Disconnect defective contact.
NO (4) normal?
CNL30.
2) Hold switch Defective hold switch Replace
ON: Max. 1 Ω NO
OFF: Min. 1 ΜΩ
A-13 Kick-down switch system Cause Remedy

YES
1
Is continuity between Wiring harness between
CNL30 (female) (17) CNL30 (female) (17) and
and chassis normal? 2 YES CNL15 (female) (1) short Repair wiring
circuiting with chassis harness or
Is continuity between replace
CNL15 (male) (1) and
1) Disconnect defective contact
NO (2) normal?
CNL30.
2) Kick-down- switch Defective kick-down Replace
1) Disconnet NO switch
ON: Max. 1 Ω
CNL15.
OFF: Min. 1 ΜΩ
2) Kick-down switch
ON: Max. 1 Ω
OFF: Min. 1 ΜΩ
Kick-down switch Hold switch
CNL30 CNL15
17
Kick-down switch
Hold switch 18
20-514
A-14 Kick-down output signal system
« Check that the fuses of CNFS2 (10), CNFS5 (6) are not blown.
switch OFF.
Cause Remedy
2 YES Go to troubleshooting of
Is voltage between engine throttle controller
YES CNLGL2 (female) (2) Wiring harness between Repair wiring
and chassis normal? CNRES (female) (2) and harness or
CNLGL2 (female) (2) replace
short circuiting with
1) Disconnect CNLGL2 NO chassis ground, or
1 2) Starting switch ON: Max. 1 V disconnection, defective
3) Kick-down switch ON: 20 - 30 V contact.
Is voltage between
CNL31 (6) and
chassis normal? 3 YES
Is voltage between
1) Insert T-adapter CNL31 (female) (6)
NO Wiring harness between Repair wiring
and chassis normal?
2) Hold switch CNL31 (female) (6) and harness or
ON: Max. 1 Ω CNFS5 (female) (6) replace
3) Kick-down 1) Disconnect CNL31 NO short circuiting with
2) 20 - 30 V chassis ground, or
switch ON: disconnection, defective
10 - 15 V contact.
+ 25 V
CNFS5
CNRES
CNL31
Kick-down signal output
CNLGL2
Switch pump cut-off
Kick-down signal
20-515
A-15 Transmission cut-off signal system
switch OFF.
Cause Remedy
YES

CNL12 (female) (1) short
1 circuiting with chassis
Is continuity between ground, or disconnection,
CNL30 (male) (16) defective contact
and chassis normal? · Wiring harness between
CNL30 (female) (16) and Repair wiring
2 YES CNL06 (female) (3) short harness or
1) Disconnect circuiting with chassis replace
Is continuity between ground
CNL30. CNL12 (male) (1) and
2) Transmission (2) normal?
NO
cut-off switch
Defective transmission Replace
ON: Max. 1 Ω
NO cut-off switch
OFF: Min. 1 MΩ 1) Disconnect
CNL12.
2) Transmission
cut-off switch
ON: Max. 1 Ω
OFF: Min. 1 MΩ
CNL30
CNL12
Transmission cut-off switch 16
Transmission
cut-off switch
Main monitor
CNL06
3
Transmission cut-off
output
20-516
20-517
A-17 Buzzer signal system

« Check that the main monitor and alarm buzzer work properly.
switch OFF.
Cause Remedy
3 YES
and chassis normal ?
2 Short circuit between Repair wiring
CNL34 (female) and harness or
Is continuity between NO resistor, or replace
YES 1) Disconnect
CNL31 (female) (15) disconnection, defective
and chassis normal? CNL31 and CNL08.
contact
2) 4 - 7 ΚΩ
1 Defective contact, or Repair wiring
Is insulation CNL31 1) Disconnect disconnection in wiring harness or
(female) (15) and CNL31, CNL08 and NO harness between CNL31 replace
CNL34. (female) (15) and CNL08
chassis normal?
2) Short circuit CNL08 (female) (6)
(female) (6) - chassis
1) Disconnect 3) Max. 1 Ω
CNL31, CNL08 and
CNL34.
CNL31 (female) (15) - harness or
2) Min. 1 ΜΩ NO CNL08 (female) (6) - replace
CNL34 (male) (7) short
ground
+ 24 V
Main monitor
CNL42
CNL06
Caution buzzer
Buzzer output
CNL43
CNL31 CNL08
Buzzer signal output 15 Buzzer ON input
CNL34
Resistor
20-518
A-18 Network signal system

switch OFF.
Cause Remedy
4 YES
Is continuity
YES between CNL30
(female) (9), and
chassis Wiring harness between Repair wiring
3
normal ? harness or
Is insulation 1) Disconnect replace
NO CNL08 (female) (2), (4)
YES between CNL30 CNL30 and
(female) (9) and short circuiting with
CNL08.
chassis 2) Short circuit chassis ground
2 normal ? CNL08 (female)
(2), (4) with chassis
Is continuity 1) Disconnect ground.
YES between CNL29 CNL30 and 3) Max. 1 Ω
(female) (1), (12) CNL08.
and chassis CNL30 (female) (9) and harness or
normal ? 2) Min. 1 ΜΩ CNL08 (female) (2), (4) replace
NO short circuiting with
1) Disconnect
chassis ground
CNL29 and
1 CNL08.
Is insulation 2) Short circuit harness or
between CNL29
NO disconnection in wiring
CNL08 (female) replace
(female) (1), (12) harness between CNL29
(1), (12) -
and chassis (female) (1), (12) and
chassis.
normal ? CNL08 (female) (1), (3)
3) Max. 1 Ω
1) Disconnect Wiring harness between Repair wiring
CNL29 and CNL29 (female) (1), (12) harness or
CNL08. NO and CNL08 (female) (1), replace
2) Min. 1 ΜΩ (3) short circuiting with
chassis ground
Main monitor
CNL29 CNL08
Netzwork (+) Netzwork (+)
Netzwork (+) 12 Netzwork (-)

Netzwork (+)
CNL30 Netzwork (-)
Signal GND
20-519
A-19 Controller power source system

« Check that fuse for the transmission controller power source is not blown.
switch OFF.
Cause Remedy
YES
1
Short circuit with chassis Repair wiring
Is voltage between ground between CNL29 harness or
CNL29 (female) (8), (female) (8), (17), (18) replace
(17), 2 YES and CNFS5 (female) (6),
(18) -(9),(19) normal? or disconnection,
CNL29 defective contact
1) Insert T-adapter (female) (9),(19)and
NO
2) 20 - 30 V chassis normal?
NO disconnection in wiring harness or
1) Disconnect
CNL29. harness between CNL29 replace
2) Max. 1 Ω (female) (9), (19) - CNCL1
(female) (9), (12) - chassis
ground
+24 V
CNFS5
CNL29
Power source 24V
GND
Solenoid power source 17
Power source 24V 18

CNCL1
GND 19
12
20-520
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (CHASSIS RELATED)
(T MODE)
POWER TRAIN
T- 1 Machine does not start ............................................................................................................... 20-552
T- 2 Travel speed is slow, thrusting power is weak, lacks power on slopes .................................... 20-554
T- 3 Excessive shock when starting machine or shifting gear .......................................................... 20-556
T- 4 Excessive time lag when starting machine or shifting gear ....................................................... 20-557
T- 5 Torque converter oil temperature is high ................................................................................... 20-558
STEERING SYSTEM
T- 6 Steering wheel does not turn ..................................................................................................... 20-559
T- 7 Steering is heavy ....................................................................................................................... 20-560
T- 8 Steering wheel shakes or there is excessive shock .................................................................. 20-561
T- 9 Machine deviates to one side when traveling ............................................................................ 20-561
T-10 Turning radius is different between left and right ...................................................................... 20-561
BRAKE SYSTEM
T-11 Brakes do not work or braking effect is poor ............................................................................ 20-562
T-12 Brakes are not released or brakes drag .................................................................................... 20-563
WORK EQUIPMENT
T-14 Boom does not rise .................................................................................................................... 20-565
T-15 Boom movement is slow or boom lacks lifting power ............................................................... 20-566
T-16 When boom is raised, it moves slowly at a certain height ........................................................ 20-567
T-17 Bucket cannot be pushed with boom cylinder (bucket floats) ................................................... 20-567
T-18 Excessive hydraulic drift of boom .............................................................................................. 20-567
T-19 Boom shakes during operation .................................................................................................. 20-568
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE ...................... 20-568
T-21 Bucket does not tilt back ............................................................................................................ 20-569
T-22 Bucket movement is slow or tilt back lacks power .................................................................... 20-570
T-23 Bucket movement becomes slow during tilt-back operation ...................................................... 20-571
T-24 Bucket cannot be pushed with bucket cylinder.......................................................................... 20-571
T-25 Excessive hydraulic drift of bucket ............................................................................................. 20-571
T-26 Bucket shakes during loading operation .................................................................................... 20-572
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT ...................... 20-572
T-28 Boom, bucket control levers are heavy or do not move smoothl .............................................. 20-573
Explanation of symbols in Table

The following symbols are used on the Cause column to show the action to be taken to remove the cause.
X: Replace, ∆: Correct, A: Adjust, C: Clean
20-551
TROUBLESHOOTING T-1
POWER TRAIN
T-1 Machine does not start
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Internal part seized or broken
.)
Was there any abnormal noise when this
etc
happened?
eal,
e
r, s
Yes = Component broken.
alv
tato
ol v
Checks before troubleshooting
tc.)
p, s
ntr
Does the machine monitor function prop-
g, e
f co
um
erly?
in
eo
e, p
uf f
valv
Is the transmission oil level correct?
bin
, sc
lv e
Is the type of oil correct?
tur
tor
ght
f va
la
,
cau
ing
Is the transmission filter or strainer clogged?
egu
es
reli
nd
O)
e
ear
alv
er
dirt
Does the electrical circuit of the transmis-
ne
s
PT
ter
Cau
sur
e
io
e(
ver
(
tive
valv
trol
sion control work properly?
uct
er
res
lv
con
con
t
fec
ps
l va
ver
e
Is the transmission oil deteriorated? Does
oid
p
alv
e
um
ue
ch
n
cin
p (d
tro
len
issio
ol v
the oil smell of burning?
t
gp
f clu
con
r
f so
que
um
f to
ntr
p
sm
rgin
Is there any damage or leakage of oil that
um
gp
no
no
no
f co
ion
tor
an
a
gp
rgin
io
can be seen externally?
ratio
io
e tr
t ch
rat
eo
ide
rat
rat
rgin
cha
id
ope
in a
rific
Is the drive shaft broken?
ins
ope
ope
ope
ins
cha
do
e fo
ked
ge
kge
tive
Is the wheel brake or parking brake locked?
tive
tive
tive
ive
aka
gge
driv
suc
aka
fec
ect
fec
fec
fec
Bre
Clo
Bre
Def
De
De
De
De
No
Air
Charging Torque
pump converter Transmision control valve
a b c d e f g h i j
Remedy C
No. Problems
1 Does not start in any transmision range
2 Does not start in certain transmisssion ranges
3 Does not start when oil temperature rises

Torque converter stall speed does not go down to specified speed
4 in any transmission range
Torque converter stall speed does not go down to specified speed
5 in certain transmission ranges
7 Transmission clutch pressure does not rise in any speed range
8 Transmission clutch pressure does not rise in certain speed ranges

9 Metal particules (aluminium, copper, iron, etc.) stuck to filter or strainer
20-552
k
Exc
l
ess
iv e le
aka
De ge
fec of o
m
tive il fr
o per om
Me atio tran
cha n in sm
n
iss
Transmission
nis
che side ion
rS tra clu
Bre ch nsm tch
aka ade iss sha
ge n im ion ft s
ins c eal
o
ide Ge lutc por
t
valve
r ieb h ( tion
tran
sm e (La se ize (wo
Bre is sin g er, d,w rn,
aka ( o bro
ge b Z
TROUBLESHOOTING
ear ahn rn, ken

ins
ide in rad oil le )
acc
g, g
ear , Ge aka
um , hou h äus ge,
p
b
valve
ula
tor s ing e ) rok
valv ) en)
De
fec e (a
Accumulator Flow control

tive bno
ope rma
rat lw
ion ear
of f of s
low poo
con l po
tro rtio
l va n)
lve
(dir
t ca
ugh
t, s
cuff
ing
)
WA-3H automatic transmission
20-553
T-1
TROUBLESHOOTING T-2
T-2 Travel speed is slow, thrusting power is weak, lacks power on

slopes
Checking for abnormalities
Measure digging operations and speed
tc.)
when traveling on level ground and on
g, e
slopes, and check if there is actually an
arin
abnormality or whether it is just the feeling
.)
ve
etc
, be
tc.)
of the operator.
val
,
e
ing
r ol
tato
ol,
pr
ont
spo
p, s
sna
of c
,
ve
pum
hes
ng,
val
lve
ratc
shi
r va
e
rol
rbin
, bu
e, s
ont
lato
, tu
her
ring
Is there any oil leaking from the joints of the
of c
egu
g
e (w
piping or valves?
arin
eal
ve
er
end
ve
ses
val
r (s
Is there any dragging of the wheel brake or
(be
sur
val
val
tion
on
res
parking brake?
ter
Cau
trol
ert
lief
suc
lati
ver
hp
onv
n
Is the tire inflation pressure and tread pat-
r re
odu
pum
nc
con
lutc
ec
rte
tern normal?
of m
sio
of c
rqu
nve
que
ing
p
Is the method of operation correct?
mis
um
e to
arg
tion
ion
tor
c
gp
ans
t ch
sid
rat
que
ide
a
rgin
e tr
r
ope
in a
ope
e in
ins
tor
cha
sid
kag
ked
ge
tive
tive
tive
t in
tive
aka
suc
lea
fec
fec
fec
fec
fec
Bre
De
De
De
De
Oil
De
Air
Charging Torque Transmission

pump converter control valve
a b c d e f g h
Remedy
No. Problems
1 Abnormality in all transmission ranges
2 Abnormality in certain transmission ranges
When oil temperature is low, abnormal noise comes from

3
charging pump
4 Torque converter oil overheats
5 Abnormality in high idling and low idling speeds
6 Abnormality in each stall engine speed
7 Torque converter relief pressure is low
8 Low in every transmission range

Transmission
9 clutch pressure Low in certain transmission ranges
10 Indicator is unstable and fluctuates violently
11 Transmission oil level changes
Metal particles stuck to transmission as trainer

12
or torque converter filter

WA320-3H manual gear shift
20-554
C
i
valve
Clo
Control
g ged
j
orif
ice
of c
Lea ont
k
kag rol
eo val
f oi ve
Lea
l
l fro
kag ms
eo eal
f oi ring
C
Bre l fro
m
aka mt of t
ge ran
Torque converter,
ins ran sm
sm
TROUBLESHOOTING
iss
transmission circuit
Clo ide i ssi ion
n
gge tran
sm o nc clu
d tr
ans issio l utc tch
Clo mis n hp pag
s isto
o
sha
gge
d to
ion
bre n sea ft
rqu a the l
Exc
ess
ec
onv r
ive erte
p
lea
valve
kag r co
eo ole
Bre f oil
r ci
rcu
aka from it
Accumulator
ge
q
ins par
ide kin
acc gb
Lea um rak
es
r
kag ula eal
eo tor
v
Others
(wo
f oi alv rn,
De l fro e (ab bro
fec m nor ken
t in sea ma )
eng l of l we
ine
rela
sha
ft in a r of
ted wo spo
par rk e ol p
t q ui orti
pm on)
ent
and
ste
erin
gc
ircu
it p
um
p
20-555
T-2
TROUBLESHOOTING T-3
T-3 Excessive shock when starting machine or shifting gear

It is difficult to measure if the shock is exces-
sive or normal, so judge that the shock is ex-
ing
cessive in the following cases.
spr
When it is clear that the shock has become
urn
greater than before.
ret
ve
When the machine is compared with an-
er
ack
val
ind
other machine of the same class and the
hp
tor
cyl
shock is found to be greater.
lutc
ula
ack
reg
of c
p
ch
re
age
t
ssu
l u
of c
Is the engine idling speed too high?
eak
pre
Is there play in any of the drive shafts?
nce
, br
tch
ing
lve
fere
clu
ses
r va
ettl
um
ion
to s
lato
Cau
circ
iss
mu
nsm
ue
nd
nd
ccu
rou
ra
isto
of a
of t
ton
le a
pis
of p
o
ion
on
in h
tor
rati
rat
urn
dra
ula
ope
ope
ret
um
il
do
tive
tive
tive
acc
gge
fec
fec
fec
ck
Clo
Stu
De
De
De
Accumulator
Control valve Transmission valve
a b f g h
Remedy C
No. Problems
1 Shock is excessive in every transmission range
2 Shock is excessive in certain transmission ranges
3 Clutch pressure is too high
20-556
TROUBLESHOOTING T-4
T-4 Excessive time lag when starting machine or shifting gear

Was there excessive time lag? Was there
any abnormality in the travel speed or thrust-
ool
ing force? Was there any lack of power
r sp
when traveling up slopes?
cto
Yes = Go to T-2 Travel speed is slow, thrust-
ele
ing power is weak, lacks power on
al s
slopes
tion
ing
ring
rec
ol)
ve
spo
al r
f di
val
l
sea
t se
it o
o rn
and
ore
aft
haf
,w
ircu
, sh
rb
ing
ing
k, s
in c
l, o
s
ack
spr
Is there any oil leaking from the joints of the
hou
pac
dra
poo
hp
en
piping or valves?
ion
v
rok
e in
n, s
lutc
lutc
val
ses
iss
e (b
isto
alv
nc
nc
on
sm
valv
Cau
kv
lati
o
sio
of p
tran
i
iss
hec
odu
tor
i
sm
sm
ar
t of
ula
of c
of m
we
ran
ran
oin
um
e to
mt
mt
on
mj
ion
acc
i
l fro
l fro
l du
rat
l fro
rat
ide
e
ope
ope
f oi
f oi
f oi
rific
f oi
ins
eo
eo
eo
eo
do
tive
tive
ge
kag
kag
kag
kag
gge
aka
fec
fec
Lea
Lea
Lea
Lea
Clo
Bre
De
De
Transmission Accumulator
control valve Transmission valve
a c e f g h i j
Remedy C
No. Problems
1 Time lag is excessive in every transmission range
2 Time lag is excessive in certain transmission ranges
3 Clutch pressure is low in every transmission range
Clutch oil pressure is low in transmission ranges where time lag

4
is excessive
20-557
TROUBLESHOOTING T-5
T-5 Torque converter oil

temperature is high
Does oil temperature rise during torque con-
tc.)
p
um
g, e
verter stall and go down when there is no
it p
arin
ircu
load?
it
ircu
tc.)
, be
gc
Yes = Selection of transmission range
r, e
dc
erin
ring
Does oil temperature rise only when carry-
gge
ato
ste
nap
ing out scooping work?
, st
clo
and
g, s
Yes = Improvement in method of operation
ine
or
uit
shin
urb
ler
lve
circ
coo
p, t
, bu
r va
ent
um
ter
ing
lato
Are the radiator water level and fan belt
ipm
end
g, p
ver
al r
equ
tension correct?
reg
con
arin
tion
(se
ork
ve
ure
suc
(be
ter
es
que
val
in w
s
ver
res
s
nd
rter
tor
lief
Cau
con
pa
t
hp
haf
nve
om
r re
r
n
pum
t
the
lutc
par
s
ue
sio
r fr
o
e
l of
c
rea
orq
ert
is
nc
f ai
ted
ing
ue
sm
sea
p
nb
t
um
sio
con
torq
o
arg
rela
e
tran
Measure the torque converter oil tempera-
id
sio
ng
from
gp
mis
t ch
ins
ue
ide
mis
edi
ine
rgin
ide
ture. Is it actually high?
s
q
in a
f oil
tran
f oil
ins
ble
eng
ans
tor
ins
cha
Yes = Defective oil transmission gauge

eo
eo
ked
ge
d tr
tive
tive
tive
ge
t in
ive
kag
kag
aka
aka
gge
suc
fec
fec
ect
fec
fec
Lea
Lea
Bre
Bre
Def
Clo
De
De
De
De
Air
Charging Torque Trans- Torque converter,

mission transmission cicuit Others
pump converter
a b c d e f g h i j k
Remedy C
No. Problems
When oil temperature is low, abnormal noise comes from charging
1
pump
2 Abnormality in high idling and low idling speeds
3 Abnormality in each stall engine speed
Abnormality in travel speed, thrusting force, and gradeability in all

4
transmission ranges
Abnormality in travel speed, thrusting force, and gradeability in all

5
certain transmission ranges
6 Torque converter relief pressure is low
7 Low in every transmission range

Transmmision clutch
8 Low in certain transmission ranges
pressure
9 Indicator is unstable and fluctuates violently
10 Transmission oil level changes
11 Metal particles stuck to transmission straniner or torque converter filter
20-558
TROUBLESHOOTING T-6
STEERING SYSTEM
T-6 Steering wheel does not turn
Yes = Steering equipment damaged or
,
TO
broken
p, P
ve
Was there previously any symptom, such
um
al
gv
as heavy steering?
cp
erin
auli
Yes = Wear of internal parts of steer-
ste
ydr
ing equipment, defective seal
of h
ide
ns
l)
or p kage
se a
ct i
ump
fe
a
ton
Is the hydraulic oil level correct?
Bre
De
pis
en
es
Is there any part broken in the steering gear
rok
s
box or steering linkage?
Cau
(b
box
der
Has the safety bar been removed from the
ear
ylin
frame?
gg
p
gc
pum
Is the steering linkage properly adjusted?
erin
ve
erin
ste
val
ch
ste
swit
ide
ief
ide
ins
rel
ol
e
nd
valv
spo
s
ga
ge
t in
ng
and
aka
erin
eri
fety
fec
Dem
Ste
Bre
Ste
De
Hydraulic Sa
pump Valves Others
a b c d e f
Remedy
No. Problems
1 Steering wheel does not turn either to left or to right
2 In Item 1, mopvement of work equipment is abnormal
3 Steering wheel turns only to one side (left or right)
4 Steering wheel is heavy and cannot be turned
5 Oil pressure in steering circuit does not rise at all
There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-559
TROUBLESHOOTING T-7
T-7 Steering is heavy

Yes = Steering equipment damaged or
broken
as heavy steering?
Yes = Wear of internal parts of steer-
ing equipment, defective seal
e
alv
gv
p
um
ve
erin
lic p
val
ste
rau
ss
al)
Is there any abnormality in the steering gear
ide
ypa
hyd
e
ns
box mount, column, or linkage?
ins
b
tive
isto
ve
Is the stopper for the steering valve control
)
fec
nut
fec
mp
i
ect
e
lever properly adjusted?
De
orm
D
fro
f
, de
Is there any leakage of oil from the hydrau-
,w
ge
ide
ring
lic hoses, valves, or cylinders?
aka
eaa
ses
Is there any scuffing of the center hinge pin
l le
urn
i
x (b
r (o
ret
bearing or steering cylinder pin or bushing? Cau
nde
oil
r bo
Is the tire inflation pressure correct?
ulic
i
gea
cyl
p
a
pum
ring
ydr
ring
lve
at h
e
ch
er
tee
Measure the operating force of the steering
f va
ste
swit
ool
es
lter
wheel and the time taken to turn the steer-
elie
ide
il c
ol
e
nd
sid
d fi
alv
spo
do
gr
ing, and check the values in the Standard

ga
t in
t in
ty v
gge
erin
gge
and
erin
Value Table to check if there is any abnor-

fec
fec
fe
Dem
Clo
Ste
Clo
Ste
De
De
Sa
mality.
Tank -
pump Valves Others
a b c d e f g i
Remedy A C C
No. Problems
1 Steering is heavy when turned in both direction (left and right)
2 Steering is heavy when turned in one direction (left or right)
3 Steering is particularly heavy when engine is at low speed
4 Boom lifting speed is low when engine is runnig at full throttle
5 Steering is heavy and steering wheel jerks
6 Hydraulic oil overheats

7 Oil pressure in steering circuit is low
8 Oil pressure rises in return piping for steering cylinder
20-560
TROUBLESHOOTING T-8, T-9, T-10
T-8 Steering wheel shakes or there is excessive shock

olt)
t, b
Is there any abnormality in the steering gear
, nu
box mount, column, or linkage?
l
sea
Is there any play in the center hinge pin
n
al v
isto
bearing or steering cylinder pin or bushing?
gv
r, p
Is there any variation in the tire inflation
erin
nde
ste
pressure?
cyli
tive
Is the steering wheel play correct?
of
fec
ce
De
l
poo
fa
sur
or s
Operate at a safe place and check how the
ide
ect
ses
steering wheel shakes and under what con-
(ins
sel
ditions.
Cau
ve
er
In cases where the steering wheel is
val
nd
cyli
heavy but does not shake, go to
ing
eer
g
T-7 Steering is heavy.
erin
f st
ste
no
itio
e
sid
e
pos
valv
t in
ong
fec
ftey
De
Wr
Sa
Valves Cylinder
a b d
Remedy A
No. Problems
1 Chassis shakes when traveling on rough road surface
2 Shakes when steering is suddenly turned during operation travel
4 Chassis shakes when engine is started
T-9 Machine deviates to one side when traveling

Cause : Defective steering valve
Wrong position of spool
: Leakage of oil inside steering cylinder
: Variation in tire inflation pressure
T-10 Turning radius is different between left and right

Cause : Defective adjustment of steering linkage
Distribution to left and right, stopper lock position
(relief sound can be heard from valve when turning is completed)
20-561
TROUBLESHOOTING T-11
BRAKE SYSTEM
T-11 Brakes do not work or braking effect is poor
Yes = Brake equipment broken
xle
Did the problem gradually appear?
ea
sid
Yes = Deterioration of seal, wear of lin-
g in
ing, disc
nin
re
e li
ssu
rak
pre
of b
e
axl
gas
Is the brake pedal play correct?
ear
xle
ide
ent
ea
te w
ins
Is there any leakage of oil from the brake
fing
fici
sid
ng
ple
tube or connector?
suf
cuf
n in
lini
om
ses
, in
Is there any deformation of the tube?
), s
ke
e
isto
to c
e
eal
axl
alv
Cau
a
Is the tire inflation pressure and tread pat-
rge
e
f br
ep
axl
ns
ev
due
ide
cha
tern normal?
o
rak
sto
arg
ide
ins
ity
tion
lve
(for
of b
r pi
s
f ch
l
tion
rma
l in
por
a
lato
ev
Checks before abnormalities
no
mp
sea
ion
it
por
bno
ircu
tal
rak
mu
ratio
t pu
rat
Measure the braking force and compare with
me
ton
ke
er a
eb
ccu
ec
ope
pilo
ope
bra
the Standard Value Table to check if the
pis
ith
h
sid
rak
a
r ot
ct w
tive
tive
tive
tive
tive
tive
brakking effect is poor.
t in
in b
ar o
fec
nta
fec
fec
fec
fec
fec
fec
We
Air
De
De
De
De
De
Co
De
De
a b c d e f g h i j
Remedy
No. Problems
1 Resistance is low when brake pedal is depressed
2 Break pedal is heavy when it is depressed
3 Abnormal operating force is needed to obtain specified braking force
4 Abnormal noise is heard from axle brake when brake is applied
5 Machine cannot travel (lacks rimpull)
Jack up 4 wheels and set axles on stand. In F1, when brakes are
6
applied, only certain wheels rotate quickly
Air can be seen flowing out when air is bled from brake circuit.
7
Returns after air is bled.
8 Abnormal oil leakage is found when checking leakage of oil inside axle.
9 Many metal particles are found in axle oil
No abnormality in operating force of travel of brake pedal, but

10
braking effect is poor
11 Number of times of braking effect is small when engine is stopped
12 Accumulator is not charged, buzzer sounds
13 There is a time lag in effect of brake
20-562
T-12 Brakes are not released or brake drag

Does the brake pedal come back fully?
Is the praking brake fully released?

Is there any abnormal heat from the brakes?
Does the machine travel smoothly under
inertia on level ground?
e
axl
e
sid
ck)
xle
es
n in
stu
ea
s
isto
Cau
ton
sid
ep
(pis
g in
rak
ve
n
lini
of b
val
ke
ke
ion
ra
bra
rat
in b
ope
ide
lity
s
tive
ma
t in
nor
fec
fec
De
De
Ab
a b c
Remedy
No. Problems
1 Brake remains applied even when brake pedal is released
When brake pedal is released and oil is bled from air bleeder ,
2
circuit pressure goes down and brake is released
Jack up 4 wheels and set axles on stand. When engine is stopped

3 and parking brake is released, certain wheels are heavy when they
are rotated by hand
20-563
20-564
WORK EQUIPMENT
T-14 Boom does not rise
Yes = Equipment seized, damaged Was
there any abnormal noise when
this happened? (from where?)
as the speed becoming slow?
Yes = Wear of internal parts, deterio-
ration in spring
il
in o
air
ve
ssi
e
p
alv
Is the travel of the boom control lever and
ol)
um
xce
es
spo
ef v
p
spool properly adjusted?
ol
re
ch
s
lve
spo
l
om
reli
sea
Cau
po
swit
f va
(bo
nd
any
pum
ton
ool
and
e
ma
ody
r pis
reli
f sp
of m
f de
t of
eb
um
nde
f
n o
o
mp
por
no
ion
valv
lic p
ion
cyli
r pu
atio
p
ratio
rat
pum
ion
rat
rau
ide
oom
e fo
per
ope
uct
ope
ope
hyd
ins
PC
driv
db
ds
eP
tive
tive
ge
tive
ive
tiv
age
PTO
gge
ectiv
aka
fec
ect
fec
fec
fec
Dam
Clo
Bre
Def
De
Def
De
De
De
No
Steering Main control

Tank - pump valve
PPC valve valve Cylinder
a b c d e f g h i j
Remedy C
No. Problems
1 Bucket cannot be operated and boom cannot be raised
Chassis can be raised with boom but boom cannot be raised, or
2
bucket can be operated but boom cannot be raised
Boom can be raised when there is no load but cannot be raised

3
when there is a load
4 Abnormal noise comes from hydraulic pump
5 Excessive hydraulic drift of boom cylinder
When engine is running at full throttle, steering operation is too

6
light and fast
When engine is running at full throttle, steering operation is heavy

7
and slow
20-565
T-15 Boom movement is slow

or boom lacks lifting
power
Is the travel of the boom control lever and
main control valve spool properly adjusted?
ent
Is there any seizure of the work equipment
stm
linkage? (Is there any abnormal noise?)
nt
me
dju
ust
ea
il
adj
ctiv
in o
There is a strong connection between lifting
ive
efe
ol)
air
power and speed, so this problem first ap-
ect
s po
rd
ve
eo
def
pears as a lack of lifting speed. Measure
ssi
om
p
alv
xce
pum
or
the boom lifting speed when the bucket is
(bo
es
ef v
ve
re
ve
ody
loaded and use the Stand-
ch
val
Cau
ol
reli
po
val
swit
eal
eb
spo
ard Value Table to judge if there is any
off
pum
ns
lief
ain
l
valv
poo
nd
ut-
and
abnormality.
isto
f re
fm
pa
of c
of s
t of
ide
dem
p
um
no
der
por
ins
ion
on
on
lic p
o
n
ylin
i
i
ratio
rat
rat
ear
rati
rat
ion
rau
mc
ope
ope
ope
or w
ope
uct
ope
hyd
boo
ds
tive
tive
tive
tive
ge
tive
ive
age
gge
aka
fec
fec
fec
ect
fec
fec
Dam
Clo
Bre
Def
De
De
De
De
De
Tank - Steering PPC Main control Cut-off

pump valve valve valve Cylinder
valve
a b c d e f g h i
Remedy C A
No. Problems
Bucket tilting power and speed are abnormal and boom lifting
1
speed is slow
Bucket tilting power and speed are normal but boom lifting speed
2
is slow
As in Item 1, but lifting speed is particularly slow when oil

3
temperature rises

5
light and fast

6
and slow
7 Excessive hydraulic drift of cylinder
8 Relief pressure or relief valve in main control valve is low
9 Relief pressure or relief valve in main control valve is too high
20-566
TROUBLESHOOTING T-16, T-17, T-18, T-19
T-16 When boom is raised, it moves slowly at a certain height

Can any deformation be seen in the boom cylinder?
Cause
Swelling or internal damage to boom cylinder tube
« For other abnormalities when the boom is raised, go to "T-15 Boom movement is slow or boom
lacks lifting power."
T-17 Bucket cannot be pushed with boom cylinder (bucket floats)

See "T-15 Boom movement is slow or boom lacks lifting power."

Is the stroke of the boom spool in the main control valve properly adjusted?
Cause
Defective seating of suction valve at boom cylinder rod end of main control valve
Oil leakage from boom cylinder piston seal
T-18 Excessive hydraulic drift of boom

Yes = Dirt caught in valve, broken part
Yes = Worn parts
Is the boom spool at the neutral position?
Yes = Seized link bushing, defect in spool detent
Troubleshooting and Cause
When measuring the hydraulic drift, is there any sound of oil leakage from inside the boom cylinder?
Yes = Defective cylinder packing
T-19 Boom shakes during operation

When digging or leveling operations are carried out with the boom control lever at HOLD, the bucket and
boom move up and down to follow the shape of the ground.
Troubleshooting and Cause
Measure the hydraulic drift of the boom and check if it is possible to lift the chassis with the boom cylinder.
1. If the hydraulic drift of the boom cylinder is outside the standard value, go to "T-18 Excessive hydraulic
drift of boom."
2. If the chassis cannot be raised with the boom cylinder, go to "T-17 Bucket cannot be pushed with
boom cylinder."
3. If the hydraulic drift of the boom is normal, operate the boom several times, and operate the boom
cylinder to the end of its stroke. Is it now possible to raise the chassis with the boom cylinder?
Yes = Vacuum had formed inside cylinder
« However, if this problem appears frequently, the suction valve at the boom cylinder rod end is
defective.
20-567
T-20 Boom drops momentarily when control lever is operated from

HOLD to RAISE
Checking problem
When the engine is run at low idling and the boom control lever is operated slowly from HOLD to
RAISE, the boom goes down under its own weight. When the lever is operated fully to the RAISE
position, the condition returns to normal.
Cause
Defective seating of check valve for boom spool in main control valve
20-568
T-21 Bucket does not tilt back

Yes = Equipment seized, damaged
Was there any abnormal noise
when this happened? (from
where?)
as the speed becoming slow?
Yes = Wear of internal parts, deterio-
ration in spring
il
in o
air
Is the travel of the bucket control lever and
ve
ssi
spool properly adjusted?
e
p
ool)
alv
pum
xce
ses
ef v
t sp
ol
re
ch
spo
Cau
reli
po
cke
swit
l
sea
nd
pum
(bu
ain
and
ton
ma
of m
ody
r pis
f de
t of
p
um
eb
mp
alv
por
nde
no
ion
lic p
alv
r pu
ef v
ratio
cyli
rat
pum
ion
ev
rau
l
poo
e fo
ope
reli
uct
ket
ope
sid
hyd
PC
driv
buc
ds
e in
tive
eP
tive
tive
tive
ive
PTO
gge
ectiv
akg
ge
fec
ect
fec
fec
fec
Dam
Clo
Bre
Def
De
Def
De
De
De
No
Steering Main control

Tank - pump valve
PPC valve valve Cylinder
a b c d e f g h i j
Remedy C
No. Problems
1 Boom cannot be operated and bucket cannot be tilted back
Chassis can be raised with bucket but bucket cannot be tilted
2
back, or boom can be operated but bucket cannot be tilted back
Bucket can be tilted back when there is no load but cannot be

3
tilted back during digging or scooping operations
5 Excessive hydraulic drift of bucket cylinder

6
light and fast
When engine is running at full throttle, steering operation is

7
heavy and slow
20-569
T-22 Bucket movement is slow or tilt-back lacks power

Is the travel of the bucket control lever and
main control valve spool properly adjusted?
nd
Is there any seizure of the work equipment
me
linkage? (Is there any abnormal noise?)
otto
er b
lind
ent
t cy
Check if there is lack of tilt-back power dur-
stm
cke
nt
ing actual operations.
me
dju
t bu
Measure the operating speed of the bucket
ust
ea
e) a
adj
and use the Standard Value Table to check
il
ctiv
in o
valv
ive
if there is any abnormality
efe
air
ect
tion
rd
ve
def
suc
eo
ssi
ol)
p
alv
or
spo
xce
um
h
es
(wit
ve
ef v
ve
ool
hp
re
l
cke
sea
s
val
lve
val
p
c
Cau
reli
po
swit
ds
(bu
a
off
ton
lief
ty v
pum
ain
l
poo
nd
ma
ut-
r pis
ody
f re
afe
of m
pa
of c
f de
of s
t of
eb
of s
no
nde
um
no
por
valv
ion
ion
on
atio
lic p
cyli
n
ratio
ratio
rat
rati
rat
tion
ide
rau
per
ket
ope
ope
ope
ope
ope
uc
ins
hyd
buc
o
ds
tive
tive
tive
tive
ge
tive
tive
ive
ge
gge
aka
fec
fec
fec
ect
fec
ma
fec
fec
Clo
Bre
Def
De
De
De
De
De
De
Da
Tank - Steering Main control Cut-off
PPC valve Cylinder
pump valve valve valve
a b c d e f g h i j
Remedy C A
No. Problems
Boom lifting power and speed are abnormal and bucket tilt-back
1
power or speed are abnormal
Boom lifting power and speed are abnormal but bucket tilt-back
2
power or speed are abnormal
3 As in Item 1, but problem is particularly bad when oil temperature
rises

5
light and fast
6
and slow
7 Excessive hydraulic drift of bucket cylinder
8 Relief pressure or relief valve in main control valve is low
9 Relief pressure or relief valve in main control valve is too high
20-570
TROUBLESHOOTING T-23, T-24, T-25
T-23 Bucket movement becomes slow during tilt-back operation

Can any deformation be seen in the bucket cylinder?
Cause
Swelling or internal damage to bucket cylinder tube
For other abnormalities when the bucket is operated, go to "T- 22 Bucket movement is slow or tilt back
lacks power."
T-24 Bucket cannot be pushed with bucket cylinder

See "T-22 Bucket movement is slow or tilt back lacks power."

Is the stroke of the bucket spool in the main control valve properly adjusted?
Cause
Defective seating of safety valve (with suction valve) at bucket cylinder rod end of main control valve
Oil leakage from bucket cylinder piston seal
T-25 Excessive hydraulic drift of bucket

Yes = Dirt caught in valve, broken part
Yes = Worn parts

Is the bucket spool at the neutral position?
Yes = Seized link bushing, defect in spool detent

Use the Standard Value Table to check if the hydraulic drift of the bucket is actually excessive.
Cause
Oil leakage inside bucket cylinder
Defective seating of safety valve (with suction valve) at bottom end
Defective oil tightness of bucket spool
20-571
TROUBLESHOOTING T-26, T-27
T-26 Bucket shakes during loading operation

(Main control valve at HOLD)
Is there play in the work equipment linkage pin, bushing? (Is there any abnormal noise?)
Cause
Defective bucket cylinder piston seal
Defective operation of safety valve (with suction valve) at bucket cylinder rod end. If any other
problem occurs at the same time, carry out troubleshooting according to the nature of the problem.
T-27 Bucket dumps momentarily when control lever is operated from

HOLD to TILT
Checking problem
When the engine is run at low idling and the bucket control lever is operated slowly from HOLD to
TILT, the bucket dumps momentarily under its own weight. When the lever is operated fully to the
TILT position, the condition returns to normal.
Cause
Defective seating of check valve for bucket spool in main control valve
20-572
T-28 Boom, bucket control levers

are heavy or do not move
smoothly
s
bolt
ing
ol
unt
spo
Check the values in the Standard Value Table
mo
, lin
to check if the operating force of the lever is
and
lve
ver
ol
actually excessive.
f va
ody
s po
ol
l le
l
poo
spo
go
eb
tro
nd
s
lve
in
alv
ya
nd
con
ol
ten
a
a
spo
ol v
bod
ol v
dy
tigh
of
r
o
and
ol
ont
r
lve
eb
ion
ont
ven
spo
ses
in c
valv
c
or t
ody
v
une
ain
C
ve
a
gp
Cau
PP
eb
fm
PC
fm
val
ol
e
atin
l
P
spo
valv
o
f
poo
o
so
yd
rol
en
ss
ess
rot
es
ont
bod
e
dne
lve
trol
dne
etw
ndn
alv
of
in c
con
n
l
Cv
lve
oun
b
poo
rou
rou
v
ss
ce
ma
f va
trol
PP
ain
r
es
fne
-of-
ran
-of-
-of-
con
no
t in
of m
alv
t in
clea
stif
cut
cut
cut
Cv
atio
ugh
ugh
ain
tive
tive
re,
tive
ing
ive
t PP
form
nt m
t ca
t ca
izu
ect
fec
tch
fec
fec
Ben
Def
Se
Dir
Dir
Ca
De
De
De
De
Be
Lever PPC valve Main control valve
a b c d e f g h i j k
Remedy C
No. Problems
1 Lever are heavy when there is a load and oil pressure is high
2 Levers become heavy as oil temperature changes
Levers become heavy at places during operation regardless of oil

3
pressure or temperature
Levers are always heavy during operation regardless of oil

4
pressure or temperature
Levers are still heavy after control lever link is disconnect at
5
valve connection
20-573
20-574
TROUBLESHOOTING OF ECSS (ELECTRONICALLY
CONTROLLED SUSPENSION SYSTEM)
(D MODE)
Judgement Table for controller electrical system .................................................................................... 20-602
D- 1 ECSS does not work .................................................................................................................. 20-603

(a) Error code [d0] is displayed ................................................................................................ 20-604
(b) Error code [d1] is displayed ................................................................................................ 20-604
(c) Error code [d2] is displayed ................................................................................................ 20-605
(d) Error code [d3] is displayed ................................................................................................ 20-605
(e) Error code [d4] is displayed ................................................................................................ 20-606
(f) No abnormality display is given ........................................................................................... 20-606
D- 2 ECSS cannot be canceled ......................................................................................................... 20-610
D- 3 Output is turned ON
(travel speed does not become 5 km/h) (deviates around 5 km/h) ........................................... 20-611
D- 4 Output is turned ON when transmission is in 1st ...................................................................... 20-611
D- 5 Output is turned ON when transmission is in 4th ...................................................................... 20-612
D- 6 Controller LED code is not displayed ........................................................................................ 20-613
D- 7 ECSS is abnormal but main monitor does not give abnormality display ................................... 20-613
20-601
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

Error code Self-diagnosis table (abnormality display)
Solenoid Solenoid Solenoid Travel speed Model Troubleshooting

(relief) (high pressure) (low pressure) sensor selection code when no
abnormality
system system system system abnormality display is given
Failure mode d0 d1 d2 d3 d4
ECSS does not
work or does not D-1 (a) D-1 (b) D-1 (c) D-1 (d) D-1 (e) D-1 (f)
work properly
ECSS cannot be
canceled D-2
Output is turned
ON but travel
speed does not D-3
become 5 km/h
(deviates)
Output is turned
ON when
transmission is in D-4
1st
Output is turned
ON when
transmission is in D-5
4th
LED code display
is not given D-6
ECSS is abnromal
but main monitor
does not give D-7
abnormality
display
20-602
TROUBLESHOOTING D-1
D-1 ECSS does not work

« Carry out troubleshooting with the starting switch ON.
« Check that the ECSS switch on the main monitor is ON.
Cause Remedy
Displaying [d0]. Go to Item (a) -
Displaying [d1]. Go to Item (b) -
2 5
YES Wich code is

monitor Displaying [d2]. Go to Item (c) -
displaying?
1
Displaying [d3]. Go to Item (d) -
Is there an
abnormality
display
7
Displaying [d4]. Got to Item (e) -
Go to Item (f) -
NO
20-603
TROUBLESHOOTING D-1
(a) Error code [d0] is displayed

Cause Remedy
YES Replace
Defective controller
1
CNAL1 (female) (21) YES
and chassis ground Defective solenoid Replace
normal? 2
Is there continuity
1) Disconnect Disconnection in wiring
between CNAL1
CNAL 1. YES harness between CNAL1 After inspection,
NO (female) (21) and 3
chassis ground? (female) (21) - CNSAS (4) repair or replace
2) DC resistance: Is there continuity - CNAF4 (female) (1)
20 - 40 Ω 1) Disconnect between CNAF4
CNAL1. NO (female (2) and
chassis ground Disconnection is wiring
2) Disconnect harness between CNAF4 After inspection,
CNAF4. 1) Disconnect NO (female) (2) - CNTL1 (8) - repair or replace
CNAF4. CNCL1 (12) - chassis
3) Connect short ground
connector to
CNAF4 (female).
(b) Error code [d1] is displayed
YES
Defective speed sensor Replace
1
and chassis ground Defective controller Replace
normal? 2
Is there continuity
1) Disconnect between CNAL1
CNAL 1. (female) (20) and Disconnection in wiring
NO YES harness between CNAL1 After inspection,
chassis ground? 3
2) DC resistance: Is there continuity (female (20) - CNSAS (5) repair or replace
20 - 40 Ω 1) Disconnect between CNAF4 - CNAF5 (female) (1)
connector to
CNAF5 (female).
20-604
TROUBLESHOOTING D-1
(c) Error code [d2] is displayed

Cause Remedy
YES Replace
Defective controller
1
and chassis ground Defective solenoid Replace
normal? 2
Is there continuity
1) Disconnect Disconnection in wiring
between CNAL1
CNAL 1. YES harness between CNAL1 After inspection,
NO (female) (11) and 3
chassis ground? (female) (11) - CNSAS (6) repair or replace
2) DC resistance: Is there continuity - CNAF6 (female) (1)
20 - 40 Ω 1) Disconnect between CNAF6
connector to
CNAF6 (female).
(d) Error code [d3] is displayed

YES
Defective speed sensor Replace
1
Does error
display go off?
YES
2
Is there continuity
1) Connect short between CNAL3
connector to NO (female) (4) and
CNT06 (female). (12)?
Disconnection in wiring After inspection,
2) Turn starting 1) Disconnect harness between CNAL3 repair or replace
switch OFF CNAL3. NO (4) - CNSAS (9) or CNAL3 (if any other
ON. (12) - CNSAS (10) controller is
3) Connect short abnormal, check
connector to all wiring
CNT06 (female). harness for the
speed sensor
system)
20-605
TROUBLESHOOTING D-1
(e) Error code [d4] is displayed

Cause Remedy
2 YES
Is continuity of
YES wiring harness
Disconnection in wiring
normal? harness between CNAL2
1 After inspection,
(female) and CNAL4
1) Disconnect (male), or contact with
Is connection of
CNAL2. chassis ground
wiring harness
normal ? 2) Is continuity between CNAL2
(female) (1) - (4) and chassis Defective contact, or
1) Disconnect ground as shown in the table? disconnection in wiring
CNAL4. harness between CNAL4 After inspection,
2) Is continuity NO (female) and chassis repair or replace
between CNAL4 (female) ground, or contact with
(1), (2), (3), (5) - chassis ground as chassis ground
shown in the table?
Table
Connector CNAL4(female) CNAL2(female)
Model (5) (2) (3) (1) (1) (2) (3) (4)
WA320-3H No No No Yes No No No Yes
WA380-3H No No Yes No No No Yes No
WA420-3H No Yes No No No Yes No No
WA470-3H No Yes Yes Yes No Yes Yes Yes
(f) No abnormality display is given

(1) Does not work at all
YES Defective controller Replace
1
Is voltage
between CNAL2
(15) and chassis 2 YES Go to
ground normal? Defective main monitor troubleshooting
Is voltage between of main monitor
CNL06 (female) (7)
1) 0 - 3 V
2) Turn starting NO and chassis Disconnection in wiring
ground normal?
switch ON. harness between CNAL2 After inspection,
3) Turn main NO (female) (15) - CNDP2 (1) - repair or replace
1) 20 - 30 V CNL06 (female) (7)
monitor ECSS
switch ON.
2) Disconnect
CNL06.
20-606
TROUBLESHOOTING D-1
(2) Works when bucket is loaded but not when empty

Cause Remedy
Defective pressure switch

YES or defective chassis Replace
2 hydraulic system
Is there continuity
YES between CNAF7 Contact of chassis ground After inspection,
(male) (1) and 3 YES with wiring harness repair or replace
(2)? between CNAL2 (female)
1 I)s there continuity
between CNAL2 (8) - CNSAS (7) - CNAF7
1) Turn starting (female) (1)
NO (female) (8) and
Zeigt
Doesdie Kontroller-
controller switch ON.
chassis ground?
LED
LED55 an ? 55?
display 2) Disconnect Defective controller Replace
CNAF7. 1) Turn starting NO
3) Empty bucket. switch ON.
1) Turn starting
switch ON. Defective chassis –
2) Empty bucket. NO hydraulic system
(3) Works when bucket is empty but not when loaded
YES Defective chassis –

hydraulic system
1
3 YES Defective controller Replace
Does controller Is voltage
LED display 55? YES between CNAL 2 Defective contact, or
ground normal? harness between CNAL2
2 After inspection,
1) Turn starting (female) (8) - CNSAS (7) -
switch ON. Is there continuity 1) 0 - 3 V NO CNAF 7 (female) (1), or repair or replace
2) Load bucket. between CNAF7 2) Turn starting between CNAF7 (female)
NO (male) (1) and switch ON. (2) - CNSAS (8) - CNAL4
(2)? 3) Load bucket. (4) - chassis ground
1) Turn starting Defective pressure switch

switch ON. or defective chassis Replace
2) Disconnect NO hydraulic system
CNAF7.
3) Load bucket.
20-607
TROUBLESHOOTING D-1
D-1 (a), (b), (c) Related electric circuit diagram

Solenoid system
CNAL1 CNSAS
11 5 1
20 6 1 2
21 4 1 2
CNAF6
2
CNAF5
CNAF4
Solenoid 1 Solenoid 2 Solenoid 3

(relief) (high (low
pressure) pressure)
8 12
CNTL1 CNCL1
D-1 (d) Related electric circuit diagram

Speed sensor system
CNAL3 CNSAS CNTL2 CNT06 Speed sensor

Speed (+)
4 9 1 1
12 10 2 2
Speed (-)
D-1 (e) Related electric circuit diagram

Model selection system
CNAL2 CNAL4 WA320 WA380 WA420 WA470

a a a a a
1 5
For connections, see
diagrams on right
b b b b b
2 2
c c c c c
3 3
d d d d d
4 1
20-608
TROUBLESHOOTING D-1
D-1 (f-(1)) Related electric circuit diagram

ECSS operation switch and network
CNAL1 CNDP2 CNL08

Netzwork (+)
1 2 1
12 3
3 2
CNAL2 4
Netzwork (-)
9 1
CNL06
15
ECSS operation switch 7
D-1 (f-(2)), (f-(3)) Related electric circuit diagram

Pressure switch system
CNAL2 CNSAS CNAF7

Pressure switch
8 7 1
8 2
CNAL4
20-609
TROUBLESHOOTING D-2
D-2 ECSS cannot be canceled

« Check that the ECSS switch on the main monitor is OFF.
Cause Remedy
YES
1
Is voltage
between CNAL2 Contact chassis ground
(15) and chassis with wiring harness
ground normal? between CNAL2 (female)
Is there continuity (15) - CNDP2 (1) - CNL06 repair or replace
1) 20 - 30 V between CNAL2 (female) (7)
2) Turn starting NO (female) (15) and
switch ON. chassis ground?
Defective main monitor Go to
3) Turn main NO troubleshooting
1) Diconnect
monitor ECSS of main monitor
CNAL2.
switch OFF.
2) Disconnect
CNL06.
CNAL1 CNDP2 CNL08

Network (+)
1 2 1
12 3
3 2
CNAL2 4
Network (-)
9 1
CNL06
15
ECSS operation switch 7
20-610
TROUBLESHOOTING D-3, D-4
D-3 Output is turned ON (travel speed does not become 5 km/h)

(deviates around 5 km/h)
Cause Remedy
Defective speed sensor, Replace or

2 YES
or defective mount of adjust
speed sensor
YES Is monitor speed
1 display incorrect?
Is machine model Defective controller Replace

1) Start engine. NO
code normal?
Go to Troubleshooting –
1) Check LED NO D-1 (e)
display code.
2) See
STRUCTURE
AND FUNCTION
for details of the
codes.
D-4 Output is turned ON when transmission

is in 1st Cause Remedy
1 YES
CNAL2 (female) (14)
harness between CNAL2 repair or replace
1) Disconnect NO
(female) (14) - CNSAS (3)
CNAL2. - speed solenoid
2) 50 - 70 Ω

CNAL2 CNSAS CNTL1 CNL04
Hi/Lo
Standard 13 2 5 7
specification Directional,
machine speed switch
14 3 6 5
Speed
To solenoid
Hi/Lo
HYPER 13 2 5 10
specification Transmission
machine controller
14 3 6 11
Speed
To solenoid
20-611
TROUBLESHOOTING D-5
D-5 Output is turned ON when transmission is in 4th

Cause Remedy
1 YES
CNAL2 (female) (13)
harness between CNAL2 repair or replace
1) Disconnect NO
(female) (13) - CNSAS (3)
CNAL2. - Hi/Lo solenoid
2) 50 - 70 Ω

13 2 5 7
14 3 6 5

13 2 5 10
14 3 6 11
20-612
TROUBLESHOOTING D-6, D-7
D-6 Controller LED code is not displayed

Cause Remedy
YES
1 Defective contact, or
Ist die Spannungs- harness between CNAL1
versorgung normal ? (female) (8), (18) - CNDP1
YES CNDP1 (male) (1)
(female) (1)
2 and chassis
1) 20 - 30 V ground normal?
Is there coninuity Anormality in fuse box Repair
2) Measure voltage between CNAL1 NO
1) 20 - 30 V
between CNAL1
NO (female) (9), (19) - 1) Disconnect Defective contact, or
(8), (18) - (9), (19). chassis ground? disconnection in wiring
CNDP1.
harness between CNAL1 After inspection,
1) Disconnect (female) (9), (19) - CNSAS repair or replace
CNAL1.
NO
(1) - CNTL1 (8) - CNCL1
(12) - chassis ground
CNAL1 CNDP1
+ 24V
8 1 Fuse box
17
18
9 CNSAS CNTL1 CNCL1

19 1 8 12
GND
D-7 ECSS is abnormal but main monitor does not give abnormality
display
Cause Remedy
Check that the ECSS controller is displaying an error code.
Go to troubleshooting of –
main monitor
20-613
20-614
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ...................... 30- 3 TRANSMISSION CONTROL VALVE

PRECAUTIONS WHEN CARRYING OUT Removal ................................................... 30- 94
OPERATION ............................................. 30- 4 Installation ............................................... 30- 96
SPECIAL TOOL LIST ...................................... 30- 6 Disassembly ............................................ 30- 97
STARTING MOTOR Assembly ............................................... 30-104
Removal and Installation ........................... 30- 9 TRANSMISSION ACCUMULATOR VALVE
ALTERNATOR Disassembly ........................................... 30-112
Removal and Installation ........................... 30-10 Assembly ............................................... 30-113
OIL COOLER DRIVE SHAFT
Removal and Installation ........................... 30-11 Disassembly ........................................... 30-115
FUEL INJECTION PUMP Assembly ............................................... 30-117
Removal and Installation ........................... 30-12 FRONT AXLE
042103
WATER PUMP Removal .................................................. 30-119

Removal and Installation ........................... 30-16 Installation .............................................. 30-121
TURBOCHARGER REAR AXLE
Removal and Installation ........................... 30-17 Removal .................................................. 30-122
NOZZLE HOLDER Installation .............................................. 30-125
Removal and Installation ........................... 30-18 FRONT DIFFERENTIAL
THERMOSTAT Removal .................................................. 30-127
Removal and Installation ........................... 30-19 Installation .............................................. 30-130
CYLINDER HEAD REAR DIFFERENTIAL
Removal and Installation ........................... 30-20 Removal .................................................. 30-132
RADIATOR Installation .............................................. 30-135
Removal and Installation ........................... 30-26 DIFFERENTIAL
ENGINE Disassembly ........................................... 30-137
Removal and Installation ........................... 30-29 Assembly ............................................... 30-140
TORQUE CONVERTER CHARGING PUMP FINAL DRIVE
Removal and Installation ........................... 30-42 Disassembly ........................................... 30-148
TORQUE CONVERTER, TRANSMISSION Assembly ............................................... 30-151
Removal .................................................... 30-43 CENTER HINGE PIN
Installation ................................................ 30-50 Removal .................................................. 30-155
TORQUE CONVERTER Installation .............................................. 30-163
Disassembly ............................................. 30-52 STEERING, ORBIT ROLL
Assembly ................................................. 30-54 Removal and Installation ...................... 30-168/1
TRANSMISSION Disassembly ........................................... 30-169
Disassembly ............................................. 30-57 Assembly ............................................... 30-172
Assembly ................................................. 30-62 STEERING VALVE
TRANSMISSION CLUTCH PACK Removal .................................................. 30-177
Disassembly ............................................. 30-68 Installation .............................................. 30-179
Assembly ................................................. 30-77 Disassembly ........................................... 30-180
PARKING BRAKE Assembly ............................................... 30-182
Disassembly ............................................. 30-89
Assembly ................................................. 30-91
30-1
STEERING, SWITCH PUMP COUNTERWEIGHT
Removal .................................................. 30-184 Installation .......................................... 30-256
Installation .............................................. 30-187 FUEL TANK
STEERING CYLINDER Removal .............................................. 30-253
Installation .............................................. 30-189 CAB
BRAKE VALVE Removal .............................................. 30-255
Installation .............................................. 30-191 MAIN MONITOR
RIGHT BRAKE VALVE (TANDEM) Removal .............................................. 30-257
Disassembly ........................................... 30-192 Installation .......................................... 30-258
Assembly ............................................... 30-193 MAINTENANCE MONITOR
LEFT BRAKE VALVE (SINGLE) Removal and Installation ..................... 30-259
Disassembly ........................................... 30-194 AIR CONDITIONER UNIT
Assembly ............................................... 30-195 Removal .............................................. 30-260
SLACK ADJUSTER Installation .......................................... 30-265
Removal .................................................. 30-196 AIR CONDITIONER CONDENSER
Installation .............................................. 30-197 Removal .............................................. 30-266
Disassembly ........................................... 30-198 Installation .......................................... 30-267
Assembly ............................................... 30-199 DRY RECEIVER
BRAKE Removal and Installation ..................... 30-268
Disassembly ........................................... 30-200 AIR CONDITIONER COMPRESSOR
Assembly ............................................... 30-206 Removal .............................................. 30-269
PARKING BRAKE DISC Installation .......................................... 30-270
042103
Removal .................................................. 30-214 TIRES
Installation .............................................. 30-216 Procedure for changing tires ............... 30-271
HYDRAULIC TANK
Removal .................................................. 30-217
Installation .............................................. 30-219
WORK EQUIPMENT, PPC PUMP
Removal .................................................. 30-220
Installation .............................................. 30-223
PPC VALVE
Removal .................................................. 30-224
Installation .............................................. 30-225
Disassembly ........................................... 30-227
Assembly ............................................... 30-228
MAIN CONTROL VALVE
Removal .................................................. 30-229
Installation .............................................. 30-231
Disassembly ........................................... 30-232
Assembly ............................................... 30-234
BUCKET CYLINDER
Removal .................................................. 30-237
Installation .............................................. 30-238
BOOM CYLINDER
Removal .................................................. 30-239
Installation .............................................. 30-240
HYDRAULIC CYLINDER
Disassembly ........................................... 30-241
Assembly ............................................... 30-244
WORK EQUIPMENT
Removal .................................................. 30-247
Installation .............................................. 30-250
30-2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
(1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked 1 ,and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVAL OF ¡¡¡ ASSEMBLY ................ Title of operation
................................................................. Precautions related to safety when carrying out the
operation
1. XXXX (1) ................................................. Step in operation
« .......................................................... Technique or important point to remember when remov-
ing XXXX (1).
2. ∆ ∆ ∆ (2): ............................................... 1 Indicates that a technique is listed for use during
installation
3. pppp assembly (3)
.................................................... See Lubricant and Coolant Table
INSTALLATION OF ¡¡¡ ASSEMBLY .......... Title of operation
l Carry out installation in the reverse
order to removal.
1 ................................................ Technique used during installation
042103
« ................................................ Technique or important point to remember when install-

ing ∆ ∆ ∆ (2).
l Adding water, oil ................................ Step in operation
« ................................................ Point to remember when adding water or oil
................................................ Quantity of filling oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools
(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
l If the coolant contains antifreeze, dispose of it correctly.

l After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
l When draining oil, prepare a container of adequate size to catch the oil.
l Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
l To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors.
l Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
l Check the number and thickness of the shims, and keep in a safe place.
l When raising components, be sure to use lifting equipment of ample strength.
l When using forcing screws to remove any components, tighten the forcing screws alternately.
l Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
« Precautions when handling piping during disassembling

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
042103
Nominal Plug (nut end) Sleeve nut (elbow end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head Split flange
number (tube end)
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15 Taper 1/8
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
L
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
DEW00401
27 07049-02734 27 22.5 34
30-4
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions for installation operations
l Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
l Install the hoses without twisting or interference.
l Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
l Bend the cotter pin or lock plate securely.
l When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
l 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.
l Clean all parts, and correct any damage, dents, burrs, or rust.
l Coat rotating parts and sliding parts with engine oil.
l When press fitting parts, coat the surface with antifriction compound (LM-P).
l After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
l When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
l When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
l When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
« When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping 100
mm from the end of its stroke.
042103
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
« When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operations
l If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
l If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
l If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for
repair, always bleed the air from the system after reassembling the parts.
« For details, see TESTING AND ADJUSTING, Bleeding air.
l Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Nature of work Symbol Part No. Part Name Q’ty Remarks
For
1 793-615-1310 Lifting tool (A) 1 FORWARD/
1st clutch
Installation,
For removal of
REVERSE/ clutch pack
2 793-615-1320 Lifting tool (B) 2 2nd, 3rd/
Disassembly, assembly of 4th clutch
transmission assembly,
transmission clutch pack A 3 793-615-1330 Pin 3
assembly For
FORWARD, Jig for
4 793-615-1220 Holder 1 REVERSE settling
piston piston seal
For 1st – ring
5 793-615-1210 Holder 1 4th piston
Removal of front B 793-520-2410 Bracket 1

differential assembly C 793-520-2510 Bracket 1
Disassembly, assembly of
differential assembly D 790-520-2620 Plate 1
E 790-425-1620 Fixture 3
Disassembly, assembly of F 790-425-1630 Fixture 3
final drive assembly
G 793-520-2320 Fixture 2
042103
H 790-101-1002 Pump 1
I 790-101-2102 Puller 1
J 790-101-2300 Push-puller 1
Installation of center
hinge pin 1 793-520-2370 Push tool 1
2 793-520-2350 Push tool 1
K
3 793-520-2540 Guide 1
4 793-520-2360 Bar 2
793-463-1110 Stopper 2
Removal of 01011-51845 Bolt 4

slack adjuster assembly L
01643-31845 Washer 8
01580-11815 Nut 4
1 793-415-1150 Plate 1
Removal of M 2 01010-51085 Bolt 4
parking brake disc
3 01580-11008 Nut 4
30-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nature of work Symbol Part No. Part Name Q’ty Remarks
790-502-1003
or Cylinder repair stand 1
N 790-502-2000
790-101-1102 Pump 1
Removal,
Steering installation
O 790-330-1100 Wrench ass’y 1 cylinder of round
head
Removal,
Socket Steering installation
P 799-302-1270 (width across flats: 50) 1 cylinder of nylon
nut
Press fitting of
790-101-5021 Grip 1 coil bushing
Kit Part No.:
01010-50816 Bolt 1 790-201-1702
Boom
Q 790-201-1841 Push tool 1 cylinder
Bucket
790-201-1851 Push tool 1 cylinder
hydraulic cylinder Steering
790-201-1751 Push tool 1 cylinder
Installation of
042103
1 790-720-1000 Expander 1 piston ring

796-720-1680 Ring 1 Boom
07281-01589 Clamp 1 cylinder
R 796-720-1690 Ring 1
2 Bucket
796-720-1650 Ring 1 Steering

Insertion of
790-101-5021 Grip 1 dust seal
Kit Part No.:
01010-50816 Bolt 1 790-201-1500
Bucket
S 790-201-1660 Plate 1 cylinder
Steering
790-201-1560 Plate 1 cylinder
Boom
790-201-1650 Plate 1 cylinder
1 793-520-2680 Installer 1
2 790-425-1640 Eye bolt 2
T 3 793-570-1010 Push plate 1
brake assembly
4 790-425-1620 Fixture 3
5 790-425-1630 Fixture 3
30-7
30-8
042103
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
Disconnect the cable from the negative (-) terminal of
the battery.
1. Open engine hood left side cover.
2. Disconnect starting motor wiring connector (1).
3. Disconnect wiring (2).
4. Remove starting motor assembly (3).
INSTALLATION OF STARTING
MOTOR ASSEMBLY
• Carry out installation in the reverse order to removal.
1
« When installing the starting motor assembly, install
ground connection (4) securely.
042103
30-9
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
the battery.
1. Open engine hood left side cover and lock in posi-

tion.
2. Disconnect 3 set of wiring (1).

« Mark the wiring with tags to prevent mistakes
when assembling.
3. Loosen mounting bolt and nut (2), and adjustment

plate mounting bolt (3).
4. Loosen locknut (4) and-adjustment nut (5), and move

alternator assembly (6) towards engine, then remove
fan belt (7) from alternator assembly (6). 1
5. Remove mount bolt and nut (2), and adjustment plate

mounting bolt (3), then remove alternator assembly
(5).
042103
INSTALLATION OF
ALTERNATOR ASSEMBLY
1
« Adjust the belt tension. For details, see TESTING
AND ADJUSTING, Testing and adjusting fan belt ten-
sion.
30-10
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1. Lift off engine hood assembly.
2. Drain engine coolant.
3. Remove turbocharger lubrication return tube (1).
4. Disconnect wiring harness clamp (2).
5. Remove oil cooler assembly (3).
6. Remove nut (4), then remove core (6) from

cover (5).
1
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
1
Core mounting nut:
042103
43.2 ± 15.7 Nm (4.4 ± 1.6 kgm)
• Refilling with water

Add water through the water filler to the specified
level. Run the engine to circulate the water through
the system. Then check the water level again.
30-11
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
1. Remove coupling cover (1) of fuel injection pump.
2. Disconnect accelerator cable (2) and stop motor ca-

ble (3).
3. Disconnect fuel hoses (4), (5), (6), and (7).

« After disconnecting fuel supply hose (4), bend it
and tie it with wire to prevent the fuel from
leaking.
4. Disconnect fuel injection pipes (8) and (9). 1
5. Remove lubrication tubes (10) and (11).
042103
6. Remove 2 lock bolts (12) of cross coupling and lami-
nate coupling. 2
« Before removing the bolts, mark the mounting
position of the laminate coupling and cross
coupling.
7. Remove fuel injection pump assembly (13).

3
30-12
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
1
Injection tube sleeve nut:
23.5 ± 1 Nm (2.4 ± 0.1 kgm)
2
Laminate coupling mounting bolt:
61.8 ± 3 Nm (6.3 ± 0.3 kgm)
3
« Install the injection pump. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting fuel
injection timing.
Injection pump mounting bolt:

29.4± 5 Nm (3.0 ± 0.5 kgm)
042103
30-13
30-14
042103
042103
30-15
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
the battery.
1. Lift off engine hood.
3. Disconnect alternator wiring (1) and water temperature

sensor wiring harness (2), loosen mounting bolt and
adjustment bolt of alternator assembly, then remove
fan belt. 1
4. Remove water pump tubes (3), (4), and (5).
5. Remove mounting bolts (6), then remove water pump

assembly (7). 2
042103
INSTALLATION OF WATER
PUMP ASSEMBLY
« Adjustthebeittension.Fordetails,seeTESTING
AND ADJUSTING, Testing and adjusting fan belt
tension.
Mounting bolt:
66.7 ± 7.9 Nm (6.8 ± 0.8 kgm)

30-16
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Lift off engine hood.
2. Remove intake connector (1), and loosen belt clamp

(2) of intake connector joint hose.
3. Remove 4 mounting bolts of flange (3) between muf-

fler assembly and turbocharger.
4. Remove turbocharger lubrication inlet tube (4) and

return tube (5).
5. Remove mounting bolts of turbocharger assembly

(6), then pull out turbocharger assembly from air
intake connector, and remove.
INSTALLATION OF
TURBOCHARGER ASSEMBLY
• Carry out installation in the reverse order to
removal.
042103
30-17
DISASSEMBLY AND ASSEMBLY NOZZELE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1. Disconnect fuel injection pipe (1) and spill
tube (2). 1
2. Remove 2 mounting bolts (3) of nozzle holder.

2
3. Screw bolt (1) (010 mm) in to mount of spill tube,

then lever with bar (12) and remove nozzle holder
assembly (4).
« Be careful not to let dirt or dust get inside.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
1
Spill pipe mounting joint bolt:
042103
24.5 ± 5 Nm (2.5 ± 0.5 kgm)
Injection pipe mounting sleeve nut:

23.5 ± 1 Nm (2.4 ± 0.1 kgm)
2
« Tighten the nozzle holder mounting bolts in turn
uniformly.
Nozzle holder assembly mounting bolt.
21.6 ± 3 Nm (2.2 ± 0.3 kgm)
30-18
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Open engine hood left side cover and lock in posi-
tion.
3. Disconnect block (1).

« Do not disconnect the hose.
4. Remove thermostat (2).
INSTALLATION OF
THERMOSTAT ASSEMBLY

042103
30-19
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
the battery.
• Drain engine coolant.
1. Remove engine hood assembly.
2. Remove exhaust muffler assembly (1) and oil filter

assembly (2).
« Remove oil filter assembly (2) together with
the filter head and 2 tubes.
« When removing the muffler assembly, be
careful not to bend the drain tube.
3. Disconnect radiator upper hose (3) and aeration tube

(4).
042103
4. Disconnect dust indicator wiring (5) and heater relay
wiring (6).
« Disconnect wiring clamps (6-1) and (6-2).
5. Remove intake connector (7), then remove air cleaner

assembly (8). 1
6. Disconnect heater relay wiring (9), remove intake

connector (10), then remove turbocharger lubrication
inlet tube (11). 2
7. Remove 6 fuel injection pipes (12), 5 fuel spill pipes

(13), and return hose (14).
30-20
8. Remove water temperature sensor connector

(15) from holder, then disconnect.
9. Remove turbocharger lubrication return tube (16).
10. Lift off turbocharger and exhaust manifold assembly

(17). 3
« Remove together with the air cleaner assembly mount-
ing bracket.
042103
11. Disconnect fuel filter hoses (18) and (19).
12. Disconnect corrosion resistor hoses (20) and (21) at

filter end.
13. Lift off intake manifold assembly (22).

« Remove with the corrosion resistor and fuel filter
assembly still installed to the intake manifold.
30-21
14. Disconnect connector (23) from water manifold
15. Remove water manifolds (24).
042103
16. Remove head cover (25). 4
17. Remove nozzle holder assembly (26). 5
30-22
18. Remove rocker arm assembly (27). 6

« Loosen the locknut, then loosen the
adjustment screw 2 - 3 turns.
19. Remove bracket (28), rocker arm housing (29),

push rods (30), and crossheads (31). 7
« Remove bracket (28) from the No. 1 cylinder
only.
042103
20. Remove cylinder head assembly (32). 8
30-23
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
1
Air cleaner intake connector clamp:
8.3 ± 0.5 Nm (0.85 ± 0.05 kgm)
2
Fuel injection pipe sleeve nut:
29.4 ± 5 Nm (3.0 ± 0.5 kgm)
Spill pipe mounting bolt:
24.5 ± 5 Nm (2.5 ± 0.5 kgm)
3
« Screw in the exhaust manifold mounting bolts 2
- 3 threads by hand, tighten mounting bolts - ,
then tighten the other mounting bolts.
Exhaust manifold mounting bolt:
66.7 ± 7.9 Nm (6.8 ± 0.8 kgm)
4
Head cover mounting bolt:
9.8 ± 1 Nm (1.0 ± 0.1 kgm)
5
« Tighten the nozzle holder mounting bolts in turn uni-
formly.
042103
Nozzle holder mounting bolt:
21.6 ± 3 Nm (2.2 ± 0.3 kgm)
6
« Check that the ball of the adjustment screw is
fitted securely in the socket of the push rod.
« Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjusting valve
clearance.
Rocker arm assembly mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
Locknut:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
7
Rocker arm housing mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
« Adjust the crosshead as follows.
i) Loosen the locknut and turn the adjustment
screw back.
ii) Press the top of the crosshead lightly and screw
in the adjustment screw.
iii) When the adjustment screw contacts the valve
stem, screw it in a further 20°.
iv) Tighten the locknut to hold it in position.
Locknut:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
30-24
« If any rust of more than 5 mm square is found on the

shaft or the thread of the bolt, replace the head bolt
with a new bolt.
« Be careful to check that there is no dirt or dust on
the mounting surface of the cylinder head or inside
the cylinder.
« When installing the gasket, check that the grom-
mets have not come out.
« Coat the thread and seat of the bolt and the seat of
the cylinder head holes completely with molybde-
num disuiphide (LM-P).
« Tighten the cylinder head mounting bolts 2 - 3 turns
by hand, then tighten in the order given in the dia-
gram.
Mounting bolt:
Anti-friction compound (LM-P)
Cylinder head mounting bolt:
1st pass: Tighten to 68.6 ± 9.8 Nm

(7.0 ± 1.0 kgm)
2nd pass: Tighten to 107.9 ± 5 Nm

(11.0 ± 0.5 kgm)
042103
3rd pass: 1. When using tool A.

• Using an angle tightening wrench,
tighten bolt 90° +30° / -0°
2.When not using tool A.
1) Using the angle of the bolt head as the
base, make start marks on the cylinder
head and socket.
2) Make an end mark at a point 90°
+30° / -0° from the start mark.
3) Tighten so that the start mark on
the socket is aligned with the end
mark on the cylinder head at the
90° +30° / -0° position.
« After tightening, make one punch mark on the bolt

head to indicate the number of times it has been
tightened.
• If any bolt already has five punch marks, do not
reuse it. Replace it with a new bolt. Refilling with
water
• Add water through the water filler to the specified
30-25
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
Release the remaining pressure in the piping.
« When operating the levers, raise portion a of the

bucket 30 - 50 mm and lower portion b to the ground,
then stop the engine.
« After operating the levers, check that the whole bot-
tom surface of the-bucket (both portion a and portion
b) are in contact with the ground.
« Loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic tank. Then operate the
control levers several times to release the remaining
pressure in the hydraulic piping.
• Remove plugs (1) and (2) at the top of the hydraulic
tank filter, and prevent the oil inside the tank from
flowing.
042103
1. Drain Loosen drain valve (3) and drain coolant.
« If the coolant contains antifreeze, dispose of it
correctly.
Coolant: 43l (including sub-tank)
2. Radiator guard
1) Remove 4 mounting bolts of radiator guard, and dis-
connect wiring connector (4) of working lamp and
radiator water level sensor (4-1) at radiator end.
2) Lift off radiator guard (5).
30-26
3. Hood
1) Disconnect connector (6) of electric wiring at
inside of rear left of hood.
2) Remove left and right radiator baffles (7).
3) Sling hood (8), then remove front and rear, left
and right mounting bolts (9) and 3 top front mount-
ing bolts (10), and lift off hood.
Hood assembly:
230 kg (without rear fender)
305 kg (with rear fender)
042103
4. Hoses
1) Disconnect radiator drain hose (1 1) from ra-

diator.
2) Disconnect radiator lower hose (12) at radiator
end.
3) Disconnect oil cooler hoses (13) at radiator end.
« After removing the hoses, fit plugs to prevent
the entry of dirt or dust.
4) Disconnect upper hoses (14) and (15), and ra-
diator spill pipe (16) at radiator end.
5. Fan guard, stay

Remove radiator tan guard (17) and radiator stay
(18).
6. Fan
Remove mounting bolts (19) of engine fan, then re-
move fan.
7. Radiator
Sling radiator assembly (20), then remove mounting
bolts (21), and lift off radiator.
Radiator assembly: 168 kg
30-27
INSTALLATION OF RADIATOR
ASSEMBLY
• Tighten drain plug and add water through the

radiator water filler to the specified level.
Cooiant: 40 l (radiator)
3 l (sub-tank)
« Run the engine to circulate the water through the

system. Then cheek the water level again.
042103
30-28
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
Release the remaining pressure in the piping. For

details, see REMOVAL OF RADIATOR ASSEMBLY.
• Remove plugs (1) and (2) at the top of the hy-

draulic tank filter, and prevent the oil inside the
tank from flowing.
Operate the bucket control lever at least 40 times

TILT - HOLD to release the pressure inside the accu-
mulator.
Depress the brake pedal at least 17 times to release

the pressure inside the brake accumulator.
When releasing the refrigerant from the air conditioner,

carry out the oil return operation, then use a gauge
manifold and release the refrigerant slowly from the
042103
core of the compressor highpressure and low-pres-

sure valves.

the battery.
1. Radiator
Remove radiator.
For details, see REMOVAL OF RADIATOR.
30-29
2. Electric wiring
1) Disconnect CNER1 connector (4) and CNER2
connector (5) of engine wiring harness (3).
2) Disconnect slow blow fuse 120A connector
(6) and 80A connector (7).
3) Disconnect cable (8) between starting motor and
battery relay.
4) Disconnect starting motor ground cable.
3. Fuelhose
1) Disconnect hose (9) between fuel tank and feed
pump at feed pump end.
2) Disconnect fuel return hose (10) at injection pump
end.
3) Disconnect spill hose (11) at fuel tank end.
« After disconnecting the hoses, fit plugs to
prevent the entry of dirt or dust.
042103
4. Air conditioner, heater hoses
1) Disconnect air conditioner hoses (12) and
(13) from compressor. 1
2) Disconnect heater hoses (14) and (15) from en-
gine.
30-30
5. Brake piping, accelerator cable

1) Disconnect hoses (16) and (17) between right
brake valve and accumulator at pedal end.
« Remove the clamps (2 places) of the brake
hoses under the floorboard.
2) Disconnect hose (18) between left brake valve
and accumulator at pedal end. 2
3) Disconnect accelerator cable (19) at bottom of
pedal.
« Remove the cable clamp under the floor
board.
4) Disconnect hose (20) between PPC accumulator and

PPC valve inside bulkhead at accumulator end.
042103
5) Disconnect hose (22) of radiator sub-tank (21) and

hose (24) of window washer tank (23) at tank end.
« Remove the hoses from the hose clamp.
6) Air conditioner hoses
• Disconnect hose (25) between compressor and
condenser at condenser end.
3
« Remove the hose clamp inside the bulkhead.

• Disconnect hose (26) between air conditioner
unit and receiver at receiver end.
4
« Remove the hose clamp inside the bulkhead.
« After removing the hoses, fit plugs to prevent
6. Bulkhead
1) Remove cover (28) at bottom front of bulkhead
(27).
30-31
2) Install eyebolts at top 4 corners of bulkhead (27),

then sling and remove bottom mounting bolts (29).
Bulkhead: 135 kg
(including accumulator charge valve)
3) Raise bulkhead (27) straight up for approx. 400 mm.
« The bulkhead comes near the cab when
it is lifted, so be careful not to hit anything.
« To prevent the bulkhead from falling after it is

raised, place blocks to the left and right on
opposite sides.
Fuel control cable (WA450-3S)

1) Disconnect fuel control cable (30) from ball joint (31).
5
2) Remove fuel control cable from bracket (32).
042103
8. Transmission support stand
Remove rear drive shaft (33), and set support stand
under transmission (34). 6
« Use a stand with adjustable height, and fit it

securely in position so that it does not come
out.
30-32
9. Engine assembly
1) Remove engine oil drain valve (35) and radiator cool-
ant drain valve (36) from fuel tank.
2) Sling engine assembly (37), and remove mounting

bolts (38) of engine flywheel portion and torque con-
verter housing
« Depending on the lifting tool, remove the muffler
and then sling.
Engine assembly: 1,120 kg

042103
3) Remove engine mount bolt (39), and lift off engine

assembly (37). 7
« Be careful of the direction of installation
of the cushions and spacers.
« The engine flywheel ring gear and torque con-
verter ring gear and shaft are mated, so set in a
horizontal position before raising the engine as-
sembly, and keep horizontal while carrying out
the operation.
« When lifting off the engine assembly, check first
that all the wiring and piping have been removed
before continuing with the operation. 8
30-33
INSTALLATION OF ENGINE
ASSEMBLY
1
Compressor hose:
7.9 ± 1.8 Nm (0.8 ± 1.2 kgm)
2 3
Accelerator cable mounting bolt:
53.9 ± 5 Nm (5.5 ± 0.5 kgm)
3
Condenser hose:
19.6 ± 24.5 Nm (2.0 ± 2.5 kgm)
4
Receiver hose:
3.9 ± 6.9 Nm (0.4 ± 0.7 kgm)
6
« Clean the connection and mating surface of the
drive shaft before installing.
Drive shaft mounting bolt:

112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
7
« Be careful of the direction of installation of the
042103
cushions and spacers at the engine mount when
assembling.
Mount bolt:
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
8
« When connecting the engine to the torque con-
verter, adjust the height so that the torque con-
verter shaft and ring gear go in smoothly.
Never try to use force when connecting.
« Use new parts for the torque converter and fly-
wheel housing O-rings.
O-ring at mating surface of torque con-
verter and engine flywheel:
Soapy water
• Refilling with oil

Tighten drain plugs (1) and (2) at the top of the
hydraulic tank filter, and add hydraulic oil through
the oil filler to the specified level.
Plug at top of filter:
11.8 ± 1 Nm (1.2 ± 0.1 kgm)
30-34
• Bleeding air
1) Bleed air from brake line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
2) Bleed air from steering line.
• Fill the air conditioner with new refrigerant.

« Precautions when filling air conditioner line with
new refrigerant
1) Keep the temperature inside the room at above
30°C.
(if the temperature is below 3°C, the system
will not work.)
2) Use R134a as the refrigerant.
3) When filling with refrigerant, always use the re-
peat vacuum method to completely evacuate.
(Attainment of vacuum: Min.750 mmhg.)
4) Charge with 1.5 - 1.6 kg of refrigerant.
5) Do not use the can of refrigerant upsidedown or
use any other mistaken method. Be careful not
to let liquid freon get into the refrigerating sys-
tem.
042103
6) Do not operate the compressor before charging

with refrigerant.
30-35
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
REMOVAL OF TORQUE
CONVERTER CHARGING
PUMP

1. Drive shaft
Remove guard of center drive shaft, and disconnect
drive shaft (1) at transmission end. 1
« Move the drive shaft towards the side of the
frame.
Center drive shaft: 36 kg
2. Piping
1) Remove suction tube (2) of charging pump from
pump. 2 1
2) Disconnect hose (3) between pump and flow
valve at pump end. 3
3. Torque converter charging pump

Remove mounting bolt (4) of charging pump, then
DEW01436
remove charging pump assembly (5). 4
5
INSTALLATION OF TORQUE 2
3
CONVERTER CHARGING
PUMP 4
1 Drive shaft:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
DEW01437
2 3
« Replace the O-ring with a new part.
4
Pump mounting bolt:
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
30-42
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
REMOVAL OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY


For details, see REMOVAL OF RADIATOR ASSEM-
BLY

flowing.

TILT÷HOLD to release the pressure inside the accu-
mulator.

042103
When releasing the refrigerant from the air condi-

tioner, carry out the oil return operation, then use a
gauge manifold and release the refrigerant slowly
from the core of the compressor high-pressure and
low-pressure valves.
1. Cover
Remove cover (3) at bottom of cab.
2. Ladders
Remove left and right ladders (3-1). 3-1
Ladder rail (right): 64.5 kg
Ladder rail (left): 59.5 kg
DEW01440
30-43
3. Electric wiring
10 11 9
Disconnect the following electric wiring.
1) Disconnect transmission wiring TL1 (4) and TL2
(5).
8
2) Disconnect floor wiring harnesses LR5 (6), LR6
(7), LR3 (8), LR4 (9), LR1 (10), and LR2 (11).
« After disconnecting the connectors, mark with 6
a tag to distinguish when installing.
4
5 7 DEW00497
10 11
8 9
6 7
042103
4 5 DEW00500
4. PPC piping
1) Disconnect hose (12) of PPC valve port “P2”,
hose (13) of port “P4”, hose (14) of port “P3”,
and hose (15) of port “P1” at valve end.
2) Disconnect hose (16) between PPC accumula-
tor and PPC valve at valve end.
3) Disconnect hose (17) of PPC valve drain port at
valve end.
« After disconnecting the hoses, mark with a
tag to distinguish when installing.
30-44
5. Brake piping
« Remove 2 brake hose clamps under floor
board.
and accumulator at pedal end.
3) Disconnect right brake valve drain hose (21)
and left brake valve drain hose (22) at rear
frame portion.
4) Disconnect hose (23) between front brake and 18 19 28
right brake valve at center hinge pin. DEW01425
21 22
042103
DEW00504
6. Air conditioner piping

1) Disconnect hose (24) between compressor and
air conditioner unit at unit end. 1
2) Disconnect hose (25) between receiver and air
conditioner unit at unit end. 2
3) Disconnect heater piping (26) and (27) at air
conditioner unit end.
7. Accelerator cable 3
Disconnect accelerator cable (28) under pedal.
26 27 25 24
« Remove the cable clamp at the floor board. DEW00505
8. Steering pipes 4
Remove the orbit-roll servo pipes (4).
30-45
9. Cab, floor board

1) Remove mounting cover (31) of floor board (30),
32
then remove 4 viscous damper mounting nuts
(32) holding floor board.
2) Fit lifting tool to cab (33) and lift off cab.
5
« Raise the cab slowly and check that all parts
have been removed before lifting off.
31
Cab, floor assembly: 470 kg
30
DEW00507 DEW00508
10. Bulkhead
1) Disconnect piping inside bulkhead. 34
i) Disconnect hose (39) between air conditioner
compressor and condenser at condenser
end. 6
« After disconnecting the hose, fit plugs in
the hose and condenser connector to
ii) Disconnect hose (34) between PPC accu-
mulator and PPC valve inside bulkhead. 33
iii) Disconnect hose (36) of radiator sub-tank
(35) and hose (38) of window washer tank DEW00509 DEW00510
(37) at tank end.
« Remove the hose from the hose clamp.
« After disconnecting the hoses, fit plugs
to prevent the entry of dirt or dust.
39
36
2) Bulkhead
i) Remove cover (40) at bottom front of bulk- 38
DEW00511
head (39-1). 35 37
ii) Remove mounting bolts (42) at top of hood
(41) and bulkhead (39-1).
« Be careful not to lose the washers and
rubber of the mounting portion.
iii) Install eyebolts at the top 4 corners of bulk- 41
head (39-1), then sling and remove the bot-
tom mounting bolts. 42
40
Bulkhead: 135 kg 39-1
(including accumulator and charge
pump)
39-1
DEW00513 DEW00512
30-46
11. Hydraulic piping 7

1) Disconnect loader pump suction tube (43) and
steering and switch pump suction tube (44) at
pump end.
Remove hydraulic tank hose (45) , remove tube
mounting bolts (43-1), then remove tube (43).
2) Disconnect tube (46) between loader pump and
main control valve at pump end and center hinge
pin end, then remove tube.
3) Disconnect PPC pump tube (47) at pump end.
4) Disconnect tube (48) between steering pump
and steering valve at pump end and center
hinge pin end, then remove tube.
5) Disconnect tube (49) between switch pump and
steering valve at pump end and center hinge pin
end, then remove tube.
6) Disconnect tube (50) between steering valve
and cooler at center hinge pin.
7) Disconnect main control valve drain hose (51).
« After disconnecting the connectors, mark with
042103
12. Transmission, cooler piping 8

1) Disconnect hose (51) between transmission con-
trol valve and cooler and hose (52) between cooler
and transmission at valve and transmission ends.
30-47
2) Disconnect hose (53) between transmission oil

filter and control valve at valve end.
3) Disconnect transmission pump outlet hose (54)
at pump end.
4) Disconnect hoses (55), (56), and (57) between
parking brake emergency release valve and
parking brake at parking brake control valve
hose end.
« Remove the clamps mounted at the trans-
mission and rear frame.
5) Remove mounting bolts of transmission filler tube
(58), and rotate to transmission side, then lock
with mounting bolts.
« After disconnecting the connectors, mark with
13. Drive shafts

1) Disconnect center drive shaft (59) at transmis-
sion end. 9
« Move the disconnected drive shaft to the
side.
042103
2) Remove rear drive shaft (60). 10
Rear drive shaft: 19 kg

« Make match marks on both the center and
rear couplings.
14. Torque converter, transmission assembly

1) Install block between bottom of engine fly-
wheel and rear axle to prevent engine from falling
when transmission and torque converter are re-
moved. 11
30-48
2) Install eyebolts to top of transmission oil filter

and top of pump mounting gear case of torque
converter and transmission assembly (61).
Torque converter, transmission assem

bly: 1,070 kg
(including pump, filter, etc.)
3) Remove mounting bolts (62) of torque converter

and transmission case, and engine flywheel
housing. 12
042103
4) Remove mount bolts (63) and (64) of torque con-

verter and transmission assembly, and raise
approx. 200 mm, then remove mount bracket
(65).
« Do this on both the left and right. 13 63
5) Lift off torque converter and transmission assem-
bly (61). 65
64
« Check that it does not hit against any other
parts, and lift off slowly.
« Check that all parts have been removed be-
fore lifting off.
DEW01455
30-49
INSTALLATION OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
1 Air conditioner unit hose:

29.4 – 34.3 Nm (3.0 – 3.5 kgm)
Receiver hose:
New refrigerant compressor oil (ND-OILB)
2 Receiver hose:
11.8 – 14.7 Nm (1.2 – 1.5 kgm)
Receiver hose:
3 Cable locknut:
53.9 ± 5 Nm (5.5 ± 0.5 kgm)
4 Joint mounting bolt:

122.6 ± 9.8 Nm (12.5 ± 1.0 kgm)
5« Align securely with the notch hole of the viscous

damper washer, then tighten.
042103
6 Air conditioner condenser hose:
Air conditioner condenser hose:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
7 8
« Replace the O-rings with new parts.
« Install the clamps before connecting the hoses
and tubes.
9 10
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
« Check that the match mark is aligned.
11
« Remove block at the bottom of the flywheel
housing.
12
« Replace the O-rings with new parts.
Mounting bolt:
68.6 ± 5 Nm (7.0 ± 0.5 kgm)
30-50
13
« Align the pin hole securely. 65 63

Mounting bolt of bracket (65):
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm) a a 64
Mount bolt (63):
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
• Adjust so that the clearance at center bolt (64)
is clearance a.
« Clearance a: 1.0 – 1.5 mm
Set bolt (64):
122.6 ± 24.5 Nm (12.5 ± 2.5 kgm)
Set bolt: Thread tightener (LT-2) DEW00527 DEW00528

11.8 ± 1 Nm (1.2 ± 0.1 kgm)
• Bleeding air
042103


new refrigerant
3°C.
(If the temperature is below 3°C, the system will
not work.)
3) When filling with refrigerant, always use the
repeat vacuum method to completely evacuate.
(Attainment of vacuum: Min.750 mmHg.)
4) Charge with 1.5 – 1.6 kg of refrigerant.
5) Do not use the can of refrigerant upside-down
or use any other mistaken method. Be careful
not to let liquid freon get into the refrigerating
system.
with refrigerant.
30-51
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Turbine, case assembly

1) Remove stator shaft and pump assembly (2)
from turbine and case assembly (3). 2
DEW00529
2) Disassemble turbine and case assembly as fol-

lows. 4
i) Remove pilot (4).
ii) Remove snap ring (5), then remove plate
(1). 5 1
042103
DEW00530 DEW00531
iii) Push boss portion of turbine (6) and re-

move from case (7).
7
DEW00532
iv) Remove mounting bolts and disconnect tur-

bine (6) and boss (18). 6
v) Remove bearing (8) from case. 8
18
DEW00533 DEW00534
30-52
2. Stator
1) Remove snap ring (9). 10 9
2) Remove stator (10).
DEW00535
3. Stator shaft
Using forcing screws , push from stator shaft (11) 11
end and disconnect from pump assembly (12).
12
042103
DEW00536
4. Gear
Remove gear (13) from pump (14). 13
14
DEW00537
5. Bearing
Remove bearing (15) from gear (13). 13
15
DEW00538
30-53
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Bearing
Install bearing (15) to gear (13).
2. Gear
Install gear (13) to pump (14). 13
Mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
042103
14
DEW00537
3. Stator shaft
1) Install seal ring (16) to stator shaft (11).
Seal ring: Grease (G2-LI)
« Make the protrusion of the seal ring uniform. 11
16
DEW00540
2) Push inner race of bearing and install pump

assembly (12) to shaft (11).
12
11
DEW00541
30-54
4. Stator
1) Install stator (10). 10 9
2) Install snap ring (9).
DEW00535
5. Turbine, case assembly

1) Assemble turbine and case assembly as follows.
i) Install bearing (8) to case.
« Press fit the bearing until it contacts the 8
case.
042103
DEW00543
ii) Install boss (18) to turbine (6).

Mounting bolt: 6
Thread tightener (LT-2)
Mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
18
DEW00533
iii) Push inner race of bearing and install tur-

bine (6) to case (7). 7
DEW00545
30-55
iv) Fit plate (1) and install snap ring (5).

v) Install pilot (4). 4
Mounting bolt:
Mounting bolt: 5 1
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
DEW00531 DEW00530
2) Install turbine and case assembly (3) to stator

shaft and pump assembly (2).
Mounting bolt:
Mounting bolt: 2
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
3
042103
DEW00529
30-56
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
11 4
1. Coupling
5
1) Pull out lower rear coupling (1). 13
2) Remove lower front coupling (2) and mounting
bolt (3), then remove coupling.
12
3) Remove sensors.
2. Accumulator valve
Remove mounting bolts (5) of accumulator valve (4), 10
then remove accumulator valve and gasket. 9
« After removing, cover with tape to prevent the 14 15 6 8 7 1 DEW00549
entry of dirt or dust.

1) Remove control valve inlet elbow (6) and elbow 21
16
(7) which goes to cooler.
2) Remove mounting bolts (9) (marked with ) of 17
control valve (8), install eyebolts (M:12mm), then
sling. 19
20
Transmission control valve: 55 kg
3) Remove mounting bolts (9) and remaining bolts 18
(marked with ), then lift off control valve as- 2
042103
sembly. 3
« After removing, cover with tape to prevent DEW00550
4. Flow valve
Remove mounting bolts (11) of flow valve (10), then
remove flow valve and O-ring.
« Remove the hose from the pump and the hose
from the oil filter.
« After removing, cover with tape to prevent the
5. Transmission oil filter

1) Remove inlet and outlet hoses of oil filter (12).
2) Remove mounting bolt of bracket (13), then re-
move together with oil filter.
6. Filler tube
Remove mounting bolts (15) of filler tube (14), then
remove filler tube.
30-57
7. Transmission, torque converter charging pump

1) Remove delivery hose (20) and hose (19), and 21
16
tubes (18) and (17) at suction end of charging
pump (16). 17
« After removing, cover with tape to prevent
the entry of dirt or dust. 19
2) Remove mounting bolts (21) of charging pump 20
(16), then remove pump and O-ring.
18
2
3
DEW00550
8. Transmission assembly
M12, P=1.75 70 112
Install transmission assembly to stand. Depth 21
Transmission assembly: 950 kg 380

« Support the transmission at the position shown 160
(949)
(939)
in the diagram on the right.
10
Flywheel
mating
120 surface
250 130 728 M16, P=2.0
042103
Depth 31
500 DEW00553
9. Torque converter case

Remove mounting bolts of torque converter case
(22), then remove from transmission case. 22
« When removing the case, slowly remove it per-
pendicularly to the mounting surface.
Transmission
case
Torque converter case: 160 kg
DEW00554
[TORQUE CONVERTER]
1. Torque converter Lifting tool
i) Remove 6 bolts installing torque converter case 24
(22) and torque converter.
ii) Fit lifting tool to gear portion of drive case (24) 23
of torque converter assembly (23) and lift off
from torque converter case (22). 22
Torque converter assembly: 56 kg
DEW00555
30-58
2. PTO gear
1) PTO idler assembly PTO gear PTO idler
i) Remove lock bolts (26) of idler shaft (25),
then remove idler shaft, O-ring (27), and
gear assembly (28).
PTO gear
DEW00556
28 25
042103
26 27 DDW00557
ii) Remove nut (29) from gear assembly (31),

then remove idler hub (30). 32 33
iii) Remove snap ring (32) and spacer (33)
from gear (31), then remove bearing (34).
31 30 29 34
DDW00558
2) PTO gear
i) Remove snap ring (35), then lower ring (35), 37 42 38 43 35 36
and remove split spacer (37).
ii) Pull out shaft (38) and remove gear (39).
iii) Remove snap rings (40) and (42), then re-
move bearings (41) and (43).
« Remove the PTO gear on the opposite
side in the same way.
41 40 39 DDW00559
30-59
[TRANSMISSION]
1. Remove input shaft assembly. 2nd, REVERSE clutch

Input shaft
2. 1st, FORWARD clutch
1) Remove seal rings (1) from clutch shaft. 3rd, 4th clutch
2) Set lifting tools A1, A2, and A3 to 1st, FOR-
WARD clutch shaft, and lift off clutch.
1st, FORWARD clutch: 76.5 kg 1
Counter gear
1st, FORWARD clutch DEW00560
3. 2nd, REVERSE clutch, 3rd, 4th clutch

Set lifting tools A1, A2, and A3 to 2nd, REVERSE A1, A2, A3
clutch shaft and 3rd, 4th clutch shaft, then raise
clutches at same time and remove.
A1, A2, A3
2nd, REVERSE clutch: 91 kg
3rd, 4th clutch: 96 kg 3rd, 4th

clutch
4. Driven gear
042103
1) Install puller to countershaft (2) and bearing (3)
1st, FORWARD cluth 2nd, REVERSE clutch
and remove bearing, then remove gear (4) from DEW00561 DEW00562
shaft.
2) Remove snap ring (5), then remove gear (6).
3) Remove shaft (2), then remove bearing (7) with
puller. 3 Puller
« When setting the puller in position, use a
4
block at the end face of the clutch shaft
when carrying out the operation. 5 2
There is oil on the shaft and gears, so be 2

7
careful not to let them slip. 6
3
5. Parking brake
4
Disassemble parking brake.
For details, see DISASSEMBLY OF PARKING DEW00563 DEW00564
BRAKE ASSEMBLY.
6. Output shaft
1) Remove mounting bolts (9) of gear cover (8), 10
then remove cover.
8
Transmission
case
DEW00565
30-60
2) Install eyebolt to output shaft (10) and lift off

output shaft. 8 13
Output shaft (including gear): 33 kg

9
14 11
3) Remove snap ring (12) of output gear (11), then
remove inner bearing (13) using puller, and 15 12
remove output gear from shaft.
16 10
4) Using puller, remove inner bearing (14) on op-
posite side of output shaft. 17 DDW00566
« When setting the puller in position, use a

block at the end face of the clutch shaft
when carrying out the operation.
Puller
There is oil on the shaft and gears, so be
careful not to let them slip.
5) Remove bearing outer race (15) from transmis- 10

sion case.
6) Remove oil seal (16) and dust seal (17) of rear

13
coupling.
042103
11 DEW00567
7. Transmission case
1) Remove O-rings (17-1) and (18) from transmis-
sion case.
2) Remove bearing (19) and snap ring (20) of
19 W
driven gear from case.
20
17-1 19
W
18 W-W
DEW00568
18
17-1
DEW00569
30-61
ASSEMBLY OF TRANSMISSION
ASSEMBLY
1. Transmission case
1) Press fit bearing (19) of driven gear to trans-
19 W
mission case, and install snap ring (20).
2) Install O-rings (17-1) and (18) to transmission 20
case. 17-1 19
W
18 W-W
DEW00568
18
042103
17-1
DEW00569
2. Output shaft
1) Press fit bearing outer race (15) to transmission 8 13
case.
2) Press fit bearing inner (14) at output shaft rear
coupling end. 9
« Press fit securely so that there is no clear- 11
14
ance at the end face of the bearing.
3) Install snap ring (12) to output shaft (10), then 15 12
install output gear (11), and press fit inner bear-
ing (13). 16 10
« Press fit securely so that there is no clear-
ance at the end face of the bearing. 17 DDW00566
4) Install eyebolt to output shaft (10), then install

shaft to transmission case.
5) Install gear cover (8) to case with mounting bolt
(9). 10
Mounting bolt:
Thread tightener (LT-2) 8
Mounting bolt: Transmission
case
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
DEW00565
30-62
3. Parking brake
a
Assemble parking brake.
For details, see ASSEMBLY OF PARKING BRAKE 16 b
ASSEMBLY.
Q
4. Rear coupling oil seal
Install oil seal (16) and dust seal (17) to transmis-
sion case so that they are at position given below.
« a: 50 ± 0.2 mm Grease
portion Q
« b: 35 ± 0.2 mm
Oil seal, lip of dust seal: Grease (G2-LI) 17
DEW00574
5. Counter gear
1) Install snap ring (5) and gear (6) to shaft (2), 3
and press fit bearing (7). 4
2) Install snap ring and gear (4) to opposite end of
shaft (2), and press fit bearing (3). 5 2
« Press fit securely so that there is no clear-
ance at the end face of the bearing. 7
6
042103
DEW00563
6. 2nd, REVERSE clutch, 3rd, 4th clutch A1, A3

Install lifting tools A2 and A3 to 2nd, REVERSE
clutch shaft and 3rd, 4th clutch shaft, raise clutches
at same time, and install to transmission case. A2, A3
« Raise 2nd, REVERSE and 3rd, 4th clutches at
the same time with the lifting tool, and turn the
3rd, 4th clutch at an angle to assemble. 3rd, 4th
clutch
7. 1st, FORWARD clutch

Install lifting tools A1 and A3 to 1st, FORWARD 2nd, REVERSE clutch
1st, FORWARD
clutch shaft, and assemble clutch in transmission DEW00576
clutch DEW00577
case.
8. Seal rings
Install seal rings (1) to shafts of 1st, FORWARD Input shaft 2nd, REVERSE clutch
clutch, 2nd, REVERSE clutch, and 3rd, 4th clutch. 3rd, 4th clutch
Counter gear
1st, FORWARD clutch DEW00560
30-63
9. Assemble input shaft assembly and gear to trans-

mission case. P
« The installed dimension of the input shaft bush-
C
ing is as follows.
« c = 2.0 ± 0.5 mm
Bushing
« Press fit securely so that there is no clearance Input shaft
at the end face of the bearing.
Portion P DEW00579
10. Torque converter

1) PTO gear 37 42 38 43 35 36
i) Install bearings (41) and (43) to case, and
secure with snap rings (40) and (42).
« Press fit securely so that there is no
clearance at the end face of the bear-
ing.
ii) Set gear (39) inside case, and insert shaft
(38) from outside of case.
« Be careful of the gear mounting posi-
042103
tion.
iii) Set split spacer (37) in position, then install 41 40 39 DDW00559
ring (36) and secure with snap ring (35).

2) PTO idler assembly
i) Press fit bearing (34) to gear (31), then
install spacer (33) and secure with snap 32 33
ring (32).
« Be careful not to forget to assemble
spacer (33).
« Press fit securely so that there is no
clearance at the end face of the bear-
ing.
ii) Install idler hub (30) to gear assembly and
tighten with nut (29).
Nut: 31 30 29 34
784.5 ± 49.0 Nm (80.0 ± 5.0 kgm) DDW00558
iii) Set gear assembly (28) inside case, insert

O-ring in case, install idler shaft (25), and 28 25
tighten with lock bolts (26).
Idler shaft mounting bolt:

112.8 ± 4.9 Nm (11.5 ± 0.5 kgm)
26 27 DDW00557
30-64
3) Torque converter
i) Fit lifting tool to gear portion of drive case
(24) of torque converter assembly (23), and
set to torque converter case (22).
ii) Tighten bolts (22-1) installing torque con-
verter case (22) and torque converter.
Torque converter mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm) 22-1
DDW00583
11. Torque converter case

Coat transmission case with gasket sealant, then set Lifting tool
torque converter case (22) in position and tighten 24
with mounting bolts.
Transmission case flange surface: 23
Gasket sealant (Three Bond 1207B)
22
Outside
042103
´1
DEW00555
´1 ´2 B
Inside H
´2
B= 2–5 mm
H= 2–5 mm
DEW00585 Gasket sealant
Torque converter case mounting bolt:

112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
DEW00586
Tool mark (spot)

22
Transmission Portion Q
case
DEW00554 DEW00587
30-65
12. Transmission, torque converter charging pump

1) Install O-ring to charging pump (16), then set to 21
16
transmission case and tighten with mounting
bolts (21). 17
« Before installing the pump, insert the pump
drive shaft inside the torque converter input 19
20
shaft assembly.
Pump mounting bolt:
279.4 ± 29.4 Nm (28.5 ± 3.0 kgm) 18
2) Fit O-rings to tubes (17) and (18) at suction 2
side of charging pump (16), then connect hose 3
DEW00550
(19) and tighten. Install O-ring to hose (20) at
discharge side also, then tighten.
Tube (17), (18) mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
Clamp of hose (19):
4.4 ± 0.5 Nm (0.45 ± 0.05 kgm)
042103
13. Filler tube 11 4
Fit filler tube (14) with mounting bolt (15) temporar-
ily, and move towards inside of transmission. 5
« After mounting the transmission on the machine, 13
install the filler tube at the specified position.
12
14. Transmission oil filter
1) Install bracket (13) and oil filter to transmission.
Oil filter mounting bolt:
10
68.6 ± 4.9 Nm (7.0 ± 0.5 kgm)
Filter bracket mounting bolt: 9
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm) 14 15 6 8 7 1 DEW00549
2) Install inlet and outlet hoses of oil filter (12).

Hose connection:
176.5 ± 29.4 Nm (18.0 ± 3.0 kgm)
30-66

1) Install gasket to transmission end, then install
eyebolt to portion of control valve (8) marked ,
and set to transmission.
2) Install to portions marked and with mounting
bolts (9), then tighten.
Mounting bolt:
Mounting bolt:
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
3) Install elbow (7) which goes to cooler and inlet
elbow (6) to control valve.
16. Flow valve

Install O-ring to flow valve (10), then install to trans- 11 4
mission case with mounting bolts (11).
Flow valve mounting bolt: 5
Flow valve mounting bolt:
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm) 12
Install O-ring to accumulator valve (4) and tighten
with mounting bolts (5). 10
042103
9
18. Couplings 14 15 6 8 7 1 DEW00549
1) Front coupling
Install front coupling (2) to output shaft, and
tighten O-ring and washer with coupling mount-
ing bolt (3).
Mounting bolt:
926.7 ± 98.1 Nm (94.5 ± 10.0 kgm)
2) Rear coupling
Install rear coupling (1) to rear end of output
shaft.
30-67
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DISASSEMBLY OF
TRANSMISSION CLUTCH PACK
ASSEMBLY A1, A2 ø140
FORWARD, ø115.3 +0.2
0
1st
FORWARD, 1ST CLUTCH ASSEMBLY
2C
1. Assembly of FORWARD clutch pack assembly
50+0.5
2C
0
6
« Lift the clutch pack assembly with lifting tools A1
110
and A2, and install to lifting stand . ø90
5
6 – 9t
FORWARD, 1st clutch assembly: 100
76.5 kg 200°
DEW00593 DEW00594
1) Seal rings
Puller
Remove 3 seal rings (1) installed to shaft.
2) Bearing, thrust washer
i) Install puller to end face of shaft, and re- 1
move bearing (2).
« When setting the puller in position, in-
stall a block to the end face of the 2
clutch shaft before carrying out the op-
eration. 4
ii) Remove thrust washer (3) and spacer (4) 2 3
042103
from shaft.
DEW00595 DEW00596
3) Needle bearing, FORWARD gear

i) Remove needle bearing (5) and FORWARD 5 6
gear (6) from shaft. 5 6
ii) Remove thrust washer (7) and spacer (7-1).
7
7-1
DEW00597 DDW00598
4) End plate
Push end plate (8) with tool in diagram below,
remove snap ring (9), then remove end plate (8)
from clutch case (10). 9
8
11
ø170
ø85
9
12
ø101.6
13
10
10
9 – 12 290 9 – 12 DEW00600 DDW00601
Tool
DEW00599
30-68
5) Clutch plates
Remove separator plates (12), disc plates (11), 12 11
and wave springs (13) from inside clutch (10).
« Be careful not to let the separator plates or
disc plates catch in the clutch case ring
groove.
13
DEW00602
6) FORWARD piston
Remove FORWARD piston (14) from inside clutch
case, then remove piston seals (15) and (16)
14 15 14
from piston.
16
042103
DEW00603 DEW00604
2. Disassembly of 1st clutch pack

« Turn over the FORWARD clutch case and set to 1st clutch pack ø78
stand . ø55
5c
8
There is oil on the clutch pack, so be careful not

to let it slip when turning it over. ø67
105
6 – 9t
100
200°
DEW00605 DEW00606

i) Remove roller bearing and outer race, then 17 Puller
install puller to end face of shaft, and re-
move bearing inner (17).
« When setting the puller in position, in- 17
stall a block to the end face of the
eration.
19 19
from shaft.
DEW00607 DEW00608
30-69
2) Needle bearing, 1st gear

i) Remove needle bearing (20) and 1st gear 20 21
(21) from shaft. 20 21
ii) Remove thrust washer (22) and spacer (22-
1).
22
22-1
DEW00609 DDW00610
3) End plate
Push end plate (8) at 1st clutch end with tool ,
remove snap ring (9), then remove end plate
8
11 9
12
10 13
042103
DEW00611 DDW00612
4) Clutch plates
Remove separator plates (12), disc plates (11),
and wave springs (13) from inside clutch case
(10).
« Be careful not to let the separator plates or 11
groove.
12
13
DEW00613
5) 1st piston
Remove 1st piston (23) from inside clutch case,
then remove piston seals (24) and (25) from 23
23
piston.
« The shape of the 1st piston is different from
the shape of the FORWARD piston on the
opposite side.
25 24
DEW00614 DEW00615
30-70
REVERSE, 2ND CLUTCH ASSEMBLY

1. Disassembly of REVERSE clutch pack A1, A2
« Lift the clutch pack assembly with lifting tools A1
and A2, and install to stand .
REVERSE, 2nd clutch
REVERSE, 2nd clutch assembly: 90 kg assembly
DEW00616
1) Seal rings
Puller
i) Install puller to end face of shaft, and re- 1
move bearing (2).
eration. 4
042103
from shaft.
DEW00595 DEW00596
3) Needle bearing, REVERSE gear

i) Remove needle bearing (5) and REVERSE 5 5 6
gear (6) from shaft.
7
DDW00620
DEW00619 7-1
4) End plate
Push end plate (8) with tool , remove snap
ring (9), then remove end plate from clutch case
(10). 9
8
11
9
12
10 13
10
DEW00600 DDW00621
30-71
5) Clutch plates
and wave springs (13) from inside clutch case.
groove.
12
13
DEW00623
6) REVERSE piston
Remove REVERSE piston (14) from inside clutch
case, then remove piston seals (15) and (16) 14
15 14
from piston.
16
042103
DEW00624 DEW00604
2. Disassembly of 2nd clutch pack

« Turn over the REVERSE clutch case and set to
stand . 2nd clutch pack

to let it slip when turning it over.
DEW00626

Puller
i) Remove roller bearing and outer race, then
install puller to end face of shaft, and re- 17
eration.
ii) Remove thrust washer (18) and spacer (19) 19
from shaft. 18 18
19
DEW00627 DEW00628
30-72
2) Needle bearing, 2nd gear

i) Remove needle bearing (20) and 2nd gear 20
21 21 20
(21) from shaft.
1).
22
22-1
DEW00629 DDW00630
3) End plate
Push end plate (8) at 2nd clutch end with tool
9
, remove snap ring (9), then remove end plate
from clutch case (10).
11 8
9
12
13
042103
10 10
DEW00631
DDW00632
4) Clutch plates
(10).
groove.
12
13
DEW00633
5) 2nd piston
Remove 2nd piston (23) from inside clutch case,
23
then remove piston seals (24) and (25) from
23
piston.
« The shape of the 2nd piston is different
from the shape of the REVERSE piston on
the opposite side.
25 24
DEW00634 DEW00615
30-73
3RD, 4TH CLUTCH ASSEMBLY

1. Disassembly of 4th clutch pack
« Lift the clutch pack assembly with lifting tools A1 A1, A2
and A2, and install to stand .
3rd, 4th clutch
3rd, 4th clutch assembly: 96 kg assembly
DEW00636
1) Seal rings
Puller

i) Install puller to end face of shaft, and re-
move bearing (2).
« When setting the puller in position, in- 2
stall a block to the end face of the
clutch shaft before carrying out the op- 1 4
eration. 3
042103
from shaft. DEW00637 DEW00596
3) Needle bearing, 4th gear

i) Remove needle bearing (5) and 4th gear (6) 5 6
5 6
from shaft.
7
7-1 DDW00640
DEW00639
4) End plate
Push end plate (8) with tool , remove snap
ring (9), then remove end plate from clutch case
(10). 9
8
11
9
10 12
13 10
DEW00641 DDW00642
30-74
5) Clutch plates
(10). 11
groove. 12
13
DEW00643
6) 4th piston
Remove 4th piston (14) from inside clutch case,
then remove piston seals (15) and (16) from 14 15 14
piston.
16
042103
DEW00644 DEW00604
2. Disassembly of 3rd clutch pack

« Turn over the 4th clutch case and set to stand 3rd clutch pack
.

to let it slip when turning it over.
DEW00646

17 Puller
i) Remove roller bearing and outer race, then
install puller to end face of shaft, and re-
eration. 18
19
from shaft. 18
DEW00647 DEW00648
30-75
2) Needle bearing, 3rd gear

i) Remove needle bearing (20) and 3rd gear 20
20 21
(21) from shaft.
3rd gear: 29 kg

1).
21
22
22-1
DEW00649 DDW00650
3) End plate
Push end plate (8) at 3rd clutch end with tool ,
remove snap ring (9), then remove end plate
8
11
9
10 12
13
042103
10
DEW00651 DDW00652
4) Clutch plates
11
(10).
12
groove.
13
DEW00653
5) 3rd piston
Remove 3rd piston (23) from inside clutch case, 23
then remove piston seals (24) and (25) from
piston. 23
« The shape of the 3rd piston is different from
the shape of the 4th piston on the opposite
side.
25 24
DEW00654 DEW00615
30-76
CLUTCH PACK ASSEMBLY
FORWARD/1st clutch
FORWARD, 1ST CLUTCH ASSEMBLY
When assembling the FORWARD, 1st clutch, al-
ways check dimension “A” of the FORWARD clutch
case.
« A: 90.5 mm A
DDW00656
1. Assembly of FORWARD clutch pack

1) FORWARD piston
Install piston seals (15) and (16) to FORWARD
14 15 14
piston (14), then install inside clutch case.
« Replace the piston seal rings with new parts.
16
042103
DEW00603 DEW00604
« After assembling the seal rings to piston, set

to tools A4 and A5 and settle for at least 5
seconds. Piston
« Carry out the settling operation for each Piston
piston.
Outer circumference of seal ring, con-
tact surface: Oil (EO10-CD)
A4 A5
DEW00659 DEW00660
2) Clutch plates
Install separator plates (12), disc plates (11), 12 11
and wave springs (13) inside clutch case (10).
« Before assembling the clutch disc plates,
put them in a soaking bath for at least 2
minutes.
Oil: EO10-CD
(API 10W-CD Class or above)
13
DEW00602
30-77
3) End plate
Assemble end plate (8) to clutch case (10), then
push with tool , and secure with snap ring (9).
9
4) Needle bearing, FORWARD gear
i) Assemble spacer (7-1) and thrust washer 8
(7) inside clutch case in order.
11 9
« Before assembling the spacer, warm it
up at 80°C – 120°C for 80 minutes. 12
13
10
Thrust washer (7): Oil (EO10-CD) 10
DEW00600 DDW00601
ii) Install FORWARD gear (6) to shaft, and

assemble needle bearing (5).
5 6
5 6
042103
7-1
DEW00597 DDW00598

i) Assemble thrust washer (3) and spacer (4) 2
to shaft in order.
« Before assembling bearing (2) and
spacer (4), warm them up at 80°C – 4
120°C for 80 minutes.
B
« When press fitting the bearing, check
3
that there is no clearance.
Thrust washer (3): Oil (EO10-CD)
ii) Press fit bearing (2) to shaft.
« After press fitting the bearing, check
the dimension of clearance B between DDW00666
spacer (4) and thrust washer (3).

« B: 0.27 – 1.23 mm
(FORWARD clutch end)
30-78
6) Seal rings
Install 3 seal rings (1) to shaft.
DEW00595
2. Assembly of 1st clutch pack

1) 1st piston
Install piston seals (24) and (25) to 1st piston 23
23
(23), then install inside clutch case.
25 24
042103
DEW00614 DEW00615

seconds. Piston
Piston
« Carry out the settling operation for each
piston.

A4 A5
DEW00659 DEW00660
2) Clutch plates
Install separator plates (12), disc plates (11),
« Before assembling clutch disc plates (1),
put them in a soaking bath for at least 2 11
minutes.
Oil: EO10-CD (API 10W-CD Class or above)
12
13
DEW00613
30-79
3) End plate
9
8
11 9
12
10 13
DEW00611 DDW00612
4) Needle bearing, 1st gear

i) Assemble spacer (22-1) and thrust washer 20 21
(22) inside clutch case in order. 20 21
up at 80°C – 120°C for 80 minutes.
ii) Install 1st gear (21) to shaft, and assemble
needle bearing (20).
22
042103
22-1
DEW00609 DDW00610

i) Assemble thrust washer (18) and spacer 17
(19) to shaft in order.
19
« Before assembling bearing (17) and C
the dimension of clearance C between DDW00677
« C: 0.14 – 1.36 mm (1st clutch end)
30-80
REVERSE, 2ND CLUTCH ASSEMBLY

When assembling the REVERSE, 2nd clutch, al-
ways check dimension “D” of the REVERSE clutch FORWARD/1st clutch
case.
« D: 90.5 mm
DDW02348
1. Assembly of REVERSE clutch pack

1) REVERSE piston
Install piston seals (15) and (16) to REVERSE 14
15 14
piston (14), then install inside clutch case.
16
042103
DEW00624 DEW00604

seconds. Piston
piston.
A4 A5
DEW00659 DEW00660
2) Clutch plates
« Before assembling clutch disc plates (11), 11
minutes.
Oil: EO10-CD (API 10W-CD Class or above) 12
13
DEW00623
30-81
3) End plate
push with tool , AND secure with snap ring
(9). 9
Thrust washer: Oil (EO10-CD)
8
11
9
10 12
13 10
DEW00641 DDW00642
4) Needle bearing, REVERSE gear

(7) inside clutch case in order. 5 6
ii) Install REVERSE gear (6) to shaft, and as-
semble needle bearing (5).
042103
7
DEW00639
7-1 DDW00640

i) Assemble thrust washer (3) and spacer (4)
to shaft in order.
« Before assembling bearing (2) and 2
spacer (4), warm them up at 80°C –
120°C for 80 minutes. 4
E
that there is no clearance. 3
DDW00688
the dimension of clearance E between
« E: 0.27 – 1.23 mm
(REVERSE clutch end)
30-82
6) Seal rings
DEW00595
2. Assembly of 2nd clutch pack

1) Install piston seals (24) and (25) to 2nd piston
(23), then install to clutch case. 23
« Replace the piston seal rings with new parts. 23
25 24
042103
DEW00634 DEW00615

seconds. Piston
piston.

A4 A5
DEW00659 DEW00660
2) Clutch plates
put them in a soaking bath for at least 2 11
minutes.
Oil: EO10-CD
12
13
DEW00633
30-83
3) End plate
push with tool , and secure with snap ring (9). 9
11 8
9
12
13 10
10
DEW00631 DDW00632
4) Needle bearing, 2nd gear

21 21 20
ii) Install 2nd gear (21) to shaft, and assemble
needle bearing (20).
22
042103
22-1
DEW00629 DDW00630

i) Assemble thrust washer (18) and spacer 17
« Before assembling bearing (17) and 19
F
the dimension of clearance F between DDW00699
« F: 0.34 – 1.56 mm
(2nd clutch end)
30-84
3RD, 4TH CLUTCH ASSEMBLY

1. Assembly of 4th clutch pack
1) 4th piston
Install piston seals (15) and (16) to 4th piston
(14), then install inside clutch case.

seconds.
« Carry out the settling operation for each
piston.
042103
2) Clutch plates
minutes.
Oil: EO10-CD
3) End plate
30-85
4) Needle bearing, 4th gear

5 6
ii) Install 4th gear (6) to shaft, and assemble
needle bearing (5).
7
DEW00639
7-1 DDW00640

i) Assemble thrust washer (3) and spacer (4)
to shaft in order. 2
120°C for 80 minutes. G
3
042103
ii) Press fit bearing (2) to shaft. DDW00709

the dimension of clearance G between
« G: 0.37 – 1.33 mm
(4th clutch end)
6) Seal rings
2
DEW00637
30-86
2. Assembly of 3rd clutch pack

Install piston seals (24) and (25) to 3rd piston (23),
then install to clutch case.
« After assembling the seal rings to piston, set to

tools A4 and A5 and settle for at least 5 sec-
onds.
« Carry out the settling operation for each piston.
Outer circumference of seal ring, contact

surface: Oil (EO10-CD)
042103
2) Clutch plates
put them in a soaking bath for at least 2 min-
utes.
Oil: EO10-CD (API 10W-CD Class or above)
3) End plate
30-87
4) Needle bearing, 3rd gear

20 21
« Before assembling the spacer, warm it up at
80°C – 120°C for 80 minutes.
ii) Install 3rd gear (21) to shaft, and assemble 21

needle bearing (20). 22
22-1
DEW00649 DDW00650

17
i) Assemble thrust washer (18) and spacer
spacer (19), warm them up at 80°C –
that there is no clearance. 18 19
Thrust washer (18): Oil (EO10-
042103
CD)
DEW00647
ii) Press fit bearing (17) to shaft. 17

« After press fitting the bearing, check H 19
the dimension of clearance H between
« H: 0.34 – 0.56 mm 18
(3rd clutch end)
DDW00721
30-88
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
DISASSEMBLY OF PARKING
BRAKE ASSEMBLY

« Release the parking brake.
1. Loosen drain plug and drain transmission oil.
Transmission: 40 l
2. Drive shaft
Remove guard of drive shaft, and disconnect lower 1
front drive shaft (1) at transmission end.
« Move the disconnected drive shaft to the right
end.
3. Suction tube
1) Remove mounting bolt (3) and washer (4) of
coupling (2) at front end of transmission, then
remove coupling.
042103
2) Remove suction tube (5) at transmission end. 2 3 4

DEW00722
4. Parking brake
1) Remove lock plates (7) of manual release bolts 6
(6) and parking brake, then remove 3 release
bolts (6). 7
2) Remove parking bake case (8).
5 8
DEW00723
3) Remove mounting bolts (10) of housing (9), then

remove housing.
9 10 DEW00724
30-89
4) Remove spline hub (12) and piston (13) from

output shaft (11), then remove springs (14) and 11 12 13
(15).
14
15
DDW00725
5) Remove mounting bolts (17) of retainer (16),

then remove retainer and shim (18). 17 18
« Check the number and thickness of the Raise
shims, and keep in a safe place.
« Sling the output shaft to prevent it from 11
falling.
Bearing
6) Remove bearing race from retainer (16), then
remove bearing inner race from output shaft
(11).
042103
16
DEW00726
30-90
ASSEMBLY OF PARKING
BRAKE ASSEMBLY
17 18
1. Parking brake Raise
1) Press fit bearing outer race to retainer (16),
and bearing inner race to output shaft (11). 11
2) Install output shaft to transmission case, then Bearing
insert shim (18) in retainer (16), and tighten
with mounting bolts (17).
« Keep the output shaft horizontal when rais-
ing it. 16
DEW00726
3) Adjusting shim
i) Assemble shim of standard value, then
tighten retainer (16) with 3 bolts. 3 places
(bolts)
« Standard shim thickness: 1.2 mm 16
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
« Assemble retainer (16) so that the 4

casting holes are at the bottom.
042103
ii) Adjust shim so that rotating torque of output

shaft is 9.8 – 98.1 Ncm (1 – 10 kgcm). DEW00728
« When doing this, check that there is no
end play.
4) Install springs (14) and (15) to retainer, then
install piston (13) and spline hub (12) to output 11 12 13
shaft (11).
Tip of spline hub: Grease (LM-G)
14
15
DDW00725
30-91
5) Set brake housing assembly (9) to transmission

front case, and install brake piston pushing tool 9 13
.
6) Push in piston (13) with bolt of pushing tool, and
tighten with 3 housing mounting bolts (10).
« Mesh the spline hub and disc before start-
ing.
12
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
10 DDW00730
Brake piston pushing tool
10° 15t
A 3-M12
300
45
0
26
30°
30°
M10,
´65
110 160
M12, ´100
All screws
27
8
M12 mm
042103
Eyebolt
mount A A-A
DEW00731
9 10 DEW00724
7) Install parking brake case (8).

8) Install parking brake manual release bolts (6), 6
and secure with lock plates (7).
7
2. Suction tube
1) Install suction tube (5).
« Use a new part for the O-ring.
5 8
DEW00723
30-92
3. Coupling
Tighten transmission front coupling (2), O-ring and 1
washer (4) with mounting bolt (3).
End face of coupling:

Anti-friction compound (LM-G)
Mounting bolt:
921.8 ± 98.1 Nm (94.0 ± 10.0 kgm)
4. Drive shaft 2 3 4
1) Connect front drive shaft (1). DEW00722
« Clean the connection and mating surface of
the drive shaft before installing.
Drive shaft:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
2) Install drive shaft guard.
5. Refilling with oil

1) Tighten drain plug and add transmission oil.
Transmission: 40 l
« Run the engine to circulate the oil through

042103
the system. Then check the oil level again.
30-93
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
3 1
ground and stop the engine. Then apply the parking 2
Disconnect the cable from the negative (–) terminal

of the battery.
DEW01456
1. Ladder
Remove left ladder (1).
Ladder (left): 66 kg
2. Covers
1) Remove left side cover (2) of rear frame. 10 11
2) Remove bottom cover (3) of cab.
3) Remove front cover (3-1) of bulkhead. 3-1
8 9
3. Electric wiring
Disconnect following electric wiring.
6 7
1) Disconnect wiring TL1 (4) and TL2 (5) for trans-
5
042103
mission. 4
2) Disconnect floor wiring harnesses LR5 (6), LR6 DEW00736 DEW00500
(7), LR3 (8), LR4 (9), LR1 (10), and LR2 (11).
3) Disconnect solenoid valve wiring (12) of trans-
mission control valve at connector.
« After disconnecting the connectors, mark 10 11 9
with tags to distinguish when installing.
8
4
5 7 DEW00497
13
12
DEW01460
30-94
5. Hydraulic piping 14
1) Disconnect hose (14) between transmission,
15
torque converter pump and flow valve at flow
valve end. 1
2) Disconnect hose (15) between flow valve and 16
transmission oil filter at flow valve end. 2 19
3) Disconnect hose (16) between transmission oil
filter and transmission control valve at control
valve end. 3
17
4) Disconnect hose (17) between transmission con-
trol valve and cooler at control valve end.
4 20 DEW01463
« Fit blind plugs in the hoses to prevent the

6. Remove flow valve (19) from transmission case.

5
042103

1) Do as follows with mounting bolts (19-1) of trans- 19-1
mission control valve.
a) Loosen bolts marked . 20
b) Remove 4 bolts at bottom.
c) Loosen 3 bolts at top to a point where they
17
extend 25 mm, then fix in position with
wedges. 6
3 bolts at top
Wedge
Valve
DEW01464
25 mm DEW01462
2) Move control valve (20) down, remove bolts

marked ∆, then install eyebolt (M=12), and lower
control valve assembly (20). 7
Transmission control valve: 55kg

« Remove the gasket from the control valve.
30-95
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1 3
Hose connection:
176.5 ± 29.4 Nm (18.0 ± 3.0 kgm)
2 4
5
Mounting bolt: Thread tightener (LT-2)
Mounting bolt:
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
6
« When installing the control valve, be careful not
042103
to hit the solenoid valve or other parts.
7
« Use a new part for the gasket.
Mounting bolt (marked with s):

Mounting bolt:
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
30-96
DISASSEMBLY OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
1. Disassembly of modulation, accumulator, upper, lower
valve
1) Remove mounting bolts (3) (marked with ) of
upper valve assembly, then remove gasket (4).
dirt or dust from entering the valve.
042103
30-97
2) Electronic controlled modulation valve (ECMV)

i) Remove mounting bolts (7) of ECMV (6), 6
9 10 6
then remove valve and O-ring (8).
ii) Remove mounting bolts (10) of connector
bracket (9), then remove bracket.
iii) Remove remaining mounting bolts (10) of
upper L cover (11), then remove cover and 7
gasket (12).
« After removing, cover with tape to pre- 11
vent dirt or dust from entering the valve.
7
11 12 8
DEW00748 DEW00749
Main relief Modulation

valve valve
Torque converter
outlet valve
042103
DEW00750
3) Modulation valve
i) Remove modulation valve (14) from upper 14 13
valve body (13).
ii) Remove spring (15) and modulation piston
(16) from modulation valve (14).
« After removing, cover with tape to pre-
vent dirt or dust from entering the valve. P
P
15 16
DDW00751
4) Main relief valve

i) Remove valves (18) and (19) from main 17 18 20 19
relief valve (17), then remove main relief
valve from valve body.
ii) Remove main relief spring (21).
DDW00752
21
30-98
5) Torque converter outlet valve

Remove dummy spool (22), torque converter
outlet spring (23) and torque converter outlet 22
valve (24) from valve body.
23
24
DDW00753
6) Pilot valve
i) Remove mounting bolts (26) from upper R
cover (25), then remove cover and gasket 26
(27). 28 25
ii) Remove pilot valve (28) and pilot spring (29)
from valve body. 27
29
042103
DDW00754
4. Disassembly of upper valve assembly

5
1) Manual valve
i) Loosen mounting bolt (2) of lock plate (1),
remove lock plate, pull out manual valve 1
spool (3), then remove O-ring (4).
ii) Remove plug (5) from valve body.
4
1
3 2 3 2
DEW00746 DDW00747
30-99
2) Upper L cover
i) Remove mounting bolts (7) of connector 7
bracket (6), then remove bracket. 6
ii) Remove remaining mounting bolts (7) of
upper L cover (8), then remove cover and 8
gasket (9).
« After removing, cover with tape to pre- 9
DDW00757
3) Pilot valve
Remove pilot valve (11) and pilot spring (12) 12 11 10
from valve body (10).
042103
DDW00758

i) Remove valves (14) and (15), and spring 13 14 16 15
(16) from main relief valve (13), then re-
move main relief valve from valve body.
ii) Remove main relief spring (17). 17
DDW00759

Remove dummy spool (18), torque converter
outlet spring (19) and torque converter outlet 18
valve (20) from valve body.
dirt or dust from entering the valve. 19
20
DDW00760
30-100
5. Disassembly of lower valve assembly

Solenoid valve
1) Solenoid valve, pilot filter Solenoid valve
i) Remove directional selector solenoid valve
(1) and O-ring from lower valve.
ii) Remove H-L selector solenoid valve (2), range
selector solenoid valve (3), and O-ring from
lower valve.
iii) Remove pilot filter from lower valve.
Solenoid valve Lower valve Pilot filter

DEW00762
1
1
2
3
042103
4 Lower valve
DDW00763
30-101
2) Lower L cover
Remove mounting bolts (6) of lower L cover (5), 6
then remove cover and gasket (7).
« After removing, cover with tape to prevent 5
dirt or dust from entering the valve. 7
DDW00764
3) Directional selector valve

Remove F return spring (9) and sleeve (10) of
directional valve from valve body (8), then re- 9
move valve spool (11). 10
11
042103
DDW00765
4) H-L selector valve

i) Remove spool (12) of H-L valve from valve 12
body.
ii) Remove plug (13) from spool (12), then 12
remove spring (14) and ball (15).
vent dirt or dust from entering the valve. 15
14
13
DDW00766
5) Range selector valve

i) Remove spool (16) of range selector valve 16
from valve body.
ii) Remove plug (17) from spool (16), then re- 16
move spring (18) and ball (19).
vent dirt or dust from entering the valve. 19
18
17
DDW00767
30-102
6) Priority valve
Remove spool (20) and stopper (21) of priority 20
21
DDW00768
7) Parking brake valve

Remove spool (22) and return spring (23) of 22
parking brake valve from valve body.
23
042103
DDW00769
8) Lower R cover
i) Remove mounting bolts (25) of lower R cover 24 29 30 31
(24), then remove cover and gasket (26). 25
ii) Remove R return spring (27) and sleeve 26
(28) of directional valve, return springs (29)
and (30) of H-L selector valve and range
27
selector valve, and spring (31) of priority
28
DDW00770
30-103
24 29 30 31
1. Assembly of lower valve assembly 25
1) Lower R cover 26
i) Install R return spring (27) and sleeve (28)
of directional valve, return springs (29) and
(30) of H-L selector valve and range selec- 27
tor valve, and spring (31) of priority valve to
valve body. 28
« Free height of spring:
42 mm (27)
48 mm (29), (30) DDW00770
150 mm (31)
ii) Install gasket (26), and tighten lower R cover
(24) with mounting bolts (25).
Lower R cover mounting bolt:

31.4 ± 2.9 Nm (3.2 ± 0.3 kgm)
042103
2) Parking brake valve
Install spool (22) and return spring (23) of park- 22
ing brake valve to valve body.
« Free height of spring: 46 mm (23)
Outside circumference of parking brake

valve spool: Oil (EO10-CD)
23
DDW00769
3) Priority valve
Install spool (20) and stopper (21) of priority 20
valve in valve body.
Outside circumference of priority valve

spool: Oil (EO10-CD)
21
DDW00768
30-104
4) Range selector valve

i) Install spring (18), ball (19), and plug (17) to 16
spool (16).
« Free height of spring: 23.5 mm 16
Range selector spool plug (17):

9.8 – 12.8 Nm (1.0 ± 1.3 kgm) 19
Range selector spool plug (17):
ii) Install spool (16) of range selector valve to 17

valve body. DDW00767
Outside circumference of range se H-L selector valve

lector spool: Oil (EO10-CD)
12
5) H-L selector valve
i) Install spring (14), ball (15), and plug (13) to 12
spool (12).
« Free height of spring: 23.5 mm
15
H-L selector spool plug (13):
9.8 – 12.8 Nm (1.0 – 1.3 kgm) 14
H-L selector spool plug (13):
042103

« Part of spool (12) on the WA400-3S is DDW00766
a different shape from spool (12) on the
WA400-3H.
ii) Install spool (12) of H-L valve to valve body.
Outside circumference of H-L se

lector spool: Oil (EO10-CD)
12 WA400-3S: 5.5 mm
WA400-3H: 8.5 mm
DEW02325
6) Directional selector valve

Install F return spring (9) and sleeve (10) of
directional valve to valve body (8), then install 9
valve spool (11). 10
« Free height of spring: 42 mm
Outside circumference of direc 11

tional selector valve spool:
Oil (EO10-CD) 8
DDW00765
30-105
« WA470-3H: 8.0 mm
WA400-3S:8.0
WA420-3H: 5.0 mm
mm
WA400-3H: 8.0 mm
DEW02326
7) Lower L cover
Install gasket (7) to valve body, and set lower L 6
cover (5) in position, then tighten with mounting
bolts (6). 5
« Use a new part for the gasket. 7
Lower L cover mounting bolt:

31.4 ± 2.9 Nm (3.2 ± 0.3 kgm)
042103
DDW00764
8) Solenoid valve, pilot filter

i) Install pilot filter to lower valve. 1
1
Filter mounting bolt: 2
68.6 ± 4.9 Nm (7.0 ± 0.5 kgm)
ii) Install O-ring to lower valve, then install H-L
selector solenoid valve (2) and range selec-
tor solenoid valve (3). 3
iii) Install O-ring to lower valve, then install di-
rectional selector solenoid valve (1).
4 Lower valve
DDW00763
« Check that the O-ring is fitted securely.

Solenoid valve
« Assemble the part of parking brake so-
Solenoid valve
lenoid valve (4) with the OUT stamp.
Solenoid valve (1) – (4):
1.7 ± 1 Nm (0.17 ± 0.1 kgm)
Solenoid valve Lower valve Pilot filter

DEW00762
30-106
042103
30-107
042103
30-108
2. Assembly of upper valve assembly

1) Pilot valve
i) Install pilot valve (28) and pilot spring (29) to 26
valve body. 28 25
« Free height of spring (29): 60 mm
27
Outside circumference of pilot
29
ii) Install gasket (27), and set upper R cover

(25) in position, then tighten with mounting
bolts (26). DDW00754
Upper R cover mounting bolt:

31.4 ± 2.9 Nm (3.2 ± 0.3 kgm)
042103

Install torque converter outlet valve (24), torque
converter outlet spring (23), and dummy spool 22
(22) to valve body.
Outside circumference of torque con

verter outlet valve spool, dummy spool: 23
Oil (EO10-CD)
24
DDW00753

17 18 20 19
i) Install main valve spring (21).
ii) Install valves (18) and (19), and spring (20)
to main relief valve (17), then install main
relief valve (17) to valve body.
Outside circumference of valves

(18), (19): Oil (EO10-CD)
Outside circumference of main re
DDW00752
lief valve spool: Oil (EO10-CD) 21
30-109
4) Modulation valve
i) Install spring (15) and modulation piston (16) 14 13
to modulation valve (14).
ii) Install modulation valve (14) to valve body
(13).
P
Outside circumference of modu
lation valve spool, piston: P
Oil (EO10-CD) 15 16
5) Electronic controlled modulation valve (ECMV) DDW00751

i) Install gasket (12), and set upper L cover
(11) in position, then tighten with mounting
bolts (10) together with connector bracket
(9). 6
9 10 6
Upper L cover mounting bolt:

31.4 ± 2.9 Nm (3.2 ± 0.3 kgm)
ii) Install O-ring (8), and tighten ECMV (6) with 7
mounting bolts (7).
« Check that the O-ring is fitted securely. 11
042103
ECMV mounting bolt (7): 12 8
11.8 – 14.7 Nm (1.2 – 1.5 kgm) 11
DEW00748 DEW00749
Main relief Modulation

valve valve
Torque converter
outlet valve
DEW00750
6) Manual valve
i) Install plug (5) to valve body.
ii) Assemble manual valve spool (3), and install
5
O-ring (4), then secure lock plate (1) with
mounting bolt (2).
1
Outside circumference of manual
Plug (4): 4
39.2 ± 4.9 Nm (4.0 ± 0.5 kgm) 1
3 2 3 2
Lock plate mounting bolt: DEW00746 DDW00747
53.9 ± 19.6 Nm (5.5 ± 2.0 kgm)
30-110
3. Assembly of modulation, accumulator, upper, lower

valve
1) Install gasket (4), then install upper valve assem-
bly with mounting bolts (3) (marked with ).
Mounting bolt:
49.0 ± 4.9 Nm (5.0 ± 0.5 kgm)
042103
30-111
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY OF
TRANSMISSION
ACCUMULATOR VALVE 2 1
2nd
1st
ASSEMBLY
FORWARD
1. Remove mounting bolts (2) of cover (1) from accu-
mulator valve assembly, then remove cover and O-
ring (3).
Accumulator valve
assembly DEW00801 DEW00802
FORWARD 1st 2nd
1) Remove accumulator valves (5) from FORWARD, 1 2
1st, and 2nd ports in accumulator body (4).
3
2) Remove accumulator spring (6) and stopper (7)
from FORWARD port. 5
4 6
from 1st port.
from 2nd port.
7
042403
3. Remove mounting bolts (2) of bottom cover (1) from
accumulator body (4), then remove cover and O-ring DEW00804
(3).
30-112
ACCUMULATOR VALVE
ASSEMBLY 2 1
2nd
1st
FORWARD
1. Install bottom cover (1) and O-ring (3) to accumu-
lator body (4), and tighten with mounting bolts (2).
Mounting bolt:
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
Accumulator valve
assembly DEW00801 DEW00802
2. Accumulator valve (WA400-3H)

1) Install accumulator spring (6) and stopper (7) FORWARD 1st 2nd
1 2
to FORWARD port, 1st port, and 2nd port.
3
« Free height of accumulator spring:
185 mm 5
« Length of stopper: 136 mm
2) Install accumulator valve (5) to each port. 4 6
Outside circumference of accumula-
tor valve: Oil (EO10-CD)
7
042403
DEW00804
30-113
4) Install accumulator valves (5) to each port.

Outside circumference of accumula-
tor valve: Oil (EO10-CD)
4. Install top cover (1) and O-ring (3) to accumulator

body (4), and tighten with mounting bolts (2).
Cover mounting bolt:

34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
042403
30-114
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE
SHAFT ASSEMBLY
a
1
1) Remove coupling and tube (1).
« Make match marks a to prevent the cou-
pling from being installed in the opposite
direction.
DEW00809
« Cover (11) is caulked at 4 places with a

punch, so do not remove it unless neces- 1 Caulking
sary.
« When removing cover (11), be careful not
to damage cover (11) or tube (1).
« When removing the caulking, use a screw-
driver to raise the caulked portion.
042403
11
DEW00810
Caulking 11 Washer
Seal
DEW00811
2) Loosen bolt (2), and remove coupling (3) and

retainer. 3
2
« Make match marks to prevent the coupling
from being installed in the opposite direc-
tion.
3) Using press, pull out flange bearing (4).
DDW00812
30-115
2. Center drive shaft, rear drive shaft

« Carry out the same operation as in Step 1) for
the front drive shaft.
« When removing the rear drive shaft, push it in
towards the transmission.
3. Spider, bearing
1) Remove bolts (6) of spider and bearing assem-
bly (5), and tap with plastic hammer to remove. 5 6
042403
DEW00813
2) Remove strap (8) of spider (7), and pull out

bearing cap (10). 8
« Use the same procedure for the front,
center, and rear drive shafts.
3 10
DEW00814
30-116
ASSEMBLY OF DRIVE SHAFT

1. Spider, bearing
1) Insert bearing cap (10) in mount of spider (7). 8
« If the spider and bearing cap is worn, re-
place the spider and bearing as a set.
« When welding strap (8) of the cap, be care-
ful not to damage the bearing with the heat.
« Assemble so that the grease nipples are
facing in the same direction.
« Use the same procedure for the front,
center, and rear drive shafts. 3 10
DEW00814
2) Set spider and bearing assembly (5) to drive

shaft mount, and lock with bolt (6).
Mounting bolt:
5 6
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
Bearing cap: Grease (G2-LI)
042403
DEW00813

1) Press fit flange bearing (4).
4
« Do not knock the flange bearing in directly
with a hammer.
DEW00817
2) Align match marks, and tighten coupling (3)

and retainer (9) with mounting bolt (2).
« Tighten the bolt to the specified tightening 2
torque after installing to the machine.
Spline portion: Grease (G2-LI)
Mounting bolt: 926.7 ± 98.1 Nm
(94.5 ± 10.0 kgm)
9
3
DEW00818
30-117
3) Align match marks, and install coupling and

tube (1).
« Check that the couplings are facing in the
same direction.
1
« If the spline is worn, replace the whole
drive shaft assembly.
Spline portion: Grease (G2-LI)
DEW00819
« If cover (11) has been removed, carry out

the operation in the following order. 1 Caulking
i) Insert seal and washer in cover (11) and
tube (1), assemble cover (11), then caulk
with a punch at points on diametrically op-
posite sides.
042403
11
DEW00810
Caulking 11 Washer
Seal
DEW00811
3. Center, rear drive shaft

« Carry out the same operation as in Step 3) for
the front drive shaft.
30-118
DISASSEMBLY AND ASSEMBLY FRONT AXLE
REMOVAL OF FRONT AXLE

ASSEMBLY

ground and stop the engine. Then apply the park-
ing brake and put blocks under the wheels to pre-
vent the machine from moving.
Release the remaining pressure inside piping.

For details, see REMOVAL OF RADIATOR AS-
SEMBLY.
• Jack up the axle, and set block under the front

frame.
1. Tire, wheel
Sling left and right tires and wheels (1) of front
axle, then remove mounting nuts and lift off. 1
1
Tire, wheel: 550 kg (23.5-25 tire)
644 kg (26.5-25 tire)
042403
DEW00822 DEW00823
2. Drive shaft
Disconnect front drive shaft (2) from front axle.
2
Front drive shaft: 31.2 kg
« Make match marks on the drive shaft and the
coupling.
DEW00824
30-119
3. Brake piping
1) Remove cover of plate at front of front frame,
disconnect front brake piping and tube (3) be-
tween brake valve and slack adjuster at slack 3
adjuster end.
2) Remove tubes (4) and (5) between slack ad-
juster and left and right wheel cylinders.
« After disconnecting the piping, fit plugs to
5
4 DEW02327
4. Front axle
1) Sling one end of front axle housing and fit a
jack under other end. 6
2) Fit jack under differential case.
3) Remove mounting bolts (7), then use hoist and
jack to maintain balance and lift off.
3
« Be careful not to let slack adjuster on top
of axle housing hit frame.
042403
Front axle: 1388 kg
7 DEW02328
4) Pull out front axle from chassis.
30-120
INSTALLATION OF FRONT
AXLE ASSEMBLY

moval.
1
Tire mounting nut:
470.7 ± 49.0 Nm (48.0 ± 5.0 kgm)
« Remove the block from under the front frame.
2
« Clean the connections and mating surface of
the drive shaft.
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
3
Front axle mounting bolt:
1618.1 ± 166.7 Nm (165.0 ± 17.0 kgm)
• Bleed the air from the brake system and carry out
an actuation check.
« For details, see TESTING AND ADJUSTING,
Bleeding air.
042403
• Add hydraulic oil through the oil filler of the hy-

draulic tank to the specified level.
30-121
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL OF REAR AXLE

ASSEMBLY

Release the remaining pressure inside piping.

SEMBLY.
• Jack up the axle, and set block under the rear

frame.
042403
Garage jack DEW00827 DEW00828
1. Tire, wheel
Sling left and right tires and wheels (1) of rear axle,
then remove mounting nuts and lift off.
1
1
644 kg (26.5-25 tire)
DEW00829
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle. 2
2
DEW00830
30-122
3. Brake piping
1) Disconnect rear brake piping and hose (3) be- 6
tween brake valve and slack adjuster at slack
adjuster end.

« Always remove the brake tubes before re-
moving the axle. There is danger that they 3
may be crushed when the axle is lifted off. 7
DEW00849
4. Grease tubes
Disconnect grease tubes (6) and (7) from rear axle
support. 4 5
042403
DEW00850
5. Rear axle, support

1) Secure axle support and rear axle with chain.
2) Sling rear axle housing with nylon lifting tool, Chain
and remove both left and right mounting bolts
(8). 3
Rear axle, support: 1376 kg
3) Pull out rear axle and support together from

chassis, then lower. 4
« Maintain the balance of the axle when low-
ering it. 8 DEW00851
« Remove the axle after removing the fuel

tank.
« For details, see REMOVAL OF FUEL
TANK.
30-123
6. Rear support
(Front Rear axle 13 (Rear
1) Sling rear support of rear axle and support support) support)
assembly, and remove thrust cap (9). 5
2) Remove thrust washer (10), thrust plate (11),

and thrust washer (12) from rear axle. 6 9
3) Lift off rear support. 7 11
Rear support: 148 kg

18 17 16 14 15 12 10
4) Remove packing (14) and bushing (15) from DEW00831
rear support. 8
7. Front support
1) Remove retainer (18) of front support, then re-
move O-ring and packing. 9
2) Remove packing (16) and bushing (17) from

front support. 10
042403
30-124
INSTALLATION OF REAR AXLE

ASSEMBLY

moval.
1
Tire mounting nut:
470.7 ± 49 Nm (48.0 ± 5.0 kgm)
« Remove the block from under the rear frame.
2
the drive shaft.
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
3
Axle support mounting bolt:
1029.7 ± 98.7 Nm (105.0 ± 10.0 kgm)
« After installing the rear axle, install the fuel tank.
« For details, see INSTALLATION OF FUEL TANK.
4
« Secure the rear axle and the axle support (rear
042403
support) with a chain.

« Be careful not to damage the packing with the
rear axle coupling.
Rear axle front mount: Grease (G2-LI)
5
Thrust cap mounting bolt:
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
Thrust cap mounting bolt:

6
Thrust washer: Grease (G2-LI)
Thrust plate mounting bolt:
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
Thrust plate mounting bolt:
30-125
7
Rear support
« Pay attention to the direction of the packing, fit
it securely in the groove, and assemble so that Packing
Clearance b
the lip is not turned over. Chamfered side
« Check that the slit in the bushing is facing the Bushing
side.
Rear axle mount: Grease (G2-LI)
8 10
« Set so that the chamfered side of the bushing is
on the axle housing side, and assemble so that
the clearance is clearance b. DEW00832
« Clearance b: Min. 0.5 mm
it securely in the groove, and assemble so that
Front support
the lip is not turned over. Clearance c
Packing
« Install the bushing and packing to the front sup-
Bushing
port in the same way as for the rear support. 14
« Clearance c: Min. 0.5 mm
042403
DEW00833
9
« Use new parts for the O-rings and packing.
it securely in the groove, and assemble so that
the lip is not turned over.
Retainer mounting bolt: 18
Thread tightener (LT-2) O-ring
• Bleed the air from the brake system and carry out
an actuation check.
Bleeding air. Packing
• Add hydraulic oil through the oil filler of the hydrau- DEW00834
lic tank to the specified level.
30-126
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
REMOVAL OF FRONT
DIFFERENTIAL ASSEMBLY


BLY.

frame.
1. Tires, wheels
Sling left and right tires and wheels (1) of front axle, 1
then remove mounting nuts, and lift off.
1
644 kg (26.5-25 tire)
042403
DEW00822 DEW00823
2. Drive shaft
1) Disconnect front drive shaft (2) from front axle.
2
Front drive shaft: 31.2 kg 2-1
« Make match marks on the drive shaft and

coupling.
2) Remove flange bearing (2-1), and move front 2

drive shaft towards right side.
DEW00837 DEW00838
30-127
3. Draining oil
Set plug (3-1) immediately at bottom, then remove it
4
and drain oil.
Axle oil: 60 l
4. Cover
Remove cover (3), then remove O-ring (4). 3
3-1 3
DEW00839 DEW00840
5. Axle shaft
Using forcing screws (Thread dia.=12mm,
Pitch=1.75mm), pull out axle shaft (5) approx. 200
mm together with sun gear (6).
5 6
042403
DEW00841
6. Slack adjuster
1) Remove following hydraulic piping clamps.
• Clamps for tube (7) between slack adjuster
and axle.
8
« Remove both the left and right clamps.
• Clamp for tube (8) between slack adjuster
and brake chamber.
2) Remove mounting bolts of slack adjuster bracket
(9), and insert block between slack adjuster and 7
axle.
« When removing the differential, set the
bracket at a height where there is no inter- DEW02329
9 DEW02330
ference.
7. Differential
1) Remove 2 mounting bolts of differential (10),
and install guide bolts (Thread Dia.=14mm, 10 11
Pitch=2mm, Length=50mm).
« Screw in the thread of the guide bolts fully.
« First, screw in the guide bolts, then remove
the remaining mounting bolts.
2) Fit lifting tool to differential case (11).
DEW00844
30-128
3) Install forcing screws, and pull differential (10)

along guide bolt to pull it out approx. 20 mm 11
from axle housing. 4
« Be careful not to damage the O-ring of the
differential.
4) Install tools B and C to jack, and insert between
differential and axle housing, then install differ-
ential (10) to tool B.
5) Adjust height of lifting tool and jack, and remove B
differential (10) slowly. 12
10
Differential: 235 kg C DEW00845 DEW00846
6) Operate jack, and pull differential out from chas-

sis, then remove O-ring (13). 5
13
042403
DEW00847
30-129
INSTALLATION OF FRONT

moval.
2-1
1
Tire mounting nut:
470.7 ± 49 Nm (48.0 ± 5.0 kgm)
2 2
• Fit flange bearing (2-1) temporarily.
• Connect front drive shaft (2) to the differential DEW00837 DEW00838
and the center drive shaft ends.
• Tighten flange bearing (2-1) fully.
« When connecting the drive shaft, clean the
mating surface of the spider and the cou-
pling, then install.
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
Flange bearing mounting bolt:
549.2 ± 58.8 Nm (56.0 ± 6.0 kgm)
3
042403
4
• Adjust the lifting tool and the height of the jack
for the differential, and assemble the differential
along the guide bolt.
« Fit the O-ring securely in the groove, and 11
be careful that it does not get caught when
installing.
• When the clearance between axle housing (12)
and differential (10) is approx. 20 mm, remove
installation tool B and tighten the mounting bolts
uniformly.
Differential mounting bolt: B
12
Differential mounting bolt: 10
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm) C DEW00845 DEW00846
5
30-130

• Tighten the drain plug and add oil through the
level plug to the specified level.
« Set the machine with the drain plug immedi-
ately at the bottom, then add oil through the
level plug.
Axle oil: 60 l
• Add hydraulic oil through the oil filler of the
hydraulic tank to the specified level.
• Bleed the air from the brake system and carry
out an actuation check.
« For details, see TESTING AND ADJUST-
ING, Bleeding air.
042403
30-131
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
REMOVAL OF REAR


BLY.
• Jack up the axle, and set block under the rear

frame.
042403
1. Tires, wheels
Sling left and right tires and wheels (1) of rear axle,
then remove mounting nuts, and lift off.
1
1
644 kg (26.5-25 tire)
DEW00829
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle. 2
2
DEW02361
30-132
3. Brake piping
1) Disconnect hose (3) (between brake valve and 6
slack adjuster) of rear brake piping at slack
adjuster end.
« Always remove the brake tubes before re-
moving the axle. There is danger that they
may be crushed when the axle is lifted off. 3 7
DEW00856
4. Grease tubes
Disconnect grease tubes (6) and (7) from rear axle
support.
4 5
042403
DEW00857
5. Rear axle support

1) Secure axle support and rear axle with chain. Chain
2) Sling rear axle housing with nylon lifting tool,

and remove both left and right mounting bolts
(8). 3
Rear axle and support: 120kg
3) Pull out both rear axle and support from chas-

sis, then lower. 4 8 DEW00858
« Maintain the balance of the axle when low-

ering it.
« Remove the axle after removing the fuel
tank.
« For details, see REMOVAL OF FUEL TANK.
30-133
6. Draining oil
Set plug (9-1) immediately at bottom, then remove it
10
and drain oil.
Axle oil: 65 l
7. Cover
Remove cover (9), then remove O-ring (10).
5
9-1 9
DEW00859 DEW00860
8. Axle shaft
Using forcing screws (Thread dia.=12mm, 14 13
Pitch=1.75mm), pull out axle shaft (11) and sun
gear (12) approx. 200 mm. 6
11 12
9. Slack adjuster
Remove cover (13) from axle, then remove slack
adjuster (14) together with bracket.
042403
DEW00861 DEW00862
10. Rear differential

Using forcing screws, lift off rear differential (15),
then remove O-ring from rear differential. 7
15
Rear differential: 244 kg
DEW00863
30-134
INSTALLATION OF REAR

moval.
1
Tire mounting nut:
470.7 ± 49 Nm (48.0 ± 5.0 kgm)
« Remove the block from under the rear frame.
2
the drive shaft.
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
3
Axle support mounting bolt:
1029.7 ± 98.1 Nm (105.0 ± 10 kgm)
« After installing the rear axle, install the fuel tank.

« For details of the installation of the fuel tank, see
INSTALLATION OF FUEL TANK.
042403
4
« When installing the rear axle to the chassis, be
extremely careful not to damage the bushing
and packing of the front support with the differ-
ential coupling.
« Secure the rear axle and the support (rear end)
with a chain, then install to the chassis.
Rear axle front support portion:
Grease (G2-LI)
5
6
« When inserting axle shaft (11), rotate the differ-
ential coupling lightly by hand to install.
Do not push it in by force.
30-135
7
« Fit the O-ring securely in the groove, and be
careful that it does not get caught when install-
ing.
Differential mounting bolt:
Differential mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)

• Tighten the drain plug and add oil through the
level plug to the specified level.
« Set the machine with the drain plug immedi-
ately at the bottom, then add oil through the
level plug.
Axle oil: 65 l
• Add hydraulic oil through the oil filler of the
hydraulic tank to the specified level.
• Bleed the air from the brake system and carry
out an actuation check.
« For details, see TESTING AND ADJUST-
ING, Bleeding air.
042403
30-136
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY OF
1. Differential gear
2
1) Remove ring gear adjustment bolt. 1
2) Loosen adjustment ring lock bolt, and remove
lock plate (2).
« Rotate the adjustment ring, and separate the
differential gear from the pinion gear.
3) Remove bearing cap (2).
« Check the match marks on the left and right
bearing caps. Make new match marks if the
old match marks cannot be seen. DEW00864
4) Remove adjustment ring (3) and bearing cup
(4).
4
3
042403
DEW00865
5) Remove differential gear (5) from differential

case.
« The pilot bearing will hit the carrier, so tip it
over slightly to the right when lifting it off.
Differential gear assembly: 75 kg 5
DEW00866
2. Plain half
1) Remove bearing (6).
2) Remove plain half (7).
« Check the match marks. Make new match
marks if the old match marks cannot be 7
seen. 6
DEW00867
30-137
3) Remove LSD inner (A) and outer (B) clutch plates,

and cage halfs (C).
4) Remove side gear (8), cross shaft (9), thrust

washer (10), and pinion gear (11). 8
042403
11 10 DEW00869
3. Ring gear, flange half

2) Remove mounting bolts, then remove ring gear
(13) and flange half (14). 12
4. Turning over
Turn over differential gear.
14
13
DEW00870
5. Pinion gear
1) Loosen mounting bolts of coupling (15).
« Leave the coupling temporarily fitted.
15
DEW00871
30-138
2) Remove pinion gear (17) from differential case

(16).
17
« Check the shim thickness and use as a 16
guide when assembling.
DEW00872
6. Pinion shaft
1) Using press, pull out pinion shaft (18).
19
042403
18
DEW00873
2) Remove bearing cups (20) and (21) from cage

(19).
21
20 19
DEW00874
3) Remove pilot bearing (22) and bearing (23)

from pinion shaft (18). 18
« Do not remove pilot bearing (22) and bear-
ing (23) unless necessary.
« Use the same procedure to disassemble the
front differential.
22 23 DEW00875
30-139
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
Block
« When replacing the pinion or ring gear, always
replace them as a set, and be careful not to mix 22
them with other sets. 18 23
Replace the flange half and plain half also as a set. 18
1. Pinion shaft
1) Press fit pilot bearing (22) to pinion shaft (18).
2) Press fit bearing (23) to pinion shaft (18).

« Press-fitting force for bearing (23), pilot DEW00876 DEW00877
bearing (22): 49 kN (5 ton)
3) Press fit bearing cups (20) and (21) to cage

(19). 25
« Press-fitting force for bearing cup: 49 kN (5 19
ton)
Inside diameter of cage, outside di-
ameter of cup: Axle oil
20
4) Assemble cage (19) to pinion shaft (18), then 21
assemble spacer (25).
There should be
042403
no clearance.
19
DEW00878 18 DEW00879
2. Adjusting preload
1) Press fit bearing (24) to pinion shaft (18).
2) Push bearing with press, and measure rotating 24

force of cage with a spring balance.
Bearing portion: Axle oil
« Coat the bearing portion fully with oil, and
settle it before measuring.
« Press force: 202 kN (20.6 ton) 18
« Reading of spring balance:
Max. 14.7 N (1.5 kg)
DEW00880
DEW00881
30-140
3) If the measured value is not within the standard

value, replace bearings (23) and (24) and spacer 24
(25) with new parts, then adjust again.
4) If the measured value is within the standard
value, check that the end play of cage is also
within the standard value. 25
« End play: Max. 0.212 mm
23
DDW00882
3. Pinion gear
1) Press fit oil seal (27) and dust seal (27A) to Make
cage (26). 27A surfaces flush Make surfaces flush
« Use new parts for the oil seal and dust seal, 10 ± 0.5 10 ± 0.5
and be careful to install facing in the correct 27A
direction.
Lip of oil seal, lip of dust seal: 27
Grease (G2-LI)
Press-fitting portion of oil seal, 26
dust seal: Thread tightener (LT-2) 27 26
042403
Front Rear
DEW00883
2) Install O-rings (26A) and (15A), then install cage

(26) and coupling (15). 15
Coupling mounting bolt:
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
15A
26
27A
26A
27
DDW00884
3) Assemble pinion gear assembly (17) to differen-

tial case (16) without installing shims.
Cage mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm) 17
16
DDW00885
30-141
4) Install tool D to differential case (16).

5) Measure distance “L” from tool D to pinion gear, D
and calculate shim thickness.
« When replacing the bearing, pinion gear,
and ring gear, use the above procedure to
adjust the shim.
Shim thickness:
Standard value – (L – thickness of tool)
« Standard value: (228 + a) – (106 + b)
Depth micrometer
DEW00887
D Thickness of tool
Dimensions a and
b stamped here L 17
16
DEW00886
042403
6) Assemble pinion gear (17) and shim to differen-
tial case (16), and tighten mounting bolts. DEW00872
Mounting bolt:
Mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2 kgm) 27 14 12
4. Ring gear
1) Knock pin (27) into flange half (14) so that it
protrudes distance a from case. a
« a = 3.5 mm
2) Press fit bearing (12) to flange half (14).
3) Install flange half (14) to ring gear (13).
Mounting bolt:
Mounting bolt: DEW00889 DEW00890
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
14 13
DEW00891
30-142
5. Side gear
Install washer (28), LSD inner (A), outer (B) clutch
plates, and cage halfs (C) and assemble side
gear (8).
« Insert the washer securely to the pin inside the
case.
Washer: Grease (G2-LI) (both faces)
6. Pinion gear
Assemble pinion gear (11) and thrust washer (10) to 9 7
cross shaft (9).
« Align the stopper position of the thrust washer
when assembling.
Thrust washer (gear contact surface): a
Axle oil
7. Plain half
1) Knock pin (27) into plain half (7) so that it 27
protrudes distance a from plain half.
« a = 3.5 mm 11
042403
10
DEW00893 DEW00895
2) Install washer (28), and assemble side gear (8).

« Insert the washer securely to the pin inside
28 8
the case.
Washer: Grease (G2-LI) (both faces)
DEW00896
3) Press fit bearing (6) to plain half (7).

4) Install plain half (7). 7
« Insert cross shaft (9) securely in the groove
6
of the case and plain half.
« Check match marks, then set in position
7
and install.
Mounting bolt:
Mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2 kgm)
DEW00897 DEW00898
30-143
8. Differential gear
1) Raise gear (5), and assemble bearing cup (4)
5
to bearing, then install to case.
4
DEW00899
2) Align with thread of differential case (16), and

install adjustment ring (3). 2
3
3) Align match mark and install bearing cap (2).
« Be careful not to damage the thread of the 16
cap.
042403
DEW00900
9. Adjusting preload of bearing

1) Turn adjustment ring with a bar until ring gear
contacts pinion gear, and adjust until there is no
more backlash.
« Rotate the bearing sufficiently to give com-
plete contact between the bearing and other
contact parts, then tap the ring gear with a
copper hammer.
« Coat the bearing well with oil.
« If the adjustment ring on one side is loos-
ened one turn, tighten the adjustment ring
on the other side by one turn. DEW00901
2) Install spring balance to ring gear, and measure

free rotation torque.
Free rotation torque:
19.6 – 24.5 N (2.0 – 2.5 kg)
« Target value: 24.5 N (2.5 kg)
DEW00902
30-144
10. Adjusting tooth contact, backlash

• Adjust the backlash as follows.
1) Adjust the ring gear with the adjustment ring.
« When doing this, turn the adjustment rings
on both sides by the same amount in the
same direction.
2) Put a dial gauge in contact with tooth face of

outside edge of ring gear, then turn adjustment
ring to adjust.
« Keep the pinion gear fixed in position and
measure at 3 or 4 places.
« Backlash: 0.30 – 0.41 mm
042403
DEW00903
• Adjust the tooth contact as follows.

1) Mix red lead (minium)with oil, then coat the tooth
face of 7 or 8 teeth of the ring gear.
2) Rotate the pinion gear forward and in reverse
and check the tooth contact.
« Use the following procedure to judge the
tooth contact and carry out adjustment.
30-145
11. Adjusting tooth contact

Coat face of 7 or 8 teeth of bevel gear lightly with red lead (minimum). Hold the bevel gear by hand to act
as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
Tooth contact Cause Procedure for adjustment

The tooth contact pattern Adjust the pinion gear by adjusting the shims at
should start from about the cage. Adjust the bevel gear in the same way as
5 mm from the toe of when adjusting backlash.
the bevel gear and cover
about 50% of the length
of the tooth. It should
be in the center of
DEW00910 the tooth height.
Bevel pinion gear is too 1. Reduce shims at pinion

far from bevel gear. gear to bring closer
to bevel gear. 2
2. Move bevel gear further
away from pinion
gear and adjust
backlash correctly. 1
DEW00904 DEW00908
Bevel pinion gear is too 1. Increase shims at pinion
042403
close to bevel gear. gear to move away
from bevel gear. 2
2. Move bevel gear closer
to pinion gear and adjust
backlash correctly.
1
DEW00905 DEW00909
Bevel gear is too close to 1. Reduce shims at pinion gear

pinion gear. to bring closer to bevel gear.
2. Move bevel gear further 2
away from pinion
gear and adjust
backlash correctly.
1
DEW00906 DEW00908
Bevel gear is too far from 1. Increase shims at pinion

pinion gear. gear to move away
from bevel gear. 2
2. Move bevel gear closer
to pinion gear and
adjust backlash correctly.
1
DEW00909
DEW00907
« When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left and
right. Always keep the same total thickness of shims.
30-146
12. Lock plate

After completing the adjustment of the tooth contact,
wipe off the red lead and install lock plate (1).
2
Mounting bolt: 1
176.5 ± 19.6 Nm (18.0 ± 2 kgm)
DEW00864
13. Adjusting bolt

After carrying out all adjustments, screw in bolt (29)
until it contacts rear face of the ring gear, then turn 29
30
back 1/2 turns and tighten locknut (30).
Adjustment bolt: Gasket sealant (LG-5)
Locknut: 225.6 ± 19.6 Nm (23.0 ± 2.0

kgm)
042403
DDW00913
30-147
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY


BLY.

frame.
042403
1. Tire, wheel
Jack up axle, and insert support stand under axle,
then lift off tire and wheel (1). 1
« After removing the tire and wheel, set the sup-
port stand under the axle housing portion.

644 kg (26.5-25 tire)
DEW00823
2. Draining oil 2 DEW00917
Set plug (2) immediately at bottom, then remove it

and drain oil.
Axle oil: 55 l 4
3. Cover
3
DEW00918 DEW00919
30-148
4. Axle shaft
Using forcing screws (Thread dia.=12mm, 5
Pitch=1.75mm), pull out axle shaft (5) approx. 200
mm.
6
Remove 3 mounting bolts, and lift off planetary car-
rier (6).
« Make match marks to use as a guide when
assembling.
« Be careful of the center of gravity, and remove
slowly. DEW00920 DEW00921
Planetary carrier: 86 kg
6. Ring gear E F
1) Using tools E and F, secure wheel hub (8) and
brake (9) in position.
9 8
« Install tools E and F at three equally spaced
places, then use a washer to adjust the
clearance.
042403
DEW00922
2) Remove mounting bolts of retainer (10), then

remove ring gear (11).
« Check the number and thickness of the 10
shims between the retainer and axle hous-
ing, and keep in a safe place.
Ring gear: 35 kg
11
DEW00923
7. Disassembly of planetary carrier

1) Using press, pull out shaft (12), and remove 12
pinion gear (13).
« Lock ball (14) is inserted in the shaft, so
be careful not to lose the ball.
« Write the number on the case and distin-
13
guish the parts to prevent the removed
parts from being mixed with other parts.
14
DEW00924
30-149
2) Remove bearing (17) from pinion gear (13).

« The bearings are settled in sets, so distin- 17 13
guish them to prevent them from being mixed
with other sets.
DEW00925
8. Disassembly of ring gear

1) Remove lock plate (21) from ring gear hub (20),
then remove ring gear (22). 20
21
22
042403
DEW00926
2) Using forcing screws (Thread dia.=12mm,

Pitch=1.75mm, Length=70mm), remove bearing
(23) from ring gear hub (20).
20
23
DEW00927
30-150
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Assembly of ring gear

1) Press fit bearing (23) to ring gear hub (20). 20 23
« After press fitting, check that there is no
clearance from the rib.
DEW00928
2) Set ring gear hub (20) to ring gear (22), and

install lock plate (21).
« Assemble the lock plates with the wide lock 20
plates on the inside.
« Remove all oil and grease from the tap
holes for the bolts.
Mounting bolt:
Mounting bolt:
31.4 ± 3 Nm (3.2 ± 0.3 kgm)
042403
22 21
DEW00929
2. Assembly of planetary carrier

1) Assemble bearing (17) to pinion gear (13), and
insert from bottom of carrier, then use lifting bar
to set to carrier mount. 13 17
« There are 3 pinion gears. Assemble them all
to the carrier.
17
DEW00930 DEW00931
2) Align carrier and gear hole, then press fit cooled

shaft (12).
12
Do not touch the cooled shaft directly by
hand.
« Press fit so that the lock ball hole is on the

outside. Stop just before the hole and align
the hole.
14
« Cool the shaft at –30°C for 20 minutes.
DEW00932 DEW00933
30-151
2) Assemble lock ball (14) to shaft, and press fit

shaft again. 7
« After press fitting the shaft, check that the
gear rotates smoothly.
14
17
13
12 DEW00934
3. Ring gear
1) Raise ring gear (11), and insert in axle housing.
« Align the spline groove and insert slowly. 11
042403
DEW00935
2) Tighten retainer (10) temporarily with 3 mount-

ing bolts, and remove tools E and F. E F
« Remove all oil and grease from the retainer
mounting bolt holes.
9 8
« Tighten the retainer temporarily without fit-
ting any shim.
« Rotate wheel hub (8) to settle the bearing,
and tighten so that the torque is constant.
Retainer mounting bolt:
72.6 ± 1 Nm (7.5 ± 0.1 kgm)
DEW00922
3) Use depth micrometer from measurement hole

of retainer (10) to measure clearance a be- 11
tween end face of retainer and end face of 10
housing.
« Measure at two places and take the aver- a
age. 10
« Shim thickness = Clearance a + 0.3 mm.
• Select the shim thicknesses to give the
minimum number of shims.
• Shim thickness: 1.0 mm, 0.5 mm, 0.2
mm, 0.05 mm
DEW00937 DEW00938
30-152
4) Install tool G to brake and wheel hub (8), then

remove retainer, install selected shim, and install
retainer again.
« When assembling the shim, always install
tool G first.
« Rotate wheel hub (8) and tighten uniformly
until the torque is the specified torque.
Mounting bolt: 8
Mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)
G
DEW00939
Assemble O-ring to wheel hub (8), then raise plan-
etary carrier (6), and install.
« Align the mounting holes and install slowly so
that the O-ring does not come out of position. 6
042403
DEW00940
5. Axle shaft
Install axle shaft (5). 5
« If the sun gear is not aligned, rotate the wheel
hub to align the position.
DEW00920
6. Cover
Insert O-ring (4) in groove of cover, and install
3
cover (3).
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
4
DEW00942
30-153
7. Tire, wheel
Install tire and wheel, then remove support.
Mounting nut:
470.7 ± 49 Nm (48.0 ± 5.0 kgm)
(Width across flats: 30 mm)
1
DEW00943

Tighten drain plug and add oil through level plug
(24) to specified level.
« Set the machine with the drain plug immediately 24
at the bottom, then add oil through the level plug.
Axle oil: 60 l (both front and rear)
042403
DEW00944
30-154
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN


BLY.

flowing.

TILT ´ HOLD to release the pressure inside the
accumulator.


042403

1. Covers
Remove cover (3) at bottom of cab. 1 2
3
DEW01466 DEW01439
2. Ladders
Remove left and right ladders (3-1). 3-1

DEW01440
30-155
3. Electric wiring
Disconnect the following electric wiring.
1) Disconnect front frame wiring FR1 (4) and FR2
(5).
2) Disconnect transmission wiring TL1 (6) and TL2
(7).
3) Disconnect floor wiring harnesses LR5 (8), LR6
(9), LR3 (10), LR4 (11), LR1 (12), and LR2
(13).
« After disconnecting the connectors, mark
with a tag to distinguish when installing.
12 13 11
10
11
10
8 9
8
6 7
4 5 DEW00500
6
042403
9 DEW01470
7
4. PPC piping
1) Disconnect hose (14) of PPC valve “P2” port, 19 14 16 18
hose (15) of “P4” port, hose (16) of ”P3” port,
and hose (17) of “P1” hose at PPC valve end.
15
2) Disconnect hose (18) between PPC accumula-
tor and PPC valve at valve end.
3) Disconnect hose (19) of PPC valve drain port at
valve end.
« When disconnecting the hoses, fit tags to 17
distinguish them. 14
16 17 15
entry of dirt or dust. DEW01471 DEW01472
20
PPC piping
DEW01473
30-156
5. Brake piping
1) Disconnect hoses (21) and (22) between R.H. 27
23
« Remove 2 clamps (24) of the brake hose
under the floor board.
2) Disconnect hose (23) between L.H. brake valve
3) Disconnect R.H. brake valve drain hose (25)
and L.H. brake valve drain hose (26) at rear
frame.
4) Disconnect hose (27) between front brake and
21 22 32
R.H. brake valve at center hinge pin. DEW01475 DEW01476
24
25 26
042403
21, 22
DEW01477 DEW01478
6. Air conditioner piping

1) Disconnect hose (28) between compressor and
air conditioner unit at unit end. 1 27
2) Disconnect hose (29) between receiver and air
conditioner unit at unit end. 2
3) Disconnect heater piping (30) and (31) at air
conditioner unit end.
7. Accelerator cable 3 30
Disconnect accelerator cable (32) at bottom of pedal. 31
« Remove the cable clamp under the floor board. 29
28
DEW01479
DEW01480
8. Orbit-roll hoses 4
1) Disconnect hoses (33) from steering valve.
35
33
34
DEW01482
30-157
9. Cab, floor board

1) Remove cover (37) at mount of floor board (36),
then remove 4 mounting nuts (38) of viscous 38
damper holding floor board.
37
36
DEW01483 DEW01484
2) Fit lifting tool to cab (39) and lift off cab.

5
« Raise the cab slowly, check that all parts
have been removed, then lift off the cab.
Cab, floor assembly: 470 kg
042403
39
DEW01485
10. Steering cylinder pin, bracket

1) Remove rod end of left and right steering cylin-
der pins (40). 40
DEW01486
30-158
11. Hydraulic hoses 7

1) Disconnect hose (42) between steering valve 44
and cooler. 42
2) Disconnect hose (43) between hydraulic pump
45
and main control valve.
3) Disconnect main control valve drain hose (44).
4) Disconnect hose (45) between switch pump and 46
steering valve and hose (46) between steering
pump and steering valve. 47
5) Remove hose mount bracket (47). 43
« When disconnecting the hoses, fit tags to
distinguish them. DEW01488
12. Drive shaft 8

49 48
Remove drive shaft guard (48), disconnect center
drive shaft (49) at flange bearing end, then move
drive shaft towards edge.

042403
DEW01489
13. Frame support

Rear frame
1) Jack up rear frame, adjust height, and insert
blocks.
« Insert blocks under the left and right sides
of the rear frame.
DEW00970
Blocks
2) Jack up front frame, adjust height, and insert Front frame

blocks. Then insert rollers between blocks and
frame so that front frame can be removed.
« Insert blocks and rollers under the left and
right sides of the front frame.
Roller
Blocks DEW00971
30-159
14. Lower hinge pin 9

Remove lock bolt, then remove lower hinge pin (50).
50
DEW01492
15. Upper hinge pin 10

1) Remove mounting bolts, then remove retainer
(51).
« Check the number and thickness of the
shims between the retainer and the frame,
and keep in a safe place.
2) Remove lock bolt (52), adjust height, and pull
out upper hinge pin (53).
« Adjust the height carefully and set to a point
where it is possible to remove the pin by 51
042403
hand. 53
DEW01493
52 DEW01491
3) Remove spacer (53-1).

53-1
DEW01494
16. Disconnection of frame 11

Pull out front frame towards front slowly and discon-
nect frame. Front frame Rear frame
« Be careful not to let the spacer at the bottom of
the upper hinge get caught in the rear frame.
« Be careful to maintain the balance when discon-
necting.
« Be careful to remove all the parts.
« Remove the safety bar.
« After disconnecting, secure the front frame in
position to keep it horizontal and prevent it from
moving. DEW00976
30-160
17. Lower hinge 12

1) Pull out bushing (59) from rear frame.
« Remove the lower hinge bushings at both
the top and bottom.
2) Remove retainer (60).

shims between the retainer and axle hous-
ing, and keep in a safe place.
042403
3) Remove dust seal (61) from retainer.

« Remove the dust seal at the frame end also.
30-161
18. Upper hinge pin 13

1) Remove mounting bolts,then remove retainer (63).
shims between the retainer and the frame,
and keep in a safe place.
2) Remove dust seal (64) from retainer.
042403
3) Remove spacer (65) and dust seal (66) from
front frame.
30-162
INSTALLATION OF CENTER
HINGE PIN
1
Air conditioner unit hose:
29.4 – 34.3 Nm (3.0 – 3.5 kgm)
Air conditioner hose: New refrigerant
compressor oil (ND-OILB)
2
Receiver hose:
11.8 – 14.7 Nm (1.2 – 1.5 kgm)
Receiver hose: New refrigerant compres-
sor oil (ND-OILB)
3
Cable locknut:
55 - 55 Nm (5.0 - 5.5 kgm)
4
« Refit orbit-roll hoses. Check the steering direc-
tion.
5
« Align securely with the notch hole of the viscous
042403
damper washer, then tighten.

7
8
« Align the match marks exactly.
103 - 123 Nm (10.3 - 12.3 kgm)
9
Outside circumference of lower hinge
pin: Grease (G2- LI)
30-163
10
Upper hinge pin
1) Assemble upper hinge pin (57), and assemble
spacer (58).
Outside circumference of hinge:
Grease (G2-LI)
2) Install retainer (56) to upper hinge pin, tighten

with 3 bolts, then select shims so that clear-
ance a between hinge and retainer is below 0.2
mm, then assemble.
« When adjusting shims, tighten retainer
mounting bolts temporarily to prevent from
turning.
« Tighten the retainer mounting bolts to the
specified torque, then tighten the pin mount-
ing bolts.
042403
Pin mounting bolt:
205.9 ± 19.6 Nm (21.0 ± 2.0 kgm)
(When adjusting shims)
Pin mounting bolt:
205.9 ± 19.6 Nm (21.0 ± 2.0 kgm)
Retainer mounting bolt:
107.9 ± 9.8 Nm (11.0 ± 1.0 kgm)
11
Connection of frame
Always use a bar when aligning the pin holes. Never

insert your fingers..
« Align the pin hole securely.
30-164
12
Lower hinge K2
1) Using tools H, I, K1, K2, and K3, press fit
bearing (56) and spacer (63) to front frame.
56 63
« When press fitting, use tool K3 as a guide.
« Be careful not to fit the bearing at an angle.
K3
« Fill the inside of the bearing with grease.
« When assembling the bearing, be careful H K1
K4
not to forget to assemble the spacer.
« The bearing clearance is adjusted, so do I
not change the combination with the spacer. Block
When replacing, always replace as a set. DEW02332
2) Press fit dust seal (55) to retainer.
« Press fit so that the dust seal lip surface is
facing the outside.
Lip of oil seal: Grease (G2-LI)
54 55
042403
DEW02333
Feeler gauge
DEW00993
3) Tighten retainer (54) with 4 mounting bolts, se-

lect shims so that maximum clearance a be-
tween retainer and hinge is less than 0.1 mm,
then assemble. Clearance
a
Mounting bolt:
19.6 ± 2 Nm (2.0 ± 0.2 kgm)
(when adjusting shims)
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
54
DDW02334
30-165
4) Press fit dust seal (64) to frame.

facing the outside.
Lip of oil seal: Grease (G2-LI) 64
DEW01505
13
Upper hinge
1) Assemble tools H, I, J, K2, K3, and K4 to top of
front frame upper hinge. Set bearing (61) in tool K4
K1, then set to press-fitting portion from above
and press fit.
« When press fitting, use tool K3 as a guide.
« Be careful not to fit the bearing at an angle. K1
« Fill the inside of the bearing with grease.
« When assembling the bearing, be careful
042403
not to forget to assemble spacer (62). K3
« The bearing clearance is adjusted, so do K2 DEW00997
not change the combination with spacer (62).

When replacing, always replace as a set.
J
I
K4
K1
From H
K3
61 62
61 Front frame
K2 Block
DEW01507
61
DEW01508
30-166
2) Press fit dust seal (58) to retainer (57).

facing the outside. 57 58
DEW02335
3) Tighten retainer (57) with 3 mounting bolts, se-

lect shims so that maximum clearance a be-
tween retainer and hinge is less than 0.1 mm,
then assemble.
Mounting bolt:
19.6 ± 2 Nm (2.0 ± 0.2 kgm)
(when adjusting shims)
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
042403
57 Feeler gauge DEW02342
57
Clearance
a
DDW02337
4) Assemble dust seal (58) and spacer (59) from

under front frame. 58
facing the outside. 59
« Assemble from below so that the large cham-
fered side of spacer (59) is on the bearing
side.
DEW02338
30-167

Tighten drain plugs at the top of the hydraulic tank
filter, and add hydraulic oil through the oil filler to
the specified level.
11.8 ± 1 Nm (1.2 ± 0.1 kgm)
• Bleeding air

new refrigerant
3°C.
not work.)
042403
(Attainment of vacuum: Min. 750 mmHg.)
system.
with refrigerant.
30-168
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL
REMOVAL OF ORBIT-ROLL
ASSEMBLY

« After stopping the engine, operate the steering wheel

to the left and right 2 or 3 times to set the steering
valve in the neutral position.
1. Covers
Remove covers (1) under cab.
042103
2. ORBIT~ROLL
1) Remove cover (2) of steering column.
2) Loosen lock bolt and pull out column joint
(3) from ORBIT-ROLL. 1
3) Remove hydraulic hoses (4).
4) Remove mounting bolts (5), then remove the ORBIT-
ROLL unit (6)
30-168/1
DISASSEMBLY AND ASSEMBLY ORBIT-ROLLL
INSTALLATION OF ORBIT-ROLL
ASSEMBLY
• Carry out installation in reverse order to removal.

1
Lock bolt:
55.9 ± 6.9 Nm (5.7 ± 0.7 kgm)
Orbit-roll mounting bolt:

112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
042103
30-168/2
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DISASSEMBLY OF STEERING
ASSEMBLY
« Use a wire brush to remove all the dirt and dust
stuck to the joint around the outside circumference
of the unit.
« Carry out the operation in a clean place to prevent

dirt or dust from sticking to the valve.
« As far as possible, hold the valve in a vice when

disassembling.
DISASSEMBLY OF ROTOR
1. Set rotor side facing up, and hold mounting flange

lightly in vice .
« Put acopper plate in contact with the vice and be

careful not to tighten the vice too hard.
042403
2. Remove screw (1), then remove end cap (2).
3. Remove O-ring (3) from end cap (2).
4. Pull out rotor set (4), then remove O-ring (5).

« Be careful not to drop the star inside the
rotor set.
5. Remove spacer (6).
30-169
6. Remove drive shaft (7).

10
7. Remove spacer plate (8).
8. Remove O-ring (9) from housing (10).
8
7
9
DLW01703
DISASSEMBLY OF CONTROL SIDE
9. Remove housing (10) from vice, and place on a clean

cloth. Be careful not to damage the finished surface.
11
10. Raise tip of snap ring (11) with screwdriver, and

remove from housing.
10
11. Turn spool and sleeve to place pin in a horizontal
042403
DLW01704
position, then push in spool and sleeve with your

thumb, and remove bushing (12) from housing.
12. Remove X-ring seal (13) from bushing (12). 12
DLW01705
13. Remove dust seal (14) from bushing (12) with screw-
driver. 13
« Be careful not to damage the bushing.
12
14
DLW01706
30-170
14. Remove 2 bearing races (15) and thrust needle (16)

from spool and sleeve.
15
16
15
DLW01707
15. Pull out spool and sleeve assembly (17) from hous-
ing (10) in the direction of the arrow.
« To prevent the spool and sleeve assembly from 10
catching in the housing, rotate the spool and
sleeve assembly slowly to the left and right when
pulling out from the housing.
17
16. Pull out pin (18) from spool and sleeve assembly
(17). 18
042403
DLW01708
17. Push spool (20) inside sleeve (19) slightly to front,

and remove 6 centering springs (21) from spool (20) 19
21
carefully by hand.
20
18. Turn spool (20) slowly and pull out from rear of sleeve
(19) (in the direction of the arrow).
19 20
DLW01709
19. Remove O-ring (22) from housing.
20. Remove set screw (23) from housing. 22
21. Screw a threaded bar into check sheet (24), and pull
out check sheet (24).
25
22. Remove O-rings (25) and (26) from check sheet (24).
28
23. Tap housing, and remove ball (27) and retainer (28). 23 24 27
26
DLW01710
30-171
ASSEMBLY OF STEERING
VALVE
« Check all parts for damage or burrs.
« Wash all metal parts in clean solvent and blow dry
with air.
« Do not use a file or polish any part with rough sand-
paper.
« Coat the O-rings with clean grease. (No need to put
grease on new X-ring seals)
« Coat the O-ring for the rotor set with a small amount
of grease.
ASSEMBLY OF CONTROL SIDE
1. Insert retainer (28) in housing with tweezers.

« Check that the retainer is not inserted at an
angle.
2. Insert ball (27).
3. Fit O-rings (26) and (25) in check sheet (24), and

push check sheet (24) into housing.
042403
« Be careful to set the top and bottom of the
check sheet facing in the correct direction.
4. Install set screw (23).

« Check that the set screw is set in slightly from
the end face of the housing.
Set screw : 11.8 Nm (1.2 kgm)
Set screw : adhesive (LT-2)
5. Assemble spool (20) and sleeve (19) so that spring

groove is on same side.
« Rotate the spool and slide it in.
« Grip the splined portion of the spool lightly and
check that the spool rotates smoothly inside the
sleeve.
« If there are match marks, check that the match
marks are aligned.
30-172
6. Align spring groove positions of spool (20) and sleeve

(19), and set on flat plate, then insert spring (21) in
20
spring groove.
« Set so that the notches at both ends are at the 21
bottom.
19
DLW01713
7. Insert pin (18) in spool and sleeve assembly (17).
17
18
042403
DLW01714
8. Insert spool and sleeve assembly (17) in housing

(10) in the direction of the arrow.
1) Keep pin horizontal and rotate to left and right a
little at a time to insert.
« Be extremely careful not to get it caught.
2) Make the spool and sleeve assembly flush with 17
the rear end face of the housing.
« If it is inserted beyond the end face, the pin will
fall out.
3) Check that spool and sleeve rotate smoothly
inside housing. 10
DLW01715
9. Install O-ring (22) to housing (10).
16 15
10. Fit 2 bearing races (15) and thrust needle (16) in 15
case (10).
22
10
DLW01716
30-173
11. Insert dust seal (14) in bushing (12).

11
12. Insert X-ring seal (13) in bushing (12).
12 14
13. Insert bushing (12) in spool, and rotate to install.
• Tap with a plastic hammer to assemble to the
specified position. 10
• It must be in contact horizontally with the bear-
ing race.
DLW01717
14. Fit snap ring (11) in housing.
Screw-
14 driver
11
12
13
22
042403
DLW01718
ASSEMBLY OF ROTOR
15. Hold flange of housing lightly in vice.

« Be careful not to tighten the vice too hard.
« Check that the spool and sleeve are set in slightly
from the housing surface with fourteen holes.
16. Insert O-ring (9) in housing.
DLW01719
17. Put on spacer plate (8), and align positions of bolt

hole and tap hole of housing. 8
DLW01720
30-174
18. Turn spool and sleeve assembly to make pin (18)

and port surface of housing parallel, then mesh pin
and yoke of drive shaft (7). Port surface
« To position accurately, draw a line on the end 7
face of the drive shaft spline. Make pin and
port surface parallel
18
DLW01721
19. Insert O-ring (5) in rotor set (4).
4
042403
5
DLW01722
20. Make O-ring (5) end of rotor set to spacer plate end,
then align insert portion of star of rotor (4) with drive. Inset portion of star of rotor set A
1) Check that lines A,B,C, and D are all parallel. B

2) Without removing joint of drive (7), position bolt
holes of rotor set. C
D
« This procedure is very important for determining 7 (Make line)
the valve timing of unit.
21. Insert spacer (6) inside rotor set.
Pin Port surface

DLW01723
1
22. Set end cap (2) on rotor set, and align bolt hole. 2
3
6
DLW01724
30-175
23. Coat thread of screw with grease, and tighten end

cap.
« Install the handle to the spool, and check that 6 4
the spool rotates.
End cap mounting screw
1 2
First step : 14.7 Nm (1.5 kgm)
Second step :
27.0 ± 1.5 Nm (2.75 ± 0.15 kgm)
3 7
5
DLW01725
042403
30-176
REMOVAL OF STEERING VALVE

ASSEMBLY

« Release the remaining pressure in the piping. For

details, see REMOVAL OF RADIATOR ASSEMBLY.

tanc filter, and prevent the oil inside the tank from
floating out.
1. Covers
2. Steering pipes
Remove the orbit-roll servo pipes (4).
.
042403
30-177
3. Hydraulic piping
Disconnect following hydraulic piping from steering
valve. ❈2
• Tube (8) between switch pump and steering valve
• Tube (9) between steering pump and steering
valve
• Tube (10) between steering valve and main con-
trol valve
• Tubes (11) and (12) between steering valve and
steering cylinder
• Tube (13) between steering valve and hydraulic
tank
4. Steering valve
Sling steering valve (6), and remove mounting bolts
(14), then lift off steering valve. ❈2
Steering valve : 24 kg
« Carry out the removal operation with two work-
ers.
The steering valve is oily, so be careful not to let
it slip.
042403
30-178
INSTALLATION OF STEERING
VALVE ASSEMBLY
❈1
« Check that the steering valve is at neutral.
❈2
« Remove the clamp to avoid applying force when
installing the tube.

Tighten the plug at the top of the hydraulic tank filter
and add hydraulic oil through oil filler to the specified
level.
Plug at top of filter :
11.8 ± 1.0 Nm (1.2 ± 0.1 kgm)
042403
30-179
DISASSEMBLY OF STEERING
VALVE ASSEMBLY
1. Relief valves 33
1) Remove overload relief valve (33) from valve hous-
ing (1).
2) Remove main relief valve (33) from plug (4) in
same way.
« Remove the O-ring at the mount, but do not
disassemble the relief valve any further. 4
1 32
DEW01028 DEW01029
2. Flow control
1) Remove plug (4).
2) Remove spring (9).
9
4
042403
DEW01030 DEW01031
3) Remove flow control spool (2).
DEW01032
30-180
4) Merge check valve

Remove plug (25), then remove spring (for merge
check valve) (35) and poppet (34) from inside.
5) Steering spool (disassembly)

1) Use an industrial drier to heat plug (18) fully
before removing it.
« The thread of plug (18) and cap screw (12)
at both ends of the spool is coated with
adhesive, so heat them fully before carrying
out the removal operation.
When assembling, replace spring (14), O-
rings (17) and (19), backup ring (20), seal
(23), and wiper (24) with new parts.
042403
6) Remove spring (for load check) (11) and poppet (10)

from inside of spool.
30-181
ASSEMBLY OF STEERING
VALVE ASSEMBLY
1. Spool assembly
1) Install poppet (10) and spring (11) to head end of
steering spool (3).
2) Install O-ring and backup ring to plug (18), then

coat thread of spool with thread tightener and
tighten.
« Be careful not to get thread tightener on the
front part of the spool (chassis ring mount).
Be careful also not to coat with too much
thread tightener and let the thread tightener
drip inside the spool.
Thread tightener: Loctite #271
Plug: 8.8 ± 1 Nm (0.9 ± 0.1 kgm)
042403
3) Merge check valve
1) Assemble poppet (34) and spring (35) to valve
housing.
2) Install O-ring, then tighten plug (25).
Plug: 63.7 ± 4.9 Nm (6.5 ± 0.5 kgm)
3) Install O-ring, then tighten plug (28).

Plug: 93.2 ± 4.9 Nm (9.5 ± 0.5 kgm)
30-182
3. Flow control
1) Fit O-ring to plug (5) and install to valve housing.
Plug: 142 ± 2.5 Nm (14.05 ± 0.25
kgm)
2) Assemble flow control spool (2) slowly.

« If any shims were removed during assembly,
assemble the same number of shims.
3) Assemble spring (for flow control) (9).

4) Fit O-ring and backup ring to plug (4) and tighten.
« When installing the plug, be careful not to
bend the spring.
Plug: 142 ± 2.5 Nm (14.05 ± 0.25
kgm)
042403
4. Relief valve
1) Install overload relif valve (33)
Valve: 73.6 ± 4.9 Nm (7.5 ± 0.5kgm)
2) Install main relief valve assembly (32) to plug (4)

Plug: 73.6 ± 4.9 Nm (7.5 ± 0.5kgm)
30-183
DISASSEMBLY AND ASSEMBLY STEERING, SWITCH PUMP
REMOVAL OF STEERING,
SWITCH PUMP ASSEMBLY


BLY

flowing out.

TILT ´ HOLD to release the pressure inside the
accumulator.

042403
low-pressure valves. 3-1
1. Covers
Remove covers (3) at bottom of cab.
2. Ladders
Remove left and right ladders (3-1).

DEW01440
30-184

brake valve and accumulator at pedal end. 6
« Remove brake hose clamps (5-1) under floor
board.
3) Disconnect accelerator cable (7) under pedal.
1
board. 4 5 7
DEW01513 DEW01514
4) Disconnect hose (8) between PPC accumulator

and PPC valve inside bulkhead at accumulator 8
end.
042403
DEW01515
5) Disconnect hose (10) of radiator sub-tank (9)

and hose (12) of window washer tank (11) at
tank end.
« Remove the hoses from the hose clamps. 14
6) Air conditioner hoses 13
i) Disconnect hose (13) between compressor
and condenser at condenser end.
2
« Remove the hose clamps inside the 10
bulkhead.
12
ii) Disconnect hose (14) between air condi-
tioner unit and receiver at receiver end. 9 11 DEW02344
3
« Remove the hose clamps inside the
bulkhead.
« After removing the hoses, fit plugs to
prevent the entry of dirt or dust. 17
18
16
4. Bulkhead
15
1) Remove cover (16) at bottom front face of bulk-
head (15).
2) Remove top mounting bolts (18) holding bulk-
head (15) and hood (17).
« Be careful not to lose the rubber and wash- 15
DEW01408 DEW01412
ers of the mounting portion.
30-185
3) Install eyebolts at top 4 corners of bulkhead

Remove clamp Eyebolt
(17), then sling and remove bottom mounting
bolts (19). 17
Bulkhead: 135 kg
(including accumulator, charge valve) 19
4) Raise bulkhead (17) straight up for approx. 400
400 mm
mm.
« The bulkhead comes near the cab when it is
lifted, so be careful not to hit anything.
(Opposite end) (This end)
« To prevent the bulkhead from falling after it DEW01529 DEW00470
is raised, place blocks on the left and right
at opposite ends.
5. Pump piping 4 23 22
1) Disconnect suction tube between hydraulic tank
and steering pump at pump end.
2) Disconnect tube (20) between steering pump
and steering valve at pump end.
3) Disconnect tube (21) between switch pump and
steering valve at pump end.
« After disconnecting the tubes, fit plugs to
042403
6. Pump 5 20 21 DEW01517
Remove mounting bolts (23) of steering and switch

pump assembly (22), then remove pump assembly.
Steering, switch pump assembly: 24 kg
30-186
INSTALLATION OF STEERING,
SWITCH PUMP ASSEMBLY

moval.
1
Accelerator cable mounting nut:
53.9 ± 4.9 Nm (5.5 ± 0.5 kgm)
2
Condenser hose:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
3
Receiver hose:
3.9 – 6.9 Nm (0.4 – 0.7 kgm)
4 5

11.8 ± 1 Nm (1.2 ± 0.1 kgm)
042403
• Bleeding air

new refrigerant
3°C.
not work.)
(Attainment of vacuum: Min. 750 mmHg.)
system.
with refrigerant.
30-187
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER ASSEMBLY

BLY.
1. Hydraulic piping
Disconnect steering cylinder rod and bottom hoses
(1) and (2) at cylinder end.
« After removing the hoses, fit plugs to prevent the
2
042403
DEW01518
2. Steering cylinder 1
1) Remove rod bolt, then remove pin (3). 3
DEW01519
2) Disconnect bottom grease tube (4).

3) Remove bottom bolt, then remove pin (5). 4
« Check the shim thickness and use as a
guide when assembling.
4) Remove steering cylinder (6).
« Carry out the removal operation with two 6
people.
« Be careful not to scratch the cylinder rod. 5
Steering cylinder: 27.7 kg
DEW01083
30-188
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
INSTALLATION OF STEERING
CYLINDER ASSEMBLY

moval.
a
1

insert your fingers. a
« Adjust the shims so that clearance a is the standard

value. DEW01084
Clearance a = Max. 0.5 mm
« Remove all grease and oil from the cylinder pin, and
wipe off the grease that is pushed out.
042403
30-189
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY
Stop the machine on level ground and install the 1

Loosen the oil filler cap slowly to release the pres-

steering wheel and control levers several times to
release the remaining pressure in the hydraulic pip- DEW02345
ing.
Release the pressure inside the accumulator by

depressing the brake pedal slowly and repeatedly 3 5 4
2
(at least 17 times) until there is no more reaction
9
when the brake pedal is depressed.
1. Covers 6
2. Piping (right brake valve)

1) Disconnect hoses (2) and (3) between ac-
042403
cumulator and brake valve, and adapters (4)
13
and (5) at valve end. 1 7 8 19 DEW01086
2) Disconnect brake valve drain hose and tube
(6) at valve end.
3) Disconnect hose (7) going to left brake valve
at valve end. 19 12 13
4) Disconnect tube (8) which goes to front
brake and tube (9) going to rear brake at
valve end. 2
11
3. Piping (left brake valve)

1) Disconnect tube (10) and hose from accumula-
tor to left brake valve at brake valve end.
3
2) Disconnect left and right brake valve hoses and
elbow (11) at brake valve end. 4 10 DEW01087
3) Remove brake valve drain tube (12) and hose at
valve end.
« After disconnecting the piping, make marks
and fit plugs to prevent the entry of dirt or
dust.
4. Wiring
Disconnect connector of brake valve switch sensor
(13).
30-190
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
5. Pedals
Pull out cotter pin (26) from pin (15) of brake pedal 18 19
(14), then pull out pin, and remove pedal.
« Carry out the same operation for both the left
and right brake pedals.
6. Brake valve 14
Remove brake valve mounting bolts (17), and dis-
connect mount flange (18) and body (19), then pull
out cap (20). 15
20 17
16
DEW01088 DEW01089
INSTALLATION OF BRAKE
VALVE ASSEMBLY
moval.
1 2 3 4
« After completing the assembly, bleed the air
042403
from the brake line.

For details of the procedure for bleeding the
air, see TESTING AND ADJUSTING.
30-191
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE
DISASSEMBLY OF RIGHT
BRAKE VALVE ASSEMBLY
(TANDEM) 1 104 4-11ø
52
2
25.75
1. Bracket assembly
1) Remove seat (1), pedal stopper (2), and boot 3
104
(3) from brake valve. 5
51.5
52
4
2) Remove mounting bolts (5) of bracket assem-
bly (4), then remove bracket assembly. 51ø
25.75
3) Remove oil seal (6) from upper portion of brake
51.5
10
valve. 6
6 6
2. Valve DEW01090 Jig q DEW01091
1) Install valve to jig with bolts (5), and secure
jig in vice.
« Make match marks before disassembling
the valve. Match marks 7
2) Remove valve mounting bolts (10), then re-
move S cylinder assembly (7). 8
3) Remove plug (13) of S cylinder assembly, then
remove spring (14) and O-ring.
4) Remove spring (11) and O-ring (12), then re- Jig
move P cylinder assembly (8).
« Remove spring (15) inside the plunger of 9
the P cylinder assembly. Vice
042403
5) Remove holder (16), springs (17), (18), and
(19) and O-ring (20) from T flange assembly DEW01092
(9).
« The cylinders, plungers, and spools inside
the T flange assembly and the S and P
cylinders form sets, so be careful not to 13
14
mix the parts for any set.
« Fit seals to prevent dirt or dust from enter- 7
13
ing, and be careful not to damage the cylin- 10
ders or flange assembly. 10 11
7 12
8
15
8
DEW01093 DEW01094
16
17 20
17
18
9
20 19
DEW01095 DEW01096
30-192
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE
ASSEMBLY OF RIGHT BRAKE

VALVE ASSEMBLY (TANDEM)
16
1. Valve 17 20
17
Install T flange assembly (9) to jig with bolts (5), 18
9
and hold jig in vice.
20 19
1) Install springs (19), (18), and (17) to T flange
assembly (9) in order, then install holder (16)
on top of spring.
2) Install O-ring (20) to T flange assembly (9). 9
O-ring: Lithium grease
3) Set P cylinder assembly (8) to T flange assem- DEW01095 DEW01096
bly (9).
« When setting in position, align the match
marks.
4) Install spring (11) and spring (15) inside plunger 13
14
of P cylinder assembly to P cylinder assembly
(8). 7
13
5) Install O-ring (12) to P cylinder assembly (8). 10
« Use a new part for the O-ring. 10 11
O-ring: Lithium grease 7 12
6) Set S cylinder assembly (7) to P cylinder as-
sembly (8), and tighten with mounting bolts (10). 8
« When setting the S cylinder assembly in 15
8
042403
position, align the match marks.

Mounting bolt: DEW01093 DEW01094
58.8 – 73.6 Nm (6.0 – 7.5 kgm)
7) Install spring (14) and O-ring to S cylinder as-
sembly (7), and tighten with plug (13).
Thread of plug: Thread tightener
(Thread lock 1303B)
Plug:
152.0 ± 24.5 Nm (15.5 ± 2.5 kgm)
2. Bracket assembly
Remove valve from jig .
1) Set T flange assembly facing up, and install oil
seal (6).
« Use a new part for the oil seal.
Lip of oil seal: Lithium grease
2) Install bracket assembly (4), and tighten with
mounting bolts (5).
Mounting bolt:
58.8 – 73.6 Nm (6.0 – 7.5 kgm)
3) Install seat (1), pedal stopper (2), and boot (3)
to valve.
30-193
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE
DISASSEMBLY OF LEFT BRAKE

VALVE ASSEMBLY (SINGLE)
1 104 4-11ø
52
1. Bracket assembly 2
25.75
1) Remove seat (1), pedal stopper (2), and boot
(3) from brake valve. 3
104
5
51.5
52
4
2) Remove mounting bolts (5) of bracket assem-
bly (4), then remove bracket assembly. 51ø
25.75
51.5
10
3) Remove oil seal (6) from upper portion of brake 6
valve. 6
6
DEW01090 Jig q DEW01091
2. Valve
1) Install valve to jig with bolts (5), and secure 7
jig in vice. Match marks
« Make match marks before disassembling
the valve. 8
Jig
Vice
042403
DEW01103
2) Remove valve mounting bolts (10), then re-

move S cylinder assembly (7). 12 10
11
3) Remove plug (10) of S cylinder assembly, then 7
remove spring (11) and O-ring (12).
9
10
DEW01104 DDW01105
4) Remove holder (13), springs (14) and (15), and 13

O-ring (16) from S flange assembly (8). 14
16
14
« The cylinders, plungers, and spools inside
the S flange and the S cylinder form sets, 16 8
15
so be careful not to mix the parts for any
set.
8
« Fit seals to prevent dirt or dust from enter-
ing, and be careful not to damage the cylin-
ders or flange assembly. DEW01106 DDW01107
30-194
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE
ASSEMBLY OF LEFT BRAKE

VALVE ASSEMBLY (SINGLE)
1
1. Valve 2
Install S flange assembly (8) to jig with bolts (5),
and hold jig in vice. 3
1) Install springs (14) and (15) to S flange assem- 5
4
bly (8), then install holder (13) on top of spring.
2) Install O-ring (16) to S flange assembly (8).
O-ring: Lithium grease 6
3) Set S cylinder assembly (7) to S flange assem- DEW01090

bly (8), and tighten with mounting bolts (9).
« When setting the S cylinder assembly in
position, align the match marks.
Mounting bolt: 13
58.8 – 73.6 Nm (6.0 – 7.5 kgm) 14
4) Install spring (11) and O-ring (12) to S cylinder 16
14
assembly (7), and tighten with plug (10).
« Use a new part for the O-ring. 16 8
15
O-ring: Lithium grease
Thread of plug: Thread tightener
8
(Thread lock 1303B)
Plug:
042403
152.0 ± 24.5 Nm (15.5 ± 2.5 kgm)

DEW01106 DDW01107
2. Bracket assembly
Remove valve from jig .
1) Set S flange assembly facing up, and install oil
12 10
seal (6).
« Use a new part for the oil seal. 11
Lip of oil seal: Lithium grease 7
2) Install bracket assembly (4), and tighten with 9
mounting bolts (5). 10
Mounting bolt:
58.8 – 73.6 Nm (6.0 – 7.5 kgm) 7
3) Install seat (1), pedal stopper (2), and boot (3) to
valve. 9
DEW01104 DDW01105
30-195
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER ASSEMBLY

Loosen the oil filler cap slowly to release the pres-

steering wheel and control levers several times to
release the remaining pressure in the hydraulic pip- L DEW01520
ing.
Release the pressure inside the accumulator by

depressing the brake pedal slowly and repeatedly
(at least 17 times) until there is no more reaction
when the brake pedal is depressed.
1
1. Raise lift arm and set tool L to lift arm cylinder rod.
« When not using tool L, set a stand under the lift
arm.
2. Remove cover (1) at front of front frame.
042403
DEW01521
3. Brake piping
1) Disconnect tube (2) between slack adjuster and
brake valve at adjuster end.
« For the rear, remove slack adjuster cover 2
(4) and disconnect tube (3).
5
2) Disconnect tubes (5) between slack adjuster
and left and right brake pistons at slack ad-
juster end.
4. Slack adjuster
Remove mounting bolts, then remove slack adjuster 6 5
(6). 1 DEW01522
5
3 4
DEW01523
30-196
INSTALLATION OF SLACK
ADJUSTER ASSEMBLY

moval.
1
Installation of the slack adjuster
« Tighten the mounting bolts temporarily, and
tighten them fully after connecting the piping.

Add oil through the oil filler of the hydraulic tank to
• Bleeding air from brake system

Bleed the air from the brake line and check that
there is no oil leakage from the connections.
Bleeding air from brake system.
« When bleeding the air from the brake line, bleed
the air at the slack adjuster end.
042403
30-197
DISASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
1 2
1. Bleeder
Remove bleeder (2) from body (1).
DEW01117
2. Cylinder
Remove mounting bolts, and disconnect body (1) 4 1
and cylinder (4) together with bracket (3).
The internal parts are under the tension of the

spring, so hold the mating surface down by
hand and remove carefully.
042403
3 DEW01118
3. Piston
1) Remove spring (5) and O-ring (6). 6 7
2) Push out piston (7), and remove O-ring.
« When removing the piston, push out slowly 6
5
with a 10 mm diameter rod.
« Be careful not to damage the thread with
the rod.
DEW01119 DEW01120
4. Poppet
4
1) Remove cover (8) from cylinder (4), then re-
move plug (9), spring (10), and poppet (11).
« When removing the poppet, blow in air from
the oil hole in the cylinder.
« Hold the cylinder oil port by hand and be 12
careful not to blow the air in strongly.
2) Remove O-ring (12) from poppet.
8 9 10 11 DEW01121
30-198
ASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
4
1. Poppet
1) Assemble O-ring (12) to poppet (11).
11 12
2) Assemble poppet (11), spring (10), plug (9),
and cover (8), then assemble to cylinder (4).
8 9 10 11
DEW01122 DEW01123
2. Piston
1) Install O-ring (13) to piston (7).
4
2) Insert piston (7) in cylinder (4).
« Check that the piston moves smoothly. 7 7
13
042403
DEW01124 DEW01125
3. Cylinder
1) Install O-ring (6) and spring (5) to cylinder.
« Installed load of spring: 4.4 kg
2) Install body (1) and cylinder (4) together with
bracket (3).
5
6
4. Bleeder DEW01126
Install bleeder (2).
1
4
2
3
DEW01128 DEW01127
30-199
DISASSEMBLY AND ASSEMBLY BRAKE
DISASSEMBLY OF BRAKE
ASSEMBLY


SEMBLY.

frame.
1
1. Tire, wheel
Jack up axle, and insert stand under axle, then lift
off tire and wheel (1).
« After removing the tire and wheel, set a stand
under the axle housing.
Tire, wheel:550 kg (23.5-25 tire)
042403
644 kg (26.5-25 tire)
DEW00823 2 DEW01130
2. Draining oil
Set drain plug (2) immediately at bottom, then re-
move plug and drain oil from case.
Axle oil: 55 l
30-200
3. Cover
4
3
DEW01131 DEW00840
4. Axle shaft
Using forcing screws (Thread dia.=12mm, 5
Pitch=1.75mm), pull out axle shaft (5) approx.
200 mm.
6
Remove 3 mounting bolts, and lift off planetary
carrier (6).
« Make match marks and use as a guide when
assembling.
« Be careful of the center of gravity and remove
042403
slowly. DEW00920 DEW01134
Planetary carrier: 86 kg
6. Ring gear
1) Using tools T4 and T5, secure wheel hub (8) 9 T4 T5 8
and brake (9).
« Install tools T4 and T5 at three equally
spaced places, then use a washer to ad-
just the clearance.
DEW01135
2) Remove mounting bolts of retainer (10), then

remove ring gear (11).
« Check the number and thickness of the 10
shims between the retainer and the axle
housing, and keep in a safe place.
Ring gear: 35 kg
11
DEW00923
30-201
7. Brake, wheel hub

1) Remove brake tube (12).
12
DEW01137
2) Sling brake and wheel hub (13), then remove

mounting bolts and lift off.
Brake, wheel hub: 195 kg

13
042403
DEW01138
8. Axle housing
Remove bearing (14), O-ring (15), trunnion (16),
14
and O-ring of trunnion mount portion from axle hous-
16
ing.
Trunnion: 54 kg
15
DEW01139
9. Piston, cylinder
1) Set wheel hub (17) at bottom, and remove tool
T4.
2) Using eyebolts, lift off cylinder assembly (18).
18
Cylinder assembly: 63 kg
17
DEW01140
30-202
3) Remove O-ring (19) from cylinder assembly.
19 DEW01141
4) Using tool T3, pull out pin (20) from cylinder

assembly, and remove rod (21) and piston re-
turn spring (22). T3 22
« The pin is small, so be careful not to lose it.
21
20
042403
DEW01142 DEW01143
5) Blow in air from brake oil filler (23) to push out

piston (24).
23
« Hold one end of the piston by hand, blow in
air slowly, and be careful not to let the
piston fly out.
« Be careful not to damage the piston.
DEW01144
6) Remove seals (25) and (26) from piston (24).

24
25
26
DEW01145
30-203
10. Outer gear

1) Remove O-ring (28) from outer gear (27).
29
30
27
28
DEW01146
2) Remove plates (29) and discs (30) from outer

gear in order, then remove spacer (31). 29
« When removing the discs, make match
marks on the inner gear and disc, outer
gear and plate, and on the spacer.
« The plates are made of a soft material, so
remove them extremely carefully and be
careful not to damage them. 30
042403
31
DEW01147
3) Using tool T2, lift off outer gear (27) from wheel
hub (35), and remove seal ring (32) and O-ring
(33).
4) Remove oil seal (34) from outer gear (27). T2
32
33
27
34
(14 mm, P = 2)
DEW01148
11. Inner gear

Remove mounting bolts, then remove inner gear
(36) from wheel hub (35). 36
35
DEW01149
30-204
12. Wheel hub

1) Remove seal ring (37) and O-ring (38) from 37
wheel hub (35). 38
35
DEW01150
2) Remove bearing cups (39) and (40) from wheel

hub. 40 39
042403
DEW01151
30-205
ASSEMBLY OF BRAKE
ASSEMBLY
40 39
1. Wheel hub
1) Press fit bearing cups (39) and (40) to wheel
hub (35).
2) Install O-ring (38) to seal ring (37), and using
tool T1, install to wheel hub.
« Use alcohol to completely remove the white
powder from the surface of the O-ring.
« Remove all oil and grease from the O-ring
contact surface of the seal ring and re-
tainer. DEW01151
« Be careful not to twist the O-ring when in-
stalling it.
37 38
042403
DEW01153
T1
DEW01154
2. Inner gear
Install inner gear (36) to wheel hub (35).
Mounting bolt: 36
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
35
DEW01149
30-206
3. Outer gear
1) Press fit oil seal (34) to outer gear (27).
Protrusion or depression
« When press fitting the oil seal, be careful of of end of oil seal and
the direction of the oil seal breather hole. 27 34 end of outer gear shall
be within 0.5 mm
Oil seal breather hole

Assemble oil seal breather
130 hole within this range
65
Oil seal breather hole
DEW01156
Assemble so that center

of three casting holes is
at bottom when mounted
on machine
32 33 t
DEW01158
042403

DEW01157
2) Install O-ring (33) to seal ring (32), and using

tool T1, install to outer gear (27).
« Use alcohol to completely remove the white 32 33
powder from the surface of the O-ring.
« Remove all oil and grease from the O-ring
contact surface of the seal ring and outer
gear.
« Tighten tool T2 uniformly so that there is
no twisting of the O-ring for the seal ring.
After press fitting, measure height t at 4
places around the circumference and check
that the difference in the measurements is DEW01159
within 1 mm.
T1
27
DEW01160
30-207
3) Using tool T2, assemble outer gear (27) to wheel

hub (35).
« When assembling, check that there are no 27
scratches on the seal ring mating surface.
« Check that the seal ring is not installed at
an angle.
Mating surface of seal ring: Axle oil 35
DEW01161
27
042403
35
DEW01162
4) Align match marks on outer gear (27) and

spacer (31), plates (29), and on discs (30) and 29
inner gear, then assemble plates and discs in
turn.
« Set with the chamfered side of the spacer
facing down.
« Check that the final plate is meshed se-
curely with the outer gear spline. 30
« Soak the discs in brake oil for at least 30
minutes before assembling.
« Align the match marks on the discs and 31
inner gear when assembling. DEW01147
5) Install O-ring (28) to outer gear (27).

29
30
27
28
DEW01146
30-208
4. Piston, cylinder
1) Install seals (25) and (26) to piston (24).
« Fit the seal in the groove securely. 24
Seal: Brake oil
25
26
DEW01145
2) Press fit piston (24) to cylinder (41).

« When press fitting the piston, tap with a 24
plastic hammer. Do not use a steel or cop-
per hammer.
« Coat the press-fitting portion of the piston
and the outside circumference of the piston
with brake oil.
Sliding surface of piston: Brake oil
042403
41 DEW01166
3) Using tool T3, insert piston return spring (22)

and rod (21) in cylinder assembly, and lock
with pin (20). T3 22
21
20
DEW01142 DEW01143
4) Install O-ring (19) to cylinder assembly.
19 DEW01141
30-209
5) Using eyebolts, install cylinder assembly (18).

Mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)
18
17
DEW01140
6) Set wheel hub (35) at bottom, and using tools

T4 and T5, tighten uniformly so that it does not T4 T5
come out.
27 35
042403
DEW01171
5. Axle housing
1) Install O-ring to trunnion and axle housing, and
14
tighten with bolts.
16
Mounting bolt:
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
2) Install O-ring (15) to trunnion (16), and press fit
bearing (14).
15
DEW01139
6. Brake, wheel hub

1) Raise brake and wheel hub (13), and set to
axle housing mount, then tighten with mounting
bolts.
« Be careful of the center of gravity and raise 13
the brake horizontally.
« If it is forced in, the O-ring will be twisted
and damaged, so align the center and in-
stall slowly.
Mounting bolt:
Mounting bolt: DEW01138
549.2 ± 58.8 Nm (56.0 ± 6.0 kgm)
30-210
2) Install brake tube (12).
12
DEW01137
7. Ring gear
1) Raise ring gear (11) and set in mounting posi-
tion, then install to axle housing. 11 10
« Align the spline groove and install slowly.
2) Tighten retainer (10) with 3 bolts temporarily,
and remove tools T4 and T5.
« Temporarily tighten the retainer without in-
serting shims.
« Rotate the wheel hub to settle the bearing
and tighten uniformly until the torque is the 11
042403
specified torque.
Retainer mounting bolt: DEW01175 DEW01176
73.6 ± 1 Nm (7.5 ± 0.1 kgm)
3) Measure clearance b between end face of hous-
ing and end face of retainer from measurement
hole of retainer (10) with depth micrometer. 11
« Measure at two places and take the aver-
age.
« Shim thickness = Clearance b + 0.3 mm.
« Select the shim thickness to give the mini- b
mum number of shims.
10
« Shim thickness: 1.0 mm, 0.5 mm, 0.2 mm,
0.05 mm
DEW01177
30-211
4) Install tools T4 and T5 to brake and wheel hub,

remove retainer, install selected shims, then T4 T5
install retainer.
« When assembling the shim, always install
tools T4 and T5 first.
« Rotate the wheel hub and tighten uniformly
until the torque is the specified torque.
Mounting bolt:
Mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)
DEW01178
Assemble O-ring to wheel hub (8), then raise plan-
etary carrier (6), set in mounting position, and in-
stall.
« Align the mounting holes and install slowly so
that the O-ring does not come out of position.
042403
6
8 DEW01179
9. Axle shaft
Install axle shaft (5). 3
« Rotate the wheel hub to align the position when 5
installing the sun gear.
10. Cover
Fit O-ring into groove of cover, and install cover (3).
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
4
DEW01180 DEW01181
11. Tire, wheel

Install tire and wheel (1) and remove stand. 1
Mounting nut:
476.7 ± 49.0 Nm (48.0 ± 5.0 kgm)
DEW00823
30-212

1) Tighten drain plug of axle, and add oil through
oil filler (42) to specified level.
« Set the machine with the drain plug imme-
diately at the bottom, then add oil through
the level plug.
Axle oil: 65 l (both front and rear)
2) Connect hose between hydraulic tank and brake

42
chamber, and add hydraulic oil through oil filler
of hydraulic tank to specified level. DEW01182
13. Testing, adjusting brake

1) Bleed air from brake line and adjust brake.
For details, see TESTING AND ADJUSTING.
2) After completing all of the operations, check for
any leakage of brake oil.
042403
30-213
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
REMOVAL OF PARKING BRAKE

DISC
1
ground and stop the engine. Then put blocks under
the wheels to prevent the machine from moving.
« Do not apply the parking brake.
1. Loosen drain plug and drain transmission oil.

2 3 4
Transmission: 40 l DEW00722
2. Drive shaft
Remove guard of drive shaft, and disconnect lower
front drive shaft (1) at transmission end. 6
1
« After disconnecting the drive shaft, move it to 7
the right.
3. Suction tube
1) Remove mounting bolt (3) and washer (4) of
coupling (2) at front of transmission, then re-
move coupling. 2
042403
2) Remove suction tube (5) at transmission end. 5 8
DEW00723
4. Parking brake
1) Remove lock plates (7) of parking brake manual
release bolts (6), then remove 3 release bolts.
2) Remove parking brake case (8).
3) Screw in 3 manual release bolts (6), and re- 6
lease parking brake.
« Distance l to screw in bolt = 28 mm
Screw in all three bolts uniformly.
´
6
6
DEW01185 DDW01186
30-214
4) Set length of bolt of tools M1, M2, and M3 to l1,

then tighten with coupling mounting bolt (3).
´1
« Length of bolt of tool l1: 70 mm
M1, M2, M3
3 DEW01187 3 DDW01188
5) Remove snap ring (9) from case, then remove

tools M1, M2, and M3.
042403
9 DEW01189
6) Remove end plate (10), plate, disc, and wave

spring from case. 3 Disc
10 DEW01190 Wave spring DEW01191
30-215
INSTALLATION OF PARKING
BRAKE DISC
Wave spring Plate
moval.
10 Disc
1
Drive shaft:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
Tool mark
2 (1 groove)
Coupling mounting bolt:
921.8 ± 98.1 Nm (94.0 ± 10.0 kgm) DDW01192
End face of coupling:
Anti-friction compound (LM-G)
3
Insert the plates and discs in the case in order, and Coupling
assemble the wave springs between the plates.
« When assembling end plate (10), pay attention
to the tool mark (one groove) on the face.
• Tighten the drain plug of the transmission, and add
oil.
Transmission: 40 l
042403
« Run the engine to circulate the oil through the Coat with anti-friction compound DDW01193
system. Then check the oil level again.
30-216
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL HYDRAULIC TANK

ASSEMBLY


SEMBLY.
1. Draining oil
1) Remove cover (1) on top of ladder, then re-
move plugs (2) and (3) at the top of the hydrau-
lic tank filter, and prevent the oil inside the tank
from flowing out. 1
042403
2) Remove plug (4) under hydraulic tank, then

loosen valve (5) and drain hydraulic oil.
Hydraulic tank: 206 l
2. Ladder floor
1) Sling right ladder floor (6), then remove mount-
ing bolts and lift off.
« Be careful of the center of gravity of the
ladder floor when lifting off.
Ladder floor: 63 kg
30-217
3. Hydraulic piping
1) Loosen clamps of hose (7) between hydraulic
tank and hydraulic pump and disconnect at tank
end.
2) Disconnect return tube (8) between main control
valve and hydraulic tank at tank end. 2
3) Disconnect tube (9) between steering valve, hy-

draulic cooler, and hydraulic tank at tank end..
3
4) Disconnect hose (10) between hydraulic tank

and brake valve at tank end.
and PPC valve at tank end.
and steering valve at tank end.
and PPC relief valve at tank end.
« After disconnecting the hoses and tubes,
mark with a tag to distinguish when installing.
« After disconnecting the hoses and tubes,
042403
fit plugs to prevent the entry of dirt or dust.
4. Hydraulic tank
Sling hydraulic tank (14), then remove mounting bolts
and lift off.
« Raise the hydraulic tank slightly and move it to
the outside to lift it off from the machine.
Hydraulic tank: 199 kg
30-218
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
1
Hydraulic tank filter plug
Plug on top of filter:
11.8 ± 1 Nm (1.2 ± 0.1 kgm)
2 3
Installation of tubes (8) and (9)

Tighten the plug on the top of the hydraulic tank
filter, and add hydraulic oil through the oil filler to
Hydraulic tank: 206 l
• Bleeding air
For details of the bleeding air from the brake sys-
tem and the hydraulic line, see TESTING AND
042403
ADJUSTING.
30-219
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
REMOVAL OF WORK
EQUIPMENT, PPC PUMP
ASSEMBLY

SEMBLY.
• Remove plugs (1) and (2) at the top of the hydrau-

from flowing out.

TILT ↔ HOLD to release the pressure inside the
accumulator.
Depress the brake pedal at least 17 times to re-

lease the pressure inside the brake accumulator.
042403
low-pressure valves. 3-1
1. Covers
2. Ladders
DEW01440
30-220

18
« Remove 2 brake hose clamps (5-1) under
floor board.
3) Disconnect accelerator cable (7) under pedal.
1
16 17 19
DEW00463 DEW00464

board. 20
and PPC valve inside bulkhead at accumulator
end.
042403
5) Disconnect hose (10) of radiator sub-tank (9)

and hose (12) of window washer tank (11) at DEW00466
tank end.
« Remove the hoses from the hose clamps.
6) Air conditioner hoses
i) Disconnect hose (13) between compressor
and condenser at condenser end.
2 26
« Remove the hose clamps inside the 25
bulkhead.
ii) Disconnect hose (14) between air condi-
tioner unit and receiver at receiver end .
3 22
« Remove the hose clamps inside the
24
bulkhead.
« After removing the hoses, fit plugs to 21 23 DEW00467
4. Bulkhead
1) Remove cover (16) at bottom front face of bulk-
head (15).
17
2) Remove top mounting bolts (18) holding bulk-
head (15) and hood (17). 16 18
« Be careful not to lose the rubber and wash-
ers of the mounting portion.
15
15 DEW01077
DEW02346
30-221
3) Install eyebolts at top 4 corners of bulkhead

Remove clamp Eyebolt
(17), then sling and remove bottom mounting
bolts (19). 17
Bulkhead: 135 kg
(including accumulator, charge valve) 19
4) Raise bulkhead (17) straight up for approx. 400
400 mm
mm.
« The bulkhead comes near the cab when it
is lifted, so be careful not to hit anything.
(Opposite end) (This end)
« To prevent the bulkhead from falling after it DEW01529 DEW00470
is raised, place blocks on the left and right
at opposite ends.
5. Pump piping 4 22 23
21
1) Disconnect suction tube between hydraulic tank
and hydraulic, PPC pump at pump end.
2) Disconnect tube (20) between hydraulic pump
and main control valve at pump end.
3) Disconnect tube (21) between PPC pump and
charge valve at pump end.
« After disconnecting the tubes, fit plugs to
042403
20
6. Pump 5 DEW01533
Remove mounting bolts (23) of hydraulic and PPC
pump assembly (22), then remove pump assembly.
Hydraulic, PPC pump assembly: 20.5 kg
30-222
INSTALLATION OF WORK
EQUIPMENT, PPC PUMP
ASSEMBLY
moval.
1
Accelerator cable mounting nut:
53.9 ± 4.9 Nm (5.5 ± 0.5 kgm)
2
Condenser hose:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
3
Receiver hose:
3.9 – 6.9 Nm (0.4 – 0.7 kgm)
4 5

042403

11.8 ± 1 Nm (1.2 ± 0.1 kgm)
• Bleeding air

new refrigerant
3°C. (If the temperature is below 3°C, the sys-
tem will not work.)
repeat vacuum method to completely evacu-
ate. (Attainment of vacuum: Min. 750 mmHg.)
system.
6) Do not operate the compressor before charg-
ing with refrigerant.
30-223
REMOVAL OF PPC VALVE

ASSEMBLY

safety bar on the frame. Lower the bucket to the 3

SEMBLY.
DEW01439

from flowing out.
3-1
TILT ↔ HOLD to release the pressure inside the
accumulator.
1. Covers
2. Ladders
042403
DEW01440

9 4 6 8
3. Hydraulic piping
1) Disconnect hose (4) of PPC valve port “P2”,
hose (5) of port “P4”, hose (6) of port “P3”, and 5
hose (7) of port “P1” at valve end.
and PPC valve at valve end.
3) Disconnect hose (9) of PPC valve drain port at 7
valve end.
4
« After disconnecting the hoses, mark with a
tag to distinguish when installing. 6 5
DEW01537 7 DEW01538

4. Cover
Remove side cover (11) of console box (10).
10
11 DEW01536
30-224
5. PPC valve
1) Remove joints (13) and (14) of rod installed to 14
PPC valve assembly (12).
2) Remove mounting bolts (15) of PPC valve as-

sembly, then remove valve assembly.
PPC valve assembly: 3 kg
15 13 12 DEW01220
INSTALLATION OF PPC VALVE

ASSEMBLY

moval.

042403

11.8 ± 1 Nm (1.2 ± 0.1 kgm)
• Bleeding air
Bleed air from PPC line.
30-225
042403
30-226
DISASSEMBLY AND ASSEMBLY PPC VALVE
DISASSEMBLY OF PPC VALVE

ASSEMBLY
1. Remove bolt (1).

1
2. Remove plate (2).
3. Remove seal (3), then remove spool (4).

« Of the 4 spools (4), make a distinguishing mark 4
on the boom LOWER spool and check the
mounting position.
2
4. Remove collar (5) from spool (4).
3
5. Remove valve assembly (6) from body (7).
5
6. Remove collar (8), then remove retainer (9), spring 9
(10), and shim (11) from valve (12). 10
« Check the number and thickness of the shims,
and keep in a safe place. 13
7. Remove spring (13) from body (7).
« The number of coils of spring (13) differs for 12
each hydraulic port, so check the mounting po-
7
042403
sition of each spring and make distinguishing

DEW01221
marks.
8 8
9 9
10 10
6 11 6
11
12 12
13
13
DEW01222
30-227
DISASSEMBLY AND ASSEMBLY PPC VALVE
ASSEMBLY OF PPC VALVE

ASSEMBLY
1. Assemble spring (13) to body (7).

« The number of coils of spring (13) differs for
each hydraulic port as shown in the chart be- 1
low, so check each spring and be sure to install
in the correct position.
4
Port position No. of coils of spring
P1 Bucket TILT
P2 Boom RAISE 11
P3 Boom LOWER 2
P4 Bucket DUMP 14
3
« The position of each port is stamped on the
5
valve body.
9
2. Assemble shim (11), spring (10), and retainer (9) to 10
valve (12), and install collar (8).
13
3. Assemble valve assembly (6) to body (7).
4. Fit O-ring to collar (5), and assemble to spool (4), 12

then install spool (4).
« For spools (4), check the mounting position of 7
042403
DEW01221
the boom LOWER spool which was marked
with a distinguishing mark, then install the
spools.
5. Fit seal (3) and install plate (2).
6. Install bolt (1). 8 8

Bolt: 44.1 ± 4.9 Nm (4.5 ± 0.5 kgm) 9 9
10 10
6 11 6
11
12 12
13
13
DEW01222
30-228
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY


SEMBLY.

from flowing out.
1. Cover
Remove inspection cover (3) of front frame.
042403
2. Bucket cylinder
1) Disconnect connector (4) of bucket positioner
wiring.
2) Disconnect grease hose (5) at front frame end.
3) Disconnect rod hose (6) at cylinder end. 1
4) Disconnect bottom hose (7) at cylinder end.
2
30-229
5) Sling bucket cylinder (10), and remove lock bolt,

then remove pins (8) and (9). 3
« When slinging, be careful of the center of
gravity and sling from two points.
« If there are shims installed, check the
number and thickness of the shims, and
keep in a safe place.
6) Lift off bucket cylinder (10).
Bucket cylinder: 192.5 kg
3. Hydraulic piping
Disconnect following hydraulic piping. 4
1) Disconnect tube (11) between hydraulic pump
and valve at main control valve end.
2) Disconnect hose (12) between cut-off valve and
main control valve at main control valve end.
3) Disconnect tubes (13) and (14) between main
control valve and dump cylinder at valve end.
4) Disconnect tubes (15) and (16) between main
control valve and lift cylinder at valve end.
042403
5) Disconnect drain tube (17) of main control valve
at valve end.
6) Disconnect tubes (18), (19), (20), (21), (22) and
(23) between PPC valve and main control valve
at main control valve end.
« After disconnecting the tubes and hoses,
mark with a tag to distinguish when install-
ing.
« After disconnecting the tubes and hoses, fit
plugs to prevent the entry of dirt or dust.
4. Main control valve

Remove mounting bolt (26), then using eyebolts, lift
off main control valve (25). 5
Main control valve: 90 kg
30-230
INSTALLATION OF MAIN

moval.
1 2
« Install the hoses without twisting or interfer-
ence.
3
Bucket cylinder
1) Align the bottom pin hole, assemble shims so
that the total for clearance a between the cylin- 9
der and frame is within the standard value,
then install pin (9).
« Clearance a: 1.5 mm
2) Align the rod pin hole and assemble pin (8).
Always use a bar when aligning the pin

042403
holes. Never insert your fingers.

a a DEW01233
4
« Be careful that the O-ring does not get caught
when installing.
« Before tightening fully, install the clamps that
were removed.
5
« When setting the valve in the mounting posi-
tion, pay attention to the balance and be care-
ful not to hit any other part inside the frame.

11.8 ± 1 Nm (1.2 ± 0.1 kgm)
• Bleeding air
Bleed air from hydraulic line.
30-231
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
042403
30-232
1. Tube,hose
1) Remove tube (2) and hose (3) from valve body
(1).
2) Remove tee (4), nipple (5), and elbow (6).
2. Spool assembly
1) Remove sleeve (7), then remove spacer (8), spring
(9), and piston (10).
2) Remove case (11), spring (12), and retainer (13),
then remove spool assembly (14).
« Do not remove plug(16) from spool (15) un-
less necessary.
3) Remove sleeve (17), then remove spacer (18),
spring (19), and piston (20).
4) Remove case (21), then remove spring (22), re-
tainer (23), spring (24), and retainer (25).
3. Main relief valve assembly

Remove main relief valve assembly (26).
4. Safety valve assembly with suction

Remove safety valve assembly (27).
The safety valve cannot be adjusted when it is in-
stalled on the machine, so do not disassemble it.
042403
5. Suction valve assembly Remove suction valve as-

sembly (28).
6. Selector valve assembly

Remove selector valve assembly (29).
7. Check valve assembly

Remove plate (30), then remove spring (31) and valve
(32).
8. Remove flange (33), then remove spring (34), seal

(35), and valve (36).
30-233
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY
042403
30-234
1. Assemble valve (36), seal (35), and spring (34) to

body (1), then fit O-ring and install flange (33).
2. Check valve assembly Assemble valve (32) and spring

(31) to body (1), then fit O-ring and install plate (30).
Mounting bolt:
88.3 ± 9.8 Nm (9.0 ±1.0 kgm)
3. Selector valve assembly
Fit O-ring and install selector valve assembly (29).
4. Suction valve assembly Fit O-ring and install suction

valve (28).
Suction valve assembly:
225.6 ± 9.8 Nm (23.0 ± 1.0 kgm)
5. Safety valve assembly with suction
Fit O-ring and install safety valve assembly (27).
Safety valve assembly:
225.6 ± 9.8 Nm (23.0 ± 1.0 kgm)
6. Main relief valve assembly
Fit O-ring and install main relief valve assembly (26).
Main relief valve assembly:
321.7 ± 47.1 Nm (32.8 ± 4.8 kgm)
7. Spool assembly
1) Push spool (14) into body (1).
042403
2) Assemble retainer (25), spring (24), and retainer

(23) to case (21).
3) Assemble spacer (18), spring (19), piston (20),
and spring (22) to sleeve (17), then fit O-ring and
assemble to case (21).
4) Fit O-ring to case (21) and install to body (1).
5) Assemble retainer (13) and spring (12) to case
(1 1), then fit O-ring.
6) Assemble spacer (8), spring (9), and piston (10)
to sleeve (7), then fit O-ring and assemble to
case (11).
7) Fit O-ring to case (1 1) and install to body (1).
Tube, hose
1) Install elbow (6), nipple (5), and tee (4) to body (1).
Nipple: 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
Tee: 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
2) Install hose (3) and tube (2).
Hose sleeve nut:
91.2 ± 12.8 Nm (9.3 ± 1.3 kgm)
Tube sleeve nut:
49.0 ± 19.6 Nm (5.0 ± 2.0 kgm)
30-235
6. Spool assembly (bucket)

1) Assemble spool (23) to body (1).
2) Assemble retainer (18), spring (17), retainer
(16), spring (15), and retainer (14), then fit O-
ring to case (13) and install.
3) Assemble retainer (22) and spring (21) to spool
(23), then fit O-ring to case (20) and install.
7. Spool assembly (boom)

1) Assemble spool (19) to body (1).
« Check that spool (19) is facing the correct
direction when assembling it to the body.
2) Assemble retainer (12) to spool (19).
3) Assemble washer (7), retainer (8), spring (9),
retainer (10), and collar (11) to bolt (6), then
6 8
hold spool in position with a wrench (width 7
across flats: 14 mm) at position a shown in
diagram on right, and tighten bolt (6). 9
11
Bolt (6):
10
13.7 ± 1.5 Nm (1.4 ± 0.15 kgm) 19
4) Assemble spring (5) and retainer (4), then fit O-
ring to case (3) and install. 12
5) Assemble retainer (18), spring (17), retainer
(16), spring (15), and retainer (14), then fit O-
042403
ring to case (13) and install.
DEW01548
8. Install cut-off valve (2) to valve body (1).
Mounting bolt:
107.9 ± 9.8 Nm (11.0 ± 1.0 kgm)
« Tighten the bolts in the order shown in the
diagram on the right.
DEW01551
30-236
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY


SEMBLY.
1. Disconnect connector (1) of bucket positioner wir-

ing.
2. Disconnect grease hose (2) at front frame end.

6
3. Hydraulic piping 1 5
1) Disconnect rod hose (3) at cylinder end.
2) Disconnect bottom hose (4) at cylinder end.
2
042403
1 DEW01552
4. Bucket cylinder
1) Sling bucket cylinder (7), then remove lock bolts, 7
and remove pin (5) and pin (6). 2
« When slinging, be careful of the center of
gravity and sling from two points.
2) Lift off bucket cylinder (1).
4
Bucket cylinder: 192.5 kg 3
DEW01553
30-237
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY

moval. 6
1
« Install the hoses without twisting or interfer-
ence.
2
Bucket cylinder
1) Align the bottom pin hole, assemble shims so a a DEW01238
that the total for clearance a between the cylin-
der and frame is within the standard value,
then install pin (6).
« Clearance a: 1.5 mm
2) Align the rod pin hole and assemble pin (5).
Always use a bar when aligning the pin

holes. Never insert your fingers.
• After completing the assembly, add hydraulic oil

through the oil filler of the hydraulic tank to the
042403
specified level.
• Bleeding air
Bleed air from hydraulic line.
30-238
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

ASSEMBLY


SEMBLY.
1. Rod pin
1) Sling boom cylinder (1), then remove lock bolt 1
7
of rod pin, and remove pin (2). 1
number and thickness of the shims, and 2
2) Start engine, and use control lever to retract
cylinder rod on side that was removed.
« Retract to a point 20 mm before the end of
the stroke.
042403
DEW02339 DEW02340
1
2. Hydraulic piping
1) Disconnect cylinder rod from connecting por-
tion. 2
2) Disconnect cylinder bottom tube (5) and hose
(6) at connecting portion. 3
« After disconnecting the tubes and hoses, fit
plugs to prevent the entry of dirt or dust.
DEW01241
3. Boom cylinder
1) Remove lock bolt of cylinder bottom pin, then
remove pin (7). 4
2) Lift off boom cylinder (1).
« Be careful of the center of gravity and lift
off slowly.
« Be careful not to damage the cylinder por-
tion.
Boom cylinder: 222 kg
30-239
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
• Carry out installation in the reverse order to re- a a

moval.
1
Start the engine, operate the control levers, and Rod pin
extend the rod. Align the pin holes and assemble
shims so that clearance a is uniform on the left and
right, then install the pin.
« Clearance a: Max. 1.5 mm
DEW01243
2 3
4
Bottom pin
Align the pin at the cylinder bottom, assemble shims
so that the total for clearance b between the cylin-
der and frame is within the standard value, then
install the pin.
Always use a bar when aligning the pin holes.
042403
Never insert your fingers.
b b DEW01244
« Clearance b: Max. 1.5 mm
30-240
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS- Steering cylinder
SEMBLY)
O 2 1
1. Set cylinder assembly (1) to tool N.

N
2. Cylinder head, piston rod assembly
• Steering cylinder assembly
1) Using tool O, remove cylinder head (2) from
cylinder.
DEW01245
2) Pull out cylinder head and piston rod assembly Steering cylinder
(3) from cylinder (4), and lift off. 4 3
« Oil will flow out when the piston rod assem-
bly is removed from the cylinder, so place
a container under the cylinder to catch the
oil.
042403
DEW01246
• Boom, bucket cylinder assembly

1) Remove mounting bolts of cylinder head (2). Boom, bucket cylinder
1 2
Width across flats of N
Cylinder bolt (mm)
Boom cylinder 27
Bucket cylinder 30
DEW01247
2) Pull out cylinder head and piston rod assembly

(6) from cylinder (7), and lift off. 7
« Oil will flow out when the piston rod assem-
bly is removed from the cylinder, so place
a container under the cylinder to catch the
oil. 6
DEW01248
30-241
3. Cylinder head
• Steering cylinder assembly P 9 3 2
1) Set cylinder head and piston rod assembly (3)
to tool N.
2) Using tool P, remove nut (8).
« Width across flats of nut: 55 mm N
3) Remove piston (9), then remove cylinder head 8
(2).
DEW01249

12 6 5
1) Set cylinder head and piston rod assembly (6)
to tool N. 10
2) Remove piston mounting bolt (10), then remove
spacer (11), piston (12), and cylinder head (5).
11
042403
DEW01250
4. Remove O-ring and backup ring (14) from piston

rod (13). 13
« Rod of boom, bucket cylinder only. 14
DEW01251
5. Disassembly of piston assembly

Remove wear ring (15) and piston ring (16) from
pistons (9) and (12).
9, 12
16
15
DEW01252
30-242
6. Disassembly of cylinder head assembly

• Steering cylinder assembly 17
1) Remove snap ring (17), then remove dust seal 18
(18).
2) Remove rod packing (19), then remove bush-
ing (20) from cylinder head (2). 2 20
3) Remove O-ring and backup ring (21).
21 19
DEW01253

1) Remove snap ring (22), then remove dust seal
22 23
(23).
25
2) Remove rod packing (24), then remove bush-
ing (25) from cylinder head (2). 2
3) Remove O-ring and backup ring (26).
26
042403
24
DEW01254
30-243
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS-
SEMBLY)
Q
« Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of all parts with engine oil be-
fore installing. Be careful not to damage the rod
25
packing, dust seals or O-rings when assembling.
1. Assembly of cylinder head assembly 2

1) Using tool Q, press fit bushing (25) to cylinder DEW01255
head (2).
2) Install rod packing (24).
3) Using tool S, fit dust seal (23), then install snap
S
ring (22).
22 23
24
042403
DEW01256
26
DEW01257
4) Install O-ring and backup ring (26). Q

« Do not try to force the backup ring into
position. Warm it in warm water (50 – 60°C)
before fitting it.
20
• Steering assembly
1) Using tool Q, press fit bushing (20) to cylinder
head (2).
2
DEW01258
2) Install rod packing (19).

3) Using tool S, install dust seal (18) to cylinder S
head.
18
19
DEW01259
30-244
4) Install snap ring (17).

5) Install O-ring and backup ring (21).
17
« Do not try to force the backup ring into
position. Warm it in warm water (50 – 60°C)
before fitting it.
21
DEW01260
2. Assembly of piston assembly

1) Using tool R1, expand piston ring (16).
« Set the piston ring on the expander and R2 16 9, 12
turn the handle 8 – 10 times to expand the
ring. R1
16
2) Remove piston ring (16) from tool R1, then
assemble to pistons (12) and (9).
3) Using tool R2, compress piston ring (16).
4) Assemble wear ring (15).
042403
DEW01261 DEW01262
3. Assemble O-ring and backup ring (14) to piston

rod (13).
« Do not try to force the backup ring into posi-
tion. Warm it in warm water (50 – 60°C) be- 9, 12 14 13
fore fitting it.
16
15
DEW01263 DEW01264
4. Cylinder head, piston rod assembly

12 6 2
1) Set piston rod assembly (6) to tool N. 10
2) Assemble cylinder head (2), piston (12), and
spacer (11) to piston rod, then tighten mount- 11
ing bolt (10).
Mounting bolt: N
Mounting bolt:
Cylinder Nm(kgm)
Boom cylinder
110.8 ± 12.8(11.3 ±1.3) DEW01265
Bucket cylinder
30-245

1) Set piston rod assembly (3) to tool N. 1
2) Assemble cylinder head (2) and piston (9) to
piston rod. 19
19
3) Assemble nut (8), and using tool P, tighten nut
(8).
Thread of piston rod:
Nut:
Width across flats Nm(kgm)

55 1422.0 ± 142.2(145 ± 14.5) DEW01266
5. Cylinder head
• Boom, bucket cylinder 7 2 6
1) Set cylinder (7) to tool N.
2) Raise cylinder head and piston rod assembly N
(6) and assemble to cylinder (7).
3) Install cylinder head (2) to cylinder (7).
Mounting bolt:
Cylinder Nm(kgm)
Boom cylinder 343.2 ± 34.3(35 ± 3.5)
Bucket cylinder 490.3 ± 49.0(50 ± 5)
042403
DEW01267
4) Remove cylinder assembly (1) from tool N.

1) Set cylinder (4) to tool N.
2) Raise cylinder head and piston rod assembly
(3) and assemble to cylinder (4).
3) Using tool O, install cylinder head (2) to cylin-
der (4).
Cylinder head:
784.5 ± 78.5 Nm (80.0 ± 8.0 kgm)
4) Bend lock of cylinder head (2) into notch at
cylinder end.
5) Remove cylinder assembly (1) from tool N.
10 DEW01268
O 2 1
DEW01269
30-246
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY


SEMBLY.
1. Bucket link, hinge pin 1

1) Sling bucket link (1), and remove mounting pin
(2).
2
« Remove the cord ring.
« Secure bucket link (1) to the bellcrank with
wire.
042403
1
DEW01549
2) Remove bucket hinge mounting pin (3).

« Remove the cord ring. 4
Never insert your fingers in the pin hole.
3) Move machine to rear and disconnect bucket

(4). 3
DEW01550
2. Bucket cylinder pin 2

Sling bucket cylinder (5), then remove mounting pin
(6), and disconnect cylinder rod and bellcrank (7). 5
« Fit a lifting tool to the bucket cylinder and fix it
6
to the rear.
7
Bucket cylinder: 203 kg
DEW01554
30-247
3. Boom cylinder pin 3

Sling boom cylinder (8), and remove mounting pin
(9). 9 8
« Set a stand under the tip of the boom.
« Insert a block on top of the axle, then lower the
cylinder.
« If there are shims installed, check the number
and thickness of the shims, and keep in a safe
place.
Boom cylinder: 153 kg

DEW01273
4. Boom, bellcrank, bucket link 4

1) Remove boom kick-out switch (10).
2) Sling boom assembly (11), then remove boom
mounting pin (12), and lift off boom assembly.
10
Boom assembly: 1170 kg
(including bellcrank, bucket link,
bellcrank pin)
« If there are shims installed at the connec-
tion of the front frame and boom, check the
042403
keep in a safe place. DEW01555
5. Bellcrank, bucket link 5

1) Sling bucket link (1), then remove mounting pin
(13), and lift off from bellcrank (7).
« Remove the cord ring.
Bucket link: 56 kg 11
13 12
DEW01275
2) Sling bellcrank (7), then remove mounting pin

(14), and lift off from boom assembly (11).
« Carry out the mounting pin removal opera- 14
tion with two people.
7
Bellcrank: 327 kg
Mounting pin: 20.5 kg
11
DEW01556
30-248
6. Dust seals, bushings 6

1) Pull out dust seal (15) and bushing (16) from
boom (11).
11
15
15
16
16 15 11 DEW01279
DEW01277

bellcrank (7). 7
7 18
17 17
17
042403
18 18
DEW01280
DEW01278

bucket link (1). 1
19
19
20
DEW01266
30-249
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY

insert your fingers.
moval.
1
Bucket and bucket link
« Be careful that the cord ring does not get
caught.
« Clearance c at mount portion: 1.5 mm c c DEW01281
• Grease all the pins after completing the

assembly.
2
Bucket cylinder
« After assembling the mounting pin, remove
the block.
042403
3
Boom cylinder
« Clearance b at mount portion: Max. 1.5 mm
Before starting the engine, place the direc-

tional lever at the N position, and check
that the parking brake is applied.
b b
DEW01282
4
Boom, bellcrank, bucket link
« Clearance a at mount portion: Max. 1.5 mm
« After assembling the pin, set a stand under

the tip of the lift arm.
a a
DEW01283
30-250
5
Bellcrank, bucket link
« Secure the bucket to the bellcrank with wire.
« Be careful that the cord ring does not get
caught.
6 Bushing
Use a press to press fit the bushing to the bucket 12 12
link, bellcrank, and boom. After press fitting, as-
semble the dust seal.
Inside surface of bushing:
Grease (G2-LI) DEW01284
042403
Hydraulic cylinder
DEW01285
30-251
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT

1. Sling radiator guard, and remove 4 mounting bolts,

then disconnect connector (2) of rear working lamp
wiring and radiator water level sensor (3) at radia-
tor end.
2. Lift off radiator guard (1).
3. Sling counterweight (4), then remove mounting bolts 3 1

and lift off. 1
2
Counterweight: 1309 kg
« When removing the counterweight, be careful

not to hit the battery box.
042403
DEW01286
INSTALLATION OF
COUNTERWEIGHT
• Carry out installation in the reverse order to re- 4

moval.
1
Mounting bolt:
926.7 ± 104.9 Nm (94.5 ± 10.5 kgm)
« When installing the counterweight, be careful
not to hit the battery box.
DEW01287
30-252
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY

1. Radiator guard
1) Remove 4 radiator guard mounting bolts, and 2 3
disconnect connector (1) of rear working lamp
wiring and radiator water level sensor (2) at 1
radiator end.
2) Lift off radiator guard (3).
042403
DEW01288
2. Draining fuel
Loosen drain valve (4) and drain fuel.
Fuel: 400 l 9
3. Drain valves 5
Remove engine oil drain valve (5) from fuel tank.
4
DEW01558 DEW01559
4. Fuel tube, wiring clamp

1) Disconnect hose (6) between fuel tank and feed
pump, fuel return hose (7), and spill hose (8) at
tank end.
2) Disconnect wiring connector (9) for fuel sensor.
3) Remove clamps at fuel tank mounting bolt for
steering oil cooler hose and hose going to trans-
mission cooler.
8
6
7 DEW01560
30-253
DISASSEMBLY AND ASSEMBLY FUEL TANK
4) Remove fuel tank air bleed tube (10).
5. Fuel tank
1) Put pallet under fuel tank (11), then put blocks
so that tank does not tilt, and support tank with 12
pallet truck.
Fuel tank: 233 kg

10
DEW01561 DEW01562
2) Remove fuel tank mounting bolts (12). 1
3) Pull out fuel tank (11) from rear of chassis.

« Maintain the balance of the fuel tank, and
operate the pallet truck to remove the tank.
11
042403
Blocks Pallet
Pallet truck DEW01534
INSTALLATION OF FUEL TANK 12

ASSEMBLY
moval. 12
1
« When installing the fuel tank, keep it horizontal,
and set it in position on the machine.
« Tighten the bolts in the following order: left,
rear, right. DEW01295
Fuel tank mounting bolt:
926.7 ± 104.9 Nm (94.5 ± 10.5 kgm)
• Tighten the drain valve and add oil through oil
filler.
11
DEW01296
30-254
DISASSEMBLY AND ASSEMBLY CAB
REMOVAL OF CAB ASSEMBLY

safety bar on the frame. Lower the bucket to the 1
1. Remove mounting bolts (3) of left and right dash-

boards (1) and (2).
3 4 DEW01297
2. Remove right cover (4).

2
3. Remove left cover (5).
042403
5
DEW01298
3
4. Disconnect electric wiring at connector (6).
5. Disconnect window washer hose (7).

« After disconnecting the hose, mark with a tag
to distinguish when installing.
6
7
DEW01299
6. Remove mounting bolts (8) of left and right dash-

8
boards, then remove left and right dashboards (1)
and (2).
7. Remove steering post and cab mounting bolts (9).
9 DEW01300
30-255
DISASSEMBLY AND ASSEMBLY CAB
8. Remove covers (10) under cab.
10
DEW01301
9. Remove 2 cab mounting bolts (11), 4 mounting

bolts (12) in the middle, and 4 mounting bolts at the 12 11
rear.
042403
DEW01302
10. Lift off cab (13).

« Keep the cab horizontal and lift it off slowly.
« Remove the plugs on top of the cab, and install
eyebolts.
Cab: 300 kg
13
DEW01303
INSTALLATION OF CAB
ASSEMBLY

moval.
30-256
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
REMOVAL OF MAIN MONITOR

ASSEMBLY
3
2
4
of the battery. 1
1. Remove dashboards (1) and (2). DEW01304
2. Remove steering post cover mounting bolts (3) and

(4).
6
3. Remove steering post cover (5).
4. Remove mounting bolt caps (7) of steering post 5

cover (6), then remove bolts.
042403
7 DEW01305
5. Remove mounting bolt caps from steering post cover

(8), then remove mounting bolts (9). 8
« Tip the steering post cover to the front.
DEW01306
6. Remove bracket (10) at back of main monitor.
10
DEW01307
30-257
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
7. Remove 8 mounting bolts (12) of main monitor (11).

« When removing the main monitor, be careful
not to subject it to any strong shock. 11
12
DEW01308
8. Disconnect wiring connectors (13), (14), (15), and

(16) from main monitor, and remove main monitor 13 14
(11). 1
15
042403
16
DEW01309
INSTALLATION OF MAIN
15 14 13
MONITOR ASSEMBLY 11

moval.
1
« Fit the connector lock securely.
16
DEW01310
30-258
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
REMOVAL OF MAINTENANCE
MONITOR ASSEMBLY

1
1. Remove cover (1) of right console box.
DEW01311
2. Disconnect connectors (2), (3), and (4) for mainte-

nance monitor wiring and bulb wiring (5) from main- 2
tenance monitor. 4
5
042403
3
DEW01312
3. Remove mounting bolts (7) of maintenance monitor

(6), then remove maintenance monitor (6).
6
7 7
DEW01313
INSTALLATION OF
MAINTENANCE MONITOR
ASSEMBLY
moval.
30-259
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT ASSEMBLY

safety bar on the frame. Lower the bucket to the Clamp 1-3

of the battery. 1-4
• Remove the cover under the cab. DEW01314 DEW01315

• After carrying out the oil return operation for the
compressor, use a gauge manifold and release the
refrigerant slowly from the core of the compressor
high-pressure and low-pressure valves.
• To carry out the oil return operation, set the fan

switch to the maximum position, then run the en-
gine at low idling and operate the air conditioner for
5 minutes. 2 3-1 3
If the refrigerant gets into your eyes, it may cause

loss of sight, so always wear safety glasses.
042403
1. Loosen clamp of heater hoses (1-3) and (1-4), and DEW01316
disconnect hoses.
2. Remove cab rear covers (2) and (3).

« Slide the operator’s seat forward and tip it to
the front.
« Remove the blind cap (3-1). 4
« Remove 2 bolts and loosen 6 bolts.
3. Remove 5 mounting bolts of cover (4), then remove

cover.
4. Remove seat support cover (5).
DEW01317
5
DEW01318
30-260
5. Remove cool and hot box assembly (6) and mount-

ing bolts (7), then remove cool and hot box assem-
bly.
6 DEW01319
6. Remove fuse box assembly bracket (8) from right

console box.
8
042403
DEW01320
7. Remove connectors (9), (10), (11), (12), (13), and

(14) from fuse box assembly bracket, and put fuse 9 10 11 12 13 14
box assembly on right console box temporarily.
« Mark the connectors with a tag to distin-
guish when installing.
DEW01321
8. Disconnect floor wiring connectors (15), (16), and

(17) from air conditioner unit wiring, then discon-
nect air conditioner relay wiring connector (18). 15
18
16 17 DEW01322
30-261
9. Remove left console box cover (19).
19
DEW01323
10. Remove left console box mounting bolts (20) and

(21), then remove left console box (22).
21
22
20
042403
DEW01324 DEW01325
11. Remove mounting bolts (24) of air conditioner unit

(23).
24
23
DEW01326
12. Remove mounting bolts (26) of air conditioner unit

(23) and air conditioner damper (25).
« Loosen mounting bolt (27).
« Loosen the 4 mounting bolts at the cab end. 27
25
23
26 DEW01327
30-262
13. Disconnect air conditioner tubes (28) and (29) from

air conditioner unit. 1
« Check that the pressure has been reduced.
« Remove the clamp.
28 29
DEW01328
14. Remove cover (30) at rear right of cab.

30
042403
DEW01329
15. Remove air conditioner filter (31), then remove duct

mounting bolts (32). 32
31
DEW01330 DEW01331
16. Remove connecting bolts (33) of air conditioner

unit (23) and air conditioner damper (25). 25
33
23
DEW01332
30-263
17. Remove clamp bolt (34) of air conditioner wiring

connector (16).
34
16
DEW01333
18. Disconnect heater hoses (35) and (36) from air

conditioner unit, then remove air conditioner unit
(23). 2
Air conditioner unit assembly: 38 kg
36
042403
23
35 DEW01334
19. Disconnect air conditioner damper wiring connector

(37) from floor wiring, then remove air conditioner
damper (25).
« After disconnecting, take steps to prevent the

entry of dust or water.
25
37
DEW01335
DEW01336
30-264
INSTALLATION OF AIR
CONDITIONER UNIT ASSEMBLY
1
Tube mounting bolt:
9.8 ± 2 Nm (1.0 ± 0.2 kgm)
« Coat the O-ring with compressor oil ND-OIL8.
2
« Pass the air conditioner drain hose through the
floor support grommet.

new refrigerant
3°C.
(If the temperature is below 3°C, the system
will not work.)
042403

system.
« Check the oil level in the compressor.
(Specified oil level: 150 +140 cc ND-OIL8)
30-265
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER
CONDENSER ASSEMBLY
Stop the machine on level ground and install the 1


DEW01337
« Open inspection cover (1) at the top of the
bulkhead and covers (2) and (3) at both sides.
042403
DEW01338 3 DEW01339
1. Disconnect electric wiring connectors (4) and (5) of

condenser. 6, 7
10
2. Disconnect left condenser hoses (6) and (7), and
right condenser hoses (8) and (9).
« After disconnecting the hoses and condenser
connections, fit plugs to prevent the entry of
dirt or dust 4
1
11
DEW01340
3. Remove condenser mounting bolts (10), then re-

move left condenser (11) and right condenser (12). 5 10
8
« The space is confined, so be careful when car-
rying out the removal operation.
12 DEW01341
30-266
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
moval.
1
« Do not remove the plugs from the hoses or
condenser connections until immediately before
installing.
« Install the hoses without twisting.
Hose, connection:
Compressor oil for new refrigerant (ND-
OIL8)
Condenser top connection:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
Condenser bottom connection:
11.8 – 14.7 Nm (1.2 – 1.5 kgm)

new refrigerant
3°C.
042403

will not work.)
system.
30-267
DISASSEMBLY AND ASSEMBLY DRY RECEIVER
REMOVAL OF DRY RECEIVER

ASSEMBLY
1
« Open inspection cover (1) at the top of the
bulkhead.
DEW01337
1. Disconnect hoses (2) and (3) of dry receiver.
« After disconnecting the hoses and dry receiver
connections, fit plugs to prevent the entry of
dirt or dust. 1 2
2. Remove mounting U-bolt (5) of dry receiver, then
remove receiver. 2 3
INSTALLATION OF DRY
RECEIVER ASSEMBLY 5
moval.
1 4
042403
« Do not remove the plugs from the hoses or dry
receiver connections until immediately before DEW01343
installing.
Hose, connection:
Compressor oil for new refrigerant (ND-
OIL8)
Receiver connection:
4 – 6.8 Nm (0.4 – 0.7 kgm)
2
Receiver mounting U-bolt:
10.8 – 26.5 Nm (1.1 – 2.7 kgm)
new refrigerant
3°C.
will not work.)
system.
30-268
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY 1


gauge manifold and release the refrigerant slowly DEW01565
« Open engine side cover (1) on the right side of

the machine. 5
6 2
1. Disconnect electric wiring connector (2) of com-
pressor clutch.
2. Disconnect hoses (3) and (4). 7

« After disconnecting the hoses and compressor
connections, fit plugs to prevent the entry of 3
042403
dirt or dust 1
4 6
DEW01566
3. Remove compressor adjustment bolt (5) and mount-
ing bolt (6), remove V-belt, then remove air condi-
tioner compressor (7). 2
30-269
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
moval.
1
« Do not remove the plugs in the hoses or con-
nections until immediately before installing.
Hose, connection:
Compressor oil for new refrigerant (NB-
OIL8)
Connection nuts of hoses (3), (4):
7.9 – 11.8 Nm (0.8 – 1.2 kgm)
1
Adjust the V-belt.

new refrigerant
042403
3°C.
will not work.)
system.
30-270
DISASSEMBLY AND ASSEMBLY TIRES
PROCEDURE FOR CHANGING

TIRES
1. Preparation:
1. 1. Park the machine on firm, level and safe ground, lower

the bucket to the ground, apply the parking brake and
place chocks at the front and rear of all the tires to secure
the machine.
1.2. Main tools

A Garage jack 15 ton 1-2 units
B Block (sleeper) 400 x 400 x 800 mm 4 pcs.

c Block (sleeper) 200 x 400 x 800 mm 2 pcs.
D Block (for stopper) determine dimension

with actual parts 2 pcs.
F Adapter (garage jack) For square, Ref. Dwg. 1 2 pcs.

042403
G Support 5 ton 2 units
H Iron plate (for floor) 900 x 1800 x 12t 4 sheets

I Iron plate (for adjusting) 200 x 300 x 19t 4 sheets
1.3. Tools used, Inspection of protective equipment

« Inspect required tools and protective equipment before
the job.
30-271

TIRES
2. Jacking-up Method:
2.1. Steering lock

Fit the steering locking bar to secure the front and rear
frames.
If the locking bar does not fit, operate the steering

until it fits. Give the driver correct signals.
2.2. Jacking-up on the front end

« Lift the front end of body using the bucket. Make sure
the bucket is horizontal before lifting.
a) Operate bucket lever to set bucket to dumping position,

lift the body gradually to lift the tires approx. 10 cm off
the ground.
042403
When the body inclines, insert blocks D (for stopper)
between rear axle and rear frame from both sides until
there is no play and set the rear axle level.
When operating bucket lever, release the parking

brake. The parking brake should be applied except
when operating bucket to ensure safety. Remove
chocks from rear tires.
When the machine is lifted with the bucket, be sure

to lock the bucket lever.
30-272

TIRES
b) Make sure the body remains stationary and set blocks

B,C under the front frame bottom and adjust the
height using iron plate I (for adjusting). The body
moves backward slightly when it is lowered. Set the
blocks taking into consideration of the allowance for
backspace.
When setting blocks on a soft ground, put iron plate

H (for floor) under blocks B, C to avoid the inclined
body from sinking.
When setting blocks, do not go between the block

and the body of a machine. Push the side of the
block with the hand to insert.
c) Operate bucket lever to tilt the bucket gradually and

lower the body until it touches the block. Make sure
that the blocks are securely holding the body and
place chocks to the front and rear of the rear tires.
042403
d) When the body is difficult to be lifted only by the

operation of bucket or a spade nose edge bucket or
a bucket with teeth is likely to damage the ground,
lift the boom and set the bucket to a dumping state
or place a sleeper under the bucket and then lower
the boom to lift the body.
Raise ( )
Hold ( )
Lower ( )
Dangerous à Float ( )
Operate boom lever, lower carefully and gradually.

Placing boom lever to float position is dangerous,
resulting in letting the lifted body drop suddenly.
2.3. When bucket is unable to be used, see Item

“Jacking-up the rear end”.
30-273

TIRES
2.4. Jacking-up the rear end
• Use garage jack A (15 ton, 1 - 2 units), adapters E,

F (for garage jack) to lift.
a) Apply parking brake and set safety bar, lift bucket,

with tilt back state, approx. 50 - 100 cm off the
ground, lock control lever and stop the engine and
then place chocks to the front and rear of the front
tires.
b) Insert blocks D (for stopper) between both sides of

rear axle and rear frame until there is no clearance
to avoid oscillation of axle.
042403
c) Jack up axle differential bottom or both sides
of axle housing to lift the body.
On a soft ground, put iron plate H (for floor) under

garage jack to avoid tilting and sinking of garage
jack.
For jacking-up axle housing, make sure that jack

adapter E or F shall not interfere with brake tube,
jack up uniformly on both sides.
30-274

TIRES
2.4.
d) Set block B, C on both sides of rear frame bottom
and adjust the height with iron plate I (for adjusting).
When setting blocks on a soft ground, put iron plate

H (for floor) under the block bottom to avoid inclined
body due to sinking.
When setting blocks, do not go between the block

and the body of a machine. Push the side of the
block with the hand to insert.
e) Lower the Jack gradually and make sure that the

body rests securely on the blocks.
042403
When 2 garage jacks are used, use both jacks to-

gether.
« Set support G under the counterweight bottom to

adjust height.
30-275

TIRES
3. Removing Tire Wheel Assembly
3.1.Temporarily hoist wheel assembly, remov wheel nuts

or bolts and hoist the assembly t remove.
a) Place the sling round the center of the ti and secure

tightly in the center. Hook chai sling between treads
of the tire and locate i a symmetrical position.
b) Remove wheel nuts or bolts and slowly hois the

assembly to remove. Leave 3 wheel nut or bolts
(equal spacing) in position, and the carefully remove
one at a time, payin attention to hoisting balance.
Be careful not to displace block D (stopper or the

axle will oscillate.
042403
4. Installing Tire Wheel Assembly
4.1 Install in reverse order of removal.
Use a crowbar to turn tire or hub to align wheel nut

mounting holes, notch first tighten in 4 pla top and
bottom and right and left. Tighten diagonal.
WA70-1 thru WA320-1, WA350-3

Mounting bolt:
927 ± 103 Nm (94.5 ± 10.5 kgm)
(Width across flats 36 mm)
WA350-1, WA380-1 thru WA500-1

Mounting bolt:
471 ± 49 Nm (48 ± 5 kgm)
(Width across flats 30 mm).
See the Shop Manual for weight
30-276
SUGGESTED DRAWING FOR

GARAGE JACK ADAPTER
We disclaim all the reponsibility for special tools
fabricated by local manufacturer.
042403
30-277
042403
30-278
40 MAINTENANCE STANDARD
Engine mount, transmission mount ............. 40- 2

Torque converter .......................................... 40- 3
Transmission ................................................ 40- 4
Transmission control valve ............................ 40-14
Drive shaft ..................................................... 40-18
Differential ..................................................... 40-20
Final drive ..................................................... 40-22
Axle mount ................................................... 40-23
Steering column, orbit roll ............................. 40-24
Steering valve ................................................ 40-26
Steering cylinder mount ................................ 40-27
Slack adjuster ............................................... 40-28
Brake valve ................................................... 40-29
Brake ............................................................ 40-32
Parking brake ............................................... 40-34
Torque converter,
transmission pump ................................ 40-35
Steering, switch pump ................................. 40-36
Hydraulic, PPC pump .................................. 40-37
PPC valve .................................................... 40-38
Cut-off valve ................................................. 40-39
Main control valve ........................................ 40-40
Boom cylinder .............................................. 40-44
Bucket cylinder ............................................. 40-45
Center hinge pin .......................................... 40-46
Work equipment linkage .............................. 40-48
Bucket .......................................................... 40-50
Bucket positioner and
boom kick-out ........................................ 40-51
40-1
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
ENGINE MOUNT, TRANSMISSION MOUNT
B
A
Kgm 123 ± 24 Nm
(12.5 ± 2.5 kgm)
Kgm 279 ± 29 Nm Kgm 927 ± 103 Nm Kgm 927 ± 103 Nm

(28.5 ± 3 kgm) (94.5 ± 10.5 kgm) (94.5 ± 10.5 kgm)
A–A B–B
SDW00331
Unit: mm
No. Check item Criteria Remedy
1 Clearance between engine 1 – 1.5 Adjust

bracket and adjustment bolt
40-2
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
kgm 30.87 ± 3.43 Nm kgm 66.15 ± 7.35 Nm kgm 30.87 ± 3.43 Nm

(3.15 ± 0.35 kgm) (6.75 ± 0.75 kgm) (3.15 ± 0.35 kgm)
1
2
kgm 66.15 ± 7.35 Nm

(6.75 ± 0.75 kgm)
SDW00403
Unit: mm
Standard size Tolerance Repair limit

1 Outside diameter of pilot 52 – 0.010 51.75
– 0.040
Inside diameter of retainer + 0.035

2 seal ring contact surface 110 0 110.5
– 0.01 Replace
Width 3 – 0.03 2.7
3 Wear of stator
shaft seal ring
Thickness 4.3 ± 0.1 3.9
Backlash between PTO

4 drive gear and drive gear 0.18 – 0.49
40-3
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1 2
kgm 113 ± 10 Nm
4 3 6 5 7 8 (11.5 ± 1.0 kgm)
16
18 21
15
20
17
23
21
25
kgm 927 ± 103 Nm
(94.5 ± 10.5 kgm)
19
21
10 27 13 24 14 11 12 26 22 9
SDW00333
40-4
Unit: mm
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
1 Clearance between pump
drive shaft and bearing +0.024 0 –0.039 –
65 +0.011 –0.015 –0.011 —
Clearance between pump

2 drive gear bearing and 120 0 +0.030 0– —
housing –0.015 0 0.045
3 Clearance between pump 40 +0.025 0 –0.037 – —

drive shaft and bearing +0.009 –0.012 –0.009
4 drive gear bearing and 80 0 +0.030 0–
housing –0.013 0 0.043 —
5 Clearance between pump 45 +0.025 0 –0.037 – —

drive shaft and bearing +0.009 –0.012 –0.009
housing –0.015 0 0.045
7 Clearance between pump 90 +0.035 0 0.013 – —

drive shaft and bearing +0.013 –0.020 0.055
housing –0.025 0 0.055
9 Clearance between output 135 +0.40 +0.063 –0.4 – —

shaft oil seal and housing +0.15 0 –0.087
10 Clearance between output 135 +0.40 +0.063 –0.4 – — Replace

shaft oil seal and housing +0.15 0 –0.087
11 Clearance between output 130 0 –0.018 0– —

shaft bearing and housing –0.018 –0.058 –0.158
12 Clearance between output 75 +0.030 0 –0.045 – —

shaft and bearing +0.011 –0.015 –0.011
13 Clearance between output 150 0 –0.018 –0.058 – —

shaft bearing and housing –0.018 –0.058 0
14 Clearance between output 85 +0.035 0 –0.055 – —

shaft and bearing +0.013 –0.020 0
Clearance (R) between
15 FORWARD, 1st clutch 160 0 +0.030 –0.055 – —
bearing and housing –0.025 0 0
Clearance (F) between
16 FORWARD, 1st clutch 160 0 +0.030 –0.055 – —
bearing and –0.025 0 0
Clearance (R) between
17 REVERSE, 2nd clutch 160 0 +0.030 –0.055 – —
Clearance (F) between
18 REVERSE, 2nd clutch 160 0 +0.030 –0.055 – —
Clearance (R) between 3rd,
19 4th clutch bearing and 130 0 +0.030 –0.048 – —
housing –0.018 0 0
Clearance (F) between 3rd,
20 4th clutch bearing and 160 0 +0.030 –0.055 – —
housing –0.025 0 0
40-5
Unit: mm

Inside diameter of seal ring
contact surface 55 + 0.05 0.05 (Wear)
0
+ 0.076
Width of seal ring groove 3.2 0 3.5
21
Width of seal ring 3.1 ± 0.05 2.8

Replace
0
Thickness of seal ring 2.29 – 0.1 2.1
Outside diameter (R) of 0

22 coupling oil seal sliding 105 – 0.087 0.05 (Wear)
surface
Outside diameter (F) of 0
23 coupling oil seal sliding 105 – 0.087 0.05 (Wear)
surface
Standard clearance Clearance limit
24 Clearance between output
shaft cover and housing 0.08 – 2.18 —
Tighten
Free rotating torque of
25 output shaft 0.1 – 1 Nm (0.01 – 0.1 kgm)

Clearance between output
26 shaft oil seal and housing
135 + 0.35 + 0.063 –0.35 – — Replace
+ 0.15 0 –0.087
27 Clearance between output 135 + 0.35 + 0.063 –0.35 – —

shaft oil seal and housing + 0.15 0 –0.087
40-6
40-7
FORWARD, 1ST CLUTCH
4 11 2 2 1 1 12 3
10 5 6 7 11 12 8 9 SDW00334
40-8
Unit: mm

Clearance (inside) between size Shaft Hole clearance limit
piston (FORWARD) and
1 shaft 96.73 0 +0.18 0.05 – 0.43
–0.015 +0.05 0.195
Clearance (outside)
between piston and 145 –0.30 +0.13 0.3 – 0.43
cylinder –0.35 0 0.48
Clearance (inside) between 96.73 0 +0.18 0.05 – 0.43

piston (1st) and shaft –0.015 +0.05 0.195
2 Clearance (outside)
cylinder –0.032 0 0.45
Clearance (R) at bearing
3 press-fitting portion of 75 +0.030 0 –0.045 – —
FORWARD, 1st clutch shaft +0.011 –0.015 –0.011
Clearance (F) at bearing
FORWARD, 1st clutch shaft +0.036 –0.015 –0.036

Thickness of separator
plate 2.0 ±0.05 1.5
5
Distortion of separator — 0.1 0.15

plate Replace
Thickness of friction 3.2 0.08 2.95

plate
6
Distortion of friction plate — 0.1 0.25
7 Load of wave spring 2134.7 N ±106.9 N 1814.2 N

(height 3.2 mm) (217.7 kg) (±10.9 kg) (185.0 kg)
8 Load of wave spring 1105.9 N ±56.9 N 938.5 N

(height 3.2 mm) (112.8 kg) (±5.8 kg) (95.7 kg)
9 End play of FORWARD 0.27 – 1.23

gear
10 End play of 1st gear 0.14 – 1.36

Thickness of FORWARD
11 clutch thrust washer 4 ±0.1 3.7
Thickness of 1st clutch

12 thrust washer 4 ±0.1 3.7
40-9
2ND, REVERSE CLUTCH

4 8 2 2 1 1 7 3
6 8 7 5 SDW00335
Unit: mm

piston (REVERSE) and
shaft 0 +0.18 0.05 –
1 96.73 –0.015 +0.05 0.195 0.43
Clearance (outside)
cylinder –0.35 0 0.48
Clearance (inside)
between piston (2nd) and 96.73 0 +0.18 0.05 – 0.43
shaft –0.015 +0.05 0.195
2 Clearance (outside)
cylinder –0.32 0 0.45
REVERSE, 2nd clutch shaft +0.011 –0.015 –0.011
Clearance (F) at bearing Replace
4 press -fitting portion of 75 +0.071 0 –0.086 – —
REVERSE, 2nd clutch shaft +0.061 –0.015 –0.061
5 End play of REVERSE gear 0.27 – 1.23
6 End play of 2nd gear 0.34 – 1.56

Thickness of REVERSE
7 clutch thrust washer 4 ±0.1 3.7
Thickness of 2nd clutch

40-10
3RD, 4TH CLUTCH
3 6 1 1 7 2
4 6 7 5 SDW00336
Unit: mm

piston (REVERSE) and
shaft 0 +0.18 0.05 –
1 96.73 –0.015 +0.05 0.195 0.43
Clearance (outside)
cylinder –0.32 0 0.45
2 press-fitting portion of 3rd, 75 +0.030 0 –0.045 – —
4th clutch shaft +0.011 –0.015 –0.011
Clearance (F) at bearing
3 press-fitting portion of 3rd, 35 +0.071 0 –0.086 – —
4th clutch shaft +0.061 –0.015 –0.061
Replace
4 End play of 3rd gear 0.34 – 1.56
5 End play of 4th gear 0.37 – 1.33

Thickness of 3rd clutch
Thickness of 4th clutch

40-11
40-12
40-13
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
UPPER VALVE ASSEMBLY
9
6
4
1
2
5
8 10 SDW00339
40-14
Unit: mm

1 Clearance between pilot
valve and body –0.035 +0.013 0.035 –
19 –0.045 0 0.058 0.065
2 Clearance between main 25 –0.035 +0.013 0.035 – 0.065

relief valve and body –0.045 0 0.058
3 Clearance between main 15 –0.02 +0.018 0.02 – 0.055

relief valve and load piston –0.03 0 0.048
4 Clearance between 25 –0.035 +0.013 0.035 – 0.044

modulation valve and body –0.045 0 0.058
Clearance between torque
5 converter regulator valve 19 –0.035 +0.013 0.035 – 0.065
and body –0.045 0 0.058
Replace
6 Clearance between 14 –0.02 +0.011 0.02 – 0.05
emergency spool and body –0.03 0 0.041
Clearance between
7 modulation valve and 6 –0.035 +0.012 0.035 – 0.065
load piston –0.045 0 0.057
Standard size Repair limit

Free length Test height Test load Free length Test load
8 Main relief valve spring
315.8 N 284.4 N
163.5 131.3 (32.2 kg) 157.0 (29.0 kg)
9 Fill valve spring 23 14 8.1 N 22.08 7.4 N

(0.83 kg) (0.75 kg)
10 Torque converter regulator 65 61 93.7 N 62.4 84.3 N

valve spring (9.55 kg) (8.60 kg)
40-15
LOWER VALVE ASSEMBLY
40-16
Unit: mm

Clearance between size Shaft Hole clearance limit
1 directional selector spool
and body –0.02 +0.013 0.02 –
19 –0.03 0 0.043 0.050
2 Clearance between H-L 19 –0.02 +0.013 0.02 – 0.050

selector spool and body –0.03 0 0.043
3 Clearance between range 19 –0.02 +0.013 0.02 – 0.050

selector spool and body –0.03 0 0.043
4 Clearance between priority 19 –0.035 +0.013 0.035 – 0.065

valve and body –0.045 0 0.058
5 Clearance between parking 19 –0.02 +0.013 0.02 – 0.050 Replace

brake valve and body –0.03 0 0.043

6 Directional selector spool
spring 78.9 N 70.6 N
42 32 (8.05 kg) 40.3 (7.2 kg)
7 H-L range selector spool 48 36.7 69.8 N 46.1 62.8 N

return spring (7.12 kg) (6.4 kg)
8 Priority valve spring 125.5 111.3 569.8 N 120.5 512.9

(58.1 kg) (52.3 kg)
9 Parking brake valve spring 46 37 81.4 N 44.2 73.6 N

(8.3 kg) (7.5 kg)
40-17
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
kgm 113 ± 10 Nm kgm 549 ± 58 Nm kgm 927 ± 103 Nm kgm 113 ± 10 Nm kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm) (56.0 ± 6.0 kgm) (94.5 ± 10.5 kgm) (11.5 ± 1.0 kgm) (11.5 ± 1.0 kgm)
kgm 113 ± 10 Nm kgm 113 ± 10 Nm kgm 113 ± 10 Nm kgm 113 ± 10 Nm

(11.5 ± 1.0 kgm) (11.5 ± 1.0 kgm) (11.5 ± 1.0 kgm) (11.5 ± 1.0 kgm) SDW00341
40-18
40-19
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
15 12 9
17
16
11
13
10
2 1
A–A
5 4 3
A A
14 8 6 7 SDW00342
40-20
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm

1 Clearance of side bearing
(outer race) 0 +0.054 0.014 –
160 –0.025 +0.014 0.079 —
2 Clearance of side bearing 105 +0.059 0 –0.079 – —

(inner race) +0.037 –0.020 –0.037
3 Clearance of pinion shaft 146.05 +0.025 –0.025 –0.075 – —

bearing (outer race) 0 –0.050 –0.025
Clearance of pinion shaft
4 bearing (inside of 69.85 +0.064 +0.013 0.064 – —
inner race) +0.051 0 0.038
Clearance of pinion shaft
5 bearing (outside of 69.85 +0.051 +0.013 –0.051 – —
inner race) +0.038 0 –0.025
6 Clearance of pilot bearing 110 0 +0.030 –0.010 – —

(outer race) –0.015 +0.010 0.045
7 Clearance of pilot bearing 110 +0.050 0 0.034 – —

(inner race) +0.034 –0.012 0.062
Clearance between
8 differential carrier and 190 –0.020 +0.046 0.030 – —
gauge –0.060 +0.010 0.106
9 Clearance between spider 34.93 –0.06 +0.10 0.11 – — Replace

and differential pinion gear –0.11 +0.05 0.21

Thickness of side gear
10 washer 4 ±0.05 3.8
Thickness of pinion gear +0.09

11 washer 1.5 –0.01 1.35

12 Backlash of bevel gear 0.3 – 0.41 —
Backlash of differential
13 gear 0.10 – 0.43 —
14 End play of pinion gear Max. 0.21
Preload of pinion shaft

15 bearing Rotating force: Max. 51.1 N (5.21 kg)
Preload of differential Rotating force: 2 – 24.5 N (0.2 – 2.5 kg)

16 side bearing [Target: 24.5 N (2.5 kg)]
Runout at rear face of

17 bevel gear Max. 0.1
40-21
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
2 6 5
kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm)
kgm 176 ± 20 Nm
(18 ± 2.0 kgm)
kgm 31 ± 3 Nm kgm 470 ± 49 Nm

(3.2 ± 0.3 kgm) (48 ± 5 kgm) SDW00343
Unit: mm

1 Clearance between
planetary shaft and bearing +0.013 0 –0.025 –
45 0 –0.012 0 —
Replace
2 Clearance between ring 180 +0.040 0 –0.065 – —
gear hub and bearing +0.015 –0.025 0.015

3 Thickness of spacer 26 ±0.1 25.5
Backlash between planet

4 gear and sun gear 0.19 – 0.43 —
Backlash between planet

5 gear and ring gear 0.19 – 0.53 —
Thickness of wheel hub

6 shim 2.025 ± 1.25 —
40-22
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
A A
kgm 1324 ± 147Nm kgm 1324 ± 147Nm

(135 ± 15kgm) (135 ± 15kgm)
kgm 279.5 ± 29 Nm
(28.5 ± 3.0 kgm)
4
3
kgm 279.5 ± 29 Nm
(28.5 ± 3.0 kgm)
2
A–A
SDW00344
Unit: mm

1 Thickness of thrust plate 20 0 —
–0.15
+0.3
2 Thickness of wear plate 5 –0.1 —
Standard Tolerance Standard Clearance Replace

Clearance between hole size Shaft Hole clearance limit
3 and shaft at front support
end 275 –0.056 +0.439 0.079 – —
–0.137 +0.023 0.576
Clearance between hole
4 and shaft at rear support 170 –0.043 +0.455 0.070 – —
end –0.106 +0.027 0.561
40-23
MAINTENANCE STANDARD STEERING COLUMN, GEAR BOX
STEERING COLUMN
Unit: mm

Clearance between size Shaft Hole clearance limit
1 steering shaft and column Replace
bearing 0 +0.15
19 –0.08 –0.05 0.05 – 0.23 0.4
40-24
40-25
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
Unit: mm

1 Steering spool return
spring
37.2 32.0 5.8 kg — 4.8 kg
2 Poppet spring 20.9 13.2 0.95 ± 0.5 kg — 0.8 kg

Replace
3 Demand spool return 81.6 68.5 27.3 kg — 22.6 kg
spring
4 Relief valve spring 24.0 22.19 18.6 kg — 14.8 kg
5 Check valve return spring 21.6 17.0 0.23 kg — 0.18 kg
40-26
MAINTENANCE STANDARD
STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
1, 2
a
3, 4
A–A SDW00348
Unit: mm

Clearance between size clearance limit
mounting pin and bushing Shaft Hole
1 at connection of steering
cylinder rod and frame 55 0 +0.046 0 – 0.092 0.050 –
–0.046 0 0.175
Clearance between
mounting pin and bushing 0 +0.046 0.050 –
2 at connection of steering 55 –0.046 0 0 – 0.092 0.175
cylinder bottom and frame
Replace
Width of boss Width of hinge Standard clearance
Connection between (clearance a + b)
3 steering cylinder and Max. 0.5
front frame 65 69 (after adjusting
with shim)
Connection between Max. 0.5
4 steering cylinder and 65 69 (after adjusting
rear frame with shim
40-27
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
kgm 55.9 ± 6.2 Nm

(5.7 ± 0.7 kgm)
3
kgm 65.7 ± 6.8 Nm

(6.7 ± 0.7 kgm)
SEW00349
Unit: mm

1 Clearance between
body and piston –0.030 +0.074 0.030 –
55 –0.076 0 0.150 0.25

Replace
2 Slack adjuster spring
43.2 N
198 38 (4.4 kg)
3 Spring 39.2 33 66.7 N

(6.8 kg)
40-28
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE (SINGLE)
2
3
kgm 66.2 ± 7.3 Nm 1

(6.75 ± 0.75 kgm)
kgm 7.8 ± 2 Nm
(0.8 ± 0.2 kgm)
6
kgm 66.2 ± 7.3 Nm
(6.75 ± 0.75 kgm)
5
7 4
kgm 152 ± 24.5 Nm
(15.5 ± 2.5 kgm) SDW00350
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1 mount hole and bracket
hole –0.025 +0.1 0.175 –
10 –0.075 0 0.025 0.25
2 Clearance between roller 10 –0.025 +0.1 0.175 – 0.25

and pin –0.075 0 0.025

3 Outside diameter of roller 30 0 29.2
–0.5
Standard size Repair limit Replace

4 Control spring
93.2 N
34 21.8 (9.5 kg) 33
5 Control spring 46.3 34.3 459.0 N 45.3

(46.8 kg)
6 Return spring 86.2 58 60.8 N 78

(6.2 kg)
7 Return spring 31.5 19.5 16.7 N 28

(1.7 kg)
40-29
BRAKE VALVE (TANDEM)
2
3
kgm 66.2 ± 7.3 Nm

1
(6.75 ± 0.75 kgm)
kgm 7.8 ± 2 Nm
(0.8 ± 0.2 kgm)
7 4
kgm 66.2 ± 7.3 Nm

(6.75 ± 0.75 kgm)
kgm 152 ± 24.5 Nm

(15.5 ± 2.5 kgm) SDW00351
40-30
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1 mount hole and bracket
hole –0.025 +0.1 0.175 –
10 –0.075 0 0.025 0.25
2 Clearance between roller 10 –0.025 +0.1 0.175 – 0.25

and pin –0.075 0 0.025

3 Outside diameter of roller 30 0 29.2
–0.5
Standard size Repair limit Replace

4 Control spring
93.2 N
34 21.8 (9.5 kg) 33
5 Control spring 46.3 34.3 459.0 N 45.3

(46.8 kg)
6 Return spring 86.2 58 60.8 N 78

(6.2 kg)
7 Return spring 31.5 19.5 16.7 N 28

(1.7 kg)
40-31
MAINTENANCE STANDARD BRAKE
BRAKE
1 kgm 279 ± 29 Nm kgm 176 ± 19 Nm 7 8 2 3 4

(28.5 ± 3.0 kgm) (18 ± 2 kgm)
kgm 926 ± 102 Nm

(94.5 ± 10.5 kgm) SEW00352
40-32
MAINTENANCE STANDARD BRAKE
Unit: mm

Free length Installed height Installed load Free length Installed load
1 Return spring
568.8 N 511.9 N
75.6 66.2 (58 kg) 74.7 (52.2 kg)

2 Thickness of plate 2.3 ±0.08 2.0
3 Thickness of disc 3.8 ±0.1 3.5
Overall assembly thickness Replace

4 of plates, discs 38.9 ±1.16 35
Wear of piston seal

5 contact surface 420 +0.097 —
0
Wear of piston seal
6 contact surface 383 +0.089 —
0
Backlash between outer
7 gear and plate 0.21 – 0.65
Backlash between inner

8 gear and disc 0.31 – 0.74
40-33
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1 2 3 SDW00353
Unit: mm
40 ±0.05 3.9
1 Thickness of plate
Distortion — 0.05 0.6
Thickness 3.2 ±0.08 2.97

Replace
Depth of
2 Brake disc lining groove 0.45 +0.175 0.3
Thickness of
lining 0.7 ±0.075
1103.2 N ±56.9 N 892.4 N

3 Load of wave spring (112.5 kg) (±5.8 kg) (91 kg)
(Height 3.2 mm)
40-34
MAINTENANCE STANDARD TORQUE CONVERTER, TRANSMISSION PUMP
TORQUE CONVERTER, TRANSMISSION PUMP
A 4 3 3
1
A–A
kgm 277 ± 32 Nm
(28.5 ± 3 kgm)
SEW00354
Unit: mm
Model Standard clearance Clearance limit

1 Side clearance SAR(3)-100 0.13 – 0.18 0.22
Clearance between inside

2 diameter of plain bearing SAR(3)-100 0.06 – 0.149 0.20 Replace
and outside of diameter
of gear shaft
Model Standard size Tolerance Repair limit
3 Depth for knocking in pin SAR(3)-100 14 0 —
–0.5
Rotating torque of
4 spline shaft 6.9 – 11.8 Nm (0.7 – 1.2 kgm)
Rotating Delivery Standard deli- Delivery

Model speed pressure very amount amount limit —
Discharge amount (rpm) [MPa (kg/cm2)] (¬/min) (¬/min)
5 Oil: EO10-CD
Oil temperature: 45 – 55°C SAR(3)-100 2,500 2.9 241 221
(30)
40-35
MAINTENANCE STANDARD STEERING, SWITCH PUMP
STEERING, SWITCH PUMP
4 2 3 1 3 2 3 1 3
kgm 277 ± 32 Nm kgm 277 ± 32 Nm

(28.5 ± 3 kgm) (28.5 ± 3 kgm)
SEW00355
Unit: mm

1 Side clearance SAR(3)71
0.10 – 0.15 0.19
SAR(3)50
Clearance between inside SAR(3)71
2 diameter of plain bearing 0.06 – 0.149 0.20 Replace
and outside of diameter SAR(3)50
of gear shaft
3 Depth for knocking in pin SAR(3)71 0
14 —
SAR(3)50 –0.5
Rotating torque of

Discharge amount (rpm) [MPa (kg/cm2)] (¬/min) (¬/min)
5 Oil: EO10-CD SAR(3)71 20.6 129 119
Oil temperature: 45 – 55°C 2,500
SAR(3)50 (210) 104 108
40-36
MAINTENANCE STANDARD HYDRAULIC, PPC PUMP
HYDRAULIC, PPC PUMP
4 2 3 1 3 2 3 1 3
kgm 277 ± 32 Nm kgm 110 ± 13 Nm

(28.5 ± 3 kgm) (11.5 ± 1 kgm)
SEW00404
Unit: mm

1 Side clearance SAR(4)140 0.11 – 0.16 0.19
SAR(1)28 0.10 – 0.15 0.19
Clearance between inside SAR(4)140 0.06 – 0.14 0.20
2 diameter of plain bearing Replace
and outside of diameter
of gear shaft SAR(1)28 0.064 – 0.119 0.20
3 Depth for knocking in pin SAR(4)140 21 0 —
SAR(1)28 10 –0.5
Rotating torque of

Discharge amount (rpm) [MPa (kg/cm2)] (l/min) (l/min)
5 Oil: EO10-CD SAR(4)140 20.6 (210) 287 266
Oil temperature: 45 – 55°C 2,200
SAR(1)28 2.9 (30) 59 52
40-37
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
kgm 44 ± 5Nm
(4.5 ± 0.5 kgm)
kgm 17.6 ± 3.9Nm

(1.8 ± 0.4 kgm)
SEW00357
Unit: mm
Centering spring Free length Installed Installed Free Installed

1 (bucket DUMP, x O.D. length load length load
boom LOWER)
56.5 x 12.2 36.0 19.6 N — 15.7 N
(2.0 kg) (1.6 kg) Replace spring
if damaged
Centering spring 29.4 N 23.5 N or deformed
2 (bucket TILT, boom RAISE) 66.8 x 12.2 36.0 (3.0 kg) — (2.4 kg)
16.8 N 13.7 N
3 Metering spring 31.4 x 7.4 29.4 (1.7 kg) — (1.4 kg)
40-38
MAINTENANCE STANDARD CUT-OFF VALVE
CUT-OFF VALVE
Unit: mm

Free length Installed length Installed load Free length Installed load
1 Unload valve spring
1.147 N 1.373 N
33 20 (0.117 kg) — (0.14 kg) Replace
2 Check valve spring 36.9 30 35.3 N — 28.4 N

(3.6 kg) (2.9 kg)
40-39
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

2-SPOOL VALVE
40-40
Unit: mm

Free length Installed Installed Free Installed
Spool return spring length load length load
1 ,
(large)
190.3 N 152.0 N
64.4 62.2 — (15.5 kg)
(19.4 kg)
2 Spool return spring 18.6 14.9 112.8 N — 90.2 N

(small) (11.5 kg) (9.2 kg)

(large) (15.2 kg) (12.2 kg)

(small) (10.6 kg) (8.5 kg) Replace

(large) (26.3 kg) (21.0 kg)

(large) (10.35 kg) (8.3 kg)
7 Spool return spring 42.0 42.0 0 — —

(small)
8 Spool return spring 42.0 42.0 0 — —

(small)

(small) (3.2 kg) (2.6 kg)

(3.2 kg) (2.6 kg)
11 Check valve spring 78.2 52.0 18.8 N — 14.7 N

(1.92 kg) (1.5 kg)
12 Float selector valve spring 53.0 40.1 161.8 N — 129.5 N

(16.5 kg) (13.2 kg)
13 Unload valve spring 82.7 47.0 49.0 N — 39.2 N

(5.0 kg) (4.0 kg)
40-41
3-SPOOL VALVE
40-42
Unit: mm

Free length Installed Installed Free Installed
Spool return spring length load length load
1 ,
(large)
190.3 N 152.0 N
64.4 62.2 — (15.5 kg)
(19.4 kg)
Spool return spring 112.8 N 90.2 N

2 (small) 18.6 14.9 (11.5 kg) — (9.2 kg)

3 (large) 64.4 62.7 (15.2 kg) — (12.2 kg)

4 (small) 18.6 15.2 (10.6 kg) — (8.5 kg) Replace
5 (large) 89.1 82.0 (26.3 kg) — (21.0 kg)

6 (large) 83.3 82.0 (10.35 kg) — (8.3 kg)
Spool return spring

7 (small) 42.0 42.0 0 — —
Spool return spring

8 (small) 42.0 42.0 0 — —

9 (small) 62.6 52.0 (3.2 kg) — (2.6 kg)
31.4 N 25.5 N
10 Spool return spring 62.6 52.0 (3.2 kg) — (2.6 kg)
18.8 N 14.7 N
11 Check valve spring 78.2 52.0 (1.92 kg) — (1.5 kg)
161.8 N 129.5 N
12 Float selector valve spring 53.0 40.1 (16.5 kg) — (13.2 kg)
49.0 N 39.2 N
13 Unload valve spring 82.7 47.0 (5.0 kg) — (4.0 kg)
40-43
MAINTENANCE STANDARD BOOM CYLINDER
BOOM CYLINDER
Unit: mm

Clearance between boom
1 cylinder rod and bushing –0.036 +0.235 0.096 –
95 –0.123 +0.060 0.358 0.658
Clearance between piston +0.350

2 rod mounting pin and inside 110 +0.200
diameter of insertion portion
Replace
Clearance between +0.207
3 cylinder bottom mounting 110 +0.120
pin and bushing
Standart size Tolerance Repair limit
4 Clearance at inside
diameter of cylinder 180 +0.30
0
40-44
MAINTENANCE STANDARD BUCKET CYLINDER
BUCKET CYLINDER
Unit: mm

Clearance between boom
1 cylinder rod and bushing 100 –0.036 +0.270 0.096 – 0.693
–0.123 +0.060 0.358
Clearance between piston –0.036 +0.207 0.156 –

2 rod mounting pin and inside 120 1.0
diameter of insertion portion –0.090 +0.120 0.297
Replace
Clearance between –0.036 +0.207 0.156 –
3 cylinder bottom mounting 120 1.0
pin and bushing –0.036 +0.120 0.297
Standart size Tolerance Repair limit

4 Clearance at inside
diameter of cylinder 200 +0.30
0
40-45
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm)
15 16
5
7
4
14
12
3 8
13
6 9
2
11 10
A–A 1 B–B
kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm)
SDW00363
40-46
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm

1 Clearance between upper
hinge pin and rear frame –0.030 +0.071 0.066 –
80 –0.076 +0.036 0.147 —
2 Clearance between upper 80 –0.030 +0.060 0.060 – —

hinge and spacer (small) –0.076 +0.030 0.136
3 Clearance between upper 80 –0.030 0 0.015 – —

hinge and bearing –0.076 –0.015 0.076
4 Clearance between upper 80 –0.030 +0.030 0.03 – —

hinge and spacer (large) –0.076 0 0.106
5 Clearance between rear 95 –0.036 +0.071 0.072 – —

frame and spacer (large) –0.071 +0.036 0.142
Clearance between front
6 frame and upper hinge 130 0 –0.048 0.088 – —
bearing –0.025 –0.088 0.023
Clearance between lower
7 hinge pin and rear frame 80 –0.030 +0.048 0.047 – —
bushing –0.076 +0.017 0.124
8 Clearance between lower 80 –0.030 0 0.015 – —

hinge pin and bearing –0.076 –0.015 0.076
Clearance between front
9 frame and lower hinge 130 0 –0.048 0.088 – — Replace
bearing –0.025 –0.088 0.023
Clearance at press-fitting
10 portion of lower hinge 105 +0.17 +0.054 0.17 – —
pin seal +0.08 0 0.026

Height of upper hinge
11 spacer (small) 36 ±0.1
Height of upper hinge

12 spacer (large) 61.5 ±0.1
Standard size Standard clearance Clearance limit

Value for shim between
13 upper hinge and retainer 1
Value for shim between

14 upper hinge and retainer 2
Tightening torque of 19.6 ± 2 Nm (2.0 ± 0.2 kgm) (when adjusting with shim)
15 upper hinge retainer
mounting bolt
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm) (final value)
Tightening torque of 19.6 ± 2 Nm (2.0 ± 0.2 kgm) (when adjusting with shim)
16 upper hinge retainer
mounting bolt
205.9 ± 19.6 Nm (21 ± 2 kgm) (final value)
40-47
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
1 2 3
J
J
E
D
F E
D H
F
BB C H
C
G
G
A A
6 5 4
2 1 1
A–A 11 B–B 12 C–C 14
5 4 6
16 9 15
D–D E–E F–F
7 8 3
G–G 17 H–H 13 J–J 10

SDW00364
40-48
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
1 bushing at both ends of
bucket link –0.036 +0.207 0.156 –
95 –0.090 +0.120 0.297 1.0
Clearance between pin and

2 bushing at connection of 95 –0.036 +0.207 0.156 – 1.0
boom and bucket –0.090 +0.120 0.297
3 bushing at connection of 110 –0.036 +0.207 0.156 – 1.0
boom and frame –0.090 +0.015 0.297
bushing at connection of –0.036 +0.207 0.156 – 1.0 Replace
4 bucket cylinder bottom and 120 –0.090 +0.120 0.299 replace if there
frame is scuffing on
Clearance between pin and pin
bushing at connection of –0.036 +0.207 0.156 – 1.0
5 bucket cylinder rod and 120 –0.090 +0.120 0.297
frame
6 bushing at connection of 125 –0.043 +0.395 0.338 –
bellcrank and boom –0.106 +0.297 0.501
bushing at connection of –0.036 +0.207 0.156 –
7 boom cylinder bottom 110 –0.090 +0.120 0.297 1.0
and frame
bushing at connection of –0.036 +0.207 0.156 –
8 boom cylinder rod and 110 –0.090 +0.120 0.297 1.0
frame
Standard clearance
Width of boss Width of hinge (clearance a + b)
9 Connection of bucket
cylinder and frame 128 +0.8 128 ± 0.8 1.4 – 3.8
0
Replace
Connection of boom and insert shims on
10 frame 127 ± 2.3 130 +2.5
0
0.7 – 7.8 both sides so
that clearance
is less than 1.5
Connection of boom and mm on both
11 bucket 119 ± 2.3 122 +1.5
0
0.7 – 6.8
left and right
Connection of bucket link +3

12 and bucket 138 –0.5
143 ± 1.5 2–7
Connection of boom
13 cylinder and frame 120 +0.8
0
125 +0.5
0
2.2 – 5.5
Connection of bellcrank
14 and bucket link 138 +3
–0.5
143 ± 1.5 1 – 5.5
Connection of bellcrank
15 and boom 220 ± 0.5 223 ± 0.5 2–4 Replace
Connection of bucket
16 cylinder and bellcrank 115 +0.8
0
118 ± 1.5 1.2 – 3.0
Adjust with shims

17 Connection of boom and 111 ± 2.5 114 ± 1.5 0–6 so that clearance
boom is less than 2.0 mm
on both left and right
40-49
MAINTENANCE STANDARD BUCKET
BUCKET
B C
B C
kgm 745 ± 107 Nm

(76 ± 11 kgm)
3
D
2
D
A–A
B–B
kgm 902 ± 39 Nm
2 (92 ± 4 kgm)
C–C D–D
kgm 902 ± 39 Nm kgm 902 ± 39 Nm

(92 ± 4 kgm) (92 ± 4 kgm) SDW00365
Unit: mm
1 Wear of bucket tooth Replace

50 18.5
2 Clearance at bucket tooth Max. 0.5 Adjust or replace

mount
3 Wear of cutting edge 93 Turn or replace
40-50
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
kgm 88 ± 34 Nm
(9.0 ± 3.5 kgm)
kgm 17.2 ± 2.4 Nm
(1.75 ± 0.25 kgm)
1 A–A
SEW00366
Unit: mm
Clearance at bucket
1 positioner switch 3–5
Adjust
2 Clearance at boom 3–5

kickout switch
40-51

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Shop Manual

01 GENERAL ......................................................................... 01-1

10 STRUCTURE AND FUNCTION ....................................... 10-1

20 TESTING AND ADJUSTING ............................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ................................... 30-1

40 MAINTENANCE STANDARD........................................... 40-1

IMPORTANT SAFETY NOTICE

PRECAUTIONS DURING WORK

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

DISTRIBUTION AND UPDATING Weight of parts of systems.

FILING METHOD Tightening Places that require special at-

Item number (10. Structure Places where oil or water must

Example 2 (Engine volume):

3. Additional pages: Additional pages are indicated

• If a part cannot be smoothly removed from the

Wire ropes 4) Do not sling a heavy load with ropes forming

2) Sling wire ropes from the middle portion of

DIMENSIONS, WEIGHTS AND OPERATING DATA

Bucket capacity as per ISO 7546 m3 4,0 4,0 4,4 4,4

Specific density t/m3 1,8 1,8 1,6 1,6

a Reach at full lift 45° mm 1.260 1.181 1.260 1.181

A Overall length mm 8.790 8.645 8.760 8.645

Machine model WA470-3

Operating weight (kg) 23,100

Bucket capacity (heaped) (m3) 4,4 (with BOC)

Travel speed FORWARD 1st (km/h) 6.4

FORWARD 2nd (km/h) 11.6

FORWARD 3rd (km/h) 21.6

FORWARD 4th (km/h) 37

REVERSE 1st (km/h) 6.7

REVERSE 2nd (km/h) 12.3

REVERSE 3rd (km/h) 22

REVERSE 4th (km/h) 37.5

Min. turning Center of outside wheel (mm) 6,320

Overall length (mm) 8,645 (with BOC)

Overall width (chassis) (mm) 3,010

Bucket width (with BOC) (mm) 3,200

(Bucket raised) (mm) 5,900

Wheelbase (mm) 3,400

Tread (mm) 2,210

Min. ground clearance (mm) 525

Height of bucket hinge pin (mm) 4,205

Dumping clearance (tip of BOC) (mm) 3,080

Dumping reach (edge of bucket) (mm) 1,181

Bucket dump angle (deg) 46

Bucket tilt angle (travel posture) (deg) 50

Digging depth (10° dump) (with BOC) (mm) 305

Machine model WA470-3

Piston displacement (cc) 11,040

Flywheel horsepower (kW (PS)/rpm) 194 (264)

Maximum torque (Nm (kgm)/rpm) 1,050 (107) / 1400

High idling speed (rpm) 2,350 - 2,450

Low idling speed (rpm) 700 - 750

Starting motor 24 V 7.5 kW

Torque converter 3-element, 1-stage, single-phase (Komatsu TCA38-4Z)

Spur gear, constant-mesh multiple-disc,

Reduction gear Spiral bevel gear, splash lubrication

Differential Straight bevel gear, torque proportioning

Final drive Planetary gear single stage, splash lubrication

Front wheel Fixed frame, full-floating type